Automobile Piston Research Articles

An enhanced nonparametric quality control chart with application related to industrial process

In various practical situations, the information about the process distribution is sometimes partially or completely unavailable. In these instances, practitioners prefer to use nonparametric charts as they don’t restrict the assumption of normality or specific distribution. In this current article, a nonparametric double homogeneously weighted moving average control chart based on the Wilcoxon signed-rank statistic is developed for monitoring the location parameter of the process. The run-length profiles of the newly developed chart are obtained by using Monte Carlo simulations. Comparisons are made based on various performance metrics of run-length distribution among proposed and existing nonparametric counterparts charts. The extra quadratic loss is used to evaluate the overall performance of the proposed and existing charts. The newly developed scheme showed comparatively better results than its existing counterparts. For practical implementation of the suggested scheme, the real-world dataset related to the inside diameter of the automobile piston rings is also used.

Особенности нестационарных тепломеханических процессов в выпускном коллекторе автомобильного поршневого двигателя размерности 8,2/7,1

The purpose of this work was to obtain experimental data on unsteady gas dynamics and the intensity of heat transfer of the flow in the exhaust system of an automobile piston engine for different initial conditions. The research was carried out on an experimental stand simulating the exhaust process in a piston engine in dynamics. The pressure at the outlet (in the cylinder) varied from 0.05 to 0.2 MPa, the speed of rotation of the crankshaft - from 600 to 3000 min-1. The method of thermal anemometry was used to determine the gas dynamic, flow and heat exchange characteristics of the flow in the exhaust system. Data on the instantaneous values of the velocity and local heat transfer of the flow in the exhaust system for different boundary conditions are presented in the article. The effect of the outlet pressure on the gas flow through the exhaust system and the level of heat transfer was analyzed. The spectral analysis of changes in the local flow velocity in the exhaust system is additionally presented in the article. The obtained patterns are useful in the applied aspect for clarifying engineering methods for calculating the exhaust system and for verifying mathematical models of gas exchange processes in automotive piston engines.

Mechanical Analysis of Downsized Automobile Piston through Simulation

Engine downsizing technology benefits the environment in terms of emission gases and also reduces the usage of fuel in automobiles. Reducing the number of pistons and or their dimensions is among the most suitable techniques for engine downsizing. However, reducing the size of the pistons will cause another issue to with withstanding the applied forces generated due to combustion gases during combustion. Therefore, in this research work, the automobile piston was analyzed through simulation using ANSYSv17.2 after a 10% stroke reduction in its dimension. Further, to advance the novelty of this research work; 02-different automobile piston shapes: and hollow and toroidal combustion chambers (HCC & TCC) were reduced for investigating mechanical analysis. For mechanical analysis: maximum principal stresses, Von-Misses stresses, and total deformation before and after downsizing were analyzed. The results revealed that the maximum principal stresses, Von-Misses stresses, and total deformation were increased by 42%, 33.5%, 41.4%, 26.7%, 14.1%, and 8.2% after downsizing the HCC and TCC pistons respectively. Additionally, TCC offered better resistance to applied forces as compared to HCC. However, the increased values were within the maximum ultimate stress of the material, and it can be concluded that the 10% by stroke downsizing is under safe mode.

New EWMA t charts for process mean

AbstractIn practice, the process standard deviation is usually unknown or is estimated inaccurately. The ‐type charts, such as the exponentially weighted moving average (EWMA) chart, which works under the assumption that the process standard deviation is either known or it is estimated accurately, may not perform well when the process standard deviation is actually unknown or estimated inaccurately. To address the aforesaid setback of the EWMA‐ chart, the EWMA‐t chart was developed for monitoring the process mean when errors in estimating the process standard deviation occur or when the standard deviation is unknown. In this paper, new EWMA‐t charts, which are also robust against estimation errors in the process standard deviation and are applicable when the standard deviation is unknown, are developed for detecting mean shifts of a normal process. The new EWMA‐t charts are developed using the newly derived t‐statistics, based on the fixed sampling interval (FSI) and variable sampling interval (VSI) features. The new FSI/VSI EWMA‐t charts are found to outperform the existing FSI/VSI EWMA‐t chart, in terms of the zero‐state (ZS) and steady‐state (SS) average, median and standard deviation of the run‐length (SDRL)/time‐to‐signal criteria, for various shift sizes in the process mean, values of smoothing parameter and shift sizes in the process standard deviation. The application of the existing and new FSI/VSI‐EWMA‐t charts for detecting increases and decreases in the process mean is demonstrated with the automobile piston rings dataset.

