DESIGN AND ANALYSIS OF A HEAVY-DUTY DIESEL ENGINE PISTON

The main objective of this project is to study the characteristics of different alloys such as Steel, Aluminum and Cast Iron and to the design and analyze the stress distribution of the piston with a suitable material above the actual engine condition for a heavy duty diesel engine. In this paper, thermal analysis and mechanical analysis is done. The parameters used for the analysis are operating gas pressure, temperature and material properties of the piston. In I.C. Engine, a piston is most complex and important part therefore for the smooth running of the vehicle; piston should be in proper working condition. Piston fails mainly due to mechanical stresses and thermal stresses. Analysis of the piston is done with boundary conditions, which includes pressure on the piston head during working condition and uneven temperature distribution from piston head to skirt. The analysis predicts that due to temperature whether the top surface of the piston may be damaged or broken during the operating conditions and also to provide sufficient cooling conditions. The theoretical design calculations are made and the CAD model is created using CREO software. CAD model is then imported into the ABAQUS software for the analysis of stress distribution.