DESIGN ANALYSIS AND OPTIMIZATION OF PISTON FOR SINGLE CYLINDER 4 – STROKE SPARK IGNITION ENGINE USING COUPLED STEADY-STATE THERMAL STRUCTURAL ANALYSIS

The aim of the study is to design, analysis and optimization of piston for a single cylinder four stroke over head valve (OHV) spark ignition engine. This paper used reverse engineering techniques, in order to obtain of an existing physical model. A three-dimensional piston has been created with the help of SOLIDWORKS and, it is imported to ANSYS environment for the coupled steady-state thermal structural analysis. The material used for piston is Die Cast Aluminium (DCA) 1, 2, and 3. The objective of this paper focuses the light weight piston design through finite element analysis, and to optimize the piston design using parametric optimization. The results obtained from coupled field analysis and parametric optimization, concluded the modified design is within the permissible limit along the selected materials for DCA2 and shows the maximum von misses stresses 78.75MPa, factor of safety (n) is 5.67 and yield strength of 165MPa and it is reduced the piston weight was 12.14 grams which is 7.42% less as compared to existing DCA1 without comprising the strength to weight ratio.