The design and additive manufacturing of an eco-friendly mold utilized for high productivity based on conformal cooling optimization

This study proposes an eco-friendly (ECO) mold that is fabricated using the laser powder bed fusion (LPBF) method, which utilizes a three-dimensional (3D) cooling channel. Unlike previous studies, we designed surface-type conformal cooling channels (CCC) based on the design concept for additive manufacturing, at a constant depth corresponding to the casting part. Pin fins were installed inside the surface-type cooling channels and aligned through numerical analysis to induce the turbulence of the coolant uniformly through the cooling channel while generating less thermal stress during solidification of the as-cast Al-Si alloy-based product, which increased the cooling efficiency of the proposed ECO mold. Moreover, the ECO mold was utilized to cast an automobile piston to demonstrate its feasibility at an industrial level. The results showed that, the casting process decreased significantly from 133 to 105 s per piston (21% reduction) compared to the conventional mold with a single columnar cooling channel. Additionally, the average grain size of the ECO mold decreased from 502 to 398 µm. The ultimate tensile strength and Rockwell hardness increased by 12.5% and 5.5%, respectively.

Analysis of Piston of Internal Combustion Engine under Thermo-mechanical Load

The main objective of this article is to study the thermal and structural performance of piston using finite element based commercial software ANSYS. Piston is modelled using SOLIDWORKS and analysis would be performed through ANSYS workbench. Optimization analysis has been performed considering three different materials such as Grey Cast iron, structural steel and aluminium alloy because these three material have good compression strength and their thermal conductivity and density will different for each one. For the same amount of pressure Aluminium alloy has shown maximum deformation and equivalent strain, where von misses stress value is minimum for it. Whereas, Structural steel and Grey cast iron shows deformation and strain values less than that of Aluminium alloy for same pressure load. Aluminium alloy has highest heat flux and lowest temperature on piston head under thermal load. Piston receives thermal energy generated via combustion and higher heat flux ensures quick cooling of component by quick drainage of thermal energy. Grey cast iron and Structural steel has half of the value of heat flux to that of Aluminium alloy. Therefore, Aluminium alloy is the preferable material for the design of automobile piston among the given three materials.

Tribological performance and scuffing behaviors of several automobile piston rings mating with chrome-plated cylinder liner

The friction and wear properties, as well as the scuffing resistance, of different piston-ring coatings mating with a chrome-plated cylinder liner were investigated. Interrupted wear tests under the lubricant starvation condition were conducted to examine the wear behavior of Cr-diamond coating (GDC) and diamond-like coating (DLC). The results indicated that the DLC coating had outstanding tribological properties (small coefficient of friction and wear loss) at 150 °C, while the GDC coating exhibited better performance at an elevated temperature (240 °C). The DLC coating had a better scuffing resistance; no material adhesion occurred for 70 min under the unlubricated condition. The interrupted wear behaviors revealed that the scuffing process of the GDC coating involved the consumption of lubricant oil with relatively stable wear, a reduction in the friction force, and the occurrence of scuffing, in sequence. In contrast, although the friction force also increased after a short period of weak friction, no scuffing was observed. This is attributed to the formation of a mixed oxide and graphitic C tribolayer.

