Topology Optimization in 3D Printed Piston

Abstract

Abstract: Piston is the main alternating mass of a single cylinder 4 stroke engine and hence contain most of the inertial forces, also modern advancement in the automotive industry for the sake of pollution control and fuel economy many of the techniques such as Downsizing of engine (turbo charging), advance spark ignition, port injection, VVA and many more are adapted and hence results in high specific loading, including thermal and mechanical loads on the several parts of engine. This paper presents the re-designing of the piston, the topology optimization techniques have been used for increasing strength and decreasing mass of the piston which is our main objective. Traditionally pistons were manufactured by casting of aluminum and grey cast iron, aluminum was used in performance oriented vehicles as it was light in weight and have addition thermal properties and also it was easy to manage the inertial forces, whereas cast iron pistons were used in industrial purpose engine (heavy duty engine) today methods are replaced with 3-D printing, as a topology optimized piston cant be manufactured with traditional methods. The procedures in the paper are done for a generalized case and not for a particular so that the same methodology can be implemented in specific cases. Also it will cover a lot about the Material selection and additive manufacturing process used for this specific application.