A Project Report

On

DESIGN AND FE ANALSYS OF DIESEL ENGINE

PISTON
A Thesis Submitted to
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, HYDERABAD
In Partial fulfillment of the Requirement for the Award of the degree of

MASTER OF TECHNOLOGY
In
ADVANCED MANUFACTURING SYSTEMS
By
BETHI NITHIN KUMAR
165U1D3304
Under the esteemed guidance of

PROF.J NARSAIAH (Ph.D)

Dept. of Mechanical Engineering AVN INSTITUTE OF ENGINEERING AND

TECHNOLOGY Koheda Road, Ibrahimpatnam, Ranga Reddy-501510, T.S 2018

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 AVN INSTITUTE OF ENGINEERING AND TECHNOLOGY Koheda
Road, Ibrahimpatnam, Ranga Reddy-501510, T.S

CERTIFICATE

This is to certify that the project report entitled

“DESIGN AND FE ANALSYS OF DIESEL ENGINE PISTON”. Submitted by
BETHI NITHIN KUMAR, bearing H.T No: 165UD13304 in partial fulfillment for the
Degree of Master of Technology in ADVANCED MANUFACTURING SYSTEMS
to Jawaharlal Nehru Technological University is a report of bonafide work carried out
by him/her under my guidance and supervision.

Prof. BASAWARAJ S
ASST PROF. J NARSAIAH HASU(Ph.D)

Project Guide Head of the Department

EXTERNAL EXAMINER

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 ACKNOWLEDGEMENT
I would like to thank my project guide Asst Prof. J NARSAIAH
and A PRAVEENA (M.Tech) Asst.Professor for their excellent guidance, support and
distinguished supervision which allowed me to complete this work.

I am very grateful to Prof. BASAWARAJ S HASU (Ph.D), HEAD OF THE

DEPARTMENT (HOD) Mechanical Engineering, who taught me and guided me with
his ideas during this project.

I would like to thank Dr. Y ELLAMRAJ Ph.D., (IIT - BOMBAY),

PRINCIPAL of AVN INSTITUTE OF ENGINEERING AND TECHNOLOGY, for
his valuable guidance and timely suggestions during the entire duration of the project
work.

I would like to thank all the Faculty of Mechanical Engineering Department of

AVN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Finally I wish all my friends, well wishers as well as to my family who have been
a constant source of encouragement and support without which it would have
been difficult to finish this project successfully.

BETHI NITHIN KUMAR

165U1D3304

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 DECLARATION
I hereby declare that the project entitled “DESIGN AND FE ANALSYS OF
DIESEL ENGINE PISTON” submitted in partial fulfillment for the Degree of Master
of Technology in ADVANCED MANUFACTURING SYSTEMS to Jawaharlal Nehru
Technological University is an authentic work and has not been submitted to any other
university/institute for the award of any degree.

BETHI NITHIN KUMAR

165U1D3304

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 INDEX
S No CONTENTS Pg No
CONTENTS V
ABSTRACT 7
LIST OF FIGURES 8
LIST OF TABLES 9
LIST OF GRAPHS 9
1. INTRODUCTION
1.1. Introduction to piston 11
1.2. Construction of piston 12
1.3. Material of the piston 13
1.4. Piston description 17
2. PARTS INSIDE THE PISTON 18
2.1. Based on head development 19
2.2. On the premise of skirt profile 20
2.3. On the premise of skirt barrel 20
3. MATERIALS FOR MANUFACTURING PISTON
3.1. Cast press barrel 21
3.2. Aluminum amalgam barrel 21
3.3. Cast iron 21
3.4. Properties of cast iron 22
4. DESIGN CALCULATIONS OF PISTON
4.1. Pressure calculations 23
4.2. Specifications 34
5. INTRODUCTION TO COMPUTER AIDED DESIGN
5.1. Introduction to cad 36
5.2. Prologue to Creo 37
5.3. Advantages of creo parametric software 39
5.4. Creo parametric module 39
5.5. 3D Model 40
5.6. 2D Model 41
6. INTRODUCTION TO FINITE ELEMENT ANALSYS
6.1. Introduction to FEA 42
7. INTRODUCTION TO ANSYS
7.1. Structural analsys 44
7.2. Ansys mechanical 44
7.3 Fluid dynamics 44
8. STATIC ANALSYS OF DIESEL ENGINE PISTON 45
8.1. Materials used 45
8.2. .iges format 46
8.3. Material-Steel 48
a) Total deformation
b) Von-mises stress
c) Von-mises strain
8.4. Material-Cast iron 49
a) Total deformation
b) Von-mises stress
c) Von-mises strain
8.5 Material Aluminum alloy 51
a) Total deformatiom
b) Von-mises stress
c) Von-mises strain
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 9. MODAL ANALSYS OF DIESEL ENGINE PISTON 53
9.1. Material-Steel 53
a) Total deformation-1
b) Total deformation-2
c) Total deformation-3
9.2. Material-Cast iron 54
a) Total deformation-1
b) Total deformation-2
c) Total deformation-3
9.3. Material-Aluminum 55
a) Total deformation-1
b) Total deformation-2
c) Total deformation-3
10. THERMAL ANALSYS OF DIESEL ENGINE PISTON 58
10.1. Material-Steel 58
a) Temperature, Heat flux
10.2. Material-Cast iron 59
a) Temperature, Heat flux
10.3. Material-Aluminum alloy 60
a) Temperature, Heat flux
11. CONCLUSION 64
12. BIBLOGRAPHY 65