Theoritical modelling and finite element analysis of automobile piston

Automobile engines have with time witnessed a favorable change with respect to fuel economy, passenger comfort, environment, and so on. The change continues with every manufacturer and researcher striving toward excellence. Pistons and their ring assembly are one of the important elements in whole engine assembly, which have metamorphosed to suit the current requirement. Improvements in design, geometry, and material have not only reduced the inertia forces but also increased the time interval between overhauls. The modification of piston crowns to introduce swirl by squish effect and material coating techniques have enhanced the features of a piston. In fact, engines today last their useful life without any significant maintenance other than renewal of oil and filters. Piston rings too have reduced in numbers and are designed to meet its functional requirement. Piston is part of corresponding engines, corresponding pumps, fuel compressors, pneumatically-pushed conical, amongst different similar mechanisms. It is the moving detail that’s had through cylindrical tube, made fuel tough through disc. The piston transforms the energy of the growing gasses proper into mechanical strength. The piston flights inside the cylinder lining or sleeve. Pistons are regularly made from aluminum (Al) or actors iron alloys. The primary reason of the task is to format a piston for 1300 cc diesel motor for two materials Cast Iron (CI) and also Light Weight aluminum Alloy. The designs of the piston are designed utilizing 3d model software program. The designs are reviewed through architectural and additionally thermal assessment through using pressure and temperature stages mainly. The result is evaluated via checking the stress, model, thermal slope and thermal trade to select the very top notch fashion of the piston.

The effect of Ni-doping on the microstructure, hot deformation behavior, and processing map of as-cast Al–Si piston alloy

Al–Si alloy is widely utilized in automobile pistons and cylinders due to good castability, high strength-to-weight ratio, excellent thermal conductivity, good resistance to corrosion/oxidation, and acceptable wear resistance. To increase the efficiency of engine motor, it is imperative to modify and engineer the microstructure of Al–Si alloy to enhance the high-temperature behavior. For this reason, in the current study, different concentration of Ni (0.8% and 2%) was doped into Al–Si alloy during casting to generate various Ni-rich intermetallic compounds within the alloy matrix. AlNiCu, AlCu, AlFeSi, and Mg2Si were found to be the main intermetallic compounds precipitated within the dendritic and interdendritic regions, which could enhance the thermal stability and high-temperature performance. High-temperature compression test at high temperatures ranging from 400 to 550 °C and at different strain rates ranging from 10−3 to 1 s−1 was carried out to develop high-temperature processing map and optimize the hot workability parameters of Ni-doped Al–Si alloy. The maximum power dissipation efficiency (η) was observed within the temperature range of 450–500 °C and strain rate of 0.05–0.08 s−1 (lower strain rate) for Al–Si–0.8%Ni alloy and within the temperature range of 450–500 °C and strain rate of 0.3–1 s−1 (medium to high strain rate) for Al–Si–2%Ni alloy. Dynamic recrystallization was found to be the primary softening mechanism at high temperatures (T > 450 °C).

Fabrication and Assessment of a Motorcycle Piston using the Traditional Sand Casting Method

The RX 100 motorcycle piston was fabricated from end-of-life automobile piston using the traditional sand casting method. The fabricated piston was subjected to thermal analysis using ANSYS R18.1 version software to ascertain its performance under thermal loads. The recycled EOL aluminium used in the fabrication of the piston was characterised using SEM-EDS to determine the composition and morphology of the material. Results obtained show that the EOL aluminium employed in the fabrication of the piston performed excellently under thermal loads, and the SEM-EDS indicates that the material is predominantly aluminium with beneficial alloying elements.

