1.1 MATERIAL PROPERTIES OF THE CRITICAL COMPONENT A good knowledge of the material properties is fundamental for any simulation. In this case he piston is made of the well known aluminum alloy 390-T5. This alloy is commonly used in high performance turbocharged diesel engines [1][2][3]. The 390-T5 chemical and mechanical properties are summarized in table 1 and 2. Quasi static Young modulus and yield stress dependency to temperature are depicted in fig. 1 and 2: Chemical composition Component Weight. % Al 78 Cu 4 – 5 Fe Max 1.3 Mg 0.45 – 0.65 Mn 16 – 18 Ti Max 0.2 Zn Max 0.1 Table 1: A390 data ABSTRACT This paper introduces a method to simplify a non linear problem in order to use linear finite element analysis. This approach improves calculation time by two orders of magnitude. It is then possible to optimize the geometry of the components even without supercomputers. In this paper the method is applied to a very critical component: the aluminium alloy piston of a modern common rail diesel engine. The method consists in the subdivision of the component, in this case the piston, in several volumes, that have approximately a constant temperature. These volumes are then assembled through congruence constraints. To each volume a proper material is then assigned. It is assumed that material behaviour depends on average temperature, stress magnitude and stress gradient. This assumption is valid since temperatures varies slowly when compared to pressure (load & stress). In fact pressure propagates with the speed of sound. The method is validated by direct comparison with non linear simulation of the same component, the piston, taken as an example. In general, experimental tests have confirmed the cost-effectiveness of this approach. Keywords: Optimization, Simulation, CAD, geometry, FEA An innovative method to speed up the Finite Element Analysis of critical engine components Luca Piancastelli*, Leonardo Frizziero*, Ilaria Rocchi* *DIN – Dipartimento di Ingegneria Industriale, Facoltà di Ingegneria, Università di Bologna Viale Risorgimento, 2 – 40136 Bologna 127