Internal Combustion Engine Piston Research Articles

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.

Numerical Thermo-Mechanical Strength Analysis of an IC Engine Component

This research investigates a thermo-mechanical strength of three geometrical shape designs of an internal combustion (IC) engine piston by a finite element analysis (FEA). FEA was performed using Solidworks software for modelling geometrical piston designs, and the models were imported into ANSYS software for thermo-mechanical fatigue simulation. The work focused on predicting high stress intensity and indicated the fatigue critical regions and life of the piston shape design. AL7075-T6 aluminium alloy was used as a piston material and thermo-mechanical fatigue simulation was conducted based on the experimental stress-number of cycles recorded data from literature. Analytical results showed the similarity of the critical failure positions to some real failures in the IC engine piston, and the shape design modification of the piston. Hence, this concept can be used to satisfy the IC engine design needs at low cost.

FINITE ELEMENT ANALYSIS OF PISTON HEAD USING CAD

The motive of undertaking this project of structural analysis of piston head is to study and evaluate the performance in real working conditions of the piston in internal combustion engine. In this paper, the work is carried out to measure the stress distribution on the top surface of the piston made up of aluminium alloy. In IC engine piston experiences uneven temperature distribution and from piston head to skirt. The analysis predicts that due to stress generated the top surface of the piston may be damage or break during the operating conditions, since the damaged or broken parts are so expensive to replace and generally are not easily available, the 3D model of piston is created using Creo. 3D model is imported to the Abaqus and FEA is performed. By identifying the true design features, the extended service life and long term stability is assured.

Выбор оптимальных газодинамических параметров радиально-осевых турбин при их совместной работе с поршневыми двигателями внутреннего сгорания

The study of radial-axial (centripetal) turbines is important for science and technology. They are widely used in the refrigeration industry, internal combustion engines, and power engineering, both in the form of auxiliary units and in autonomous power units. The article offers a method for selecting the gas-dynamic parameters of the centripetal turbine in order to obtain the highest efficiency and the best size of the turbine. The increased manufacturability of the turbine is provided due to the absence of a straightener at the outlet of the impeller and the use of straight blades in the impeller. The dependence of the efficiency of a centripetal turbine on the profiles of the blades and the radial dimensions of the nozzle apparatus and the impeller, as well as on the length of the impeller blades is investigated. Considering the recommended optimal parameters, the calculation of a pulsed centripetal turbine operating in conjunction with a four-stroke piston internal combustion engine is performed.

Methods for rapid estimation of indicator and efficient efficiency of internal combustion engines

The article discusses the issue of a quantitative computational assessment of the efficiency of the thermal cycle of a piston internal combustion engine based on the values of the effective and indicator efficiency. A simplified technique for the operational assessment of the efficiency of the thermal cycle of a piston internal combustion engine is proposed. The technique is based on a mathematical description of thermodynamic processes occurring during the development of the thermal cycle of an engine with ignition of the working mixture from compression (diesel engine), which allows it to be expanded to new engines, including those operating under electronic control. Keywords heat cycle; the working process; diesel; heat content of the working fluid; expansion

Possibility of using gas lubricant in the cylinders of internal combustion engines of transport vehicles

The prospects of using the gas-static suspension of the internal combustion engine piston in transport vehicles and power plants are considered. The diagram of the piston and the method for calculating the stiffness and bearing capacity of the gas layer surrounding the piston are presented, as well as the results of experiments that showed the relevance of this method. The possibility of gas and static centering of the engine piston is confirmed. Keywords: internal combustion engine, piston, gasstatic suspension, stiffness, bearing capacity, gas medium. lysenkojo@mail.ru

Manufacturing and Characterization of Functionally Graded Material Automotive Piston Using Centrifugal Casting Technique

The process of fabricating reliable materials according to efficient usage has become one of the most vital concerns. In this paper, the fabrication of functionally graded materials (FGMs) is the target using a specified application of an internal combustion engine piston model to achieve such a gradient. With a convenient rotational speed under the concept of centrifugal casting technique, the required gradient piston was successfully produced from two pure aluminum alloys A336 and A242 by such a new mechanical technique for having the required gradient. The percentages of internal ingredients, mainly, silicon were controlled axially through the piston. Chemical composition analysis, micro-hardness and wear resistance tests were performed to check the gradient and to know the difference between mechanical properties for each piston portion from its top combustion chamber to its skirt, achieving compatible results through performed tests. Obvious opposite direction gradient of silicon content to copper content appeared. Micro-hardness, wear resistance and coefficient of friction values showed a successfully gradient in the axial direction of the piston model.