Gr–Al composite reinforced with Si3N4 and SiC particles for enhanced microhardness and reduced thermal expansion

Thermal management remains an important consideration for many applications such as automobile pistons, dies in furnaces and heat sinks in electronics, where high thermal conductivity and low coefficient of thermal expansion are desired. In this paper, we report an improved microhardness value and negative coefficient of thermal expansion (CTE) for Gr–Al composites by incorporating silicon nitride (Si3N4) and silicon carbide (SiC) into Gr–Al matrix. Si3N4 and SiC particles (average size of 72 nm) were obtained after 30 and 50 h of ball-milling, respectively. Gr–Al composite were reinforced with Si3N4 and SiC particles (4, 8, 12 and 16 wt% each), and then sintered at a temperature of 560 °C, pressure of 50 MPa, heating rate of 50 °C/min and dwelling time of 10 min using spark plasma sintering system. The sintered samples were characterized for morphology, microhardness, relative density, coefficient of thermal expansion and wear resistance. Addition of 16 wt% Si3N4 reduced relative density from 99.9 to 89.47% indicating lower densification. CTE decreased with increased Si3N4 fraction reaching minimum value of 12.37 × 10–6 °C (which is 42.5% reduction) for Gr–Al + 12 wt% Si3N4. However, Gr–Al + 8 wt% SiC + 8 wt% Si3N4 composite has the minimum negative CTE (− 21 × 10–6 °C), maximum displacement (2.48 mm), maximum displacement rate (1.12 mm/s) and minimum hardness value (26.8 GPa). While the hardness was marginally increased with Si3N4, addition of 12 wt% SiC + 12 wt% Si3N4 raised the hardness by 37%. Also, the wear area increased with applied force. These results indicate that Gr–Al + 8 wt% SiC + 8 wt% Si3N4 composite is suitable for applications requiring combination of low (negative) thermal expansion, high microhardness value and maximum densification. Effectively, the synergic effect of combined SiC and Si3N4 particles has been brought to the fore.

Уравновешивание моментов двигателя VR5 с учетом дезаксажа и угла развала цилиндров

Automobile piston engines with a desaxial crank mechanism are characterized by increased vibration activity associated with a cyclic change in the pressure of the working fluid in the cylinders and inertial forces associated with the reciprocating and rotational movement of the crank mechanism moving masses. Properties reflecting the consumer properties of the engine, including acoustic characteristics, are largely determined by the level of vibration of the structural elements of the desaxial crank mechanism and, first of all, by the balance of inertial forces during operation. The article discusses balancing of five-cylinder four-stroke VR type engines with a desaxial crank mechanism and uniform flash alternation. The authors introduce formulas that can be used to determine and analyze moments of the inertia forces of the reciprocating and rotating masses arising in VR5 engines at the set values of the cylinder camber angle, the ratio of the crank radius to the connecting rod length and the relative displacement of the cylinder axis. A method of balancing the moments of inertia forces of the reciprocating and rotating masses is proposed.

STRUCTURAL, THERMAL AND THERMO-MECHANICAL ANALYSIS OF FOUR STROKE PETROL ENGINE PISTON USING CAE TOOLS

As we are known numerous reciprocating parts is contained in IC Engine which are responsible for giving the motion. The abnormal piston working is given poor performance in comparison of other parts. The main intention of this research is to investigate and analyse the stress distribution of automobile piston at definite engine Condition. In this paper pressure (Mechanical), thermal (Heat) and thermo-mechanical analysis is accomplished by help of CAE Tool. The constraint used for the analysis is pressure of operating gas, temperature and material properties of piston. In this research piston are designed for a single cylinder four stroke petrol engine using CATIA V5R20 and analysis is performed by ANSYS 14. Two different material are induced in this investigation. First one is Aluminium alloy and second is Cast Iron. In this end of the Results are shown and a comparison is made to find the most suited material for splendour automobile vehicle piston by various CAE analyses.

Thermal Barrier Coating Development on Automobile Piston Material (Al-Si alloy), Numerical Analysis and Validation

