The piston is a heart of the engine and its working condition is the most exceedingly bad one of the key parts of the engine in the workplace. A piston is a segment of responding piston, responding pumps, gas compressors and pneumatic chambers, among other comparative systems. It is the moving part that is contained by a barrel and is made gas-tight by piston rings. In a piston, its motivation is to exchange force from growing gas in the barrel to the crankshaft through a piston bar and additionally associating pole connecting rod. In this study, firstly, thermal analyses are investigated on a piston, made of Cast Aluminum alloy and titanium alloy. Then, structural analyses are performed on piston of titanium alloy & Aluminum alloy material by means of using ANSYS workbench. The effects of thermal behaviors of the pistons are investigated. The main objective is to investigate and analyses the thermal stress distribution of piston at the real engine condition during combustion process. This work advancement by utilizing finite element analysis to anticipate the higher stress and critical area are on the component. In order to find the displacement, thermal and stress appropriation of the piston, ANSYS software is utilized to analyze the piston under the thermal loads and mechanical loads.

1. DESIGN AND ANALYSIS OF HCCI ENGINE PISTON
FINAL REVIEW
Guided by:
Mr. Karikalan M.E., Ph.D
Professor Dept - Automobile Engg.,
VISTAS.
Presented by:
Harihara Soori G
Reg No: 19806105
M.E- Automobile Engg
II Year – IV Sem

2. Abstract
The piston is a heart of the engine and its working condition is the most exceedingly bad one
of the key parts of the engine in the workplace. A piston is a segment of responding piston,
responding pumps, gas compressors and pneumatic chambers, among other comparative
systems. It is the moving part that is contained by a barrel and is made gas-tight by piston
rings. In a piston, its motivation is to exchange force from growing gas in the barrel to the
crankshaft through a piston bar and additionally associating pole connecting rod. In this study,
firstly, thermal analyses are investigated on a piston, made of Cast Aluminum alloy and
titanium alloy.
Then, structural analyses are performed on piston of titanium alloy & Aluminum alloy
material by means of using ANSYS workbench. The effects of thermal behaviors of the
pistons are investigated. The main objective is to investigate and analyses the thermal stress
distribution of piston at the real engine condition during combustion process. This work
advancement by utilizing finite element analysis to anticipate the higher stress and critical area
are on the component. In order to find the displacement, thermal and stress appropriation of
the piston, ANASYS software is utilized to analyze the piston under the thermal loads and
mechanical loads.

3. INTRODUCTION
● 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.
● 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.
● This paper describes the stress distribution on piston of internal combustion
engine by using FEA. The FEA is performed by CAD and CAE software.
● The paper describes the FEA technique to predict the higher stress and critical
region on the component. With using CATIA V5 software the structural model
of a piston will be developed. Using ANSYS software, simulation and stress
analysis is performed.

4. OBJECTIVE
● The main objectives are to investigate and analyze the thermal stress and
mechanical stress distribution of piston at the real engine condition during
combustion process.
● To analyse the stress distribution on piston of internal combustion engine by
using FEA.
● The aim of work is to predict the higher stress and critical region on the
component using FEA technique.

5. METHODOLOGY
Literature
Review
Problem
Identification
Modeling In
CATIA
Results And
Discussion
Comparison
Of Results
Analysis
Using ANSYS
Conclusion

6. LITERATURE STUDY
CATIA:
Source: www.intrinsys.com
According to Amit Patel, CATIA stands for Computer Aided Three Dimensional Interactive Application
and it was initially developed for use in designing the Dassault Mirage fighter jet by French Company
Dassault Systems in 1977. CATIA had developed into much more than a CAD software package which
in turn incorporated the CAM and CAE software packages.
ANSYS:
Source: https://www.researchgate.net
According to Mohammad Moghimi, ANSYS is to conduct the ray tracing required to quantify the
optical performance of a line concentration Concentrated Solar Power (CSP) Receiver as well as the
conjugate heat transfer modelling required to estimate the thermal efficiency of such a receiver. The
main purpose of ANSYS workbench, is to maximize the performance of linear CSP reflect layout and
receiver configurations.

7. LITERATURE STUDY
Aluminum Alloy Piston study :
Cole G.S. and Sherman A.M., studied the replacement of cast iron and steel in automotive component
like piston with lightweight aluminum alloy casting to improve the performance and efficiency.
Casting study : Electro plating method which was explained by Han and More K.L. (2003).
Haque M.M and Young J.M. (2001) referred the low expansion group of aluminum–silicon alloy as
piston alloy, since this group of alloy provides the best overall balance of properties.

