1. The document discusses different types of pistons used in internal combustion engines, including their purpose, design, and history. It describes trunk pistons, crosshead pistons, and slipper pistons. 2. CATIA is introduced as a CAD/CAM/CAE software suite used to facilitate product design and development. Its history and applications are overviewed. 3. The basic commands in CATIA for modeling are outlined, including how to create sketches, profiles, and geometric shapes using tools like lines, arcs, and circles. Operations for modifying sketches like trimming are also mentioned.

1. 1
CHAPTER-1
INTRODUCTION
A piston is a component of reciprocating engines, reciprocating pumps, gas
compressors and pneumatic cylinders, among other similar mechanisms. 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 and/or connecting rod. In a pump, the function is reversed
and force is transferred from the crankshaft to the piston for the purpose of compressing or
ejecting the fluid in the cylinder. In some engines, the piston also acts as a valve by
covering and uncovering ports in the cylinder wall. The petrol enters inside the cylinder
and the piston moves upwards and the spark plug produces spark and the petrol is set on
fire and it produces an energy that pushes the piston downwards.
1.1 INTERNAL COMBUSTION ENGINES
An internal combustion engine is acted upon by the pressure of the expanding
combustion gases in the combustion chamber space at the top of the cylinder. This force
then acts downwards through the connecting rod and onto the crankshaft. The connecting
rod is attached to the piston by a swivelling gudgeon pin (US: wrist pin). This pin is
mounted within the piston: unlike the steam engine, there is no piston rod or crosshead
(except big two stroke engines) .
The pin itself is of hardened steel and is fixed in the piston, but free to move in the
connecting rod. A few designs use a 'fully floating' design that is loose in both components.
All pins must be prevented from moving sideways and the ends of the pin digging into the
cylinder wall.
Gas sealing is achieved by the use of piston rings. These are a number of narrow
iron rings, fitted loosely into grooves in the piston, just below the crown. The rings are
split at a point in the rim, allowing them to press against the cylinder with a light spring
pressure. Two types of ring are used: the upper rings have solid faces and provide gas
sealing; lower rings have narrow edges and a U-shaped profile, to act as oil scrapers.
Pistons are cast from aluminium alloys. For better strength and fatigue life, some
racing pistons may be forged instead. Early pistons were of cast iron, but there were

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obvious benefits for engine balancing if a lighter alloy could be used. To produce pistons
that could survive engine combustion temperatures, it was necessary to develop new alloys
such as Y alloy and Hiduminium, specifically for use as pistons.
A few early gas engines had double-acting cylinders, but otherwise effectively all
internal combustion engine pistons are single-acting. During World War II, the US
submarine Pompano was fitted with a prototype of the infamously
unreliable H.O.R. double-acting two-stroke diesel engine. Although compact, for use in a
cramped submarine, this design of engine was not repeated.
1.1.1 TRUNK PISTONS
Trunk pistons are long relative to their diameter. They act both as a piston and
cylindrical crosshead. As the connecting rod is angled for much of its rotation, there is also
a side force that reacts along the side of the piston against the cylinder wall. A longer
piston helps to support this.
Trunk pistons have been a common design of piston since the early days of the
reciprocating internal combustion engine. They were used for both petrol and diesel
engines, although high speed engines have now adopted the lighter weight slipper piston.
A characteristic of most trunk pistons, particularly for diesel engines, is that they
have a groove for an oil ring below the gudgeon pin, in addition to the rings between the
gudgeon pin and crown.
To make these more compact, they avoided the steam engine's usual piston rodwith
separate crosshead and were instead the first engine design to place the gudgeon pin
directly within the piston. Otherwise these trunk engine pistons bore little resemblance to
the trunk piston; they were extremely large diameter and double-acting. Their 'trunk' was a
narrow cylinder mounted in the centre of the piston.
1.1.2 CROSSHEAD PISTONS
Large slow-speed Diesel engines may require additional support for the side forces
on the piston. These engines typically use crosshead pistons. The main piston has a
largepiston rod extending downwards from the piston to what is effectively a second
smaller-diameter piston. The main piston is responsible for gas sealing and carries the
piston rings. The smaller piston is purely a mechanical guide. It runs within a small
cylinder as a trunk guide and also carries the gudgeon pin.

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1.1.3 SLIPPER PISTONS
A slipper piston is a piston for a petrol engine that has been reduced in size and
weight as much as possible. In the extreme case, they are reduced to the piston crown,
support for the piston rings, and just enough of the piston skirt remaining to leave two
lands so as to stop the piston rocking in the bore. The sides of the piston skirt around the
gudgeon pin are reduced away from the cylinder wall. The purpose is mostly to reduce the
reciprocating mass, thus making it easier to balance the engine and so permit high speeds.
A secondary benefit may be some reduction in friction with the cylinder wall, since the
area of the skirt, which slides up and down in the cylinder is reduced by half. However
most friction is due to the piston rings, which are the parts which actually fit the tightest in
the bore and the bearing surfaces of the wrist pin, the benefit is reduced.
1.2 CATIA
Catia (an acronym of computer aided three-dimensional interactive application) a
multi-platform computer-aided design(CAD)/computer manufacturing (CAM)/computer-
aided engineering (CAE) softwaresuite developed by the company Dassault Systems. It is
written in the C++.
Catia (computer aided three-dimensional interactive application) started as an in-
house development in 1977 by french aircraft manufacturer avions marcel dassault, at that
time customer of the cad/cam cad software[1] to develop dassault's mirage fighter jet. it was
later adopted in the aerospace, automotive, shipbuilding, and other industries.
1.2.1 HISTORY
Initially named cati (conception assistéetridimensionnelle interactive – french
for interactive aided three-dimensional design ), it was renamed catia in 1981 when
dassault created a subsidiary to develop and sell the software and signed a non-exclusive
distribution agreement with ibm.
In 1984, the Boeing Company chose CATIA V3 as its main 3D CAD tool,
becoming its largest customer.
In 1990, General Dynamics Electric Boat Corp chose CATIA as its main 3D CAD
tool to design the U.S. Navy's Virginia class submarine. Also, Lockheed was selling
its CADAM CAD system worldwide through the channel of IBM since 1978.

