· High temperature will cause rapid wear, fatigue or damage to PISTON HEAD, PISTON SKIRT, PISTON COMPRESSION, RING GROOVES and PISTON IN HOLE. 1 School of Mechatronic Engineering, University Malaysia Perlis, Pauh Putra Campus, 02600 Arau, Perlis 2 School of Material Engineering, University Malaysia Perlis, Taman Muhibbah, 02600 Jejawi. Arau, Perlis 3 CAE Division, MODENAS Sdn. Bhd, Kawasan Perindustrial Gurun, Gurun, Kedah A. INTRODUCT ION: PROBLEM IN PISTON DAMAGE OF REGULAR AA332 ALLOY (CASES FROM MODENAS) · The difference in the temperature of the piston head which occurs during the flow of combustion gases or fuel collision may be the cause to get high thermal stress and stress crack propagation will be occur due role material properties. TEMPERATURE DISTRIBUTION HEAT FLUX VON-MISSES STRESS AT PIN SLOT PISTON DEFORMATION VON-MISSES STRESS AT PISTON HEAD B. OBJECTIVES ANSYS SIMULATION CODE DEVELOPMENT (ANSYS APDL) · highest hardness · good wear resistance 1. DETAIL DRAWING 2. SOLID MODELING 3. MESHING 4. THERMO-MECHANICAL LOADING 5. RESULTS PISTON HEAD FAILURE HOLE IN PISTON CROWN DAMAGE BY BROKEN PISTON PIN IMPACT MARK ON PISTON CROW N PISTON TOP AND PISTON CROWN EROSION FIG. 1 C. METHOD: DEVELOPING THERMO- MECHANICAL ALGORITHM D. CONCLUSION/NOVELTY SOLVE BY INTRODUCING Mg2Si 1. Numerical thermo-mechanical model is successfully developed for piston stress-strain damage analysis. 2. At present, it proved to work well on the failure prediction of hole in piston, broken piston pin, impact on piston crown and piston crown erosion; but still need further validation and verification. 3. New reinforced Mg2Si AA320 piston is having less maximum deformation of the piston was 0.7512mm and occurred at the piston top surface edges. Piston-cylinder gap is 1.95mm. Maximum coupled thermal-mechanical stress of 836MPa, THIS IS RELATIVELY SMALL COMPARED TO EXISTING USED AA332 PISTON - Ruslizam Daud 1 , Khairel Rafezi 2 , Oii Seng Chew 1 , Fizam Zainon 1 , Mohd Shukry Abd. Majid 1 , Mohd Afendi Rojan 1 , Khairul Anuar Hamid 3 To develop the new numerical Mg2Si Reinforced AA332 Alloy Piston Head and Pin Damage Model using Finite Element Analysis

Thermo-mechanical Model of New Reinforced AA332 Alloy Piston (1)

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High temperature will cause rapid wear, fatigue or damage to PISTON HEAD, PISTON SKIRT, PISTON COMPRESSION, RING GROOVES and PISTON IN HOLE.

1School of Mechatronic Engineering, University Malaysia Perlis, Pauh Putra Campus, 02600 Arau, Perlis2School of Material Engineering, University Malaysia Perlis, Taman Muhibbah, 02600 Jejawi. Arau, Perlis 3CAE Division, MODENAS Sdn. Bhd, Kawasan Perindustrial Gurun, Gurun, Kedah

A. INTRODUCTION: PROBLEM IN PISTON DAMAGE OF REGULAR AA332 ALLOY (CASES FROM MODENAS)

The difference in the temperature of the piston head which occurs during the flow of combustion gases or fuel collision may be the cause to get high thermal stress and stress crack propagation will be occur due role material properties.

TEMPERATURE DISTRIBUTION

HEAT FLUX

VON-MISSES STRESS AT PIN

SLOT

PISTON DEFORMATION

VON-MISSES STRESS AT

PISTON HEAD

B. OBJECTIVES

ANSYS SIMULATION CODE DEVELOPMENT (ANSYS APDL)

highest hardness good wear resistance

1. DETAIL DRAWING 2. SOLID MODELING

3. MESHING

4. THERMO-MECHANICAL LOADING

5. RESULTS

PISTON HEAD FAILURE

HOLE IN PISTON CROWN

DAMAGE BY BROKEN PISTON

PIN

IMPACT MARK ON PISTON

CROWN

PISTON TOP AND PISTON

CROWN EROSION

FIG. 1

C. METHOD: DEVELOPING THERMO-MECHANICAL ALGORITHM

D. CONCLUSION/NOVELTY

SOLVE BY INTRODUCING

Mg2Si

1. Numerical thermo-mechanical model is successfully developed for piston stress-strain damage analysis. 2. At present, it proved to work well on the failure prediction of hole in piston, broken piston pin, impact on piston crown and piston crown erosion; but still need further validation and verification.3. New reinforced Mg2Si AA320 piston is having less maximum deformation of the piston was 0.7512mm and occurred at the piston top surface edges. Piston-cylinder gap is 1.95mm. Maximum coupled thermal-mechanical stress of 836MPa, THIS IS RELATIVELY SMALL COMPARED TO EXISTING USED AA332 PISTON

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Ruslizam Daud1, Khairel Rafezi2, Oii Seng Chew1, Fizam Zainon1, Mohd Shukry

Abd. Majid1, Mohd Afendi Rojan1, Khairul Anuar Hamid3

To develop the new numerical Mg2Si Reinforced AA332 Alloy Piston Head and Pin Damage Model using Finite Element Analysis

Thermo-mechanical model of new reinforced AA332 Alloy piston.vsdThermo-mech model