ijpam.eu S TRUCTU RAL AND THERMAL ANALYSIS ON PIST ON

STRUCTURAL AND THERMAL ANALYSIS ON PISTON USING COMPOSITE

MATERIAL

R.Prabou

1,C.Jagadeesh Vikram

2,P.Naveenchandran

3& E.Raja

4

1M.Tech Student,

2 Assistant-Professor,

3Professor,

4Assistant-Professor,

Department of Automobile Engineering,

BIST,BIHER, Bharath University, Chennai, India – 73.

Abstract—Metal Matrix Composites (MMCs)have evoked a distinct fascination as of late for potential

applications in Aerospace and car businesses attributable to their better Strength than weight proportion

and high temperature resistance. Composite materials are picking up significance for their favorable

circumstances including ease, straightforwardness and effortlessness of operation. Composites containing

hard oxides (like SiC) are favored for high wear resistance alongside expanded hardness, enhanced

erosion resistance and high temperature oxidation resistance when contrasted with amalgam and

immaculate metal. Composite covering is utilized with the end goal of wear resistance. With expanding

accessibility of micron-sized particles of SiC, there is developing enthusiasm for the electrolytic and

electro less co-statement of these particles.

In this work, material organization test, hardness test, of such composite coatings are done. The impact of

molecule size and number of particles suspended is accounted for. Sic Composites have been kept on

Aluminum by throwing process. The subsequent castings are examined utilizing checking electron

microscopy and hardness tests. The cylinder is demonstrated utilizing Pro-E out of control fire 4.0

displaying and dissected utilizing ANSYS 14.5 reproduction programming for Aluminum (Pure) and

Aluminum-SiC and the outcomes were examined.

Keywords: Piston, Pro-E, ANSYS.

I. INTRODUCTION

1.1 COMPOSITE MATERIAL

1.1.1 DEFINITION:

Composite materials are characterized as the blends of materials in distinctive creation or structure on a large

scale. The composite materials in light of the metals are said to be the Metal Matrix Composites[1-6].

Fig.1.Composite materials

The individual parts stay separate and unmistakable inside of the completed structure[7-15].

Run of the mill built composite materials include:

Composite building materials, for

example, bonds, concrete

Reinforced plastics, for example, fiber-

strengthened polymer

Metal Composites

International Journal of Pure and Applied MathematicsVolume 119 No. 12 2018, 10003-10020ISSN: 1314-3395 (on-line version)url: http://www.ijpam.euSpecial Issue ijpam.eu

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Ceramic Composites (composite clay and metal grids)

Composite materials are generally used for structures, expansions and structures, for instance, watercraft

bodies, race auto bodies, shower backs off, baths[16-20], and limit tanks, pantomime shake and refined marble

sinks and edges. The most extraordinary specimens perform routinely on rocket in asking for site[21-26].

1.2 COMPOSITES IN ANSYS

Composite materials have been used as a piece of structures for a long time. Starting at late composite

parts have been used comprehensively as a piece of plane structures, automobiles, wearing stock, and various

buyer things. Composite materials are those containing more than one fortified material, each with particular

fundamental properties. The essential purpose of inclination of composite materials is the potential for a high

extent of solidness to weight[27-30].

Fig.2.Trunk pistons

Composites utilized for regular building applications are propelled fiber or overlaid composites, for

example, fiberglass, glass epoxy[31-39], graphite epoxy, and boron epoxy. ANSYS permits us to model

composite materials with particular components called layered components. When we manufacture our model

utilizing these components, we can do any auxiliary investigation (counting nonlinearities, for example, huge

avoidance and stress solidifying).

1.3 MODELING COMPOSITES

A chamber is a piece of reacting engines[40-46], reacting pumps, gas compressors and pneumatic

barrels, among other equivalent instruments. It is the moving section that is contained by a barrel and is made

gas-tight by chamber rings. In an engine, its inspiration is to trade control from developing gas in the chamber to

the crankshaft by method for a barrel bar or potentially partner post. In a pump[47-53], the limit is pivoted and

power is traded from the crankshaft to the barrel with the ultimate objective of pressing or propelling the fluid in

the chamber. In a couple engines, the chamber similarly goes about as a valve by covering and uncovering ports

in the barrel divider.

