Design and static thermal analysis of piston

DESIGN AND STATIC THERMALANALYSIS OF
PISTON USING THERMAL BARRIER COATING
MATERIALS USING FEM
A THESIS SUBMITTED IN PARTIAL
FULFILLMENT OF THE REQUIREMENTS FOR
THE AWARD OF THE DEGREE OF B.TECH

CONTENTS
ABSTRACT
INTRODUCTION
THERMAL BARRIER COATING
TBC COATING IN CYLINDER LINER
OBJECTIVE OF THE PROJECT
METHODOLOGY
CONSIDERATION DESIGN ON THE PISTON PARAMETERS
PISTON DESIGN IN CATIA
STATIC ANALYSIS OF PISTON
BOUDARY CONDITIONS
CONCLUSION

ABSTRACT
Piston is considered to be one of the important parts of an internal combustion engine. It is a part
which bears the pressure & temperature of the combustion of the gas inside the cylinder.
The project aims at to increase the performance of the engine by using the Thermal Barrier
Coating (TBC). Now a days widely using Internal combustion engines High temperature produced
in an I.C engine may contribute to high thermal stresses.
The literature survey shows that ideal piston consumes heat produced by burnt gases resulting in
decrease of Engine overall Efficiency. The Aim of the project is UNICORN 150CC engine is
considered and TBC material with 0.4mm thickness is coated on the piston crown. 3D modeling of
the piston and crown surface design is done 3D designing using the catia software.
In this project taking 3 different Cases regular piston materials (Al-sic,TI64ALV, AL4032 and 2
TBC Materials (Mgzr03,Ni-cr-al). Finite Element analysis is used to calculate stresses, strains,
deformations ,temperature distributions and heat flux distribution on piston crown. Finally
concluded the which material is the suitable for the Internal combustion engine based on the
results.

INTRODUCTION
Introduction An internal combustion engine is defined as
an engine in which the chemical energy of the fuel is
released inside the engine and used directly for mechanical
work, as opposed to an external combustion engine in
which a separate combustor is used to burn the fuel. In a
spark ignition engine, the fuel is mixed with air and then
inducted into the cylinder during the intake process. After
the piston compresses the fuel-air mixture, the spark
ignites it, causing combustion. The expansion of
the combustion gases pushes the piston during the power
stroke.

Working process of 4-stroke engine
.

THERMAL BARRIER COATING
CERAMIC COATED COMBUSTION CHAMBER
The engine exhaust temperature has increased in the case of TBC engine
(from 4100C to 4280C) which promotes better energy recovery .The
insulation of the combustion chamber with ceramic coating influences
the performance and exhaust emissions of the CI engine. The insulation
modifies the boundary conditions for the combustion process which in
turn shortens the ignition delay period hence lowers the fuel
consumption, reduces the heat loss and increases the exhaust
temperature, which in turn influences the engine performance and
emissions. Ceramic coatings provide potential for higher engine thermal
efficiencies, longer life and higher reliability of engine components.
Thermal barrier coatings offer the possibility of reducing particulate
emissions.

Thermal barrier coatings decrease the amount of condensable hydrocarbons.
Under low load and speed conditions the base engines produces plate like
particles, the TBC engine produces smaller spherule particles.ZrO2 stabilized
with Y2O3 over NiCrAlY binding layer as a coating material gives good results
for aluminum alloyed pistons. As ceramic coating material, ZrO2 stabilized
with Y2O3 is expensive for practical usage. Cylinder walls also can be coated
to reduce heat rejection. Zirconia ceramics have attracted much attention since
their discovery, and the materials, which are very strong and tough at room
temperature, can be made by control of the phases. Understanding of the phase
transitions is crucial to appreciate the properties of zirconia ceramics.
Zirconium dioxide (ZrO 2) has a monoclinic crystallographic structure at
ambient temperatures. Upon raising the temperature, the oxide undergoes the
phase transitions from monoclinic to tetragonal with a transitional temperature
of 1170 °C. From tetragonal to cubic, the transition temperature is 2370 °C. At
2680 °C and above, the material melts. The transformation from tetragonal to
monoclinic phase with decreasing temperature at approximately 1170 °C is
quite disruptive and renders pure ZrO2 unusable as a high-temperature
structural ceramic. This disruption is caused by a 6.5% of volume expansion
upon transformation from tetragonal to monoclinic phase, a change which could
cause structural failure of any ceramic coating. The effects of Thermal barrier
coating in internal combustion engine are listed below

