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Transient state thermal analysis of a 4 stroke CI engine Piston
1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 04 | Apr 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 305 Transient state thermal analysis of a 4 stroke CI engine Piston Harsh Vardhan1, Gaurav Kumar Netam2, Jayant3, Pushpendra Singh4 1Student, B. Tech (Mechanical Engineering), Delhi Technological University, New Delhi, India 2 Student, B. Tech (Mechanical Engineering), Delhi Technological University, New Delhi, India 3 Student, B. Tech (Mechanical Engineering), Delhi Technological University, Rohtak, Haryana, India 4Associate Professor, Dept. of Mechanical Engineering, Delhi Technological University, New Delhi, India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - This study employs ANSYS software to conduct a comparative investigation of the thermal behavior of an internal combustion (IC) engine piston made of four different materials, Aluminium Alloy, AlSi10Mg, Titanium Alloy (Ti-6Al-4V) and Gray Cast Iron. The goal is to examine the thermal behavior of the piston built of each material under various operating circumstances. The temperature distribution and heat flux within the piston for each material are the main topics of the simulations, which also consider a variety of boundary conditions. Results are given, compared, and their implications for choosing materials for IC engine piston applications are examined. This study illustrates the capability of ANSYS in simulating and comparing the thermal behavior of intricate mechanical systems and offers insightful information about the comparative thermal behavior of an IC engine piston constructed of four different materials. Key Words: IC Engine, Heat flux, Temperature Distribution 1.INTRODUCTION The design and material choices used for internal combustion (IC) engine parts like pistons have a significant impact on the engine's overall effectiveness and performance. Thermal behavior of IC engine pistons is one of the crucial elements that might have a considerable impact on their performance. The engine's overall performance and dependability may be impacted by the high temperatures and pressures the piston is subjected to during operation. These conditions can also lead to material degradation and thermal strains. The thermal behavior of an IC engine piston made of four different materials—Aluminum alloy, AlSi10Mg, Titanium Alloy (Ti- 6Al-4V) and Gray Cast Iron—is compared in this research using the ANSYS program. The goal is to examine the thermal response of the piston made of each material and offer details on how an IC engine piston made of various materials compares thermally. The study focuses on the temperature and thermal stresses within the piston for each material, while the simulations consider various thermal loads and boundary conditions. The findings of this study offer useful knowledge for engineers engaged in IC engine design and optimization. This study can assist engineers in making the best material choice for the piston to achieve the desired performance and dependability of the engine by evaluating the thermal behavior of the piston constructed of various materials. The thermal behavior of the pistons in IC engines may be studied using the ANSYS simulations in an economical and effective manner, which is crucial as engine efficiency and environmental restrictions become more stringent. 1.1 Piston Terminology Fig 1.1: Piston Terminology The crown, which is the top of the piston, is made to resist the high pressure and high temperature of the combustion chamber. The lower part of the piston, called the skirt, acts as a guide to make sure the piston goes straight and stays in the right alignment with the cylinder bore. The wrist pin, which is another name for the piston pin, joins the piston to the connecting rod and enables reciprocating movement of the piston. Piston rings, which are used to seal the combustion chamber and transport heat to the
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 04 | Apr 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 306 cylinder walls, are mounted to the piston's outer circle. The total length of the piston is length from piston crown to bottom of piston. Sum of the length of the upper platform, the length of the annular section and the length of the skirt. The portions on the piston between the piston rings known as "ring lands" give the rings structural support and keep them from spinning within the piston groove. The piston rings are held in position by the machining channels in the ring grooves of the piston. 1.2 Piston Design Internal combustion engine piston design is a complicated procedure that considers a variety of aspects in order to obtain the best performance and efficiency. For the purpose of this analysis, we have taken dimensions of a 4- stroke diesel engine piston into account. We have used ANSYS software for the purpose of design. Table 1: Piston Dimensions Fig 1.2: Model in ANSYS 2. Transient State Thermal Analysis Thermal analysis of pistons is done to assess how well they can tolerate the high temperatures and thermal stresses that occur during engine running. We can find possible weak spots in the piston design and strengthen it for better heat dissipation and decreased thermal stresses by assessing temperature distribution and heat flux. 2.1. Selection of Material Consideration of several parameters, including as thermal conductivity, specific heat capacity, thermal expansion coefficient, and strength, is necessary when choosing a material for a piston's thermal analysis. The best materials to employ in pistons are those that have the correct mix of these characteristics, resulting in an engine that runs reliably and effectively. Materials used for this project are Aluminium alloy, AlSi10Mg, Titanium alloy (Ti-6Al-4V) and Gray cast iron. Table 2: Materials Properties 2.2. Generating Mesh To generate mesh, the default mode was used with tetrahedral elements, the solid model being meshed into 23290 elements and 41502 nodes.