8. MATERIAL SELECTION
i)High-intensity heat. When the temperature is 300~400 degree, it has also enough mechanical
properties to prevent the parts damaged.
ii) Good thermal conductivity and poor heat absorptive. Not only reduce the temperature of the top and
ring, but also reduce the thermal stress.
iii) The expansion coefficient is small. Keep the small gap with the piston and cylinder.
iv) The specific gravity is small. Reduce the reciprocating inertia force of the piston group to reduce the
mechanical load of the crankshaft and connecting rod.
v) Good wear properties.
vi) Good manufacturability and cheap.
Based on the related researches, we considered three materials for analysis.
i. Aluminum alloy is mostly used material in making car pistons, and experiments using other
material such as cast iron, cast steel, ceramics and carbon.
ii. Titanium alloy, which has very high tensile strength and toughness. It is light in weight, have
extraordinary corrosion resistance and the ability to withstand extreme temperatures.
iii. Silicon Carbide Reinforced Zirconium di-boride

9. PROBLEM IDENTIFICATION
• The function of the piston is to absorb the energy released after the combustion and to produce
useful mechanical energy. When the combustion of fuel takes place in heavy diesel engine cylinder,
high temperature and pressure develops. Because of high speed and at high loads, the piston is
subjected to high thermal and structural stresses.
• The investigations indicate that the greatest stress appears on the upper end of the piston and stress
concentration is one of the main reason for fatigue failure.
• Due to stress concentration and high thermal load the upper end of the piston, crack generally
appears. This crack may even split the piston.

10. Material Properties of Piston
S.NO Materials /Properties Aluminium Alloy
Silicon Carbide
Reinforced
Zirconium di-
boride
Aluminium Silicon
Carbide
1 Density [Kg/m3] 2770 2060 2937
2 Young's Modulus [Mpa] 7.10E+04 4.86E+05 2.30E+05
3 Poisson's Ratio 0.33 0.11 0.24
4 Yield Strength [Mpa] 280 930 450
5 Ultimate Strength [Mpa] 310 1070 550
6
Thermal Conductivity
[w/mk]
174 93.7 197
7 Specific Heat [J/kgk] 0.13 500 894
8
Co-Efficient ofThermal
Expansion [k-1]
1.00E-06 5.90E-06 0

11. MODELLING OF PISTON
Two dimensional drawing of piston Three dimensional model for Piston

12. Task Status
1 Collect specification of piston Completed
2 Preparation for 1st review Completed
3 Selection of material Completed
4 Pre-installation with design consideration of design challenges Completed
5 Modelling completed
6 Preparation of 2nd review completed
7 Ansys pre simulation study completed
8 Launch simulation completed
9 Preparation of 3rd review completed
10 Final report preparation completed
11 Final presentation completed
WORK COMPLETED:

13. ANALYSIS OF PISTON HEAD
Static Structural
Analysis
Boundary conditions are provided as specified in the above image.

14. ANALYSIS OF PISTON HEAD
Total Deformation of
Aluminum Alloy
From the above result analysis we see that
the deformation value of 0.17243mm is
maximum.

15. ANALYSIS OF PISTON HEAD
Equivalent Elastic
Strain of Aluminum
Alloy
The elastic strain is defined as the limit for the
values of strain up to which the object will
rebound and come back to the original shape
upon the removal of the load. From the above
result analysis we see that the equivalent elastic
strain value of 0.0096448 is maximum and
1.4725e-6 is minimum.

16. ANALYSIS OF PISTON HEAD
Equivalent Stress of
Aluminum Alloy
Equivalent stress is widely used to represent
a material's status for ductile material.
Equivalent stresses consider different
effects resulting from multiaxial residual
stress states. From the above result analysis
we see that the equivalent stress value of
678.01 MPa is maximum and 0.038164
MPa is minimum.

17. ANALYSIS OF PISTON HEAD
Steady State Thermal
Analysis of Aluminum
Alloy
Boundary conditions are provided as
specified in the above image.

18. ANALYSIS OF PISTON HEAD
Steady State Thermal
Analysis of Aluminum
Alloy –Temperature
From the above result analysis we see that the
temperature value of 750ºC is maximum and
627.74 ºC is minimum for the piston steady
state thermal analysis of Aluminum Alloy.

19. ANALYSIS OF PISTON HEAD
Steady State Thermal
Analysis of Aluminum
Alloy – Total Heat Flux
From the above result analysis we see that
the total heat flux value of 3.8219 W/mm² is
maximum and 2.2227e-5 W/mm² is
minimum for the piston steady state thermal
analysis of Aluminum Alloy.

20. ANALYSIS OF PISTON HEAD
Total deformation of
Aluminum Silicon
Carbide
From the above result analysis we see that
the total deformation value of 0.053637
mm is maximum for the piston static
structural analysis of Aluminum Silicon
Carbide.

21. ANALYSIS OF PISTON HEAD
Equivalent Elastic
Strain of Aluminum
Silicon Carbide
From the above result analysis we see that the
Equivalent Elastic Strain value of 0.0029662
is maximum and 4.586e-7 is minimum for the
piston static structural analysis of Aluminum
Silicon Carbide.

22. ANALYSIS OF PISTON HEAD
Equivalent Stress of
Aluminum Silicon
Carbide
From the above result analysis we see
that the Equivalent Stress of 675.7
MPa is maximum and 0.036482 MPa
is minimum for the piston static
structural analysis of Aluminum
Silicon Carbide.