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 DESIGN AND FE ANALYSIS OF DIESEL ENGINE
PISTON

ABSTRACT
Piston is a segment of responding engines, responding pumps, gas blowers and pneumatic

barrels, among other comparable components. It is the moving segment that is contained by a

barrel and is made gas-tight by piston rings. The piston changes the vitality of the growing

gasses into mechanical vitality. The piston rides in the barrel liner or sleeve. Pistonns are

regularly made of aluminum or cast press combinations. The primary point of the task is to plan

a piston for 1300cc diesel engine for two materials Cast Iron and Aluminum Alloy. The

condescends of the piston are displayed utilizing PRO-E programming. The outlines are assessed

by basic and warm investigation by applying weights and temperatures individually. The

outcome is assessed by checking the pressure, dislodging, warm angle and warm transition to

choose the best plan of the piston. Basic and Thermal examination are done in ANSYS

programming.

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 LIST OF FIGURES

Fig. No Title Page No

1. Nomenclature of piston 12
2. Construction of piston 13
3. Piston description 18
4. 3D Model 40
5. 2D Model 41
6. Geometry of piston 46
7. Material-Steel 48
a) Total deformation
b) Von-mises stress
c) Von-mises strain
8. Material-Cast iron 49
a) Total deformation
b) Von-mises stress
c) Von-mises strain
9. Material-Aluminium alloy 51
a) Total deformation
b) Von-mises stress
c) Von-mises strain
10. Material-Steel 53
a) Total deformation1
b) Total deformation2
c) Total deformation3
11. Material-Cast iron 54
a) Total deformation1
b) Total deformation2
c) Total deformation3
12. Material-Aluminum alloy 55
a) Total deformation1
b) Total deformation2
c) Total deformation3
13. Material-Steel 58
Temperature, Heat flux
14. Material-Cast iron 59
Temperature, Heat flux
15. Material-Aluminum alloy 60
Temperature, Heat flux

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 LIST OF TABLES

Table No Title Page No

1. Static analysis 61
2. Modal analysis 61
3. Thermal analysis 61

LIST OF GRAPHS

Table No Title Page No

1. Deformation 61
2. Stress 61
3. Strain 61
4. Heat flux

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INTRODUCTION TO PISTON

In each engine, barrel assumes an imperative job in working and creating results. Barrel frames a

guide and bearing for the little end of interfacing pole and furthermore transmits the power of

blast in the chamber, to the wrench shaft through associating bar. The barrel is the single, most

dynamic and exceptionally basic segment of the car engine. The Piston is a standout amongst the

most urgent, yet especially behind-the-arrange parts of the engine which does the basic work of

passing on the vitality got from the burning inside the ignition chamber to the crankshaft. Just

stated, it conveys the power of blast of the burning procedure to the crankshaft. Aside from the

basic occupation that it does above, there are sure different capacities that a barrel constantly

does - It frames a kind of a seal between the ignition chambers shaped inside the barrels and the

crankcase. The barrels don't let the high weight blend from the burning chambers over to the

crankcase.