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In 1992, CADAM was purchased from IBM, and the next year CATIA CADAM
V4 was published.
In 1996, it was ported from one to four Unix operating systems, including
IBM AIX, Silicon Graphics IRIX, Sun Microsystems SunOS, and Hewlett-Packard HP-
UX.
In 1998, V5 was released and was an entirely rewritten version of CATIA with
support for UNIX, Windows NT and Windows XP (since 2001).
In the years prior to 2000, problems caused by incompatibility between versions of
CATIA (Version 4 and Version 5) led to $6.1B in additional costs due to years of project
delays in production of the Airbus A380.
In 2008, Dassault Systems released CATIA V6. While the server can run
on Microsoft Windows, Linux or AIX, client support for any operating system other than
Microsoft Windows was dropped.
In November 2010, Dassault Systems launched CATIA V6R2011x, the latest
release of its PLM2.0 platform, while continuing to support and improve its CATIA V5
software.
1.2.2 SCOPE OF APPLICATION
Commonly referred to as a 3D Product Lifecycle Management software suite,
CATIA supports multiple stages of product development (CAx), including
conceptualization, design (CAD), engineering (CAE) and manufacturing (CAM). CATIA
facilitates collaborative engineering across disciplines around its 3DEXPERIENCE
platform, including surfacing & shape design, electrical fluid & electronics systems
design, mechanical engineering and systems engineering.
CATIA facilitates the design of electronic, electrical, and distributed systems such
as fluid and HVAC systems, all the way to the production of documentation for
manufacturing.
1.2.3 APPLICATIONS
Goodyear uses it in making tires for automotive, ship building , industrial
equipment and aerospace and also uses a customized CATIA for its design and
development. Many automotive companies use CATIA for car structures – door beams, IP

5. 5
supports, bumper beams, roof rails, side rails, body components because of CATIA's
capabilities in Computer representation of surfaces.
1.2.4 COMMANDS USED IN CATIA FOR MODELING
CATIA Version 5 Basic Concepts
The main objective of this lesson is to present the necessary tools and concepts for
the user to successfully navigate the CATIA V5 environment. Some things in this lesson
are covered in general terms while others are covered in detail. The user is expected to
learn and understand each item as presented in the lesson. Tools and concepts that are
briefly introduced in this lesson lay the foundation for gaining deeper knowledge in later
lessons. Another purpose of the general introduction is to present the user with enough
information to promote self-discovery of CATIA V5.
1.2.4.1 CATIA V5 STANDARD SCREEN LAYOUT
The following standard screen layout shows you where different tools and toolbars
are located. The numbers coordinate with the following pages where the tool label is
bolded. The tool label is followed by a brief and in some cases, steps on how to use and/or
access the tool shown in a below Figure 1.1.
Fig.1.1Catia standard screen layout

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1.2.4.2 THE START MENU
The Start pull down menu gives you access to all of the CATIA V5 Workbenches.
The availability of the workbenches will depend on the CATIA V5 licenses configuration,
the one shown in Figure 1.2.
The workbenches used in this workbook will be found under Mechanical Design,
Shape, and Digital Mockup Workbench Categories. If you select the arrow to the right of
the Workbench Category the workbenches organized within that category will be
displayed, shows the workbenches organized under the Mechanical Design Category, the
Part Design Workbench is the highlighted workbench.
Fig.1.2 Start menu
1.2.4.3SELECT THE PART DESIGN WORKBENCH ICON
The Welcome to CATIA V5 window displays. This icon is located in the toolbars
along the right side of the display, near the top. Notice that the three favorite workbenches
that were chosen display here as well. This provides another method for switching between
workbenches shown in a Fig 1.3.

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Fig.1.3 Workbench icon
1.2.4.4THE STANDARD WINDOWS TOOLBAR
The Standard Windows toolbar contains your standard MS Windows pull down
menus, reference Figure There are specific CATIA V5 tools found in the different pull
down menus. The tools you will be required to use in this workbook will be defined in the
lesson that they are used in. as shown in Fig 2.4
Fig.1.4 Tool bar
File Menu :The options under the File pull down menu are very similar to most other MS
Windows programs as shown in Fig 1.5.
Edit Menu :The first few options under the Edit pull down menu is very similar to most
other MS Windows programs. The first options are also available on the Standard, such as
the Undo [Ctrl+Z], Repeat [Ctrl+Y], Cut [Ctrl+X], Copy [Ctrl+C] and Paste [Ctrl+V]as
shown in Fig 1.6.
Delete [Del]: This is one of the numerous methods CATIA V5 allows for you to delete
selected items.
Update [Ctrl+U]: The Update tool allows you to force the document to be updated. There
is a toggle in Tools>Options that allows CATIA V5 to update automatically. When the
Update tool is dimmed there is no update to be performed.
Search [Crtl+F]: The Search tool allows you to search the document for almost any type
of variable. Selecting this tool brings up a Search window that allows you to input specific
parameters to help narrow the search.
Links: The Links tool allows you to view all documents that are linked to the current
document. This is a very useful tool when dealing with a multitude of linked documents
such as assemblies.