TBC COATING IN PISTON THE PERFORMANCEAND EMISSION
EFFECTS OFTHERMALBARRIER
coating used in piston investigated experimentally by laksmanan. Thermal barrier coating used in piston
increasing the brake thermal efficiency and decreasing the specific fuel consumption for Light heat
Rejection engine with thermal coated piston compared to the standard engine. There was increasing the
NOx emission and O2 for thermal barrier coated engine. However there was decreasing the CO and HC
emissions for thermal coated piston engine compared to the standard engine. TBC, using PSZ, applied to
the combustion chamber of the internal combustion engine showed some improvement in fuel economy
with a maximum of up to 4% at low engine power. The peak cylinder pressures were increased by a
magnitude of eight to ten bars in the TBC piston engine, in particular at high engine power outputs, though
the exhaust gas temperatures were generally lower, indicating good gas expansion in the power stroke. The
unburned hydrocarbon concentrations were increased most seriously at low engine speed and/or low engine
power output with a TBC piston engine. The authors suspected that this could be due to the porous
quenching effect of the rough TBC piston crowns, where oxidation of hydrocarbons was unable to be
achieved by the combustion air. Sampling of cylinder pressures in the cylinders showed that the ignition
point of the TBC piston engine advanced slightly relative to the baseline engine, indicating the
improvement in ignitability and heat release before the top dead center, which caused the peak cylinder
pressure to rise.

TBC COATING IN CYLINDER LINER
At present TBCs are applied to combustion components of IC engines, mainly
for pistons crow, valves, cylinder cover, and cylinder liner. However, the
extended application of TBC to cylinder liner has not been explored practically.
Cylinder liner is one of the important components of IC engine which severely
under goes wear and tear due to reciprocating motion of piston. At the same
time, linear as subjected to thermal stresses caused by hot gasses of combustion.
TBC in the place of linear has to play very important role in minimizing wear
and tear, heat transfer from cylinder to surroundings. The problem presently
faced in implementing of TBC as engine cylinder is thermal mismatch which
mainly occurs due to improper adhesion and difference in thermal expansion
coefficient between bond coat and cylinder materials. TBC must also withstand
wear and tear. There is a need to overcome these problems for employing TBC
to engine cylinder as a liner the present work is undertaken with the following
main objects.

1. To search a proper bond coatings and top coat materials based on
composition of substrates.
2. Selection of proper coatings techniques.
3. Preparation of plasma sprayed coated samples for various tests.
4. To check the microstructure and Topology of coating.
5. To check the surface texture parameter of coating.
6. To determine the bond strength of coating.
7. To determine micro hardness of coating.
8. To determine abrasive wear of coating.
9. To determine erosion wear of coating.
10. To establish the suitability of coatings for its application in internal
combustion Engine as a linear.

PERFORMANCE AND EMISSION EFFECT IN SI
ENGINE
 Zirconia is a low thermal conductivity material, it reduces the heat loss
from the cylinder to the surroundings. Therefore the efficiencies are increased
and the emissions are reduced because of various chemical reactions takes place
inside the cylinder at high temperature.
 Brake thermal efficiency and mechanical efficiency of coated piston are
increased by the average value of 9% and 25% respectively. 7% reduction in
total fuel consumption and 6% reduction in specific fuel consumption were
achieved with the coated piston. 14% of NOX emissions were reduced due to
coating because of nitrogen has observed by zirconia. 23% of unburned HC
emissions were reduced by using the coated piston.
 CO emissions are reduced by 48% because of at high temperature CO
easily combines with O2 and reduces CO emission.

LITERATURE REVIEW
The work on performance of TBC on various piston materials, as seen in the
literature, is shown in table They have shown simulated results using finite elements
method based software as ANSYS, in majority. It can be seen that almost all studies
are done on diesel engine and many of them done on piston material as aluminum
alloys.
The main material in composition of TBC are seen to be NiCrAl and YSZ(Yttria
stabilized zirconia) followed by others which are mullite, alumina, zirconium etc.
The major performance measures studied by various authors are temperature
distribution, deformation, thermal stresses, fuel and brake thermal efficiency.
The temperature distribution in piston is crucial parameter influencing the thermal
stresses and deformation. The thermal insulation thus obtained is supposed to lead,
to an improvement in the engine’s heat efficiency and a reduction in fuel
consumption. The thickness of coating applied ranges from 0.1to 0.8 mm. Ekrem
Buyukkaya and Muhammed Cerit investigated the effects of ceramic coating over
diesel engine piston using 3D finite element method; they found that maximum
surface temperature of the coated piston with material which has low thermal
conductivity is improved approximately 48% for the AlSi alloy and 35% for the
steel.
EkremBuyukkaya, Department of Mechanical Engineering, Esentepe Campus,
Turkey.. Thermal analysis of functionally graded coating AlSi alloy and steel
pistons... Thermal analyses were employed to deposit metallic, cermet and ceramic
powders such as NiCrAl, NiCrAl+MgZrO3 and MgZrO3 on the substrate. The
numerical results of AlSi and steel pistons are compared with each other. It was
shown that the maximum surface temperature of the functional graded coating
AlSi alloy and steel pistons was increased by 28% and 17%, respectively.

