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International Journal of Research in Engineering and Applied Sciences(IJREAS)

Available online at http://euroasiapub.org/journals.php

Vol. 7 Issue 8, August-2017, pp. 56~69

ISSN (O): 2249-3905, ISSN(P): 2349-6525 | Impact Factor: 7.196

International Journal of Research in Engineering & Applied Sciences

Email:- [email protected], http://www.euroasiapub.org

An open access scholarly, online, peer-reviewed, interdisciplinary, monthly, and fully refereed journal

56

Design and Analysis of Diesel Piston

Nethula Arun1

M.Tech Student

Department of Mechanical Engineering

1,2Godavari Institute of Engineering and Technology, Rajahmundry 533101.

Andhra Pradesh, India

M Varaprasada Rao2

Dean Academics

Department of Mechanical Engineering

1,2Godavari Institute of Engineering and Technology, Rajahmundry 533101.

Andhra Pradesh, India

Abstract:

The world vision for the high efficient compression ignition (CI) engines components especially,

diesel engine pistons of automobiles which are well developed and can sustain for optimal

operating conditions and their utilization is increasing day-by-day. As a result, researchers in the

area of diesel engine pistons also increased. Though the development in the diesel engine piston

components has reached a level of technological maturity, engineers are facing many problems

in the design and development of the diesel engine pistons due to the complexities in the

materials involved in it which affects the sustainability and life of the piston. This paper aims at

developing a piston of automobiles which can sustain optimal operating conditions and resistive

to sulphidation, other design complexities and analyze the piston with advanced alloys

HAYNES®556, INCONEL® 625 and compare the results with alloy A356 which is used currently.

The design of diesel piston is carried out in Solid works Part Design and the analysis of diesel

piston with different alloys is carried out in Solid works Simulation.

Keywords: Alloys, Diesel Piston, A356, HAYNES® 556, INCONEL® 625, Simulation

Introduction

Applications of compression ignition (CI) engines are rising day by day and are even used for the

scientific investigations, marine, research and development, defense, etc. The development of

diesel vehicles reached a level of technological maturity. However, the largest design

considerations of these engines are the piston geometry which can operate at optimal operating

conditions for longer periods by sustaining the wear and tears caused due to sulphidation, stress

corrosive cracking, etc. The damaged piston affects the performance of the engines and is also

responsible for formation of flue gases during combustion phase.

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In this paper, we detail the procedure for designing and analyzing piston for a diesel engine of

automobiles by using advanced alloys like HAYNES® 556 and INCONEL® 625 and present a new

geometry for the piston. The procedure for analyzing the effects of pressure and temperature on

the piston which are formed during combustion process due to which the piston life is affected is

also discussed.

Governing equations

The method used in the analysis of designs in Solidworks Simulation is the Finite Element

Analysis (FEA).

Finite Element Analysis used in simulation packages or solvers generally comprises of three

steps. They are as follows:

A. Pre-processing: In this step, the finite element mesh for the designed model is developed and

boundary conditions, material properties, and loads are applied to the designed model.

B. Solution: In this step, the problem is solved for the given loads and boundary conditions. The

results such as Von Mises stress, strain, displacements, thermal effects, etc., are obtained in this.

C. Post-processing: In this step, the results are visualized in the form of contours, deformed

shapes, and plots. This step helps in the debugging, verification and validation of results.

Figure 1 shows the flow chart of steps involved in finite element analysis.

Fig.1: Finite Element Analysis flowchart








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Material properties

In this study, high-temperature steel alloys are the materials used. The alloy steels used are:

A. A356

B. HAYNES® 556 alloy (UNS R30556)

C. INCONEL® 625

Table1 shows the material properties.

Properties A356 HAYNE S®566 INCONEL ®625

Yield strength

4.15e+008

N/m2

7.9 e+008

N/m2

7.58e+008

N/m2

Tensile strength

4.7e+008

N/m2

8.15 e+008

N/m2

1.103e+009

N/m2

Elastic modulus

7.2e+010

N/m2

2.05e+011

N/m2

2.048e+011

N/m2

Poisson’s ratio

0.33 0.382 0.312

Mass density

2800

kg/m3

8230

kg/m3

8440

kg/m3

Shear modulus

2.8e+010

N/m2

7.9e+010

N/m2

7.8 e+010

N/m2

Thermal expansion coefficient

2.3 e-005 /Kelvin

1.71 e-006 /Kelvin

1.31 e-006 /Kelvin

Methodology

The design of diesel piston is done in Solid works part design and Solid works Simulation issued to

analyze the model.

A. The design of the Diesel Piston:








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InFigure2, the design of diesel piston is shown. The piston is represented in the isometric view.

Fig.2: Diesel Piston Isometric View

Volumetric properties of the models are shown in Table2.