23. ANALYSIS OF PISTON HEAD
Steady State Thermal
Analysis of Aluminum
Silicon Carbide
Boundary conditions are provided as
specified in the above image.

24. ANALYSIS OF PISTON HEAD
Steady State Thermal
Analysis of Aluminum
Silicon Carbide–
Temperature
From the above result analysis we see that
the temperature value of 750ºC is
maximum and 640.24 ºC is minimum for
the piston steady state thermal analysis of
Aluminum Silicon Carbide.

25. ANALYSIS OF PISTON HEAD
Steady State Thermal
Analysis of Aluminum
Silicon Carbide– Total
Heat Flux
From the above result analysis we see that
the total heat flux value of 3.8626 W/mm² is
maximum and 2.2545e-5 W/mm² is
minimum for the piston steady state thermal
analysis of Aluminum Silicon Carbide.

26. ANALYSIS OF PISTON HEAD
Total Deformation of
Silicon Carbide
Reinforced Zirconium
Di-Boride
From the above result analysis we see
that the total deformation value of
0.022762 mm is maximum for the piston
static structural analysis of Silicon
Carbide Reinforced Zirconium Di-
Boride.

27. ANALYSIS OF PISTON HEAD
Equivalent Elastic
Strain of Silicon
Carbide Reinforced
Zirconium Di-Boride
From the above result analysis we see
that the equivalent elastic strain value
of 0.0014502 is maximum and
2.0026e-7 is minimum for the piston
static structural analysis of Silicon
Carbide Reinforced Zirconium Di-
Boride.

28. ANALYSIS OF PISTON HEAD
Equivalent Stress of
Silicon Carbide
Reinforced Zirconium
Di-Boride
From the above result analysis we see that the
equivalent stress value of 702.25 MPa is
maximum and 0.04868 MPa is minimum for
the piston static structural analysis of Silicon
Carbide Reinforced Zirconium Di-Boride.

29. ANALYSIS OF PISTON HEAD
Steady State Thermal
Analysis of Silicon
Carbide Reinforced
Zirconium Di-Boride
Boundary conditions are provided as
specified in the above image.

30. ANALYSIS OF PISTON HEAD
Steady State Thermal
Analysis of Silicon
Carbide Reinforced
Zirconium Di-Boride
– Temperature
From the above result analysis we see that
the temperature value of 750°C is
maximum and 547.19°C is minimum for
the piston steady state thermal analysis of
Silicon Carbide Reinforced Zirconium Di-
Boride.

31. ANALYSIS OF PISTON HEAD
Steady State Thermal
Analysis of Silicon
Carbide Reinforced
Zirconium Di-Boride
– Total Heat Flux
From the above result analysis we see that
the total heat flux value of 3.5523 W/mm²
is maximum and 2.0143e-5 W/mm² is
minimum for the piston steady state
thermal analysis of Silicon Carbide
Reinforced Zirconium Di-Boride.

32. RESULT ANALYSIS OF PISTON
S.NO
Materials
/Results
Aluminium
Alloy
Silicon Carbide
Reinforced
Zirconium di-
boride
Aluminium Silicon
Carbide
1
Temperature
[Degree
Celicuis]
627.74 547.19 640.24
2
Total Heat
Flux
[W/MM2]
3.8219 3.5523 3.8626
3
Deformation
[MM]
0.17243 0.022762 0.053637
4
Equivalent
Stress [MPA]
678.01 702.25 675.7
5
Equivalent
Strain
[mm/mm]
0.0096448 0.0014502 0.0029662

33. CONCLUSION
Modelling of a Diesel Engine’s Piston Head is done using 3D modeling software
CATIAV5. Impact and Thermal analysis is done on the piston head for different
materials. The materials used for analyzing are Aluminium alloy, Aluminium
Silicon Carbide, Silicon carbide reinforced Zirconium di-boride. At present the
piston head is coated with Aluminium alloy, this gets replaced with Silicon
Carbide and Silicon Carbide reinforced Zirconium di-boride.
By observing the Impact and Thermal analysis results like Temperature, Total
Heat flux, Equivalent Stress and Strain the values for Aluminium Silicon Carbide
has the better results when compared to the Aluminium alloy. Therefore for High
temperature withstand and better impact properties Aluminium Silicon Carbide
can be used.

34. REFERENCE
1. Srinath M and Rajasekhara Babu K 2015 Static and Thermal Analysis
of Piston International Journal of Engineering of Technology, Management and
applied sciences.
2. Szmytka F, Salem M, Aria FR and Oudin A 2015 Thermal fatigue
analysis of Automotive Diesel piston Experimental procedure and numerical
protocol International Journal of Fatigue.
3. Miller RA, 1997, Thermal Barrier Coatings for Air-crafts engines:
History and directions, Journal of Thermal Spray Technology.