International Journal of Scientific Research in Engineering and Management (IJSREM)

Volume: 09 Issue: 03 | March - 2025 SJIF Rating: 8.586 ISSN: 2582-3930

Design and Stress Analysis of an IC Engine Piston Using

Different Materials
1,
M.Pavan sai, 2,J.Jagadeesh, 3,R.Vijaya, 4,V.Krishna Shravan,
5,
M.Suresh 6, V Sai Srikanth
1,2,3,4,5
Mechanical, Raghu Institute of Technology, Visakhapatnam, Andhra Pradesh, India
6
Mechanical, Raghu Engineering College, Visakhapatnam, Andhra Pradesh, India

1. ABSTRACT

The project titled “Design and Analysis of an IC Engine Piston” focuses on developing an optimized piston design
for an internal combustion (IC) engine through advanced modelling and simulation techniques. The piston is a
critical component subjected to extreme mechanical and thermal loads during engine operation, making its design
and material selection essential for ensuring durability and performance.
The project begins with the conceptual design of the piston using SolidWorks software, incorporating standard
design parameters such as bore diameter, stroke length, and compression ratio. Finite Element Analysis (FEA) is
then used to evaluate the structural integrity of the piston under thermal and mechanical stresses during the
combustion cycle. The analysis includes stress distribution and deformation to identify potential failure zones.
Material selection is also considered, comparing conventional aluminium alloys with advanced materials such as
reinforced composites to enhance strength and heat dissipation. Design modifications, including optimization of
piston geometry and weight reduction, are implemented to improve engine efficiency and reduce wear.
The results of the analysis provide insights into improving piston durability and performance, contributing to the
development of more efficient and reliable IC engines. This study offers a comprehensive approach to enhancing
the design lifecycle of engine pistons by integrating simulation, material science, and mechanical analysis
Keywords: stress distribution, deformation, potential failure zones

2. INTRODUCTION works proposing, for engine pistons, new geometries,

materials and manufacturing techniques, and this
Engine pistons are one of the most complex components evolution has undergone with a continuous improvement
among all automotive and other industry field over the last decades and required thorough examination
components. The engine can be called the heart of a of the smallest details. Notwithstanding all these studies,
vehicle, and the piston may be considered the most there are a huge number of damaged pistons. Damage
important part of an engine. There are lots of research mechanisms have different origins and are mainly wear,
S.NO MATERIALS temperature, and fatigue related. But more than wear and
1. AL D16T fatigue, damage of the piston is mainly due to stress
development, namely- Thermal stress, Mechanical stress.
2. GRAY CAST IR This paper describes the stress distribution on piston of
internal combustion engine by using FEA. The FEA is
3. AISI 4041
performed by CAD and CAE software.
4. AL 6061 2.1. MATERIALS

© 2025, IJSREM | www.ijsrem.com DOI: 10.55041/IJSREM42950 | Page 1

 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 09 Issue: 03 | March - 2025 SJIF Rating: 8.586 ISSN: 2582-3930

TABLE 2.1 MATERIAL DETAILS channel geometry, were parameterized for

This paper presents a detailed study of the design and optimization.
analysis of a piston using SolidWorks and ANSYS. The Step 2: Structural Analysis
primary objective is to model a piston in SolidWorks, 1. Mesh generation: A finite element mesh was
then perform stress and deformation analyses in ANSYS generated for the piston geometry using ANSYS Meshing.
to evaluate the structural integrity and performance of the 2. Material properties: Material properties for the
piston under typical operational loads. The study focuses piston material (e.g., aluminum alloy) were assigned.
on understanding the stress distribution across the piston, 3. Boundary conditions: Boundary conditions, such as
identifying regions of high stress concentration, and loads and constraints, were applied to simulate engine
analyzing the deformation behavior to ensure the piston’s operating conditions.
durability and reliability. By combining SolidWorks for 4. Structural analysis: A static structural analysis was
precise geometric modeling and ANSYS for advanced performed using ANSYS Mechanical to evaluate piston
simulation capabilities, this research aims to provide deformation, stress, and strain.
valuable insights into the optimization of piston design
for improved engine performance and longevity. Step 3: Stress and Total deformation Analysis
1. material properties for the piston material were
The paper is structured as follows: the design assigned
methodology using SolidWorks is presented, followed by 2. Stress application: the material behaves elastically,
the setup of the simulation in ANSYS, including meshing, meaning that it returns to its original shape after the
loading conditions, and analysis types. The results of the load is removed.
stress and deformation analyses are discussed in detail, 3. Total Deformation Analysis: This type of analysis is
followed by conclusions on the effectiveness of the used to evaluate the large deformation behavior of the
design and recommendations for future improvements piston, including plastic deformation and contact between
1. Design and optimize a piston geometry using components.
SOLIDWORKS. Step 4: Optimization
2. Conduct structural and thermal analyses of the piston 1. Design of experiments: A design of experiments
using ANSYS. (DOE) approach was used to evaluate the effects of
3. Investigate the effects of design parameters, such as design parameters on piston performance.
piston shape, material, and cooling channel geometry, on 2. Response surface methodology: Response surface
piston performance.. methodology (RSM) was used to optimize piston design
parameters for improved structural and thermal
performance.