МОДЕЛИРОВАНИЕ ПРОЦЕССА СГОРАНИЯ В ДИЗЕЛЬНОМ ДВИГАТЕЛЕ

The issues of combustion processes and the organization of the combustion workflow in diesel engines are relevant in view of the tightening of economic and environmental requirements for them. The problem of saving liquid fuels remains one of the most acute in the provision of fuel and energy resources. The development of highly efficient methods for organizing work processes when burning natural gas in a compressed or cryogenic state in the cylinders of internal combustion piston engines and determining ways to further reduce toxic emissions, increase fuel efficiency and reliability in promising gas engines is an urgent task. Mathematical modeling of liquid fuel combustion is a complex task, since it requires taking into account a large number of complex interrelated processes and phenomena. The article presents a simple 3-D model of cylinder diesel tractor engine D 144, the re- sults of numerical simulation of combustion of liquid and gaseous fuel in the cylinder of the diesel engine D-144. The article presents the results of modeling, including graphs of the dependence of nitrogen oxides, particles in outgoing gases, depending on the consumption of gaseous fuel in the form of pure methane. Additionally, tempe- rature and velocity contours are shown. The corresponding conclusions are made.

Control of the formation of structural properties of hypereutectic aluminum alloys during injection molding with crystallization

The paper presents the results of the research aimed at developing an automated control system for the process of forming the properties of metal products under the conditions of pressure application on the crystallizing metal. The results of the work are related to the automated control system for technological processes (ACS TP) and can be used in the manufacture of internal combustion engine pistons from alloys based on aluminum with a high silicon content. The object of control is molten metal, the technological equipment is a hydraulic horizontal press for casting with crystallization under pressure. The paper shows the possibility of controlling the formation of the properties of the final product. The results of the work are confirmed by the example of studies of the microstructures of the obtained samples. The method for applying pressure to a crystallizing metal and the way to control this method are proposed.

The moment of inertia of V-shaped internal combustion engines

This work contains a solution to the problem of developing a mathematical model and the results of numerical simulation of the change in the inertia of the moving mass V-shaped piston internal combustion engines (ICE) reduced to the axis of rotation of the crankshaft depending on the angle of rotation of the crankshaft during one revolution. The solution of this problem is an important step in the mathematical description of the dependence of the torque developed by the V-shaped piston ICE, depending on the angle of rotation of the crankshaft. Knowing the dependence of the torque developed by the V-shaped piston ICE, depending on the angle of rotation of the crankshaft, is a prerequisite for designing and optimizing the design of non-linearly loaded processing equipment using V-shaped piston ICEs as the drive. The results of mathematical modeling show that the moment of inertia of the moving masses of the V-shaped piston ICE reduced to the axis of rotation of the crankshaft is constantly changing during one revolution of the crankshaft. The greatest change in the moment of inertia of the moving masses reduced to the axis of rotation of the crankshaft takes place in 2- and 4-cylinder V-shaped piston internal combustion engines.

Investigation of the pressure and heat treatment effect on the ICE piston blanks mechanical and structural properties from high-strength aluminum alloy B95

The features of the production of internal combustion engine pistons are analysed. On the basis of the analysis, the expediency of developing a new, more improved technology for the production of piston blanks was revealed. The choice was made in favour of the injection molding process. It is shown that the high quality of workpieces with minimal material and energy costs can be ensured by imposing high pressure on the metal prior to crystallization. The scientific and technical literature is analysed, where attention is drawn to the relevance of the processes of processing crystallizing metal by pressure using hydraulic press equipment. However, it can be seen from the available sources that the possibility of pressure treatment of liquid metal prior to the onset of crystallization remains unexplored. Investigations of the mechanical properties of the resulting blanks of internal combustion engine pistons have been carried out, and the microstructures of the alloy obtained under different crimping modes have been studied. As a result of the research, the most optimal technological modes of pressure application were determined. The process of applying pressure to the crystallizing metal has been developed.

Забезпечення енергоефективності трансмісій автомобілів і тракторів при модернізації зі зміною числа циліндрів ДВЗ