Choosing the best possible component sort

Defining the layered setup

Specifying disappointment criteria

Following displaying and post-handling rules

International Journal of Pure and Applied Mathematics Special Issue

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High Temperature Mechanical Properties of Silicon Carbide Particulate Reinforced Cast

Aluminum Alloy Composite

The impact of high temperature on mechanical properties of silicon carbide particulate fortified cast

aluminum compound composite has been examined

Limited Element Analysis of Reverse Engineered Internal Combustion Engine Piston

The inside burning motor cylinder is broke down utilizing ANSYS limited component investigation.

The heap following up on the cylinder crown is of 4 Mpa and the maximum temperature following up

on the cylinder crown is 360ºC

Raised Temperature Mechanical Properties of Aluminum silicon carbide composite

Mechanical properties of aluminum composite fortified with silicon carbide particles were concentrated

on. Time burst creep tests completed at 300 oC demonstrated that the composites shows higher wet

blanket resistance when contrasted with the framework compound aside from at moderately low stretch

Examination of Misshappening in composite cylinders of an inside ignition motor

The paper exhibits a few consequences of re-enactment exploration of composite cylinders utilized as a

part of an immediate infusion diesel motor. An improvement endeavour connected to cylinder shape

and measurements of preforms fixed in cylinders is likewise displayed, in admiration of existing warm

loads and particular temperature circulation and additionally dissemination of anxiety and strain with

respect to bearing of de-development moderately to worldwide direction

2.1 PISTON

The barrel of an inside start engine is followed up on by the heaviness of the developing smoldering

gasses in the blazing chamber space at the most elevated purpose of the barrel. This power then acts downwards

through the interfacing shaft and onto the crankshaft. The joining shaft is associated with the barrel by a

swivelingGudgeon stick (US: wrist stick). This stick is mounted within the chamber: not at all like the steam

engine, there is no barrel post or crosshead. The stick itself is of cemented steel and is modified in the chamber,

however permitted to move in the joining shaft. A few layouts use a 'totally skimming' arrange for that is free in

both fragments. All pins must be kept from moving sideways and the completions of the stick plunging into the

chamber divider, by and large bycirclips.

2.2 INTERNAL COMBUSTION ENGINES

The cylinder of an interior ignition motor is followed up on by the weight of the growing burning

gasses in the burning chamber space at the highest point of the barrel. This power then acts downwards through

the interfacing pole and onto the crankshaft. The joining pole is connected to the cylinder by a

swivellingGudgeon pin (US: wrist pin). This pin is mounted inside of the cylinder: dissimilar to the steam

motor, there is no cylinder pole or crosshead. The pin itself is of solidified steel and is altered in the cylinder,

however allowed to move in the uniting pole. A couple outlines utilize a 'completely skimming' plan that is free

in both segments. All pins must be kept from moving sideways and the finishes of the pin diving into the

chamber divider, generally bycirclips.


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Fig.3.Crosshead pistons

Gas settling is refined by the usage of chamber rings. These are different limited iron

rings, fitted openly into segments in the chamber, just underneath the crown. The rings are

part at a point in the edge, allowing them to press against the chamber with a light spring

weight. Two sorts of ring are used: the upper rings have solid faces and give gas settling;

bring down rings have tight edges and a U-framed profile, to go about as oil scrubbers. There

are various prohibitive and unobtrusive component arrange highlights associated with barrel

rings.

Fig.4.Slipper pistons


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Fig.5.Deflector pistons

3.1 ALUMINIUM GENERAL INFORMATION

3.1.1 CHEMICAL DEFINITION

Aluminum: a chemical element (symbol Al) with an atomic number of 13,

An atomic weight of 26.98, and

Single stable isotope: 27.

Aluminum is a soft, silvery metal.

Relative density: 2.70 kg/dm3

Melting point: 660°C

A dainty, waterproof layer of aluminum oxide is framed on contact with the air. Aluminum is an essential

development material in blend with different metals. The real mixes of aluminum are the oxide, hydroxide,

chloride, sulfate, silicate, and acetic acid derivation.

ALUMINIUM GENERAL INFORMATION

In 2011, Aluminum praised its 125th commemoration!

In 1761, a Frenchman named de Morveau found a formerly obscure material. He gave it the name

'alumina', from the Latin word 'alumen', which signifies 'light'.

In 1787, the scientific expert Lavoisier discovered that alumina was an oxide of a metal that was

obscure around then.