Imdat Taymazinvestigated the effect of thermal barrier coatings on diesel engine
performance his results indicate a reduction in fuel consumption and an
improvement in the efficiency of the diesel engine.
P. M. Pierz investigated the thermal barrier coating development for diesel engine
aluminum piston he found that the resulting predicted temperatures and stresses
on the piston, together with material strength information, the primary cause of
coating failure is proposed to be low cycle fatigue resulting from localized yielding
when the coating is hot and in compression.
O. Altun ,Mechanical Engineering Department , Turkey., Investigated in Problems
for determining the thermal conductivity of TBCs by laser-flash method., Laser-
flash method is the most widely used experimental technique to determine the
thermal conductivity of APS TBCs at high temperatures. The research contributes
to better understanding and recognition the importance of sample preparation in
laser-flash method.
S. C. Mishra., Laser and Plasma Technology Department, Mumbai, India.
Investigated in Microstructure, Adhesion, and Erosion Wear of Plasma Sprayed
Alumina–Titanium Composite Coatings.. Adhesion strength value of the coating
varies with operating power. The trend of erosion of the coatings seems to follow
the mechanism predicted for brittle materials. Coating deposited at 18kW power
level shows a higher erosion rate than that of the sample deposited at 11kW
power level

Mr.Bhavin D. Patel, Prof.Ramesh N. Mevada, Prof. Dhaval P. Patel, reviewed many
papers to improve the efficiency of an I.C. Engine and it is reflected different
methodology such as thermal barrier coating, HVOF (High velocity oxygen fuel)
coating, Particle image velocimetry (PIV), Coating thickness and roughness effect
etc. And such system they had applying such kind of coating process those are
metal sheet, gas turbine, parabolic reflector, automobile industry etc. Some research
paper indicated about optimization method applied coating structure and FEA
analysis or CFD analysis. In CI and SI engine, they were done component level
coating as per design requirement for surface roughness and life of component.
There was not work done on energy saving during power stroke and there is not any
provision for inside coating method from above research paper survey.
Dipayan Sinha , Susenjit Sarkar and Samar Chandra Mandal, In the present
work a piston has been analyzed numerically with a FEA software named
ANSYS Workbench to evaluate its thermo mechanical capability under a
predefined thermal and structural load. To enhance the performance of the
engine, weight of the piston has been kept minimum by optimizing different
dimensions. In this process of optimization the stress has also been kept under
a certain limit and this process of optimization has been done in a software
named Solid Works. To improve the thermal performance of the piston
different Thermal Barrier Coatings (TBC) have been imposed and their thermo
mechanical performance have been evaluated through couplefield analysis in
ANSYS.

PROJECT OVER VIEW
PISTON DESIGN FEATURES
1. Have sufficient mechanical strength and stiffness.
2. Can effectively block the heat reached the piston head.
3. High temperature corrosion resistance.
4. Dimensions as compact as possible, in order to reduce the weight of the
piston.

OBJECTIVE OF THE PROJECT
1. Analytical design of piston using unicorn 150cc petrol engine specifications.
2. Obtaining design of piston using catia v5 and then imported in Ansys 16.2
3. Meshing of design model using ANSYS 16.2.
4. Analysis of piston by static analysis and thermal analysis method.
5. In this project taking 3 different Cases regular piston materials (Al-
sic,TI64ALV, AL4032 and 2 TBC Materials (Mgzr03,Ni-cr-al). Finite Element
analysis is used to calculate stresses, strains, deformations ,temperature
distributions and heat flux distribution on piston crown.
6. Finally concluded the which material is the suitable for the Internal
combustion engine based on the results.