2.2. METHODOLOGY Step 5: Results and Discussion

1. Results: The results of the structural and thermal
This study employed a computational approach, analyses were compared and discussed.
utilizing SOLIDWORKS for piston design and ANSYS 2. Discussion: The effects of design parameters on
for structural and thermal analysis. The methodology piston performance were discussed, and
consisted of the following steps: recommendations for optimal piston design were
provided.
STEP 1: Piston Design Software Used:
1. Geometry creation: A piston geometry was created - SOLIDWORKS 2022 (or latest version)
using SOLIDWORKS, considering typical piston - ANSYS 2022 R1 (or latest version)
dimensions and features.
2. Parameterization: Key design parameters, such as 3. LITERATURE REVIEW
piston shape, material, and cooling channel geometry,
were parameterized for optimization. in this paper [1], the main objective of this research work
is to investigate and analyze the stress distribution of
piston at actual engine condition. in this paper pressure

© 2025, IJSREM | www.ijsrem.com DOI: 10.55041/IJSREM42950 | Page 2

 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 09 Issue: 03 | March - 2025 SJIF Rating: 8.586 ISSN: 2582-3930

analysis, thermal analysis and thermo-mechanical analysis of piston. The specifications used for the study of these
are done. the parameter used for the analysis is the pistons belong to four stroke single cylinder engine of
coefficient of thermal expansion and material properties Triumph scramble 400 X. The results predict the
of piston. in i.c. engine piston is the most complex and
maximum stress and critical region on the different
important part therefore for the smooth running of vehicle
piston should be in proper working condition. piston fails aluminum alloy pistons using FEA. It is important to
mainly due to mechanical stresses and thermal stresses. locate the critical area of concentrated stress for
analysis of piston is done with boundary conditions, which appropriate modifications. Static and thermal stress
includes pressure on piston head during working analysis is performed by using ANSYS 19. The best
conditions and uneven temperature distribution from Aluminum Alloy material is selected based on stress
piston head to skirt. the analysis predicts that due to analysis results.
temperature the top surface of the piston may be damaged
The analysis results are used to optimize piston
or broken during the operating conditions, because
damaged or broken parts are so expensive to replace and geometry of best aluminum alloy. [5] In this study, firstly,
generally are not easily available. thermal analyses are investigated on a conventional
The CAD model was created using SOLIDWORKS piston, made of aluminum alloy for design 1 and design 2
software. The CAD model is then imported into ANSYS parameters. Secondly, thermal analyses are performed on
software for geometry and meshing purposes. The FEA piston material by means of using a commercial code,
performed by using ANSYS 19. [2] In this present work a namely ANSYS. The effects of coating on the thermal
piston designed for a single cylinder four stroke petrol behaviors of the pistons are investigated. The finite
engine using SolidWorks software. Complete design is element analysis is performed by using computer aided
imported to ANSYS 19 software then analysis is design software.
performed. Four different materials have been selected for The main objective is to investigate and analyze the
structural and thermal analysis of piston. Results are thermal stress distribution of pistons at the real engine
shown and a comparison is made to find the most suited condition during combustion process. This thesis
design [3]. describes the mesh optimization by using finite element
This paper describes the stress distribution and analysis technique to predict the higher stress and critical
thermal stresses of three different aluminum alloys piston region on the component. In this work, the main emphasis
by using finite element method (FEM). The parameters is placed on the study of thermal behavior of functionally
used for the simulation are operating gas pressure, graded coatings obtained by means of using a commercial
temperature and material properties of piston. The code, ANSYS, on aluminum piston surfaces. The analysis
specifications used for the study of these pistons belong to is carried out to reduce stress concentration on the upper
four stroke single cylinder engine of Triumph scrambler end of the piston i.e. (piston head/crown and piston skirt
400 X. This paper illustrates the procedure for analytical and sleeve). With computer aided design SolidWorks
design of four aluminum alloy pistons using specifications software, the structural model of a piston will be
of four stroke single cylinder engine of Triumph scrambler developed. Furthermore, the finite element analysis is
400 X motorcycle. The results predict the maximum stress done using Computer Aided Simulation software ANSYS.
and critical region on the different aluminum alloy pistons
using FEA.
It is important to locate the critical area of concentrated
stress for appropriate modifications. Statistic and thermal
stress analysis are performed by using ANSYS 19. The
best aluminum alloy material is selected based on stress
analysis results. The analysis results are used to optimize
piston geometry of best aluminum alloy [4] This paper
describes stress distribution and thermal stresses of four
different aluminum alloys piston by using finite element
method (FEM).
The parameters used for the simulation are
coefficient of thermal expansion and material properties