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Construction of Piston:-

Its top referred to by numerous names, for example, crown, head or roof and thicker than base

segment. Base bit is known as skirt. There are grooves made to suit the pressure rings and oil

rings. The section, made for oil ring, is more extensive and more profound than the depressions

made for pressure ring. The oil ring scraps the overabundance oil which streams into the barrel

inside through the oil return openings and in this manner abstaining from achieving the burning

chamber yet greases up the gudgeon stick to some degree. In a few plans the oil ring is given

underneath the gudgeon stick manager .The space between the sections are called as terrains.

The measurement of barrel constantly kept littler than that of chamber in light of the fact that the

barrel achieves a temperature higher than barrel divider and extends amid engine activity. The

space between the barrel divider and barrel is known as barrel leeway. The width of the barrel at

crown is marginally not exactly at the skirt because of variety in the working temperatures.

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Again the skirt itself is likewise marginally decreased to take into consideration uneual extension

because of temperature contrast as we move vertically along the skirt the working temperature

isn't uniform however somewhat diminish.

Materials for the Piston:-

Cast Press, Aluminum Alloy and Cast Steel and so on are the basic materials utilized for barrel

of an Internal Combustion Engine.Cast Iron barrels are not reasonable for fast engines due its

more weight. These barrels have more noteworthy uality and protection from wear. The

Aluminum Alloy Piston is lighter in weight and enables much lower running temperatures as a

result of its higher warm conductivity. The coefficient of improvement of this kind of chamber is

around 20% not as much as that of unadulterated aluminum chamber anyway higher than that of

cast sueeze barrel and barrel divider.

To maintain a strategic distance from seizure on account of higher development than chamber

wall,more barrel leeway reuired to be provided.It results in barrel slap after the engine is begun

yet at the same time warming up and tends to isolate the crown from the skirt of the barrel.

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Cutting a vertical opening will maintain a strategic distance from this detriment. This opening

aides in taking up warm development thus the general breadth of the barrel isn't reuired to be so

decreased as to impede the protected activity between the barrel dividers and the barrels. To

build the life of notches and to lessen the wear,a ferrous metal rings are embedded in the furrows

of fast engines.

Plan of Piston:- A barrel does the messy work of really taking the brunt of the power of blast

emerging of the ignition of the fuel and passes it onto the crankshaft (the huge, substantial piece

of a engine that pivots because of the development of the barrel). It takes a colossal measure of

weight (around 1000 Psi) despite the serious warmth that it needs to take. Presently, when

outlining barrels, the weight is a genuine deciding variable. Envision the situation - on one hand

you would reuire the barrels to have the capacity to get everything that warmth and weight,

however then again, regardless you need it light. Material sciences act the hero again with

aluminum standing out for the decision - with its ideal uality to-weight proportion; the way that it

is effortlessly machinable, has an awesome warm conductivity (can exchange warm rapidly) and

above all, it is light weight, aluminum is the decision material for making barrels today.

Be that as it may, the elder sibling cast press is additionally utilized for the development of

barrels for the previously mentioned reasons, aside from that it is substantial and conseuently is

utilized for constrained applications - like moderate speed engines and such. You could have

accepted a canny figure with respect to what might happen when you understand that solids grow

when warmed; so when the barrel takes such an extensive amount warm; it does need to extend,

isn't that right? When it does, won't it be stuck inside the chamber? Won't your engine hack up

and slow down? The resonating answer is NO, on the grounds that the barrel is worked so that

takes into consideration this extension. From the photo above, you would understand that the

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crown (leader of the barrel) takes warm and henceforth extends more than alternate parts of the

barrel. So this zone, the upper piece of the barrel, is machined to a distance across somewhat

lesser than whatever remains of the barrel (the skirt, fundamentally).

Amazingly, one more method for controlling the barrel's extension is cut a space into the skirt

(the fundamental body of the barrel). So when the barrel warms, up the skirt basically closes

itself because of the metal extension and keeps the barrel to grow outwards and contact the

barrel. Keeping in mind the end goal to diminish wear and increment the life of barrel grooves in

rapid engines,a ferrous metal rings are embedded into the depressions. The barrel rings,which are

likewise called as pressure rings are fit intently in the depressions gave in the piston.These rings

are exhausted before the wearing of the barrel and barrel wall.Hence by supplanting the same,we

can maintain a strategic distance from substitution of barrel or chamber.