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 04 | Apr 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 307 Fig 2: Mesh Model in Ansys 3. RESULTS We have performed transient state thermal analysis on the piston and compared results of four materials with the boundary condition of temperature being set as 400°C at the top of piston. Aluminium Alloy Fig 3.1: Temperature Distribution of Al Alloy Fig 3.2: Heat flux distribution of Al Alloy Graph 3.1: Time vs Temperature for Al Alloy Graph 3.2: Time vs Heat flux for Al Alloy
4.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 04 | Apr 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 308 AlSi10Mg Fig 3.3: Temperature Distribution of AlSi10Mg Fig 3.4: Heat flux distribution of AlSi10Mg Graph 3.3: Time vs Temperature for AlSi10Mg Graph 3.4: Time vs Heat flux for AlSi10Mg Ti-6Al-4V Fig 3.5: Temperature Distribution of Ti-6Al-4V Fig 3.6: Heat flux distribution of Ti-6Al-4V
5.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 04 | Apr 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 309 Graph 3.5: Time vs Temperature for Ti-6Al-4V Graph 3.6: Time vs Heat flux for Ti-6Al-4V Gray Cast Iron Fig 3.7: Temperature Distribution of Gray Cast Iron Fig 3.8: Heat flux distribution of Gray Cast Iron Graph 3.7: Time vs Temperature for Gray Cast Iron Graph 3.8: Time vs Heat flux for Gray Cast Iron
6.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 04 | Apr 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 310 The results from the transient state thermal analysis of piston are presented in a tabular format below: Table 3: Results of Analysis Chart: Max. heat flux distribution for different materials The results of the thermal study of pistons constructed of various materials offer some intriguing new information about how well these materials transport heat. The substance that transfers heat the fastest is aluminium alloy, which has a maximum heat flux value of 2.6812e6 w/m2. The closest competitor, AlSi10Mg, has a maximum heat flux value of 2.0283e6 w/m2. The maximum heat flux values for Ti-6Al-4V and grey cast iron are lower, at 7.2417e5 w/m2 and 1.6447e6 w/m2, respectively. CONCLUSION The alloy made of aluminium has a maximum heat flux value of 2.6812e6 W/m2, which is the highest. This shows that under specific operating situations, the aluminium alloy piston may face high heat loads, which could cause thermal stress and deformation. Nonetheless, the aluminium piston is also capable of effectively dispersing heat and maintaining lower temperatures under typical working conditions, as indicated by the lowest heat flux value of 3.3e-4 W/m2. The Ti-6Al-4V alloy, in contrast, has a maximum heat flux value that is substantially lower (7.2417e5 W/m2), indicating that it would be subject to less thermal stress and deformation than the aluminium alloy. However, the titanium piston may not be as efficient at dispersing heat under low-load circumstances, as indicated by the minimum heat flux value of 1.752e-6 W/m2. For both the lowest and maximum heat flux, grey cast iron and the AlSi10Mg alloy have intermediate values. In comparison to titanium alloy, the AlSi10Mg alloy has a higher maximum heat flux value, but a lower minimum heat flux value. The grey cast iron has a lower maximum heat flux value than the other materials, but it also has a lower minimum heat flux value, suggesting that its temperature distribution may be more consistent. The materials' thermal conductivity and specific heat capacity are to blame for these outcomes. In comparison to Ti-6Al-4V and grey cast iron, aluminium alloy and AlSi10Mg have stronger thermal conductivities allowing them to transmit heat more effectively. It is crucial to remember that these results do not necessarily represent the materials' general performance in a piston application. While choosing a material for piston manufacture, other aspects such as mechanical qualities, price, and availability should also be taken into consideration. Overall, the study's findings can help engineers and designers make knowledgeable selections when choosing materials for piston applications. REFERENCES 1. Balahari Krishnan S, Aezhisai Vallavi MS, Arunkumar M and Haripraveen A - “Design and Analysis of an IC Engine Piston using Composite Material “European Journal of Advances in Engineering and Technology, 2017, 4 (3): 209-215 ISSN: 2394 - 658X 2. Preeti Kumari, Anamika, Dr.H.C.Thakur, “Thermal Analysis of Piston of IC engine” International Journal of Scientific & Engineering Research, Volume 7, Issue 12, December-2016, ISSN 2229- 5518, PAGE 374-381 3. B.A.Devan, G.Ravindra Reddy,”Thermal analysis of Aluminum alloy Piston”, International Journal of Emerging Trends in Engineering Research (IJETER), Vol. 3 No.6,Pages:511-515(2015) 4. K. Mayandi, R. Muneendra Reddy, B. Jaya Harsha Vardhan, Y. Anand Babu,” STATIC AND THERMAL ANALYISIS OF PISTON USING ANSYS WITH 0.00E+00 1.00E+06 2.00E+06 3.00E+06 Aluminium Alloy AlSi10Mg Ti-6Al-4V Gray Cast Iron Max Heat Flux Distribution Max Heat Flux