8. 8
Properties [Alt+Enter]: The Properties tool allows you to view and/or modify the
properties of the selected element. This tool is also available contextually (selecting the
element and then selecting the right mouse button).
Scan or Define In Work Object: This tool allows you to review how the part in the
document was created, step-by-step. This is a powerful design and review tool that is
covered in depth in the Part Design Lesson.
Fig.1.5 File menu Fig.1.6 Edit menu
View Menu
Most of the tools in this pull down menu have to functions dealing with the
visualization of the CATIA V5 document. Many of the tools can be accessed from the
bottom toolbar, quick keys and contextually (right mouse click). Figure 1.6 displays the
tools available in the View pull down menu. The following is a brief description of each
tool found in the View Pull Down Menu.
Toolbars: Toolbars allows you to toggle additional toolbars on and off. If a particular tool
gets closed you can use this tool to turn it back on. This is covered in more detail later in
this lesson.
Command List: This tool brings up the Command List window that lists all the CATIA
V5 commands. For example if you wanted to create a Point and could not find the Point

9. 9
tool, you could go to View > Command List and browse for the Point, select Point and
enter the appropriate values for X, Y and Z.
Geometry: This is a toggle tool that places the geometry into hide/show (visible/not
visible). CATIA V5 Workbook
Specification: This is a toggle tool that places the Specification Tree into hide/show.
Notice that there is also a quick key for this, F3.
Compass: This is a toggle tool that places the compass into hide/show.
Reset Compass: This tool allows you to reset the compass back to its original location and
orientation.
Tree Expansion: This tool allows you to expand the Specification Tree automatically, at
specified levels, or contract the Specification Tree.
Full Screen: This tool allows the workspace to take the entire area of the screen, all the
tools and toolbars disappear. This option provides significantly more work area for your
geometry. To bring back all the toolbars, make sure your cursor is over an open section of
the workspace and select the right mouse button.
1.2.4.5COMMANDS DESCRIPTION
Creating a positioned sketch Enables you define (and later change) explicitly the
position of the sketch absolute axis. this offers of the following advantages
you can use the absolute axis directions like external references for the sketched profile
geometry.
when the geometry of the parts evolves and the associated position of the sketch changes.
the shape of the sketched profile (2d geometry of the sketch ) remains unchanged (even if
the sketched profile is under constrained)
Select the sketcher icon and click the desired reference plane either in the geometry
area or in the specification tree, or select a planar surface. this creates a ''non positioned
''sketch . the sketch absolute axis may ''slide'' an the reference plane when the part is
updated.
.

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sketch one plane of the local axis. h and v are aligned to the main axis of this selected
plane. associatively is kept between both the plane and the sketch.
Exit is used to exit the sketcher workbench whenever you want.
Grid activated this option makes your sketch begin or end on the points of the grid .as
you are sketching the points are snapped the intersection points of the grid.
Sketched geometry
Profile how to create a closed profile .a profile may also be open (if you click the
profile end point in the free space). profiles may be composed of lines and arcs, which you
create either by clicking or using the Sketch tools toolbar.
Line (active by default) , tangent arc .
Rectangle shows how to create to create a rectangle in the direction of your choice
by defining three extremity points of the rectangle. In this task, we will use the Sketch
tools toolbar but of course you can create this oriented rectangle manually. For this, move
the cursor to activate Smart Pick and click as soon as you get what you wish.
oriented rectangle cylindrical elongated hole key hole
hexagon
Elongated Hole this all are included in same icon.
circle This task shows how to create a circle. In this task, we will use the Sketch tools
toolbar but of course you can create this circle manually. For this, move the cursor to
activate Smart pick and click as soon as you get what you wish. Some other commands in
circle below.
Operation on sketched geometry:
Corners This task shows how to create a rounded corner (arc tangent to two curves)
between two lines using trimming operation. You can create rounded corner between
curves.
You can create several corners just by multi - selecting for example, the rectangle
end points and enter a radius value in the Radius field (Sketch tools toolbar). Four corner
are created at the same time with the same radius value.

11. 11
options included in trim command:
no trim trim one trim both elem.
Chamfer (ctrl h)This task shows how to create a chamfer between two lines
trimming either all, the first or none of the elements, and more precisely using one of the
following chamfer definitions:
1.2.4.6 TRANSFORMATIONS
Symmetry shoes you how to repeat existing Sketcher elements using a line, a
construction line of an axis. In this particular case we will duplicate a circle.
translate Elements shoe you to perform a translation on 2D elements by defining the
duplicate mode and then selecting the element to be duplicated. Multi-selection is not
available The application provides a powerful command for translating elements. you
may either perform a simple translation (by moving elements) or create several copies of
2D elements. Translating element also means re-computing distance, angle and/or length
constraint values, of needed. Be careful: only non-foxed elements are updated.
Rotate Elements shoe you to rotate elements by defining the duplicate mode and
then selecting the element to be duplicated. In this scenario, the geometry is simply
moved. But note that, you can also duplicate elements with the Rotation command.
Rotating elements also means re-computing distance values into angle values, if needed.
Be careful: only non-fixed elements are updated.
Offset shows hoe to duplicate an element of the following type: line, arc of circle.
You can also duplicate by offset one of the following: an edge, a face (all the boundaries
of this face are offset) or a geometrical feature (for example, by selecting a join or another
sketch in the specification tree).
Offset options:
Offset 2D geometry,
Use offset tools,
Offset 3D geometry,
Modify a 3D geometry offset.

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Constraints (Dialog Box) (Crtl O) shows you how to set various geometrical
constraints using a dialog box. For example, you can use the Constraint command to
finalize your profile and set constraints consecutively. You may define several constraints
simultaneously using the Constrain Definition dialog box, or by means of the contextual
command (right-click).
Dimensional/Geometrical (Ctrl C) shows you how to set dimensional of
geometrical constraints between one, two of three elements. The constrains are in priority
dimensional. Use the contextual many to get other types of constraints and to position this
constraint a desired. In this particular case, we will set constrains between to elements by
selecting the command and then a line and a circle.
1.2.4.7 SKETCH- BASED FEATURES
Feature are entities you combine to make up your part. The features presented here
are obtained by applying commands on initial profiles created in the Sketcher workbench
(See CATIA-Dynamic sketcher User's Guide Version 5) pr in the Generative shape Design
workbench (See CATIA Generative shape Design User's Guide Vision 5) as well as
surfaces. Some operations consist in adding material, others in removing material. In
this section, you will learn how to create the following features:
Pad Creating a pad means extruding a profile of a surface in one or two directions.
The application lets you limits of creation as well as the direction of extrusion. This task
shoes you how to create a basic pad using a closed profile, the Dimension and Mirrored
extent options.Pad options:
Up to Next
Up to Plane
Up to Last
Up to Surface
HoleCreating a pocket consists in extruding a profile or a surface and removing the
material resulting from the extrusion. The application lets you choose the limits of
creation as well as the direction of extrusion. The limits you can are the same as those
available for creating pads. To know how to use them, up to Next Pads, Up to Last Pads,
Up to Plane pads, Up to Surface pads.