The spillage of the high temperature gases created amid control stroke in the burning chamber is

averted by barrel rings.The barrel rings shape a compelling seal and in the meantime transmit

warm from crown to the barrel dividers and subseuently keep the temperature inside as far as

possible. There ought to be somewhere around two barrel rings in every barrel of inside ignition

engine.For the higher limit engines,there are four or even six barrel rings have been used.The

number of rings is relying on the limit and size of the I.C.Engine. Keeping in mind the end goal

to accomplish the powerful seal against greasing up oil and high weight gases leakage,a

incredible weight must be exerted,by each ring on the barrel walls.To deliver this effect,the rings

are made somewhat bigger in the distance across than that of chamber bore and cutting little hole

which is incompletely limited when the ring is fitted.The end hole in the barrel ring gives

adaptability to the ring and a similar time taking into account warm extension.

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There are another rings utilized in barrel grooves,called as, Oil Scraper Rings.The capacity of

these rings are,only as much amount of the oil as it only adeuate to keep up legitimate grease is

permitted to achieve the skit.The abundance oil which would have spilled in the ignition

chamber without filling any valuable need and fairly prompting carbonizationis scratched off by

the oil scrubber ring.

While mounting the barrel rings over the piston,a awesome consideration ought to be taken to

guarantee that the holes of different rings ought not fall in a similar vertical line. The barrel rings

of inside burning engines are made in different areas such as,standard,tapered,grooved,wedge

and L shape.Whereas oil scrubber rings are made as,narrow,wide,tapered and six portion line

segment. The cast press alongside 2.5% silicon will give a decent wear protection from barrel

ring.In instance of traveler cars,the barrel rings are typically plated with Chromium Tin or

Cadmium.The plating diminishes the rate of chamber wear and conseuently expands the life of

inner burning engine.

The barrel engine was first proposed by R.P. Pescara and the first application was a solitary

barrel air blower. The engine idea was a theme of much enthusiasm for the period 1930-1960.

These original barrel engines were no matter what contradicted barrel engines, in which the two

barrels were mechanically connected to guarantee symmetric movement. Barrel engines gave a

few preferences over ordinary innovation, including minimization and a without vibration plan.

The main effective use of the barrel engine idea was as air blowers. In these engines, air blower

chambers were coupled to the moving barrels, freuently in a multi-arrange design. A portion of

these engines used the air staying in the blower chambers to restore the barrel, conseuently

taking out the reuirement for a bounce back gadget. Barrel air blowers were being used on the

grounds that it has favorable circumstances of high proficiency, conservativeness and low

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commotion and vibration After the achievement of the barrel air blower. Various barrel gas

generators were produced, and such units were in across the board use in substantial scale

applications, for example, stationary and marine power plants). High operational adaptability,

and magnificent part stack execution has been accounted for such engine

PISTON DESCRIPTION

Pistons climb and down in the barrels which applies a power on a liuid inside the chamber.

Barrels have rings which serve to keep the oil out of the burning chamber and the fuel and

ventilate of the oil. Most barrels fitted in a chamber have barrel rings. Usually there are two

spring-weight rings that go about as a seal between the chamber and the barrel wall, and

something like one oil control ring s underneath the weight rings. The pioneer of the barrel

can be level, swell or for the most part shaped. Chambers can be produced or tossed. The

condition of the barrel is commonly balanced yet can be special. An excellent kind of cast

chamber is the hypereutectic barrel.

The barrel is an essential segment of a barrel engine and of pressure driven pneumatic

frameworks. Barrel heads shape one mass of an extension chamber inside the barrel. The

contrary divider, called the barrel head, contains bay and fumes valves for gases. As the barrel

moves inside the barrel, it changes the vitality from the extension of a consuming gas as a rule

a blend of petroleum or diesel and air into mechanical power as a responding direct

movement. From that point the power is passed on through an associating pole to a

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crankshaft, which changes it into a revolving movement, which typically

Drives a gearbox through a grasp. Parts of a run of the mill, four stroke cycle, DOHC barrel

engine. (E) Exhaust camshaft, (I) Intake camshaft, (S) Spark plug, (V) Valves, (P) Piston, (R)

Connecting pole, (C) Crankshaft, (W) Water coat for coolant stream.