Abstract This work is focused on the thermal barrier coating (TBC) development on aluminium - silicon (Al-Si) alloy casting materials, widely used as automobile components (cylinder blocks, pistons etc.). TBCs enable enhanced combustion within the chambers of diesel engines resulting in improved performance and components life. Uniform coating thickness development on complex contours of automobile pistons is a challenging task worldwide which results in varying thermal barrier characteristics across the non-uniform thickness. In consistent (in thickness) coatings are most likely to lead to uneven thermal barrier effects across the TBC thicknesses which directly affect the performance and the lubrication system of the engine. This warrants the development of stable and consistently thick coatings for ideal performance of the Low Heat rejection (LHR) engine. The present research work involved building different thicknesses (100, 125 and 150µm) of commercial 6-8%Yttria stabilized zirconia (YSZ) TBCs on 50µ to 75µ thick nickel aluminide (NiAl) bond coat. The influence of thickness on thermal barrier characteristics via experimentation and numerical analysis has been studied. Flat plates machined from automobile pistons were used as substrates. The coatings were characterized for thermal barrier effects for hot ceramic surface face temperatures up to 550°C (by using oxy-acetylene flame to heat up the TBC surface), structural phase analysis by X-ray Diffraction (XRD) and microstructure analysis in metallographic cross section by employing Scanning Electron Microscope (SEM). An analytical investigation also was carried out to determine the approximate temperature at each interface. A code was developed to calculate the temperature drops across the coated plate and the net heat available at the coated surface using MATLAB. This is important considering the effects, small changes in temperatures will bring on the creep life on the metal.

COMPUTATIONAL AND EXPERIMENTAL DETERMINATION OF ENERGY LOSS OF THE OPERATING FLUID IN THE INTAKE SYSTEM OF THE AUTOMOBILE PISTON PNEUMATIC ENGINE USING THE EXERGY METHOD

The application exergy method of the thermodynamic analysis for determining the energy loss of the operating fluid in the intake system of the automobile piston pneumatic engine using experimental data of its engine test rigs has been considered. The analysis of the performed exergy calculational and experimental research on the evaluation of energy loss in the intake system of the engine for current modes of its operation has been presented. The sample of a piston pneumatic engine for a combined automobile power unit created at the ICE Department of KhNAHU requires further improving and developing especially such components and systems as those connected to the burn process. A compressed air intake system is one of them. Compressed air is not only some working fluid for a pneumatic engine but the energy source for its intake system. The energy loss factor like reliability and durability is referred to the performance and efficiency factors. The object of the study is a pneumatic engine created by converting a gasoline four-cylinder four-stroke ICE at the ICE Department of KhNAHU. The experimental research was carried out by laboratory engine test rigs of the pneumatic engine with speed characterization provided that two thermodynamic parameters of compressed air at the intake were kept constant for each characteristic: pressure p s = idem and temperature Т s = 293 K. In each test mode all external parameters of the pneumatic engine were recorded and indicator diagrams of the first cylinder were taken. Each speed characteristic consisted of 6–8 modes p s = idem and Т s = 293 К = idem with changing the rotational rate of the crankshaft n, rpm, from minimally stable (about n=200 rpm) to maximum possible n = 1000 ± 50 rpm It should be noted that there is an operating fluid pressure drop in the intake system chamber due to available inconvertibilities: throttling in the test port, hydraulic loss along the intake port as a result of fluid friction, swirls and other gas-dynamic phenomena. The exergy loss of the operating fluid enthalpy in the intake system D вп =Е вп -Е нап with the intake pressure р s = 0.5 MPais 13.3 kW, with the intake pressure р s = 0.7 MPa is 15.0 kW, with the intake pressure р s = 0.9 MPa is 16.9 kW, with the intake pressure р s = 1.1 MPa is 19.7 kW.

Mechanical Properties, Material and Design of the Automobile Piston: An Ample Review