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 04 | Apr 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 311 VARIOUS MATERIALS” International Research Journal of Modernization in Engineering Technology and Science, Volume:03/Issue:05/May-2021, Impact Factor- 5.354, PAGE 3035-3044 5. Prashant Kumar, PG Scholar, Abhishek Bhandari, Sunil Kumar Chaturvedi,” Design and thermal analysis of ic engine piston design using catia and Ansys software” SSRG International Journal of Mechanical Engineering Volume 6 Issue 10, 12-19, October 2019 ISSN: 2348 – 8360 6. Atthuru Kalyan , Dr. D. R. Srinivasan,” Static and Thermal Analysis of a Piston with Different Thermal Barrier Coatings”, International Journal of Scientific Engineering and Research (IJSER) ISSN (Online): 2347-3878 Impact Factor (2020): 6.733 7. Thirakavinod Kumar, B. Ravisekhar,“Thermal & Static Analysis On IC Engine Piston Using Fea”, IJATES,Issn2348-7550,Volume 4, Issue No. 12,December-2016, Page. No. 225-231 8. Yash Dhamecha, Vaibhav Saptarshi, Shubham Parikh, Tejasve Parnami,” Design and Analysis of Piston using Different Materials”, International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 12 | Dec 2020 p-ISSN: 2395-0072 9. Ajay Raj Singh*, Dr. Pushpendra Kumar Sharma, Design, Analysis and Optimization of Three Aluminium Piston Alloys Using FEA “Journal of Engineering Research and Applications www.ijera.com ISSN : 2248-9622, Vol. 4, Issue 1( Version 3, January 2014, pp.94-102 10. A.R. Bhagat , Y.M.Jibhakate “Thermal Analysis And Optimization of I.C. Engine Piston Using finite Element Method “International Journal of Modern Engineering Research (IJMER) vol.2, Issue.4, July- Aug 2012 pp-2919-2919 ISSN: 2249-6645 11. Mr.Jadhav Vishal, Dr. R.K. Jain, Mr. Yoge A.ndra S.Chauhan,” DESIGN AND ANALYSIS OF ALUMINUM ALLOY PISTON USING CAE TOOLS”, “INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH TECHNOLOGY, ISSN: 2277-9655 Impact Factor: 4.116 [Vishal*et al., 5(7): July, 2016] ISSN: 2277-9655 IC™ Value: 3.00 12. PAGADALA SIDDIRAJU, KOPPULA VENKATESWARAREDDY “DESIGN AND ANALYSIS OF THE PISTON BY USING FIVE DIFFERENT MATERIALS”, INTERNATIONAL JOURNAL OF ADVANCE SCIENTIFIC RESEARCH AND ENGINEERING TRENDS || Volume 6 || Issue 2 || February 2021 || ISSN (Online) 2456-0774 13. Subodh Kumar , SRCEM, Banmore M.P. India; C. S. Koli, SRCEM, Banmore M.P. India “A Review Paper on Thermal Analysis of Piston by Finite Element Analysis” IJSRD - International Journal for Scientific Research & Development| Vol. 5, Issue 12, 2018 | ISSN (online): 2321-0613 14. Pathipati Vasu, Dr.M.Sri Rama Murthy, P.S.Amarnadh, “Design and Analysis of IC Engine Piston with Different Materials”, International Journal of Research e-ISSN: 2348-6848 p-ISSN: 2348-795X Volume 05 Issue 07 March 2018 15. V G Cioată, I Kiss, V Alexa and S A Rațiu, “Mechanical and thermal analysis of the internal combustion engine piston using Ansys” International Conference on Applied Sciences (ICAS2016), V G Cioată et al 2017 IOP Conf. Ser.: Mater. Sci. Eng. 163 012043 16. Valentin Mereuta,” Static and Thermal Analysis of Piston using FEM Analysis” International Journal for Research in Applied Science & Engineering Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor :6.887 Volume 6 Issue I, January 2018 17. J. Srikanth, Mr. A. Jithendra Kumar, “Modeling and Static Thermal Analysis of IC Engine Piston by using Different Materials”, International Journal of Applied Sciences, Engineering and Management ISSN 2320 – 3439, Vol. 06, No. 02, April 2017, pp. 265 – 272 18. Kunal Saurabh1*, Saurabh Kumar Rai1, Shravan Yadav1, Sanjay Kumar Yadav1 , AkhandPratap Singh1, “A Review Paper on Design Analysis of Internal Combustion Component, International journal of adavance research in science and engineering vol no.6 Special issue no.2, december 2017,ISSIN 2319-8354 19. Satish Sharma, P.S. Dhakar,” A Review Study of Steady State Thermal Analysis of Piston by Finite Element Method (FEM)” International Journal of I.C. Engines and Gas Turbines Vol. 3: Issue 1
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