METHODOLOGY
1. Analytical design of piston, using specification of four stroke single
cylinder engine of UNICORN 150 motorcycle created.
2.Creation of 3D model of piston using CATIA V5 and then imported
in ANSYS 16.2.
3. Analysis of piston using FEA method.
4.Comparative performance of In this project taking 3 different Cases
regular piston materials (Al-sic,TI64ALV, AL4032 and 2 TBC
Materials (Mgzr03,Ni-cr-al). Finite Element analysis is used to
calculate stresses, strains, deformations ,temperature distributions
and heat flux distribution on piston crown.
5.Select the best Material for piston material

PROBLEM IDENTIFICATION
A piston is a component of reciprocating IC engines. It is the moving
component that is contained by a cylinder and is made gas-tight by piston rings.
In an engine, its purpose is to transfer force from expanding gas in the cylinder
to the crankshaft via a piston rod. Piston endures the cyclic gas pressure and the
inertial forces at work, and this working condition may cause the fatigue
damage of piston, such as piston side wear, piston head cracks and so on
working condition of the piston of an internal combustion engine is so worst are
high chances of failure of piston due to wear and tear. So there is necessary to
analyze area of maximum stress concentration, Shear stress, Total deformation
and temperature distribution and heat flux on piston. The objective of the
present work is to design and analysis of piston made UP of (Al-sic,TI64ALV,
AL4032 and 2 TBC Materials for piston crown 0.4mm (Mgzr03,Ni-cr-al) these
materials

DESIGN CONSIDERATIONS FOR A PISTON
In designing a piston for an engine, the following points should be taken into
consideration:
It should have enormous strength to withstand the high pressure.
It should have minimum weight to withstand the inertia forces.
It should form effective oil sealing in the cylinder.
It should provide sufficient bearing area to prevent undue wear.
It should have high speed reciprocation without noise.
It should be of sufficient rigid construction to withstand thermal and mechanical
distortions.
It should have sufficient support for the piston pin.

MATERIAL PROPERTIES
MATERIAL
PROPERTIES
DENSTIY(g/cm3) POSSIONS RATIO(u) YOUNGS MODULUS(Gpa) THERMAL
CONDUCTIVITY
SPECIFIC
HEAT
AL4032 2..6 0.33 79 142w/m.k 870J KG/M3
Ti-6Al-4V 4.4 0.33 113 7.3W/M.K 553 J KG/M3
AL-SIC 2.7 0.34 190 160W/M.K 826 J.KG/M3
MGZro3 5.6 0.2 46 0.8W/MOK 400J/(kg/M3
NI-CR-AL 7.8 0.27 90 16.1W/MOK 764 J.KG/M3

ENGINE SPECIFICATIONS
In this work, a piston of two wheeler 150cc Honda Unicorn
Engine is considered with specifications as: Engine type air
cooled 4-stroke, Bore × Stroke (mm) = 57×58.6, Displacement =
149.5CC. Maximum Power = 13.8bhp at 8500rpm, Maximum
Torque = 13.4Nm at 6000rpm, Compression Ratio =
9.35/1.Theoretical designing of piston was done using standard
design procedure. The piston specifications

CONSIDERATION DESIGN ON THE PISTON
PARAMETERS

PISTON DESIGN IN CATIA
Create the half piston profile in sketcher workbench next go to exist work bench (part design) now go to the
sketched based features and go to shaft option apply angle 360 after create the planes offset to xy planes
create the circles and apply pocket around the up to surface now go to mirror option apply mirror finally as
shown the figure below

STATIC ANALYSIS OF PISTON
Combustion of gases in the combustion chamber exerts pressure on the head of
the piston during power stroke. The pressure force will be taken as boundary
condition in static analysis. Fixed support has given at surface of pin hole. Due to
the piston will move from TDC to BDC with the help of fixed support at pin hole.
So whatever the load is applying on piston due to gas explosion that force causes
to
NODES:14298
ELEMENTS:8151

BOUDARY CONDITIONS
STATIC ANALYSIS
Boundary condition of static analysis
1. Maximum pressure load at the top surface of the piston crown 14.06 Mpa
2. Temperature at the top surface of the piston crown 600OC and ambient
temperature is 29oc, Convection is 0.002w/mm2
3. Piston pin holes are fixed DX = DY = DZ = 0
THERMAL ANALYSIS
Boundary condition of Thermal analysis

RESULTS AND DISCUSSIONS
The constructed of piston in catiav5 R20 software
and analyzed using ANSYS V16.2 and the results
are depicted below. Combustion of gases in the
combustion chamber exerts Boundary condition of
static analysis Boundary conditions of thermal
analysis pressure on the head of the piston during
power stroke. Fixed support has given at surface of
pinhole. Because the piston will move from top
dead center to bottom dead centre with the help of
fixed support at pinhole as shown below figures.