This paper is about the mechanical properties and shape of the automobile piston in the engine. Currently downsizing of the engine is attractive field for the research which benefitted in the reduction of fuel consumption and emission pollutants from the engine. While on the other side various pressure boosters attached with the engine piston-cylinder to maintain the output power at the bar/more than the bar. These attachments cause to produce high stresses and displacement vectors in the piston-cylinder and the gas forces generated during the combustion cause to produce thermal stresses on the face of the piston which sometime may leads to the failure of piston material. To withstand all these problems the material must be strong enough. Al-Si alloy is the main alloy material to manufacturing the piston because of low co-efficient of thermal expansion, minimum weight, high hardness and strength and good wear resistance properties. In result; Shallow depth Combustion Chamber (SCC) is most suitable for low speed while Omega Combustion Chamber (OCC) is preferred for high speed, but both combustion chamber produce high amount of NOx. Maximum suitable percentage is of Si is up to 12% to 19%. While centrifugal casting is most right method to manufacture the piston and heat treatment at 540°C for 8 h and aging at 190°C for 8 h is correctly choice to achieve optimum mechanical properties by heat treatment. The ingredient material of the Al-Si alloy, the casting techniques and heat treatment techniques directly affects the mechanical properties of the piston in downsizing engine. A very careful observation is required during the manufacturing of automobile piston to achieve desired mechanical properties.

Optimization of the Automobile Parts Mixed Production Line Based on EM-Plant

The balance of mixed production line is the key issue, which means to adjust the working load to make working hour equal to production TAKT as well as to average the working hour of each station. Firstly, the automobile piston mixed production line system was analyzed by eM-Plant, which was carried out by object-oriented modeling and process-oriented simulation. After evaluating the production line performance, including the utilization rate of equipment and worker, the bottlenecks of the mixed production line were indentified. Finally, the relative measures were put forward to solve it, which makes the enterprise obtains the ability of rapid response to market demands.

Defects Reduction in Manufacturing of Automobile Piston Ring Using Six Sigma

Six Sigma is one of the best emerging approaches for quality assurance and management in automobile parts manufacturing. In this research, Quality Management tools such as COPQ analysis, Data Analysis, Pareto charts, Cause and Effect diagrams, Process Capability Study, Failure Mode Effects Analysis (FMEA), Design of Experiments (DOE), Visual and Control Charts etc. are used in defining the problems in order to find the root causes for the problem and carrying out experiments in order to suggest improvements, through which the company could bring in Quality and Stability in their process. Two main reasons that strongly effect the product rejections are discovered. The new improved process is validated through a Pilot batch run. Using the six sigma method, the rejection percentage is reduced by 13.2% from the existing 38.1% of rejection. Further improvement in the rejection is expected in the long run after the continuous implementation of all the solutions.

Design and Moldflow Analysis of Piston Cooling Nozzle in Automobiles

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.

A Survey for Rhinitis in an Automotive Ring Manufacturing Plant

We report findings regarding otolaryngologist-confirmed rhinitis, current exposure to MWF aerosols, fungi, and endotoxins for workers in a plant manufacturing automobile piston rings. Questionnaire data showed that 61.5% of 187 workers exhibited rhinitis-related symptoms. Rhinitis was confirmed in 99 of 115 workers whom were medically examined. Otolaryngologist-confirmed rhinitis was present in 10 of 19 grinding workers (52.6%), 67 of 142 production workers (47.2%), and 22 of 26 quality control (QC) workers (84.6%). These rates are much higher than the rates of rhinitis-related symptoms in automobile plants and other occupational settings and quite high even allowing for the common occurrence of rhinitis in the general population. We found that rhinitis could develop even in workers exposed to less than 0.5mg/m(3) MWF aerosol. The average exposure to fungi exceeded 10 x 10(3) CFU/m(3), a level higher than that reported for other automobile plants. Although we were unable to identify significant risk factors for rhinitis using only the physician-confirmed rhinitis cases, this study concludes that exposure to MWF aerosol, which would include microbes and metals, could contribute to a high occurrence of rhinitis in grinding and production workers. Forty-nine workers (63.6%) of 77 rhinitis patients in grinding and production operations were determined to handle synthetic MWF directly. For QC workers, for whom the prevalence of physician-confirmed rhinitis was highest, exposure to a low level of MWF aerosol, including specific microbe species we couldn't identify, bright light, dry air, and certain work characteristics during inspection are possible risk factors for development of rhinitis. Further studies including identification of fungi species should be conducted so a firm conclusion can be made regarding the development of rhinitis in QC manufacturing plant workers.