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Rib shows you how to create a rib that is how to sweep a profile along a center curve
to create material. To define a rib, you need a center curve, a planner profile and possibly
a reference element of a pulling direction
Stiffener shows you how to create a stiffener by specifying creation directions. Open
profile has been created in a plane normal to the face on which the stiffener will lie.
1.2.4.8 DRESS-UP FEATURES
Create an Edge Fillet: Click this icon, select the edge to be filleted, enter the radius
value and set the propagation mode in the dialog box.
Create a Variable Radius Fillet: Click this icon, select the edge to be filleted, enter
new radius values for both of the detected vertices, click as many points as you wish on
the edge and enter appropriate radius values for each of them. if needed, define a new
variation mode.
Create a chamfer: Click this icon, select the edge to be chamfered, set the creation
mode then define the parameters you have set.
Create a Basic Draft: Click this icon, set the Selection by neutral face selection
mode or select the face to be drafted, then enter the required parameters.
Create a Draft with a Parting Element: Click this icon, set the Selection by neutral
face selection mode or select the face to be drafted, expand the dialog box then enter the
required parameters.
1.2.4.9REFERENCE ELEMENTS
Create a Point: Click this icon, choose the reaction method then define the required
parameters.
Create a Line: Click this icon, choose the reaction method then define the required
parameters.

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Create a Plane: Click this icon, choose the reaction method then define the required
parameters.
1.2.4.10 TRANSFORMATION FEATURES
Create a Translation: Click this icon, select the body to be translated, define the
translation direction and enter the distance value.
Create a Rotation: Click thisicon, select the body to be rotated, define the rotation
axis and enter the angle value.
Create symmetry: Click this icon, select the body to be duplicated and define the
symmetry reference.
Create a Mirror: click this icon, select the body to be mirrored and define the
reference.
Create a Rectangular Pattern: Click this icon, select the feature to be duplicated,
define the creation directions, choose the parameters you wish to define and set these
parameters.
1.2.4.11 SURFACE-BASED FEATURES
Split means you can split a body with a plane, face or surface. The purpose of the
task is to show how to split a body by means of a surface.
Thick surface means you can add material to a surface in two opposite directions by
using the Thick Surface capacity. This task shows you how to do so.
1.2.4.12 VIEW TOOLBAR
Fly mode: Sets the fly mode. This is a very powerful and fun tool.
Fit All In: This tool will show the extent of all the graphics currently on the screen.
It is a quick way to see what elements are on the screen and where they are in relationship
to one another.

15. 15
Pan: This tool allows you to move the part around on the screen. The part does not
change its location in the XYZ coordinate system, only in relationship to the screen.
Rotate: This tool allows you to rotate the part in three dimensional space. It will
place a representation of a space ball (sphere) in the center of the screen. There is a three-
dimensional X on the space ball, you drag the X to where you want on the space ball and
the part will rotate accordingly. This tool is critical to part manipulation. It is important
that you get the hang of rotating the part to the orientation you want. This tool must be
selected every time you want to rotate the part.
Zoom In: This is similar to other graphics programs. This allows you to get a closer
look at finer detail. Press the middle mouse button, hold it down as you press the left
mouse button and release it. Now use the mouse to drag the cursor up the screen and the
part will Zoom In.
Zoom Out: This is similar to other graphics programs. This allows you to get the big
picture, making the part smaller. Press the middle mouse button, hold it down as you press
the left mouse button and release it. Now drag the mouse down the screen and the part will
Zoom Out.
Normal View: This tool allows you to view a particular plane/surface in a true length
view. You specify the plane/surface and CATIA V5 will rotate the plane/surface 90
degrees to your screen view.
Hide/Show: This tool allows you to select any entity or multiple entities and place
them in “no show space”. This removes the selected entity/entities from the “working
space”. Sometimes there are entities that you want to keep for future references but do not
want them visually
in the way.
. The Apply Material Tool : This tool allows you to apply a material to your solid.
Applying a material will give it the properties of the material such as the density so CATIA
V5 can calculate weight, volume and other part analysis information. Applying material
also gives the solid the texture and color of the selected material. CATIA V5 has a library
of material. The use of this tool is covered in the Part Design Lesson. Remember, to see the

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material applied to the solid you must select Apply Material in the Applies Customized
View Parameters.
1.3 ANSYS
ANSYS, Inc. is an American Computer-aided engineering software developer
headquartered south of Pittsburgh in Cecil Township, Pennsylvania, United States. Ansys
publishes engineering analysis software across a range of disciplines including finite
element analysis, structural analysis, computational fluid dynamics, explicit and implicit
methods, and heat transfer.
1.3.1 HISTORY
The company was founded in 1970. by John A. Swanson as Swanson Analysis
Systems, Inc (SASI). Its primary purpose was to develop and market finite element
analysis software for structural physics that could simulate static (stationary), dynamic
(moving) and thermal (heat transfer) problems. SASI developed its business in parallel
with the growth in computer technology and engineering needs. The company grew by 10
percent to 20 percent each year, and in 1994 it was sold to TA Associates. The new owners
took SASI’s leading software, called ANSYS, as their flagship product and designated
ANSYS, Inc. as the new company name.
Ansys has acquired a number of companies since 2000, including ICEM CFD
Engineering, Space-claim, CADOE S.A., of Lyon, France, a company specializing in
parametric analysis, and numerous French clients, including , Renault and Airbus, and
CFX (2003); Century Dynamics, Harvard Thermal, and Fluent Inc. (2006); Ansoft
Corporation (2008); Apache Design Solutions (2011); Esterel Technologies (2012); EVEN
and Reaction Design (2013);[13] and Spaceclaim Corporation (2014).
Ansys was listed on the NASDAQ stock exchange in 1996. In 2011, Investor's
Business Daily gave the firm a top score on its SmartSelect composite ratings.The
organization claims to reinvest 15 percent of its revenues each year into research to
continually refine the software.
1.3.2 ANSYS WORKBENCH
ANSYS can import CAD data and also enables to build geometry with its "pre-
processing" abilities. Similarly in the same pre-processor, finite element model (a.k.a.