The article investigates the energy efficiency of motor-transmission units when using internal combustion engines with different numbers of cylinders. Transmissions, those in a unit with piston internal combustion engines are loaded with uneven torque, which is the cause of torsional vibrations of their parts. Torsional vibrations create additional dynamic loads on the transmission elements, and also reduce its efficiency. To ensure a high level of energy efficiency of the engine-transmission unit, the elastic-inertial parameters of the transmission must be matched with the amplitude-frequency characteristics of the torque of the installed engine. When replacing a serial internal combustion engines with an engine with output characteristics different from the prototype, it is necessary to assess the vibration resistance of the modernized engine-transmission unit, which was done in this work. As a criterion for vibration resistance of the modernized machine unit, the cyclic elastic efficiency of the transmission was used. This factor takes into account the natural frequency of the transmission input shaft, as well as the amplitude and frequency of vibration of the engine torque. The decisive influence on the vibration characteristics of the engine is exerted by the rotational speed of its crankshaft and the number of cylinders. When conducting a comparative assessment of the energy efficiency level of the modernized engine-transmission unit, it was assumed that before the modernization the transmission was in a unit with a single-cylinder internal combustion engine. As a result of the study, the conditions for ensuring the vibration resistance of engine transmission units have been determined, a method has been developed for comparative analysis of the energy efficiency indicators of engine transmission units with different numbers of internal combustion engine cylinders, and possible ways to increase the energy efficiency of engine units of cars and tractors during modernization with a change in the number of internal combustion engine cylinders are indicated.

Influence of operational factors on the properties of working fluids of piston engines

The paper is devoted to the study of the regularities of changes in the quality of working fluids circulating through the systems of internal combustion piston engines. During the research, the parameters of fluids that characterize its operational properties, as well as external effects that can lead to changes in the properties of the fluid, were determined. It is shown that the deterioration of the quality of engine oil and coolant of piston engines during operation is caused by the destruction of additives that are part of the fluid and provide their required properties. A laboratory installation has been developed and created that allows simulating thermal and mechanical effects on working fluids similar to those acting during circulation through engine systems. The graphical dependencies obtained as a result of the experiment are presented. Mathematical processing of the experimental data allowed obtaining regression dependencies that correctly describe the processes of changes in time of the most important characteristics of working fluids under the action of cyclic thermal and mechanical effects. The described method can be used to study the influence of operational factors on the properties of various working fluids of internal combustion piston engines.

Estimation of the efficiency of the thermal cycle of a piston internal combustion engine

Authors Rusinov R.V., Hoodorozhkov S.I., Dobretsov R.Yu., kgm-spb@mail.ru. Estimation of the efficiency of the thermal cycle of a piston internal combustion engine The article proposes a simplified technique for the operational assessment of the efficiency of the heat cycle of a piston internal combustion engine. A feature of the developed computational model is the release of the amount of heat consumed for the production of only mechanical energy in the form of a separate component of the heat balance of the cycle. The value of this component is determined by calculation (or according to the results of experiments) in advance, which makes it possible to reduce the number of pre(determined initial data. The methodology is based on a mathematical description of thermodynamic processes occurring during the development of the thermal cycle of an engine with ignition of the working mixture from compression (diesel engine), which allows it to be expanded to new engines of design, including those operating under electronic control. The objects for the application of the calculation method can be diesel engines installed on transport vehicles, both individually and as part of a hybrid power plant, as well as engines of stationary or transportable power plants. The very principle underlying the model can be implemented for engines of other purposes and other thermal cycles. Keywords: heat cycle; the working process; diesel; heat content of the working fluid; expansion

Estimation of Design Parameters of the Crank-Connecting Rod Mechanism of Engines for Mobile Agricultural Machines

An accurate choice of the design model of the crank-connecting rod mechanism of piston internal combustion engines affects the accuracy of the calculation results and their complexity. At present, most of scientists and technicians choose a two-mass design model to analyze the operation of the crankconnecting rod mechanism. The model considers only the rotational and reciprocating movements of two masses, which are connected by a rigid weightless rod. This model significantly simplifies the calculations, neglects the elastic deformations of the parts of the crank-connecting rod mechanism, and eliminates the need for compiling the equations of dynamics in partial derivatives. However, the model has a number of drawbacks. The calculation results obtained using the two-mass model exhibit significant errors, which mainly depend on the design features of the connecting rod assembly. The paper discusses multi-mass design models, where the connecting rod assembly can comprise several lumped masses located along its length. In this case, the plane-parallel motion of these masses is added. The masses have weightless and absolutely rigid bonds. Forces and moments acting on the piston assembly and the crank are calculated according to the equations compiled. Comparison of the calculation results with the results obtained for a two-mass model can be used to determine errors and choose a design model that provides the required accuracy. The considered design model is of interest to engineers and technicians engaged in the design and calculation of the crank-connecting rod mechanism of piston internal combustion engines.

Investigation on properties of LM26 hybrid composite material with ceramic reinforcements

Aluminium composite materials were extensively used in aerospace, defence and in the field of automobile because of its higher ratio of strength to weight including other mechanical properties. The objective described in this paper is the investigation of the (SiC) silicon carbide properties and (B4C) boron carbide properties particulate combinations (2 + 4), (3 + 3), (4 + 2), volume % respectively and 100 vol% aluminium alloy LM26 hybrid composite fabricated by stir casting process. This hybrid composite can be used as an alternative to steel for internal combustion engine pistons. The microstructure analysis shows fairly even distribution of particles and some agglomeration of SiC and B4C. Also it was observed that these particles were having blunted and granulated morphological features. The experimental results show that the composite having 2% SiC, 4% B4C and 94% LM26 combination has higher hardness and tensile strength. The linear mixture model and desirability function analysis predicts values which are confirming to the observed values shows the capability of experimental design and the model suitability.