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In 1821, bauxite was found at Les Baux

3.2 ALUMINIUM ALLOY

Aluminum can be alloyed with manganese, silicon, magnesium, zinc and different components. The

expansion of a little sum (0.5-3%) of one or more different metals is adequate to improve certain helpful

properties of aluminum, for example, quality, hardness, and weld capacity or erosion resistance. The most

widely recognized material utilized for car cylinders is aluminum combination because of its lightweight, ease

and satisfactory quality. Silicon is the major alloying component added to aluminum, which offers weight

lessening to the cylinder, change in hardness, quality, wear and scrape resistance.

Table.1 Chemical composition

3.3 COMPARISON OF ALUMINIUM ALLOY AND ALSIC:

The major advantages of using aluminium alloy are tied directly to its’ remarkable properties.

Element Composition Element Composition

Si 0.4430 Zn 0.0001

Fe 0.1638 Cr 0.0024

Cu 0.0041 Ti 0.0078

Mg 0.5832 Ca 0.0003

Mn 0.0132 Al 98.751

PROPERTIES: Aluminium

alloy

AlSiC

Density (g/cm3) 2.7-2.8 2.835-2.9

Young’s Modulus (Pa) 0.75E-11 0.83E-11

Co-efficient of thermal

expansion (/k)

24*E-6 1.55*E-6

Thermal conductivity

(W/mK)

173 216.69

Poisons ratio (1/m) 0.33 0.3

Tensile strength (MPa) 230-570 420-640

Yield strength (MPa) 215-505 293-600

Melting point (deg C) 501 688.23


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Table.2.Comparison of Aluminium alloy and AlSiC

3.4 ADVANTAGES OF ALUMINIUM ALLOY:

• Corrosion Resistance of Aluminum Alloys

At the point when aluminum is presented to air, a flimsy oxidized film shapes at first glance, shielding the metal

from erosion. Whenever scratched, the layer quickly changes holding the insurance. This component is used in

development, structures and family unit utensils.

• Attractive and Esthetically Pleasing Finish

The normal metallic surface of aluminum is stylishly satisfying; the surface supplied is sufficient and does not

require further wrapping up. In the event that extra insurance is required, the regular oxide film may thickened

by anodizing without influencing the metal's appearance.

• Wide Range of Available Finishes

An extensive variety of completions may be connected to aluminum, to improve its surface attributes, or adjust

its appearance. The metallic surface may be shaded by compound or anodizing

3.5 ALUMINIUM SILICON CARBIDE ALLOY

Aluminum combinations are not suitable for high temperature applications in light of the fact that elastic

and weakness qualities are not as high as coveted in the temperature scope of 500 F to 700F. The most

noteworthy temperature of any point in cylinder must not surpass more than 66% of the liquefying point

temperature of the aluminum combination. Subsequently the point of confinement temperature for the aluminum

combination is of 640K. So they are not suitable for high temperature applications.

So we are strengthening silicon carbide in aluminum composite to make the cylinders to withstand high

temperatures which has high liquefying temperature when contrasted and aluminum amalgam. Aluminum

silicon carbide amalgam demonstrates great improvement of the mechanical properties like extreme rigidity,

yield quality, hardness and pliability at raised temperatures.

Properties of Different Material used for the Finite Element Analysis

Table.3Aluminium silicon carbide alloy properties

Material Elastic

Modulus

GPa

Poisson

ratio (μ)

Coefficient

of thermal

expansion

X 10-5 /°K

Thermal

conductivi

ty W /mK

Density

Kg/m3

Al-10 wt. % SiC 77.4 0.33 2.0 173 2744.0

Al-20 wt. % SiC 86.0 0.32 1.75 168 2788.0

Al-30 wt. % SiC 92.0 0.31 1.55 164 2835.0


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3.6 ADVANTAGE AND APPLICTIONS

Composite cylinder made of metal framework composites high quality maintenance on maturing at

serious situations. Contrasted with aluminium amalgam, the aluminium silicon carbide composite is found to

have lesser distortion, lesser anxiety and great temperature dispersion. Rather than these a portion of the

impediments confronted by aluminium combination cylinder are cured by these aluminium silicon carbide

composite cylinder.

Era, bundling, structural engineering, and electrical transmission, transport, nourishment readiness,

vitality, applications. Contingent on the application, aluminum can be used to supplant distinctive materials like

copper, steel, zinc, tin plate, stainless steel, titanium, wood, paper, concrete and composites. A couple of

outlines of the regions where aluminum is used are given as a part of the going with portions.