17. 17
mesh) which is required for computation is generated. After defining loadings and carrying
out analyses, results can be viewed as numerical and graphical.
ANSYS can carry out advanced engineering analyses quickly, safely and
practically by its variety of contact algorithms, time based loading features and nonlinear
material models.
ANSYS Workbench is a platform which integrates simulation technologies and
parametric CAD systems with unique automation and performance. The power of ANSYS
Workbench comes from ANSYS solver algorithms with years of experience. Furthermore,
The object of ANSYS Workbench is verification and improving of the product in
virtual environment.ANSYS Workbench, which is written for high level compatibility with
especially PC, is more than an interface and anybody who has an ANSYS license can work
with ANSYS Workbench. As same as ANSYS interface, capacities of ANSYS Workbench
are limiteddue to possessed license. Structural Analysis.
1.3.3PARTS
 ANSYS Autodyne ANSYS Autodyne is computer simulation tool for simulating the
response of materials to short duration severe loadings from impact, high pressure or
explosions.
 ANSYS Mechanical ANSYS Mechanical is a finite element analysis tool for structural
analysis, including linear, nonlinear and dynamic studies. This computer simulation
product provides finite elements to model behaviour, and supports material models and
equation solvers for a wide range of mechanical design problems. ANSYS Mechanical

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also includes thermal analysis and coupled-physics capabilities involving acoustics,
piezoelectric, thermal structural and thermo-electric analysis.
 Fluid Dynamics ANSYS Fluent, CFD, CFX, and related software are Computational
Fluid Dynamics software tools used by engineers for design and analysis. These tools
can simulate fluid flows in a virtual environment — for example, the fluid dynamics of
ship hulls; gas turbine engines (including the compressors, combustion chamber,
turbines and afterburners); aircraft aerodynamics; pumps, fans, HVAC systems, mixing
vessels, hydro cyclones, vacuum cleaners, etc.
1.3.4. ELECTRONICS
 ANSYS HFSS ANSYS HFSS is a Finite Element Analysis tool for simulating full-
wave electromagnetic fields. HFSS incorporates finite element, integral equation, and
hybrid methods to solve a wide range of microwave, RF and high-speed digital
applications.
 ANSYS Maxwell ANSYS Maxwell is a Finite Element Analysis tool for
electromagnetic field simulation, primarily for engineers tasked with designing and
analyzing electromagnetic and electromechanical devices, including motors, actuators,
transformers, sensors and coils. ANSYS Maxwell incorporates finite element method
solvers to solve static, frequency-domain, and time-varying electromagnetic and
electric fields.
 ANSYS SI wave
ANSYS SIwave is a specialized design platform for power integrity, signal
integrity and Electromagnetic interference (EMI) analysis of electronic packages and
PCBs.

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CHAPTER-2
STATIC STRUCTURAL
The Structural template defines a basic structural simulation process that can be
used to simulate and evaluate the displacements, stresses, strains, and forces in structures
or components caused by loads that do not induce significant inertia and damping effects.
2.1 EXPORTING MATERIALS
Material Assignment
You can export a material for use in another project. Exporting materials is only supported
for files. Follow the procedure below:
1. In the Material Assignment panel, click the link to the material.
2. Click the library show the source information of the material which includes the
library name, material name, and library location.
3. Click Export this material to a library.
4. Aside from exporting the material to an already loaded library, you have two
options:
2.2 GEOMETRY
A simulation process typically requires a geometry that represents a physical object
that you want to apply to your engineering simulation. ANSYS AIM enables you to import
various geometric and CAD file types. The geometry you provide will be used as the basis
for the subsequent assignment of mesh generation, physics, and results properties and
tasks.
You can import one or more geometry files into your study, or configure various
aspects of the simulation ahead of time
For instance, you can import a single geometry that represents both a fluid and
structural region, or you can import more than one geometry file: one that represents a
fluid flow region, and the other that represents a structural region.

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2.3 MESHING
ANSYS AIM provides meshing capabilities for various geometric models.
when the imported geometry represents a structural region (or solid part), or when the
imported geometry represents a fluid region (or fluid flow volume), use part-based
meshing to create a mesh. you can also use part-based meshing to create separate meshes
for fluid regions and structural regions when you import multiple geometry files.
when the imported geometry represents solid parts and a flow volume needs to
be extracted, use a volume creation task, along with flow volume meshing, to create a
mesh. in this case, meshing the flow volume involves identifying the location of the flow
volume, generating a surface wrap mesh for the extracted volume, and then meshing the
volume itself. when the imported geometry represents multiple solid parts that you want to
unite to create a single flow region, or if you want to simplify a body with many surface
patches, use a volume creation task to simplify the geometry and generate the surface
mesh, and then use flow volume meshing to create the volume mesh.
2.4 BOUNDARY CONDITIONS
Depending on the type of physics involved (fluid flow, structural, steady-state
thermal),or electric conduction, ANSYS AIM provides several means to control the
solution of the physics simulation.
ANSYS AIM allows you to specify physical conditions at the boundaries of your model
and apply them to your simulation.
2.5 STRUCTURAL BOUNDARY CONDITIONS
Boundary conditions for structural physics include:
 Externally applied forces, pressures, and moments
 Supports
 Steady-state inertial forces
 Zero and nonzero displacements
 Temperature Conditions (for thermal strain)

21. 21
2.6 STATIC STRUCTURAL SOLVER OPTIONS
Solver Options
When you create your physics solution using a template, a number of solver options are set
up using standard defaults. You can modify the default values for a given physics solution
on the Solver Settings and Output Controls panels.
Solver Settings
On the Solver Settings panel, the settings available define the solver and the options
available to allow you to run a physics solution. Launch controls control how the solver is
launched and how the solver data is managed. Properties include solver file locations, file
names, and distributed solve controls.
Output Controls
In the Output Controls panel, you can control how the solution data is written to the
output file by defining one or more output specifications, which set the solution location,
output type, and frequency. These output specifications are processed sequentially based
on the order they are listed in the Output Controls panel.
By default, three output specifications are created for a static structural physics solution:
 Nodal DOF Solution
 Nodal Reaction Loads
 Element Nodal Stresses
If you want to add Strain or other output types to the result file, you can create additional
Output Controls objects for the same location.