Design With Alloy

Mass Volume Density Weight

A356 0.705664 kg 0.00025202 m3 2800.03 kg/m3 6.91551 N

HAYNES®556 2.07415 kg 0.00025202 m3 8230.08 kg/m3 20.3266 N

INCONEL®625 2.12707 kg 0.00025202 m3 8440.08 kg/m3 20.8453 N

B. The meshing of models:

Solid works Simulation software is used to mesh the diesel piston. For stress analysis, Finite

element methods are used in the generation of meshes. Tetrahedron type of cells is used in the

meshes. The Cartesian immersed body meshe type of meshing is issued in the generation of the

grid. The general meshing information which is for both the models in all types of studies is shown

in Table3

Mesh Type Solid mesh

Mesh Element Type Tetrahedron

Jacobian points 4

Solver type FFE Plus

Following parts gives the complete details of meshing.

C. Meshing information of Diesel Piston:

Tables4,5 and 6 gives the information of the meshing during analysis using alloys A356,

HAYNES®556 and INCONEL®625.








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Table 4

Analysis with A356:

Table 5

Analysis with HAYNES®556:

Mesh Details Static1 Static2

Mesh type Solid mesh Solid mesh

Mesh Element Type

Tetrahedron on

Tetrahedron

Jacobian points

4 4

Element Size 3.15914mm 3.15914mm

Tolerance 0.157957mm

0.157957mm

Total Nodes 88476 88476

Total Elements

59303 59303

Maximum Aspect Ratio

32.926 32.926



Mesh Element Type

Tetrahedron Tetrahedron

Jacobian points

4 4

Element Size 3.15914mm 3.15914mm

Tolerance 0.157957mm 0.157957mm


Total Elements

59303 59303


32.926 32.926








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Table 6

Analysis with INCONEL®625:

These are the meshing details of the diesel piston during two different studies performed by using

alloys A356, HAYNES®556 and INCONEL®625.

RESULTS AND DISCUSSIONS

The Finite Element Analysis and simulations are done on the models with alloys A356, HAYNES®

556 and INCONEL®625. Results such as Von Mises stress are obtained. The results obtained are

shown below:

A. Static1:

Gravity causes the load mg on the diesel piston which isused as a type of load in static1 analysis.

Elastic supports are used as fixtures at the holes provided on the piston for Gudgeon pin which

connects the connecting rod and piston. The analysis results of a static study on the diesel piston

with alloys A356, HAYNES®556 and INCONEL®625 are shown in Table 7.

The analysis criterion and the test conditions are:

Acceleration due to gravity which is equal to 9.8m/s2 causes the load on the diesel piston. The

failure stress criterion used in the study is the Von Mises stress failure criterion.



Mesh Element Type

Tetrahedron on

Tetrahedron

Jacobian points

4 4

Element Size 3.15914m 3.15914mm

Tolerance 0.157957mm 0.157957mm


Total Elements

59303 59303


32.926 32.926








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Table 7

Model Von Mises Stress(min)

Von Mises Stress(max)

DieselPiston A356

2.728e+001 N/m2

3.211e+004 N/m2

Diesel Piston

HAYNES ®556 1.562e+002 N/m2 9.262e+004 N/m2

Diesel Piston

INCONEL ®625 2.751e+002 N/m2 9.863e+004 N/m2

B. Static2:

The loads applied in the static2 study are due gravity which causes the load mg on the diesel

piston, the pressure exerted on the piston head during combustion of fuel in the combustion

chamber of the diesel engine and the thermal load effects on the piston. Elastic supports are used

as fixtures at the holes provided on the piston for Gudgeon pin which connects the connecting rod

and piston. The analysis results of a static study on the diesel piston with alloys A356,

HAYNES®556 and INCONEL®625 are shown in Table8.

Acceleration due to gravity which is equal to 9.8m/s2 causes the load on the diesel piston. At

thermal load such as temperature T=400ºC and pressure load P=6.5N/mm2 are applied in static

2 studies.

The failure stress criterion used in the study is the Von Mises stress failure criterion.

Table8

Model Von Mises Stress(min)

Von Mises Stress(max) DieselPiston

A356 7.548e+006

N/m2

1.241e+009

N/m2

Diesel Piston

HAYNES ®556 2.375e+006 N/m2 3.562e+008

N/m2

Diesel Piston

INCONEL ®625 1.723e+006 N/m2 2.339e+008

N/m2

The results such as Von Mises stress obtained as a result of simulations done on diesel piston using

Solid Works Simulation. Plots obtained in the studies static1 and static2 are plotted and are shown

below.








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A. Static1:

Plots for Von Mises stress are obtained at different nodes using Probe tool in Static1 study. The

plots are plotted against Von Mises stress and nodes.

i.PlotResultsforA356alloy: ii. Plot Results for HAYNES®556alloy:

.