PARTS INSIDE THE PISTON

1.Piston head or crown: - The barrel head or crown might be that convex or curved relying

on the plan of combustion chamber.

a. It with stands the weight of gas in the chamber.

b. The choice of barrel crown basically relies on the reuirement of esteems for the burning

chamber.

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2. Pistonrings: - These are utilized to seal the barrel keeping in mind the end goal to avoid

hatiage of the gas past the barrel.

a. To go about as section of warmth spill out of barrel crown to the mass of the chamber.

b.To go about as a greasing up oil controller on the chamber divider so as to limit wear.

c.To ingest some piece of the barrel because of side push.

d.The material for barrel rings is typically solid metal and composite cast press because of

their great wearing characteristics and likewise they hold thespring ualities ever at high

temperatures.

Barrel Rings Are Two Types :-

1. Pressure rings - >a. Fixing of the burning gas.

b.Heat exchange from barrel crown to the barrel divider.

2. Oil control rings - > to keep exorbitant oil from

Going through the end hole of rings and between the barrel divider and the ring face.

Diverse Typesof Pistons

Different sorts of barrels are utilized on various engines. This is on the grounds that each

sort satisfies some particular necessities on a specific engine.Some barrels have complex

head development, some have uniuely shaped skirts, and other have geometrical uirks. In

light of different contemplations, the barrels might be ordered as takes after.

1. Based on head development:

a. Diverter head barrel

b. ignition chamber compose barrel

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 c. Domed and discouragement headed barrel.

2.On the premise of skirt profile :

a. Shoe barrel

b. Cutway barrel

3.On the premise of skirt barrel:

a. strong skirt barrel

b. split skirt barrel

4.On the premise of different claims to fame:

a. Cam ground barrel

b. Decrease barrel

c. Oval barrel

Materials for Manufacturing Pistons

Aluminum composites give light barrels and for better warmth dissemination, aluminum

combinations are the perfect materials because of their high warm conductivity. Aliminium is 3

times lighter than cast press. Its uality is great at low temperatures yet is looses around half of its

uality at temperatures above around 320 c .Its development is around 2 ½ times that of cast press

and the protection from scraped spot is low at hight temperatures. Anyway these

disadvantageous properties of aluminum have now been ever dropped by alloying it with

different materials and by creating propelled outlines of barrels. The split skirt, T-sotted and in

addition cam ground, oval segmented barrels produced using aluminum amalgams are for the

most part utilized which can be firmly fitted into the chamber destined to dispose of "barrel

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slap". A covering of aluminum oxide or tin on aluminum compounds barrels has been observed

to be defensive against "scraping" or "halfway seizure" amid pursuing in upgrade.

(a) For a cast press barrel the temperature at the focal point of the barrel head (Tc) is around

425c to 450c under full load conditions and the temperatures at the edges of the barrel head (Tb)

is around 200c to 225c.

(b) For aluminum amalgam barrel, Tc is around 260c to 290c and Te is around 185c to 215c.

Since the aluminum amalgams are about*** three times lighter than cast press, Therefore its

mechanical uality is great at low temperatures, however they lose their strength(about half) at

temperatures over 325c.

CAST IRON:- It is acuired by remeltingmigiron with coke andfurnaces by the definition cast

press is an amalgam and iron and carbon containing more 2% of carbon. Itcontains carbon - 3.0-

4.0%

Siliver-1.0-3.0%

Manganes-0.5-1.0%

Sulfur-upto0.1%

Phosphors-upto0.1%

Press - leftover portion.

PROPERTIESOF CAST IRON:-

1. It is fragile material.

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2. Great throwing

3. High compressive uality.

4. High wheel obstruction.

5. Poor machineability

6. Rigidity - 100 to 200mpa

7. Compressive uality 400 to 1000mpa

8. Shear uality - 120mpa.

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 DESIGN CALCULATIONS OF PISTON

Pressure Calculation

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 INTRODUCTION TO CAD

PC supported plan (CAD) is the utilization of PC frameworks (or workstations) to help in the

creation, adjustment, examination, or enhancement of an outline. PC supported outline writing

computer programs is used to grow the proficiency of the originator, improve the idea of

arrangement, upgrade exchanges through documentation, and to make a database for amassing.

PC supported outline yield is routinely as electronic records for print, machining, or other

amassing exercises. The term CADD (for Computer Aided Design and Drafting) is in like

manner used.