22. 22
CHAPTER-3
LITERATURE REVIEW
An optimized piston which is lighter and stronger is coated with zirconium for bio-
fuel. In this paper[1], the coated piston undergone a Von misses test by using ANSYS for
load applied on the top. Analysis of the stress distribution was done on various parts of the
coated piston for finding the stresses due to the gas pressure and thermal variations.
Vonmisses stress is increased by 16% and deflection is increased after optimization. But all
the parameters are well with in design consideration
Design, Analysis and optimization of piston [2] which is stronger, lighter with
minimum cost and with less time. Since the design and weight of the piston influence the
engine performance. Analysis of the stress distribution in the various parts of the piston to
know the stresses due to the gas pressure and thermal variations using with Ansys
With the definite-element analysis software, a three-dimensional definite-element
analysis [3] has been carried out to the gasoline engine piston. Considering the thermal
boundary condition, the stress and the deformation distribution conditions of the piston
under the coupling effect of the thermal load and explosion pressure have been calculated,
thus providing reference for design improvement. Results show that, the main cause of the
piston safety, the piston deformation and the great stress is the temperature, so it is feasible
to further decrease the piston temperature with structure optimization.
This paper [4] involves simulation of a 2-stroke 6S35ME marine diesel engine
piston to determine its temperature field, thermal, mechanical and coupled thermal-
mechanical stress. The distribution and magnitudes of the afore-mentioned strength
parameters are useful in design, failure analysis and optimization of the engine piston.
After studied the literature we are improving the Analysis results in the form of
mesh generation and design concepts.

23. 23
CHAPTER-4
COMPONENT DESCRIPTION
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 and/or connecting rod. As an important part in an engine, 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/crown cracks and so on.
Piston features include the piston head, piston pin bore, piston pin, skirt, ring grooves, ring
lands, and piston rings. The piston head is the top surface (closest to the cylinder head) of
the piston which is subjected to tremendous forces and heat during normal engine
operation.The investigations indicate that the greatest stress appears on the upper end of
the piston and stress concentration is one of the mainly reason for fatigue failure
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 mechanical distortions.
 It should have sufficient support for the piston pin.
In engine, transfer of heat takes place due to difference in temperature and from
higher temperature to lower temperature. Thus, there is heat transfer to the gases during
intakes stroke and the first part of the compression stroke, but the during combustion and
expansion processes the heat transfer take place from the gases to the walls. So the piston
crown, piston ring and the piston skirt should have enough stiffness which can endure the
pressure and the friction between contacting surfaces. In addition, as an important part in
engine, the working condition of piston is directly related to the reliability and durability of
engine.

24. 24
4.1MATERIALS
The piston acts as a movable end of the combustion chamber. The stationary end of
the combustion chamber is the cylinder head. Pistons are commonly made of a cast
aluminium alloy for excellent and lightweight thermal conductivity. Thermal conductivity
is the ability of a material to conduct and transfer heat.
Commonly used materials for IC engine pistons are cast iron, cast steel, forged
steel, cast aluminium alloys and forged aluminium alloy.
4.2ENGINE SPECIFICATIONS
Table.4.1: Engine specification
4.3 CHARACTERISATION OF MATERIALS
The materials chosen for this work are A2618, A4032 and for an internal
combustion engine piston. The relevant mechanical and thermal properties of A2618,
A4032 and aluminium alloys are listed in the following table 4.1, 4.2.
The relevant mechanical and thermal properties of A2618, A4032
PARAMETERS VALUES
Engine Type Four stroke, Petrol engine
Induction Air cooled type
Number of cylinders Single cylinder
Bore 51 mm
Stroke 48.8 mm
Length of connecting rod 97.6 mm
Displacement volume 99.27 cm3
Compression ratio 8.4
Maximum power 6.03 KW at 7500 rpm
Maximum Torque 8.05 Nm at 5500 rpm
Number of revolutions/cycle 2

25. 25
Table.4.2 :Characterisation of materials
4.4METHODOLOGIES
 Analytical design of pistons using specifications of Bajaj Kawasaki petrol engine.
 Creation of 3D models of piston using ANSYS.
 Meshing of 3D models using ANSYS.
 Analysis of pistons using static stress analysis method.
 Comparative performance of three aluminium alloy pistons under static stress
analysis method.
S
N
PARAMETERS A2618
A4032
1 Elastic Modulus (GPa)
73.7 79
2 Ultimate Tensile Strength (MPa) 480 380
3 0.2% Yield Strength (MPa 420 315
4 Poisson’s Ratio 0.33 0.33
5
Thermal Conductivity (W/m/oC)
147 154
6
Coefficient of Thermal Expansion (1/K) 25.9 x 10-6 79.2 x 10-6
7 Density (Kg/m3)
2767.9 9 2684.9 5

26. 26
 Analysis of pistons under thermal and mechanical loads i.e. the pistons are
subjected to a uniform gas pressure and non-uniform temperature distribution.
 Comparative performance of the three aluminum alloy pistons under thermal and
mechanical loads i.e. the pistons are subjected to a uniform gas pressure and non-
uniform temperature distribution.
 Select the best suited aluminum alloy.
 Analyze the optimized model under static stress.
 Analyze the optimized model under thermal and mechanical loads
4.5 ANALYTICAL DESIGN
IP = Indicated power produced inside the cylinder (W)
η = Mechanical efficiency = 0.8
n = Number of working stroke per minute = N/2 (for four stroke engine)
N = Engine speed (rpm)
L = Length of stroke (mm)
A = Cross-section area of cylinder (mm2)
Lc=Length of connecting rod (mm)
r = Crank radius (mm)
a = Acceleration of the reciprocating part (m/s2)
mp = Mass of the piston (Kg)
V = Volume of the piston (mm3)
Th=Thicknessofpistonhead(mm)
D = Cylinder bore (mm)
pmax= Maximum gas pressure or explosion pressure (MPa)
σt= Allowable tensile strength (MPa)
σut =Ultimate tensile strength (MPa)
F.O.S = Factor of Safety = 2.25
K = Thermal conductivity (W/m K)