Graph1:Von Mises Stress in Static1 study Graph2:Von Mises Stress in Static1 study








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iii.Plot Results for INCONEL®625alloy:

Graph3:Von Mises Stress in Static1 study

B. Static2:

Plots for Von Mises stress are obtained at different node susing Probe tool in Static2 study. The

plots are plotted against Von Mises stress and nodes.

i.PlotResultsforA356alloy: ii.Plot Results for HAYNES®556 alloy:

Graph4:Von Mises Stress in Static2 study Graph5: Von Mises Stress in Static2 study








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iii.Plot Results for INCONEL®625alloy:

Graph6: Von Mises Stress in Static2 study

The tabulated results of diesel piston are shown in contours as follows:

Static 1

The post-processing results consist of surface plots for the Von Mises stress which are obtained

at different nodes in Static1. The surface plots are plotted against Von Mises stress and nodes of

Diesel piston.

i. Surface Plot Results for A356 alloy:

Fig.3:VonMises stress








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ii. Surface Plot Results for HAYNES®556 alloy:


iii. Surface Plot Results for INCONEL®625 alloy:

Fig.5:Von Mises stress

Figures3, Figure4 and Figure5 shows the results of diesel piston analyzed with alloys A356,

HAYNES®556 and INCONEL®625 in static1 study.

Static2:

The post-processing results consist of surface plots for the Von Mises stress which are obtained

at different nodes in Static1. The surface plots are plotted against Von Mises stress and nodes

of Diesel piston.

i. Surface Plot Results forA356alloy:








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ii. Surface Plot Results for HAYNES®556 alloy:


iii. Surface Plot Results for INCONEL®625 alloy:


Figures6, Figure7 and Figure8 shows the results of diesel piston analyzed with alloys A356,

HAYNES®556 and INCONEL®625 in static2 studies.








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Interpretation of Results:

The simulations result in such minimum Von Mises stress and maximum Von Mises stress is

obtained in both the static 1 study and static 2 studies on the diesel piston. The values minimum

Von Mises stress and maximum Von Mises stress are very less compared to the Yield strength of

alloys A356, HAYNES® 556 and INCONEL® 625 in static 1 study. Hence the designs are considered

to be successful.

VI. Conclusion

In Static study 1 the computed results show that the Von Mises stress for the diesel piston is

under the yield point of the material. Therefore, the designs are successful.

However, the minimum and maximum values of Von Mises stress for Static studies 1 and 2 using

the alloys A356, HAYNES® 556 and INCONEL® 625 vary in both the studies. In Static 1 study, the

alloy A356 has the least maximum Von Mises Stress value 3.211e+004 N/m2 which is less than

the values of HAYNES® 556 alloy, 9.262e+004 N/m2 and INCONEL® 625 alloy, 9.863e+004 N/m2.

In this case, alloy A356 is superior compared to HAYNES® 556 and INCONEL® 625.

But the Static 2 study conducted on diesel piston considering the optimal operating conditions of

an automobile diesel engine, the diesel piston designed with the alloys A356 starts yielding since

the maximum Von Mises Stress, 1.241e+009 N/m2 far exceeded the yield stress value,

4.15e+008N/m2 at the test conditions. This shows that the presently used alloy A36 has less

sustainability at optimal operating conditions.

On the other hand, the Static 2 study conducted on diesel piston considering the optimal operating

conditions of an automobile diesel engine, the diesel piston designed with the alloys HAYNES®

556 and INCONEL® 625 does not yield since the maximum Von Mises Stress values do not exceed

the yield strength of the materials.

Therefore, the study gives the following conclusions that alloy HAYNES® 556 and INCONEL® 625

can be used in the diesel piston which can with stand for a long period of time under the optimum

working conditions.

Suggestions:

INCONEL® 625 alloy is preferred to use over the alloy HAYNES® 556 in diesel piston design since

in the static 2 study which is conducted at optimal operating conditions, the maximum Von Mises

Stress of INCONEL® 625 is 2.339e+008 N/m2 which is less than the maximum Von Mises Stress

of HAYNES® 556, 3.562e+008 N/m2.

From this study, we conclude that a diesel piston designed with either INCONEL® 625 alloy or

HAYNES® 556 alloy as discussed can be used for diesel engines in automobiles.








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REFERENCES

[1] Glinsner, Karl, Olejniczak, Martin, “Piston,” European Patent, Patent No.: EP 1 348 859 B1.

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Seok Gunpo-si, Lee, Jae Seung Ansan-si, “Piston,” European Patent, Patent No.: EP 1 790 881

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[3] Glinsner, Karl, Olejniczak, Martin, “Piston,” European Patent, Patent No.: EP 1 348 8 59 B2.

[4] Kumai, Toyota-shi, Aichi-ken, Michio Nagano, “Piston equipped with piston ring,” European

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[5] Ishida, MasaoSuwa-shi, Nagano-ken, “Combination of a piston and a piston ring,” European

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Design and Analysis of Diesel Piston Nethula Arun …euroasiapub.org/wp-content/uploads/2017/09/5EASAug-5399...2017/09/05 · Design and Analysis of Diesel Piston Nethula Arun1 M.Tech