Finite Element Analysis Lab
OEL Report
Analysis of a piston head in ANSYS
Registration Number/Name
F20602011 Abdullah Shoukat
F20602037 Farhan Yousaf
F20602057 Muneeb Ahmed
Department Instructor’s Name Date
ME - 20 Lec. Khubaib Haider Jan 23, 2024
Table of Contents:
Abstract ……………………………………………………………………. 03
Introduction ………………………………………………………………... 03
Selection Purpose of Topic ……………………………………………….... 04
Methodology ………………………………………………………………. 04
Geometry and Meshing ……………………………………………………. 05
Material Properties and BCs ………………………………………………. 06
Structural Analysis ……………………………………………………….... 06
Thermal Analysis ………………………………………………………….. 07
Modal Analysis ……………………………………………………………. 08
Results and Discussion ……………………………………………………. 08
Conclusion ………………………………………………………………… 09
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Abstract:
This report presents a comprehensive analysis of a piston head using advanced
simulation techniques in ANSYS. The study focuses on three key aspects:
thermal behaviour, structural integrity, and vibrational characteristics of the
piston head. The motivation behind this analysis is to enhance the understanding
of the piston's performance under various operating conditions, leading to
improved design and durability. Additionally, the methodology presented in this
report serves as a valuable framework for similar analyses in the field of
automotive and mechanical engineering.
Introduction:
The piston head is a critical component in internal combustion engines, playing
a pivotal role in the conversion of chemical energy from fuel into mechanical
power. It is situated at the top of the engine cylinder and undergoes complex
thermal, structural, and dynamic loads during each combustion cycle.
The primary functions of a piston head include sealing the combustion chamber,
transferring the force generated by the expanding gases to the crankshaft, and
dissipating heat produced during combustion. Achieving these functions
demands a delicate balance between material properties, thermal management,
and structural integrity. Any shortcomings in the design or performance of the
piston head can lead to reduced engine efficiency, increased wear and tear, and
potential catastrophic failure.
This report focuses on a detailed analysis of the piston head using state-of-the-
art simulation techniques in ANSYS. The investigation spans three key
domains: thermal behaviour, structural integrity, and modal characteristics. By
delving into these aspects, we aim to uncover insights that contribute to the
enhancement of piston design, addressing challenges related to heat dissipation,
mechanical strength, and dynamic stability.
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Selection Purpose of Topic:
Central to this selection is the recognition of the piston head as a pivotal
component within internal combustion engines, exerting a direct influence on
overall engine performance, efficiency, and longevity. The complexities
associated with the piston's operation, including exposure to high temperatures,
dynamic loads, and rapid cyclic movements, prompt an in-depth investigation
into its behaviour under diverse conditions. By integrating thermal, structural,
and modal analyses, the chosen topic adopts a multidisciplinary approach,
acknowledging the diverse factors influencing the piston head's performance.
This comprehensive analysis not only facilitates a nuanced understanding of the
piston's response to thermal stress, structural forces, and dynamic stability but
also enables the identification of potential areas for improvement.
Methodology:
Following are steps taken to perform above analysis:
1. Post-processing: For thermal analysis, temperature distribution, and
thermal stress visualizations identify potential stress concentrations.
Structural analysis focuses on Von Mises stress, deformation, and factor
of safety assessments, while modal analysis visualizes natural frequencies
and mode shapes.
2. Geometry and Meshing: Begin by creating a detailed 3D model of the
piston head geometry, capturing intricate features and surfaces accurately.
Utilize SolidWorks to develop the geometry and import it into ANSYS
for further analysis. Generate a high-quality mesh with refined elements
to ensure accurate representation of the geometry and capture critical
details.
3. Material Properties and BCs: Define the material properties of the
piston head material, considering its thermal and mechanical
characteristics. Establish realistic boundary conditions, including thermal
loads, pressure distribution, and mechanical constraints, based on actual
operating conditions within the engine.
4. Thermal Analysis: Conduct steady state thermal analysis to simulate the
heat distribution and dissipation during engine operation. Apply realistic
temperature boundary conditions, considering the combustion process,
heat transfer, and cooling mechanisms.
5. Structural Analysis: Perform static and dynamic structural analyses to
assess the mechanical strength and deformation of the piston head. Apply
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mechanical loads and constraints, considering forces from combustion,
inertia, and other external factors.
6. Modal Analysis: Conduct modal analysis to determine the natural
frequencies and mode shapes of the piston head. Identify critical modes
that may lead to resonance-related issues and affect the piston's
operational stability.
Geometry and Meshing:
Following 3D geometry of piston head is created in SolidWorks and Imported in
Ansys:
Mesh is generated on body with refinement of side phases where changes are
more than other parts:
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Material properties and BCs:
Following materials are used in our analysis:
Material Young’s Poisson’s Ratio Thermal
Modulus (GPa) Conductivity
(W/m.K)
Aluminium 72.4 0.33 237
Structural Steel 200 0.3 60.5
Grey Cast Iron 110 0.28 53
Following BCs are applied in structural analysis:
Structural Analysis:
Structural analysis is conducted to assess the mechanical strength and
deformation of the piston head under different loading scenarios. By applying
realistic boundary conditions and material properties, the study aims to predict
potential weaknesses and deformation patterns, contributing to the optimization
of the piston's structural design.
Structural analysis results for Structural Steel:
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Thermal Analysis:
The thermal analysis investigates the heat distribution and dissipation within the
piston head during engine operation. Finite Element Analysis (FEA) is
employed to simulate the steady thermal, aiding in the identification of critical
areas prone to thermal stress and potential failure points. Thermal analysis
results for Grey Cast Iron:
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Modal Analysis:
Modal analysis is utilized to investigate the natural frequencies and mode
shapes of the piston head. Understanding the vibrational characteristics is
crucial for preventing resonance-related issues that could compromise the
piston's performance and longevity. The study employs modal analysis to
identify critical modes and assess their impact on the piston's operational
stability.
Modal analysis results for Grey Cast Iron:
Results and Discussion:
The integration of thermal, structural, and modal analysis results allowed for a
holistic understanding of the piston head's performance. Correlations between
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thermal effects and structural responses informed multidisciplinary
optimizations, achieving a balance between thermal dissipation, mechanical
strength, and dynamic stability. Design iterations based on these findings led to
an improved piston head design with enhanced overall performance.
Comparisons with experimental data validated the accuracy of the simulation
results, demonstrating the reliability of the ANSYS analysis. Sensitivity analysis
highlighted influential parameters, guiding future simulations and designs. The
practical implications of this study extend to the automotive industry, offering a
robust methodology for optimizing piston head design and contributing to
advancements in internal combustion engine technology.
Material Equivalent Total Heat Flux
Stress Deformation x 10^6
(MPa) (mm) (W/m2)
Aluminium 174 0.082 3.12
Structural Steel 177.5 0.055 1.80
Grey Cast Iron 177.5 0.055 …
Conclusion:
The thermal, structural, and modal analysis of the piston head in ANSYS has
yielded valuable insights essential for enhancing the design and performance of
internal combustion engines. The comprehensive examination of temperature
distributions, stress patterns, and dynamic characteristics has provided a holistic
understanding of the piston head's behaviour under diverse operating conditions.
Through careful integration of results and multidisciplinary optimizations, the
project has successfully identified areas for improvement, leading to an
enhanced piston head design. This study contributes to the continual evolution
of internal combustion engine technology, fostering efficiency, reliability, and
sustainability.
(The End)