27. 27
T= Temperature at the centre of the piston head (K)
Te = Temperature at the edge of the piston head (K)
HCV = Higher Calorific Value of fuel (KJ/Kg) = 47000 KJ/Kg
BP = Brake power of the engine per cylinder (KW)
m = Mass of fuel used per brake power per second (Kg/KW s)
C = Ratio of heat absorbed by the piston to the total heat developed in the cylinder = 5%
b = Radial width of ring (mm)
Pw = Allowable radial pressure on cylinder wall (N/mm2) = 0.025 MPa
σp = Permissible tensile strength for ring material (N/mm2) = 1110 N/mm2
h = Axial thickness of piston ring (mm)
h1= Width of top lands (mm)
h2= Width of ring lands (mm)
t1 = Thickness of piston barrel at the top end (mm)
t2 = Thickness of piston barrel at the open end (mm)
ls = Length of skirt (mm)
µ = Coefficient of friction (0.01)
l1 = Length of piston pin in the bush of the small end of the connecting rod (mm)
do = Outer diameter of piston pin (mm)
Model calculations:
η = Brake power (B.P)/ Indicating power (I.P)
Therefore, I.P =
𝐵.𝑃
η
= 6.2/0.8 = 7.75 KW
Also, I.P = P x A x L x N /2
I.P = P x (
𝜋
4
)𝑑2
x L x (
𝑁
2
)Type equation here.
Substituting the values from Table
Mechanical efficiency of the engine (η) = 80 %

28. 28
7.75 x 1000 = P x
𝜋
4
×(0.051)2 x (0.0488) x
5000
(2×60)
So, P = 18.66 x 105 N/m2 or P = 1.866 MPa
Maximum Pressure pmax = 10 x P
= 10 x 1.866 = 18.66 MPa
Analytical design for A2618 alloy piston
Analytical design for A2618 alloy piston is as follows:
Thickness of the Piston Head
According to Grashoff’s formula the thickness of the piston head is given by
th = D√
3pmax
16σt
where
σt=
σut
2.25
= 213.33 MPa
Therefore th = 51 x √
(3 x 18.66)
(16 x 213.33)
= 6.53 mm
Empirical formula:
th = 0.032 D + 1.5 = 3.2 mm
On the basis of the heat dissipation, the thickness of the piston head is given by:
th =
C x HCV x m x BP] x 106
(12.56 x K (Tc – Te)
=
[0.05 x 47000 x 34.45 x 10−3 x 6.2] x 106
(12.56 x 147 x 20 x 3600 )
= 3.775 mm
The maximum thickness from the above formula is th is 6.53 mm.
Piston Rings
The radial width of the ring is given by:
b = D √
3 pw
σp
= 51 √
3 x 0.025
110

29. 29
= 1.33 mm
Axial thickness of the piston ring is given by:
h = (0.7b to b) = 0.7 x 1.33 = 0.932 mm ≈ 1 mm
Width of Top Land and Ring Lands
Width of top land:
h1 = (th to 1.2 th) = 6.53 mm
Width of ring land:
h2 = (0.75h to h) = 0.75 mm
Piston Barrel
Thickness of piston barrel at the top end:
t1 = 0.03 D + b + 4.9
= 0.03 x 51 + 1.33 + 4.9 = 7.76 mm
Thickness of piston barrel at the open end:
t2 = (0.25 t1 to 0.35 t1)
= o.25 x 7.76 = 1.94 mm ≈ 2 mm
Length of the skirt
Ls = (0.6 D to 0.8 D)
= 0.6 x 51 = 30.6 mm
Length of piston pin in the connecting rod bushing
L1 = 45% of the piston diameter
= 0.45 x 51 = 22.95 mm
Piston pin diameter do = (0.28 D to 0.38 D)

30. 30
= 0.28 x 51 = 14.28 mm
The centre of the piston pin should be 0.02 D to 0.04D above the centre of the skirt.
Similarly, analytical design of A4032is carried out and the results are summarized as
follows
Analytical design for A4032 alloy piston
Thickness of the Piston Head: th = 7.3 mm.
Piston Rings: b = 1.33 mm and h = 1 mm.
Width of Top Land: h1 = 7.3 mm
Ring Lands: h2 = 0.75 mm
Thickness of piston barrel at the Top end: t1 = 7.76 mm
Open end: t2 = 2 mm Length of the skirt: ls = 30.6 mm
Length of piston pin in the connecting rod bushing:
l1 = 22.95 mm
Piston pin diameter: do = 14.2

31. 31
CHAPTER-5
PROCEDURE FOR MODELING OF PISTON
5.1 PROCEDURE
Start → mechanical design → part design to activate the part design workbench
Fig.5.1 procedure
Click on the sketcher → select the XY plane
Fig.5.2 plane
Select the profile → portray the profile of the main body

32. 32
Fig.5.3 2D piston profile
Select the shaft command → click on ok→ select the axis→ click on enter
Now we can generate the 3d model of piston with help of shaft command
Fig.5.4 3D piston model

33. 33
Select the plane → click ok → select circle → draw a circle → select pocket
command up to surface → ok
Fig.5.5 3D Modeling of piston
The require model is to be designed with help of catia v5 software .