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 09 Issue: 03 | March - 2025 SJIF Rating: 8.586 ISSN: 2582-3930

4. MECHANICAL PROPERTIES
1. PROBLEM STATEMENT AND
SOLUTION
TABLE 4.1 MECHANICAL PROPERTIES OF THE
MATERIALS
No. of 1
cylinders
Rated Speed 6500 R.P.M
Bore x 89*64 MM
5. MECH D16T GRA AISI40 AL60 Stroke
ANICA ALUMI Y CAST 41 61 Max. Power 40 PS @8000 R.P.M
L NIM IRON STEE Max. Torque 37.5 NM @6500
PROP ALLOY L R.P.M
ERTY Compression 12: 1
Ultimate 560- 200– 585– 310- Ratio
Tensile 580 350 655 350
TABLE 5.1 ENGINE SPECIFICATIONS
strength
(MPA)
Yield 460- 150– 415– 275- 1.2. DESIGN CALULATATIONS
strength 480 250 515 310
(MPA) 5.2.1 PISTON DESIGN PARAMETERS
Shear 300- 150– 315– 200-
Strength 350 200 400 230 Taking AL Alloy Material
(MPA) (i) Thickness of Piston Head (th) :
Young's 70-75 100– 190– 68.9-
Modulus (E) 150 210 70 The piston thickness of piston head calculated using
(GPa) the following Grashoff’s formula,
Density 2.85 6.9– 7.85 2.70
(G/CM³) 7.3 th = D√(3pmax/16σt)
Coefficient 22.6 × 10–12 × 11.7 × 23.6× Where P= maximum pressure in N/mm² = 8 N/mm²
of Thermal 10⁻⁶ 10⁻⁶ 10⁻⁶ 10⁻⁶
Expansion(/° D= cylinder bore/outside diameter of the piston in
C) mm.
Thermal 130 50–60 45- 150–
conductivity 50 160 σt = permissible tensile stress for the material of the
W/m·K piston = 124.4MPa

Therefore, th = 89√ (3*8/16*124.4) = 9.77mm

The maximum thickness from the above formula (th)

is 9.77 mm.

(ii) Radial Thickness of Ring (t1)

The radial width of the ring is given by:

T1 = D√ (3*pw/ σt)

Where Pw= pressure of fuel on cylinder wall in

N/mm². Its value is limited from 0.025N/mm ² to

0.042N/mm².

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 09 Issue: 03 | March - 2025 SJIF Rating: 8.586 ISSN: 2582-3930

nr = 4 rings.
Therefore, T1 = 89√(3*0.042/ 124.4) = 2.83mm.

(iii)Axial Thickness of Ring (t2)

5.2.2THEORETICAL STRESS CALCULATIONS
The thickness of the rings may be taken as
σb = Pzmax *(ri/δ) ²
t2 = 0.7t1 to t2
Pzmax = Max. Gas Pressure (5 MPa)
Therefore, t2 = 0.7 t1 = 0.7*2.83 = 1.98mm.
ri = Crown Inner Radius = [D/2 – (s+t1+dt)]
(iv) Width of the top land (b1)
s = 0.05*D = 4.45mm
The width of the top land varies from
dt = 0.0008m
𝐛𝟏 = 𝐭𝐇 𝐭𝐨 𝟏.𝟐 𝐭𝐇
ri = 37.2192 mm
Therefore, 𝐛𝟏 =1.2*9.77 = 11.724 mm.
δ = Thickness of Piston Crown
(v) Width of other lands (b2)
δ = 0.08D to 0.1D = 0.1*89 = 8.9mm
Width of other ring lands varies from
σb = 5*(37.2192/8.9)²
𝐛𝟐 = 𝟎.𝟕𝟓 𝐭𝟐 𝐭𝐨 𝐭𝟐
σb = 87.45 MPa
Therefore, 𝐛2 = 0.75*1.98 = 1.485 mm.
Hence required theoretical stress obtained from
(vi) Thickness of Barrel at the top end (t3) calculation is 87.45 MPa

Radial Depth of Piston ring grooves (b) is about 5.3 THE MODEL OF THE PISTON
0.4mm more than radial thickness of piston rings(t1),
therefore

b = 0.4+t1 = 3.23mm
t3 = 0.03*D+b+4.5 = 0.03*89+3.23+4.5
t3 = 10.4m.

