Swati S Chougule, Vinayak H Khatawat / International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 3, Issue 2, March -April 2013, pp.1724-1731 1724 | P a g e Piston Strength Analysis Using FEM Swati S Chougule*, Vinayak H Khatawate** * (Second Year M.E. CAD/CAM & Robotics, Department of Mechanical Engineering, PIIT, New Panvel, Mumbai University, Navi Mumbai, Email) ** (Asst. Prof. Department of Mechanical Engineering, PIIT, New Panvel, Mumbai University, Navi Mumbai) ABSTRACT This work describes the stress distribution of the piston by using finite element method (FEM). FEM is performed by using computer aided engineering (CAE) software. The main objective of this project is to investigate and analyze the stress distribution of piston at the actual engine condition during combustion process. The parameter used for the simulation is operating gas pressure and material properties of piston. The report describes the mesh optimization by using FEM technique to predict the higher stress and critical region on the component. The piston under study belongs to the two stroke single cylinder engine of SUZUKI Max100 motorcycle. Aluminum is selected as piston material. It is important to locate the critical area of concentrated stress for appropriate modification. Computer aided design (CAD) software PRO-E Wildfire 4.0 is used to model the piston. And static stress analysis and dynamic analysis is performed by using ANSYS 14. Based on stress analysis results the weight optimization of piston is done using ANSYS 14. Keywords: Dynamic Analysis, FEM, Optimization, Piston Analysis, Piston Strength Analysis, Static Analysis, Two Stroke I. INTRODUCTION In internal combustion engine, piston is one of the important components. It reciprocates within the cylinder bore by force produced during the combustion process. The two main requirements of the piston are as follows: 1- It should contain all the fluids above and below the piston assembly during the cycle. 2- It should transfer the work done during combustion process to the connecting rod with minimal mechanical and thermodynamic losses. Five main properties of a piston are: 1- Sufficient thermal conductivity 2- Low thermal expansion 3- High hot strength 4- High strength to weight ratio 5- High resistance to surface abrasion Figure 1.1: Labeled Image of a Piston and Con-Rod. The piston is the heart of the internal combustion engine and is subjected to loads such as thermal and structural stress. The piston reciprocates within the cylinder. The two extremes of this motion are referred to as Top Dead Center (TDC) and Bottom Dead Center (BDC) shown in Fig. 1.2. Figure 1.2: Cross Section of a Reciprocating Engine [3] Top Dead Center is the position of the piston that creates the smallest volume in the cylinder, which is defined as the clearance volume, Vc. This is where combustion takes place in the engine and is also known as the combustion chamber. The Bottom Dead Center is when the piston creates the largest volume in the cylinder [3]. The distance between TDC and BDC is referred to as the stroke, and the volume which the piston displaces during this moment, is