Its usage in laying out electronic systems is known as electronic arrangement engineization, or

EDA. In mechanical diagram it is known as mechanical arrangement automation (MDA) or PC

helped drafting (CAD), which joins the route toward making a particular outline with the use of

PC programming.

PC helped configuration programming for mechanical layout uses either vector-based

representations to outline the objects of ordinary drafting, or may in like manner make raster

delineations exhibiting the outward presentation of formed things. Regardless, it incorporates

something past shapes. As in the manual drafting of specific and building delineations, the yield

of CAD must pass on information, for instance, materials, techniues, estimations, and

protections, as demonstrated by application-specific conventions.

PC supported outline may be used to setup curves and figures in two-dimensional (2D) space; or

twists, surfaces, and solids in three-dimensional (3D) space. PC supported plan is a basic present

day workmanship extensively used in various applications, including auto, shipbuilding, and

flight endeavors, mechanical and basic blueprint, prosthetics, and some more.

36
Computer aided design is likewise broadly used to deliver PC movement for embellishments in

films, promoting and specialized manuals, freuently called DCC computerized content creation.

The advanced universality and intensity of PCs implies that even scent jugs and cleanser

distributors are composed utilizing methods incomprehensible by specialists of the 1960s. As a

result of its huge financial significance, CAD has been a noteworthy main thrust for explore in

computational geometry, PC designs (both euipment and programming), and discrete differential

geometry.

Prologue TO CREO

PTC CREO, some time ago known as Pro/ENGINEER, is 3D demonstrating programming

utilized in mechanical building, outline, fabricating, and in CAD drafting administration firms. It

was one of the initial 3D CAD demonstrating applications that utilized a control based

parametric framework. Utilizing parameters, measurements and highlights to catch the conduct

of the item, it can advance the improvement item and additionally the plan itself.

The name was changed in 2010 from Pro/ENGINEER Wildfire to CREO. It was reported by the

organization who created it, Parametric Technology Company (PTC), amid the dispatch of its

suite of outline items that incorporates applications, for example, gathering demonstrating, 2D

orthographic perspectives for specialized illustration, limited component examination and that's

only the tip of the iceberg.

PTC CREO says it can offer a more effective outline involvement than other displaying

programming on account of its interesting highlights including the joining of parametric

and direct demonstrating in one stage. The total suite of uses traverses the range of item

advancement, giving creators choices to use in each progression of the procedure. The

product likewise has a more easy to understand interface that gives a superior ordeal to

37
 planners. It likewise has community oriented limits that make it simple to share plans and

roll out improvements. There are endless advantages to utilizing PTC CREO. We'll

investigate them in this two-section arrangement.

First up, the greatest favorable position is expanded profitability in light of its proficient and

adaptable outline capacities. It was intended to be less demanding to utilize and have highlights

that take into account configuration procedures to move all the more rapidly, making a

fashioner's profitability level increment.

Some portion of the reason efficiency can be expanded is on the grounds that the bundle offers

instruments for all periods of advancement, from the earliest starting point stages to the hands-on

creation and assembling. Late stage changes are regular in the outline procedure, yet PTC CREO

can deal with it. Changes can be made that are reflected in different parts of the procedure.

The synergistic ability of the product likewise makes it less demanding and uicker to utilize. One

reason it can process data all the more rapidly is a result of the interface among MCAD and

ECAD plans. Outlines can be adjusted and featured between the electrical and mechanical

fashioners taking a shot at the undertaking.

The time spared by utilizing PTC CREO isn't the main favorable position. It has numerous

methods for sparing expenses. For example, the expense of making another item can be brought

down in light of the fact that the advancement procedure is abbreviated because of the

robotization of the age of cooperative assembling and administration expectations.

PTC likewise offers thorough preparing on the most proficient method to utilize the product.

This can spare organizations by wiping out the need to procure new representatives. Their

preparation program is accessible on the web and face to face, yet materials are accessible to get

to whenever.

38
A special component is that the product is accessible in 10 dialects. PTC knows they have

individuals from everywhere throughout the world utilizing their product, so they offer it in

different dialects so about any individual who needs to utilize it can do as such.