34. 34
CHAPTER-6
SIMULATION PROCEDURE
6.1 ANSYS WORKBENCH
Click on ansyswork bench →double click on static structural
Fig.6.1: Ansys work bench
double click on engineering data→adding the new materials with help of property of
material
Fig.6.2:Material insert

35. 35
click on geometry→ import geometry→ select the project piston
Fig.6.3: Import geometry
6.2 MESHING OF 3D MODEL OF PISTON
Click on mesh→ select default mesh→ right click solve
Fig.6.4:Mesh model

36. 36
Static structural→insertapplying boundary conditions
Fig.6.5:Boundary condition
solution→ right click insert → deformation → total.
Fig.6.6:Total Deformation
6.3 DEFORMATION

37. 37
Fig.6.7:Deformation
6.4 VON-MISES STRESS
Fig.6.8:Von-miss stress
6.5 FACTOR OF SAFETY

38. 38
Fig.6.9: Factor of safety
6.6 STUDY STATE THERMAL
Click on ansys work bench →double click on study state thermal
Fig.6.10:Import geometry
Double click on engineering data →add new material with help of properties of material

39. 39
Fig.6.11:Material Insert
Click on geometry→ import geometry→ select the project piston
Fig.6.12:Import geometry
6.7 MESHING OF 3D MODEL OF PISTON

40. 40
Click on mesh→ select default mesh→ right click solve
Fig.6.13:Meshing
Static structural→ insert applying boundary conditions
Fig.6.14:Boundary condition
Solution→ right click insert → thermal→ select temperature

41. 41
Fig.6.15:Boundary condition
6.8 TEMPERATURE DISTRIBUTION
Fig.6.16:Temperature distribution
6.9 TOTAL HEAT FLUX

42. 42
Fig .6.17:Total heat flux
6.10 GRAPHS
6.10.1Pressure vs deformation
Graph.6.1: pressure vs deformation
The graphs draw between the pressure vsdeformation as shown figure 6.18. Load
increases, deformation changes linearly.
6.10.2 pressurevs equivalents von-mises stress

43. 43
Graph.6.2:pressure vs equivalent (von-mises) stress
CHAPTER-7

44. 44
RESULTS
Thus the design, analysis and optimization of piston is successfully completed with
help of ‘CATIAV5’ and ‘ANSYS14’
This chapter describes the results of the experiment s, which were conducted on a
piston and in a modelling on a personal computer. We are conducting the project to
calculate the deformation , temperature distribution and von-mises stress. In this reaserch
we have to compare the two materials and to find the which one is better suitable .we are
mainly considers the parameters like mass, deformation, heatflux factor of safety.
Table.7.1: Comparing results
CHAPTER-8
S.NO MATERIALS HEAT
FLUX
(W/mm2)
Factor of
safety
Deformation
(mm)
Mass(Kg)
1 Aluminium
A 4032
4.89713 2.02 0.12911 0.12691
2 Aluminium
A 2618
4.57845 2.56 0.13839 0.13084

45. 45
CONCLUSION
It is concluded from the results that the weight and volume of Aluminium A4032
is least among the another materials. Hence the forces are less, which enhances the
performance of the engine. The FOS Aluminium A4032 of 2.02 is , much higher than the
other materials, so further development of high power engine using this material is
possible. Further research may be done to select a material with less weight and higher
strength, so as to reduce the forces.
The first main conclusion that could be drawn from this work is that although
thermal stress is not the responsible for biggest slice of damaged pistons, it remains a
problem on engine pistons and its solution remains a goal for piston manufacturers. From
the analysis, it is evident that thermal stress was higher than mechanically induced stress
hence it could be concluded that the piston would fail due to the thermal load rather than
the mechanical load and hence during optimization design, this could be put into
consideration to ensure that thermal load is reduced.
It can also be deduced that individually, thermal and mechanical stress proportions
have a direct influence on the coupled thermal-mechanical stress hence during design each
load can be considered and reduced independently. It can be concluded that the piston can
safely withstand the induced stresses during its operation. The stress obtained by
theoretical calculation and FEA found to be approximately same.
And it will last a problem for long because efforts on fuel consumption reduction
and power increase will push to the limit weight reduction, that means thinner walls and
higher stresses. To satisfy all the requirements with regard to successful application of
pistons, in particular mechanical and high temperature mechanical fatigue and
thermal/thermal–mechanical fatigue there are several concepts available that can be used to
improve its use, such as design, materials, processing technologies, etc.
CHAPTER-9

46. 46
REFERENCES
[1] LINEAR STATIC STRUCTURAL ANALYSIS OF OPTIMIZED PISTON FOR BIO-
FUEL USING ANSYS International Journal of Mechanical and Production
Engineering Research and Development (IJMPERD) ISSN 2249-6890 Vol. 3, Issue 2,
Jun 2013, 11-20 © TJPRC Pvt. Ltd. By CH. VENKATA RAJAM, P. V. K. MURTHY
, M. V. S. MURALI KRISHNA.
[2] Design Analysis and Optimization of Piston using CATIA and ANSYS International
Journal of Innovative Research in Engineering & Science ISSN 2319-5665(January
2013, issue 2 volume 1)by CH. VENKATA RAJAM, P. V. K. MURTHY, M. V. S.
MURALI KRISHNA, G. M. PRASADA RAO.
[3] AN ANALYSIS TO THERMAL LOAD AND MECHANICAL LOAD COUPLING
OF A GASOLINE ENGINE PISTON Journal of Theoretical and Applied Information
Technology 20th February 2013. Vol. 48 No.2© 2005 - 2013 JATIT & LLS. By
HONGYUAN ZHANG, ZHAOXUN LIN, DAWEI XU.
[4] Simulation of Thermal-Mechanical Strength for Marine Engine Piston Using FEA
Journal of Engineering Research and Applications www.ijera.com ISSN : 2248-9622,
Vol. 4, Issue 3(Version 1),by Elijah MusangoMunyao, Jiang Guo He, Yang Zhiyuan,
Zou Xiang Yi .
[5] Piston Strength Analysis Using FEM Swati S Chougule, Vinayak H Khatawat /
International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-
9622 www.ijera.com Vol. 3, Issue 2, March -April 2013, pp.1724-1731 by Swati S
Chougule, Vinayak H Khatawate.