Packaging

Transport

Marine Applications

Building and Architecture

4.1 CAD/CAE

PC supported configuration or CAD has extremely expansive significance and can be characterized as

the utilization of PCs in creation, adjustment, examination and enhancement of an outline. CAE (Computer

Aided Engineering) is alluded to PCs in engineering examination like anxiety/strain, heat exchange, and stream

investigation. Computer aided design/CAE is said to can possibly drastically build profitability than any

advancement since power. Computer aided design/CAE constructs quality structure idea to conclusive item.

Rather than acquiring quality control amid the last examination it adds to a procedure in which quality arrives

through the life cycle of the item. Computer aided design/CAE can dispense with the requirement for models.

Be that as it may, it required models can be utilized to affirm rather anticipate execution and different attributes.

Computer aided design/CAE is utilized in various commercial enterprises like assembling, car, aviation,

throwing, mold making, plastic, hardware and other broadly useful businesses. Computer aided design/CAE

frameworks can be comprehensively separated into low end, mid end and top of the line frameworks. Low-end

frameworks are those frameworks which do just 2D demonstrating and with just little 3D displaying capacities.

As indicated by industry static's 70-80% of every single mechanical creator still uses 2D CAD applications. This

may be for the most part because of the high cost of top of the line frameworks and an absence of skill.

Mid-end frameworks are really comparable top of the line frameworks with all their outline capacities

with the distinction that they are offered at much lower costs. 3D sold demonstrating on the PC is expanding in

light of numerous reasons like moderate and capable equipment, solid sound programming that offers windows

instance of utilization abbreviated outline and generation cycles and smooth incorporation with downstream

application. More creators and designers are moving to mid end framework.

Top of the line CAD/CAE programming's are for the complete displaying, investigation and

assembling of items. Top of the line frameworks can be envisioned as the mind of simultaneous designing. The

outline and improvement of items, which took years in the past to finish, is currently made in days with the

assistance of top of the line CAD/CAE frameworks and simultaneous building.

5.1 MODELING:

Model is a Representation of a thing, a system, or an idea in some structure other than that of the

substance itself. Exhibiting is the strategy of conveying a model; a model is a representation of the improvement

and working of some course of action of side interest. A model resembles however less troublesome than the

structure it addresses. One inspiration driving a model is to engage the master to anticipate the effect of changes


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to the structure. From one perspective, a model should be an adjacent figure to the real structure and join a vast

segment of its striking components. Of course, it should not be perplexing to the point that it is hard to

appreciate and attempt distinctive things with it.

A good model is a sensible trade off amidst genuineness and ease. Re-establishment experts endorse

growing the eccentrics of a model iteratively. A basic issue in showing is demonstrate authenticity. Demonstrate

endorsement systems join reproducing the model under known data conditions and differentiating model yield

and structure yield. All things considered, a model proposed for a re-institution study is a logical model made

with the help of entertainment programming.

Software for modelling:

•Solid works

•Creo (Pro-E)

•CATIA

•Unigraphics, etc

5.2 CREO 2.0

Creo Elements/Pro (once Pro/ENGINEER), PTC's parametric, incorporated 3D CAD/CAM/CAE

arrangement, is utilized by discrete producers for mechanical building, plan and fabricating. Made by Dr.

Samuel P. Geisberg in the mid-1980s, Pro/ENGINEER was the business' first effective guideline based

requirement (in some cases called "parametric" or "variational") 3D CAD displaying framework. The parametric

displaying approach utilizes parameters, measurements, components, and connections to catch planned item

conduct and make a formula which empowers outline computerization and the improvement of configuration

and item advancement forms.

This blueprint philosophy is used by associations whose thing framework is family-based or organize

driven, where a prescriptive design system is essential to the achievement of the arrangement procedure by

embedding building necessities and associations with quickly streamline the layout, or where the resulting

geometry might puzzle or based upon numerical proclamations. Creo Elements/Pro gives an entire course of

action of setup, examination and manufacturing capacities on one, fundamental, flexible stage. These required

limits fuse Solid Modeling, Surfacing, Rendering, Data Interoperability, Routed Systems Design, Simulation,

Tolerance Analysis, and NC and Tooling Design. Like any item it is perseveringly being made to consolidate

new helpfulness.

The purposes of enthusiasm underneath plan to plot the degree of abilities to give a survey as opposed

to giving specific inconspicuous components on the individual helpfulness of the thing. Creo Elements/Pro is an

item application within the CAD/CAM/CAE arrangement, nearby other relative things at this moment

accessible. Creo Elements/Pro is a parametric, component based showing incorporating configuration merged

with a single database rationale with bleeding edge standard based setup limits. It offers through and through

control of complex geometry, as exemplified by the trajpar parameter. The capacities of the thing can be part

into the three crucial headings of Engineering Design, Analysis and Manufacturing.