(vii) Thickness of Barrel at the open end (t4)

t4 = 0.25t3 to 0.35t3
t4= 0.25t3 = 0.25*10.4
Fig 5.3.1 The model of the piston
t4= 2.6mm

(viii) Piston Pin Diameter (d0)

d0 = 0.3D = 0.3*89
d0 = 26.7mm.

(ix) Number of Rings (nr)

nr = D/(10*t2)
= 89/(10*1.98)

© 2025, IJSREM | www.ijsrem.com DOI: 10.55041/IJSREM42950 | Page 5

 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 09 Issue: 03 | March - 2025 SJIF Rating: 8.586 ISSN: 2582-3930

5.3.2 The model of the Piston 6. EQUIVALENT STRESS AND

5.4 ANALYSIS OF PISTON IN ANSYS:
TOTAL DEFORMATION OF AL
5.4.1 MESHING

FIG 5.4.1. MESHING OF PISTON

5.4.2 BOUNDARY CONDITIONS

D16T
FIG 6.1 EQUIVALENT STRESS AND TOTAL DEFORMATION
OF AL D16T AT 5MPA

7.RESULTS
7.1 Materials Used for Piston:

• AL D16T
FIG 5.4.2 PRESSURE APPLIED ON PISTON
• GRAY CAST IRON
5.4.3 FIXED SUPPORTS
• AISI 4041

• AL 6061

• The structural static analysis is conducted on

piston by using these different materials. First
the analysis is carried out by AL D16T and then
the Parameters like von-mises stresses and
deformation is found. Later the analysis is
performed on piston by GRAY CAST IRON,
FIG 5.4.3 FIXED SUPPORTS APPLIED ON PISTON AISI 4041 and AL 6061 and above parameters
are calculated.

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 09 Issue: 03 | March - 2025 SJIF Rating: 8.586 ISSN: 2582-3930

MAXIMUM EQUIVALENT
STRESS(MPA)
7.3 GRAPHS:
MATERI AT AT
AT AT AT
ALS 20 25
5MP 10M 15M
MP MP
A PA PA
A A
101. 203.1 304.7 406. 507.
AL D16T 59 8 7 36 95

GRAY 102. 308.8 411. 514.

205.9
CAST 95 5 8 75
IRON
102. 204.8 307.2 409. 512.
AISI 4041 41 2 3 64 05
101. 203.6 305.4 407. 509. fig 7.3.1 Graphical representation of Stress at 5MPA
AL 6061 81 2 3 24 04

7.2 The obtained results are tabulated in the

below table:

7.2.1 Maximum Equivalent Stresses Obtained

For 4 Different Materials
TABLE7.2.1MAXIMUM EQUIVALENT STRESSES
OBTAINED FOR 4 DIFFERENT MATERIALS
7.2.2 Maximum Deformation Obtained For 4
Fig 7.2.2 Graphical Representation of stress at 10 MPA
MAXIMUM DEFORMATION
(mm)
MATER
AT AT AT AT AT
IALS
5MP 10M 15M 20M 25M
A PA PA PA PA
AL 0.062 0.125 0.188 0.250 0.31
D16T 688 34 01 67 334
GRAY
0.040 0.081 0.121 0.162 0.20
CAST
634 267 9 53 317
IRON
AISI 0.021 0.042 0.063 0.084 0.10
4041 134 267 401 534 567 Fig 7.3.3 Graphical representation of Total deformation at 10
0.061 0.123 0.185 0.247 0.30 MPA
AL 6061 98 96 94 92 99
Different Materials
7.2.2 MAXIMUM DEFORMATION OBTAINED FOR 4
DIFFERENT MATERIALS

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 09 Issue: 03 | March - 2025 SJIF Rating: 8.586 ISSN: 2582-3930

Fig 7.3.4 Graphical Representation of Stress at 15MPA Fig 7.3.5 Graphical representation of Total deformation at
15MPA

Fig 7.3.6 Graphical Representation of Stress at 20 MPA Fig 7.3.7 Graphical representation of Total Deformation at
20MPA

Fig 7.3.8 Graphical representation of Stress at 25 MPA Fig 7.3.9 Graphical representation of Total Deformation at 25
MPA

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 International Journal of Scientific Research in Engineering and Management (IJSREM)
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CONCLUSION Applications (IJERA), vol.4, issue 11(version5),

November 2014, PP.60-64.
This research outlines a numerical method for determining the
optimal piston design. the initial stage involves performing • [4] S. Srikanth Reddy, Dr.B. Sudheer
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 International Journal of Scientific Research in Engineering and Management (IJSREM)
Volume: 09 Issue: 03 | March - 2025 SJIF Rating: 8.586 ISSN: 2582-3930

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