Computer Simulation of the Technology for Producing a Stamped Billet for the Piston of an Internal Combustion Engine of an Unmanned Aerial Vehicle

The technological process of hot-die forging billets for the piston of an internal combustion engine (ICE) of an unmanned aerial vehicle (UAV) made of AK4-1 aluminum alloy using the Deform-3D software package has been modeled. The object of simulation is a real ICE piston mounted on a Russian UAV. During modeling, the following parameters are introduced: the temperature of the tooling and the billet is 450°C, the ambient temperature is 20°C, the speed of the punch is taken as 5 mm/s, and the Siebel friction index is 0.4. A rigid plastic medium is chosen as the material model. The number of elements (6000) is assigned so that at least three of them fit in the narrowest section of the part. Thus, using the example of a stamped piston forging, it is shown that, using computer simulation in the Deform-3D program, it is possible to develop processes of hot-die forging of aluminum alloy billet for the manufacture of pistons for UAV ICEs. At the same time, computer modeling allows you to design a tool, evaluate the power parameters of the hot-die forging process, study the nature of the shape of the billet during die forging, and make the necessary adjustments to the virtual technological process that will make it possible to select the most optimal technical solutions when designing a real process. This computer-simulation technique can be extended to other stamped forgings from aluminum alloys.

Computer simulation of the technology for AK4-1 alloy die forging production for an internal combustion engine piston

The process of hot die forging of AK4-1 aluminum alloy billets for the piston of an internal combustion engine (ICE) for an unmanned aerial vehicle (UAV) was simulated using the Deform-3D software package. The object of research was an ICE piston mounted on one of the UAV types of Russian production. Simulation was performed using the following parameters: tooling and billet temperature was 450 °C, ambient temperature was 20 °C, punch speed was 5 mm/s, and Siebel friction index was 0.4. Rigid plastic medium was chosen as a material model. The number of elements (6000) was selected so that at least 3 elements fit in the narrowest section of the part. Thus, as illustrated by the piston die forging, computer simulation in the Deform-3D software makes it possible to develop hot die forging processes for making aluminum alloy billets for UAV ICE pistons. At the same time, computer simulation can be used to evaluate the power parameters of the hot die forging process, study the nature of billet forming in die forging, make necessary adjustments to the virtual process, and develop the design of a die forging tool in order to select the most effective process solutions when designing a real process. The described computer simulation technique can be extended to other aluminum alloy die forgings.

The analysis of the thermal barrier coating using Ansys software

The main source of energy for the propulsion of automotive and trucks is still internal combustion piston engines. These are constantly improved in such a way as to achieve the lowest possible consumption of low-emission fuel. The results of the simulation of new technologies are confirmed in experimental stands, thus being the basis for the development of internal combustion engines. This paper shows the theoretical simulation of temperature distribution and thermal flow distribution when a thermal barrier is applied to the engine combustion chamber components. More specifically, the impact of thermal barriers on the surface of the piston crown shall be investigated.

Assessing the forcing level of air cooled diesel engine considering parameter spread of boosting system

Spread of parameter values of piston internal combustion engine boosting parts is normally due to extreme deviations (spread, error margin) of original parts and quality of assembly. Spread of relation of boosting pressure to counter pressure at outlet of turbo compressors Pk/Pt of the same type affects not only the engine parameters, but also thermal expansion of cylinder-piston group parts and cylinder head. At stable relation value of Pk/Pt, boosting pressure and maximal air flow, turbo compressor allows us to reduce the thermal factor of combustion chamber and cylinder head due to higher values of air excess ratios. This is very important, first of all for air cooled engine as in case of dramatic surge of its thermal factor we face a risk of cracks occurring in inter valve and inter valve- nozzle connectors of cylinder head fire bottom, cracking of setting bevels at valves of gas distribution mechanism. We analyzed the impact of technological spread of boosting details parameter on the value of achieved forcing limit. Impact analysis of technological spread of turbo compressor parameters on diesel engine performance was done on the basis of test results of ten B-400 engines, fitted with randomly selected pairs of TKP8,5-C7 turbo compressors out of a lot of 20 pieces. For each turbo compressor we determined preliminarily characteristics and efficiency factors nK, of turbine nT and of a unit as a whole n™.