MATERIAL
PROPERTIES
VON-MISSES
STRESS(Mpa)
TOTAL
DEFORMATIO
N(mm)
SHEAR
STRESS(Mpa)
TEMPERATU
RE
DISTRIBUTIO
N(oc)
TOTAL HEAT
FLUX
MGZRO3+AL4032 95.765 0.00866 54.794 325.71 1.3111
MGZRO3+ TI-6AL-
4V
95.135 0.00860 54.433 329.43 1.2889
MGZRO3+ALSIC 93.875 0.0084 53.712 323 1.323
NI-CR-AL+AL4032 91.985 0.0083 52.631 314 1.3809
NI-CR-AL + TI-6AL-
4V
90.094 0.0081 51.55 319 1.35
NI-CR-AL +ALSIC 88.582 0.0079 50.468 306 1.43

MGZRO3 +AL4032 MATERIAL
Von-misses stress Shear stress Total heat flux
Total deformation Temperature distribution

MGZRO3+ TI-6AL-4V MATERIAL
Von-misses stress Total deformation Shear stress
Temperature distribution Total heat flux

MGZRO3+ALSIC
Temperature Distribution Total Heat flux

NI-CR-AL+AL4032 MATERIAL

NI-CR-AL + TI-6AL-4V

NI-CR-AL +AL-SIC
Von-misses stresss Total deformation Shear stress

Von-misses stress(Mpa)
95.765
95.135
93.875
91.985
90.094
88.582
84
86
88
90
92
94
96
98
MGZRO3+AL4032 MGZRO3+ TI-6AL-
4V
MGZRO3+ALSIC NI-CR-AL+AL4032 NI-CR-AL + TI-6AL-
4V
NI-CR-AL +ALSIC
A GRAPH OF VON-MISSES STRESSES(Mpa) WITH DIFFERENT
MATERIALS
VON-MISSES STRESS(Mpa)

0.00866
0.0086
0.0084
0.0083
0.0081
0.0079
0.0074
0.0076
0.0078
0.008
0.0082
0.0084
0.0086
0.0088
4V
4V
NI-CR-AL +ALSIC
A GRAPH OF TOTAL DEFORMATION(mm) WITH DIFFERENT MATERIALS
TOTAL DEFORMATION(mm)

54.794
54.433
53.712
52.631
51.55
50.468
48
49
50
51
52
53
54
55
56
MGZRO3+AL4032 MGZRO3+ TI-6AL-4V MGZRO3+ALSIC NI-CR-AL+AL4032 NI-CR-AL + TI-6AL-4V NI-CR-AL +ALSIC
A GRAPH OF SHEAR STRESS(Mpa) WITH DIFFERENT MATERIALS
SHEAR STRESS(Mpa)

325.71
329.43
323
314
319
306
290
295
300
305
310
315
320
325
330
335
4V
4V
NI-CR-AL +ALSIC
A GRAPH OF MINIMUM TEMPERATURE DISTRIBUTION(oc) WITH
VARIOUS MATERIALS
TEMPERATURE DISTRIBUTION(oc)

1.3111
1.2889
1.323
1.3809
1.35
1.43
1.2
1.25
1.3
1.35
1.4
1.45
MGZRO3+AL4032 MGZRO3+ TI-6AL-4V MGZRO3+ALSIC NI-CR-AL+AL4032 NI-CR-AL + TI-6AL-4V NI-CR-AL +ALSIC
A GRAPH OF TOTAL HEAT FLUX WITH VARIOUS MATERIALS
TOTAL HEAT FLUX

CONCLUSION
Design and static thermal analysis is done using unicorn 150 bike
dimensions, The applications of thermal barrier coatings to various
components of combustion zone of an engine such as piston and
cylinder liner has produced significant improvements in thermal and
mechanical efficiency and other performance parameters of the engine
like specific fuel consumption and reduces exhaust emission. Thus this
project explores various aspects, effect and application of thermal
barrier coating in piston, cylinder liner, SI engine This project work
concerned with the design and Static & thermal analysis of ceramic
coated Piston. While comparing these materials, it is found that is NI-
CR-AL+ALSIC MATERIAL better suited for high temperature
applications. On evaluating the contours for temperature distribution,
heat flux & Deformation & von-misses stress Shear stresses values are
less compared to the remaining materials. Finally indicates that the
piston coated with thermal barrier materials shows a lot of heat resistant
ability which can lead to better utilization of heat produced in the
combustion chamber as heat dissipation will be lesser which ultimately
can improve the engine efficiency.

Design and static thermal analysis of piston

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