Abstract
Automobile industries have shown great interest in replacing metal to plastic parts in order to reduce the cost and weight of the components. This can be achieved mostly be replacing metal component with injection molded components. Our study deals with the use of mold flow simulation in as a case study of metal to plastic conversion of the automobile component piston cooling nozzle. In this context the aluminium piston cooling nozzle is replaced by Nylon66+30GF piston cooling nozzle. Then based on the final product design, hand injection mold of the component was designed and manufactured. Finally the plastic part has to be tested for the working conditions, its performance in usage and compared with the aluminium part. Keywords: Metal to Plastic, Finite Element Analysis, Piston Cooling Nozzle
Highlights
The current trend in the automobile industry is towards increase in the power density of the engine and making lighter engines
The aluminium piston cooling nozzle is manufactured by castings followed by secondary operations for drilling holes which leads to increase in production time
Piston cooling nozzle used in automobiles is made up of metals like steel, aluminium
Summary
The current trend in the automobile industry is towards increase in the power density of the engine and making lighter engines. The aluminium piston cooling nozzle is manufactured by castings followed by secondary operations for drilling holes which leads to increase in production time. This can be reduced by using plastic as replacement of the metal apart from the weight and cost reduction [1]. An excessive temperature of the piston results in piston scuffing increased blow by owing to sticking of the piston rings to grooves and an increased oil consumption caused by wear of piston rings and ring grooves These in turn decrease the reliability and durability of the engine significantly. The other is improvement of material strength in the high temperature region
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