ADVANTAGES OF CREO PARAMETRIC SOFTWARE

1. Optimized for display based ventures

2. Increased designer efficiency

3. Better empowered idea plan

4. Increased designing abilities

5. Increased assembling abilities

6. Better recreation

7. Design abilities for added substance fabricating

CREO parametric modules:

• Sketcher

• Part demonstrating

• Assembly

• Drafting

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3D MODEL

40
2D MODEL

41
 INTRODUCTION TO FEA

Finite component examination is a techniue for unraveling, typically around, specific issues in

designing and science. It is utilized basically for issues for which no correct arrangement,

expressible in some numerical shape, is accessible. Thusly, it is a numerical as opposed to a

systematic strategy. Strategies for this compose are reuired in light of the fact that scientific

techniues can't adapt to the genuine, entangled issues that are met with in designing. For

instance, building uality of materials or the numerical hypothesis of flexibility can be utilized to

compute diagnostically the anxieties and strains in a bowed shaft, however neither one of the

wills be extremely effective in discovering what is going on in part of an auto suspension

framework amid cornering.

One of the main utilizations of FEA was, undoubtedly, to discover the burdens and strains in

building parts under load. FEA, when connected to any practical model of a building part, reuires

a gigantic measure of calculation and the improvement of the strategy has relied upon the

accessibility of reasonable advanced PCs for it to keep running on. The strategy is presently

connected to issues including an extensive variety of wonders, including vibrations, warm

conduction, liuid mechanics and electrostatics, and an extensive variety of material properties,

for example, straight versatile (Hookean) conduct and conduct including deviation from Hooke's

law (for instance, pliancy or elastic flexibility).

Numerous complete broadly useful PC bundles are currently accessible that can manage an

extensive variety of marvels, together with more specific bundles for specific applications, for

instance, for the investigation of dynamic wonders or expansive scale plastic stream. Contingent

upon the sort and many-sided uality of the investigation, such bundles may keep running on a

microcomputer or, at the other extraordinary, on a supercomputer. FEA is basically a piece-wise

42
process. It very well may be connected to one-dimensional issues, however more often than not

there is a region or volume inside which the arrangement is reuired. This is part up into various

littler zones or volumes, which are called limited components. Figure 1 demonstrates a two-

dimensional model of a spanner that has been so separated: the procedure is called discretisation,

and the gathering of components is known as a work.

43
INTRODUCTION TO ANSYS

Structural Analysis

ANSYS Autodyn is PC recreation apparatus for reproducing the reaction of materials to brief

term serious loadings from affect, high weight or blasts.

ANSYS Mechanical

ANSYS Mechanical is a limited component investigation instrument for basic examination,

including direct, nonlinear and dynamic investigations. This PC reenactment item gives

limited components to display conduct, and backings material models and condition solvers

for an extensive variety of mechanical plan issues. ANSYS Mechanical likewise incorporates

warm examination and coupled-material science abilities including acoustics, piezoelectric,

thermal– basic and thermo-electric investigation.

Fluid Dynamics

ANSYS Fluent, CFD, CFX, FENSAP-ICE and related programming are Computational Fluid

Dynamics programming instruments utilized by engineers for outline and investigation. These

apparatuses can mimic liuid streams in a virtual domain — for instance, the liuid elements of

ship frames; gas turbine engines (counting the blowers, burning chamber, turbines and max

engine propulsion); airplane streamlined features; pumps, fans, HVAC frameworks, blending

vessels, hydro twisters, vacuum cleaners, and so on.

44
 STATIC ANALYSIS OF DIESEL ENGINE PISTON

Materials used

Steel

Young’s modulus = 205000mpa

Poisson’s ratio = 0.3

Density = 7850kg/mm3

Cast iron

Young’s modulus = 110000 mpa

Poisson’s ratio = 0.28

Density = 7200

aluminum alloy

Young’s modulus = 68900mpa

Poisson’s ratio = 0.32

Density = 4150

45
Save creo Model as .iges format

→→Ansys → Workbench→ Select investigation framework → static auxiliary → double tap

→→Select geometry → right snap → import geometry → select peruse →open part → alright