Mechani.5.3 ENGINEERING DESIGN


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Fig.7.Piston dimensions

Creo Elements/Pro offers a scope of devices to empower the era of a complete computerized

representation of the item being planned. Notwithstanding the general geometry devices there is likewise the

capacity to create geometry of other incorporated configuration trains, for example, mechanical and standard

channel work and finish wiring definitions.

Mechanical assemblies are furthermore open to reinforce aggregate headway. Different thought

diagram devices that give ahead of time Industrial Design thoughts can then be used as a part of the downstream

method of building the thing. These range from sensible Industrial layout draws, making sense of with point cl-

oud data and intensive free-form surface gadgets.

We made model Piston utilizing CREO programming. The models are demonstrated as follows,

Fig:8 SKETCH FOR PISTON MODELING


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Fig:9 HOLE FOR PIN

Fig:10 HOLE CONSTRAINED

Fig:11 CONSTRAINED PISTONS


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Fig:12 COMPLETED PISTON

6.1 FINITE ELEMENT METHOD

The Finite Element Method (FEM) is a solid numerical system for dissecting building plans. FEM

replaces a mind boggling issue with numerous basic issues. It partitions the model into numerous little bits of

basic shapes called components. Components offer normal focuses called hubs. The conduct of these

components is surely understood under all conceivable backing and stack situations. The movement of every

hub is completely depicted by interpretations in the X, Y, and Z bearings. These are called degrees of flexibility

(DOFs). Examination utilizing FEM is called Finite Element Analysis (FEA). Ansys plans the comparisons

overseeing the conduct of every component looking into its availability to different components. These

comparisons relate the removals to known material properties, restrictions, and loads.

Next, the system sorts out the mathematical statements into a vast arrangement of synchronous

logarithmic comparisons. The solver finds the removals in the X, Y, and Z bearings at every hub. Utilizing the

relocations, the project ascertains the strains in different headings. At last, the system utilizes scientific

expressions to ascertain stresses. Limited component continues at present broadly utilized as a part of the

building examination. The techniques are utilized broadly in the investigation of solids structure has exchanged

and limited component routines are valuable in essentially every field at designing examination.

The limited component system is a numerical examination strategy for acquiring roughly answer for

assortments of building in the limited component investigation real continuum or body of the matter like strong,

fluid or gas is spoken to as a collection of sub division called limited component. These limited components of

field variable inside the limited component can roughly by the single capacity.

The around capacities are characterized as far as the estimations of the field variable of the hubs by

illuminating the strong variables the aggregate estimations of the field variable of the hubs by understanding the

strong variables the aggregate estimations of the hubs by soling the strong variables the aggregate estimations of

the field variable can be figured out.

6.2 STEPS IN FEA

Definitions of the issue and its space.

Discretisation of the space the continuum.

Identification of state variable.

Formulation of the issue.

Establishing coordinate framework.


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Constructing surmised capacities for the components.

Obtaining component lattice and mathematical statement.

Coordinate change.

Assembly of component mathematical statements.

Introduction of the last arrangement of synchronous mathematical statement.

Interpretations of the results.

6.3 BASIC COMPONENTS OF FEA

Pre-processor

Post processor

General post processor

Solution

6.4 ADVANTAGES OF FEA

Applicable to any field issue, for example, recuperate exchange stress examination, attractive field and

so forth.

There is no network confinement.

Approximately it is effortlessly enhanced by evaluating the cross section so that more components

show up where field slopes are high and more determination is required.

Compounds that have diverse conduct and distinctive scientific portrayal can be tackled.

FEA structure nearly looks like intently the real body or locale to be analysed.

6.5 USES OF FEA

Structural analysis

Fluid flow analysis

Heat transfer analysis

Mass transport

CONCLUSIONS

A piston made of composite material (aluminium silicon carbide) is designed and analyzed

successfully. Composite piston made of metal matrix offers high strength retention on ageing even at severe

environments. Compared to aluminium, the aluminium silicon carbide is found to have lesser deformation,

lesser stress and good temperature distribution. Some of the limitations faced by aluminium piston are overcame

by the aluminium silicon carbide piston. From this project we get the clear knowledge about the composite

material AlSiC and its features.

ACKNOWLEDGMENT

The authors would like to acknowledge the support of Mechanical Engineering Department of Saintgits

College of Engineering for conducting the present investigation.


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