Ansys Project Work

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ANALYSIS OF INTERNAL COMBUSTION ENGINE PISTON USING ANSYS

A PROJECT REPORT

By

P.VIGNESH

in partial fulfillment of the requirements for the Certificate of the

MASTER DIPLOMA IN CADD MD3

In

Nelson towers,1 st wing,3 rd floor 51,NM road,Chennai-600029

SIGNATURE OF INSTRUCTOR

Mr. M.SANTHOSH

SIGNATURE OF BRANCH MANAGER

Mr. K.VINOD KUMAR

SIGNATURE OF PROJECT IN CHARGE SIGNATURE OF TECHNICAL COORDINATE



Mrs. PRABHA Mr. M.SANTHOSH

TABLE OF CONTENTS

CHAPT ! N" T#T$ PA% N"1 #NT!"&'CT#"N 12 & (#%N AN& #MP$ M NTAT#"N 23 P!#NT (C! N &!A)#N%( 5* (T!'CT'!A$ ANA$+(#( 9

5 TH !MA$ ANA$+(#( 166 M"&'$ & (C!#PT#"N 20

C"NC$'(#"N 21



INTRODUCTION

&a aged or .ro/en arts are generall too e ensi e to re la4e, or are no longer a aila.le and this is

arti4 larl rele ant to the a to o.ile ind str owing to the e er-in4reasing a44idents .

!e erse ngineering ! 7 has .een s 44essf ll e lo ed to for ossi.le re4o er of a da aged or .ro/en

art8

'sing this ethod ! we generate a CA& odel of a da aged internal 4o . stion #C7 engine iston and

then se the state-of-the-art AN(+( finite ele ent anal sis a4/age to erfor a linear stati4 and a 4o led

ther al-str 4t ral anal sis of the 4o onent8

Ne4essar .o ndar 4onditions were a lied for the art odel in Ans s to o.tain s 44essf l res lts of the

str 4t ral and ther al anal sis8

rther, a ara eteri4 e al ation of the aterial ro erties is-:- is o erating 4onditions is 4arried o t to

generate a relational data.ase for the iston to arri e at o ti al design sol tions nder different o erating

4onditions8

Ans s 4an .e sed in 4on; n4tion with finite ele ent anal sis to odel o.solete rod 4t geo etries and

aterial odels to redesign and generate new odels to s it e isting 4 linders and other asse .lies8



DESIGN AND IMPLEMENTATION

Reverse Engineering:

#t<s a ( ste ati4 e al ation of a rod 4t with the r ose of re li4ation8 This in ol es design of a new art, 4oof an e isting art, re4o er of a da aged or .ro/en art, i ro e ent of odel re4ision and ins e4tion of an eri4al odel8

Ad antages of the te4hni= e in4l de i ediate feed.a4/, data red 4tion, dire4t generation of geo etr andhigher re4ision of the final rod 4t8

Digiti !ti"n#

&igiti>ation is the ro4ess of 4a t ring the data of the h si4al odel and 4on erting it into digital for 8

The iston is odeled fro 4lo d oints o.tained . laser .ea s4anning8 The oints are ;oined . lines and then4reating .o nding areas and filling the ol e8 $ater the geo etri4 solid odel is i orted to P!"- a4/age8

M"$%&ing#

The s4anned at4hes are transfor ed into a 4losed se4tion Piston odel sing P!"- software8

CA& odel has the fle i.ilit of in4or orating 4hanges and interfa4ing with CAM whi4h in4reases the rod 4tionrates8The art odel 4reated is sa ed in #% ( for at and is e orted to AN(+(8



An!&'sis#

A new Ans s wor/.en4h is o ened and the solid art odel that is generated in Pro- is i orted into thiswor/.en4h8

Ther al and (tr 4t ral t es ha e .een sele4ted in referen4e and ele ent t e is sele4ted to .e solid 20 node 90

The ther al and str 4t ral .o ndar 4onditions ha e .een a lied to the solid Piston odel and are eshed singesh tools8

Te erat res and loads ha e .een a lied in the areas of the odel8

The generated esh is sol ed and lotted8 The nodal sol tions and on ises stress atterns are 4reated andres lts are re4orded and sa ed8

The generated i ages 4learl e lain ario s ro erties of the iston s 4h as its defle4tion at ario s load4onditions, .ending o ents, stress al es et48



&ata<s and .o ndar 4onditions sed in anal sis are as follows?

Str()t(r!& !n!&'sis@7 13 10 3 NB 2

Poisson<s ratio P!@+7 083Press re on the to area 600 NB 2

le ent t e solid .ri4/ node *5 solid*57Mesh area set i4/ all7Mesh sha e tetrahedralMesh t e free esh

T*%r+!& !n!&'sisTher al 4ond 4ti it D@7 *0 )B D le ent t e solid .ri4/ node *5 solid*57Mesh area set i4/ all7Mesh sha e tetrahedralMesh t e free eshTe at to area 600

Te at .otto area 500



PRINT SCREEN DRA,INGS-PRO E AND ANSYS/



PISTON SOLID PART GENERATED IN PRO E



PISTON IMPORTED TO ANSYS WORKBENCH



PISTON AFTER MESHING



PISTON AFTER LOADING AND APPLIED BOUNDARY CONDITIONS (STRUCTURAL

ANALYSIS



DEFORMED PISTON AFTER STRUCTURAL LOADING



PISTON DOF AND DISPLACEMENT !ECTOR SUM



!ON MISES STRESS



PISTON AFTER THERMAL LOADING (THERMAL ANALYSIS



PISTON"THERMAL GRADIENT !ECTOR SUM



PISTON"THERMAL NODAL TEMPERATURES



MODULE DESCRIPTIONIt is a well known fact that 60E of the total engine e4hani4al ower lost is generated . iston ring

asse .l 8 The iston s/irt s rfa4e slides on the 4 linder .ore8 A l .ri4ant fil fills the 4learan4e .etween the

s rfa4es8 The s all al es of the 4learan4e in4rease the fri4tional losses and the high al es in4rease the

se4ondar otion of the iston8

This #nternal Co . stion #C7 engine iston is ade of an al in allo whi4h has a ther al e ansion

4oeffi4ient, 0E higher than the 4 linder .ore aterial ade of 4ast iron8

This leads to so e differen4es .etween r nning and the design 4learan4es8 Therefore, anal sis of the iston

ther al .eha ior is e tre el 4r 4ial in designing ore effi4ient engine8

Here the iston erfor an4e was e al ated for different 4lasses of Al ini allo s s 4h as MAH$ series o t

of whi4h MAH$ 1*2 aterial odel is .est s ited for the range of o erating 4onditions for the iston nder

4onsideration8

The load was aried fro 50E to 225E of the ean 4al4 lated load with a target al e of the ind 4ed stress .eing

e= al to the 4o ressi e ield strength of the aterial8 The MAH$ 1*2 is safe for to a ea/ o erating load of

200E the ean load or a.o t 6 MPa7 a4ting on the iston head8



CONCLUSION

The res lts of this anal sis show that re erse engineering 4an .e sed in 4on; n4tion with finite

ele ent anal sis to odel o.solete rod 4t geo etries and aterial odels to redesign and generate

new odels to s it e isting 4 linders and other asse .lies8#t is also seen that the &esign@ lorer within the AN(+( )or/.en4h en iron ent 4an .e sed

er effe4ti el to reali>e an ara etri4 o ti i>ation8

Ansys Project Work

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