→→ Select work on work seat → right snap →edit

Double tap on geometry → select MSBR → alter material →

46
Select work on left side part tree → right snap → produce work →

Select static auxiliary right snap → embed → select rotational speed and settled help → Select

removal → select reuired zone → tap on apply → put X,Y,Z part zero →

Select power → select reuired zone → tap on apply → weight

Select arrangement right snap → illuminate →

Arrangement right snap → embed → misshapening → add up to → Solution right snap →

embed → strain → eual (von-mises) →

Arrangement right snap → embed → stretch → eual (von-mises) →

Right tap on distortion → assess all outcome

47
 MATERIAL – STEEL

TOTAL DEFORMATION

VON-MISES STRESS

48
 VON-MISES STRAIN

MATERIAL -CAST IRON

TOTAL DEFORMATION

49
VON-MISES STRESS

VON-MISES STRAIN

50
 MATERIAL – ALUMINUM ALLOY

TOTAL DEFORMATION

VON-MISES STRESS

51
VON-MISES STRAIN

52
 MODAL ANALYSIS OF DIESEL ENGINE PISTON

MATERIAL – STEEL

TOTAL DEFORMATION1

TOTAL DEFORMATION2

TOTAL DEFORMATION3

53
MATERIAL – CASTIRON

TOTAL DEFORMATION1

TOTAL DEFORMATION2

54
TOTAL DEFORMATION3

MATERIAL – ALUMINUM ALLOY

TOTAL DEFORMATION1

55
TOTAL DEFORMATION2

TOTAL DEFORMATION3

56
57
 THERMAL ANALYSIS OF DIESEL ENGINE PISTON

MATERIAL – STEEL

TEMPERATURE

HEAT FLUX

MATERIAL – CAST IRON

TEMPERATURE

58
HEAT FLUX

59
MATERIAL –ALUMINUM ALLOY

TEMPERATURE

HEAT FLUX

60
RESULT TABLES

STATIC ANALYSIS

MATERIAL DEFORMATION(mm) STRESS(N/mm2) Strain

Steel 0.0059487 67.508 0.00033915

Cast iron 0.01817 67.771 0.00061901

Aluminum alloy 0.016742 67.096 0.00094959

MODAL ANALYSIS

MATERIAL freuency deformation1` freuency deformation2(mm) freuency deformation

(hz) (mm) (hz) (hz) 3(mm)

Steel 6787.1 72.637 10333 63.784 14514 80.754

Cast iron 5290 75.886 8010.2 66.629 11266 84.467

Aluminum 6740.1 122.17 10349 107.28 14511 135.5

alloy

Thermal analysis

MATERIAL Temperature (0C) Heat flux(W/mm2)

Steel 129 0.68408

Cast iron 129 0.65715

Aluminum alloy 129 0.88043

61
Graphs

DEFORMATION(mm)
0.02
0.018
0.016
0.014
0.012
0.01
DEFORMATION(mm)
0.008
0.006
0.004
0.002
0
Steel Cast iron Aluminum alloy

Stress

stress
68

67.8

67.6

67.4

stress
67.2

67

66.8

66.6
Steel Cast iron Aluminum alloy

62
strain

Strain
0.001
0.0009
0.0008
0.0007
0.0006
0.0005
Strain
0.0004
0.0003
0.0002
0.0001
0
Steel Cast iron Aluminum alloy

Heat flux(W/mm2)
1
0.9
0.8
0.7
0.6
0.5
Heat flux(W/mm2)
0.4
0.3
0.2
0.1
0
Steel Cast iron Aluminum alloy

63
CONCLUSION

Physically, synthetically and mechanically aluminum is a metal like steel, metal, copper, zinc,

lead or titanium. It very well may be liuefied, thrown, framed and machined much like these

metals and it conveys electric current. Truth be told freuently the me gear and manufacture

strategies are utilized concerning steel. Aluminum is a light metal with a particular weight of2.7

g/cm3, about a third that of steel. For instance, the utilization of aluminum in vehicles diminishes

dead-weight and vitality Consumption while expanding load limit. Its quality can be adjusted to

the application reuired by changing the organization of its combinations. By watching the static

investigation the pressure esteems are less for aluminum amalgam material than steel and cast

press. By watching the warm investigation the warmth transition esteems are more for aluminum

amalgam than steel and cast press. So it very well may be finished up the aluminum composite is

better material for piston.

64
 BIBLOGRAPHY:

1 .Sl.No - 1 Auther-Ever J. Barbero . Book Title-Interduction To Composite Material Design.

Year – 2011. ( Page-1to 21).

2. Sl.No-2 V.D.A.Lessios . Book Titel-Structural Desing Of An Advanced Composite For An

Aeronautical Hydralic Actuator. Vol.No 2. Page No-52 To 86

65