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A basic automated CAD modelling approach for an IC engine piston

Conference Paper  in  AIP Conference Proceedings · November 2022

DOI: 10.1063/5.0114356

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RESEARCH ARTICLE | NOVEMBER 29 2022

A basic automated CAD modelling approach for an IC engine

piston
Bill Christopher Sirigiri  ; Jayakiran Reddy Esanakula

AIP Conference Proceedings 2648, 020023 (2022)

https://doi.org/10.1063/5.0114356

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 A Basic Automated CAD Modelling Approach for an IC
Engine Piston
Bill Christopher Sirigiri a) and Jayakiran Reddy Esanakula b)

Department of Mechanical Engineering, Sreenidhi Institute of Science and Technology, Hyderabad, India.

Corresponding authors: a)christopherbill07@gmail.com, b)ejkiran@gmail.com

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Abstract. Since their introduction, internal combustion engines have been widely used in the automotive industry. As a
result, the IC engine's efficiency is always in need of improvement. In the operation of an IC engine, the piston is one of
the most crucial parts. In today's industry, the technique for increasing the performance of IC engine pistons is critical.
Typical CAD modelling approaches for IC engine pistons are time-consuming because of the complexity of geometry and
design calculations. Because of various interrelated plan concerns, a minor change in the size or shape of the IC engine
assembly will result in a large chain reaction in computing the associated adjustments. As a result, the piston's CAD model
should be updated to reflect the IC engine's changes (s). These problems can be handled by automating the process through
CAD modelling techniques such as parametric modelling. This paper provides a foundation for generating a CAD model
of an IC engine piston using SolidWorks. A customised GUI was designed in the CAD programme to aid the design
engineers in feeding the input data. The solution presented makes use of design data reuse. The modelling and design time
for the IC engine piston can be lowered using the proposed method. The recommended approach is also demonstrated in
this paper.

INTRODUCTION
The automobile business is one of the world's most profitable and in-demand industries in total revenues and
demand. The engine of a car is among the most crucial parts of a vehicle. An engine is the machine that converts
chemical energy into mechanical energy. The fuel burns in an internal combustion engine (IC engine) to produce heat,
which is subsequently utilised to perform labour. A piston is a crucial component in these engines because it guides
the movement of the connecting rod while also delivering gas pressure forces to modify the volume inside the cylinder.
A cylinder encloses the forward and backward moving components, and piston rings keep them gastight. The force
from expanding gas is transferred to the crankshaft via the piston and connecting rod. The piston function is critical
to the IC engine's efficiency. The IC engine will come to a halt if the piston fails to work properly. Mechanical and
thermal stresses are the principal causes of piston failure [1]. There is always a need for a better IC engine piston
design in order to avoid self-failure. Furthermore, if the new design is offered at a faster pace, it is unquestionably
advantageous to automotive manufacturers. There are a variety of tools available to help speed up the design process
[2]. The IC engine piston and its components are seen in Figure 1.

Fourth International Congress on Advances in Mechanical Sciences

AIP Conf. Proc. 2648, 020023-1–020023-10; https://doi.org/10.1063/5.0114356
Published by AIP Publishing. 978-0-7354-4242-9/$30.00

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FIGURE 1. An IC engine piston and its parts as 1. Piston head, 2. Piston rings, 3. Piston pin

Knowledge-Based Engineering (KBE)

KBE is an automation approach that illustrates the use of AI methodologies in conjunction with CAD technology,
allowing for customised or alternative design automation solutions [2]. The development of Knowledge-Based
Systems (KBS) has greatly reduced the design time [2]. KBS has also become a valuable tool for visualising and
assessing the design process, thanks to the usage of simulation tools. In the design, manufacturing, and production
areas, KBE is one of KBS's technology-based solutions. KBE is one of the greatest quick design technologies, hence
it's used for mass customisation [3]. The ultimate purpose of the KBE system should be to consolidate the best design
methodologies and engineering experience into a corporate knowledge base. The KBS's architecture is seen in Figure
2.

FIGURE 2. Knowledge-Based System architecture [4].

Need of CAD-Modeling in the modern era

When it comes to CAD modelling, most industry wants to save money because it is a time-consuming and labor-
intensive process. The typical technique of designing in an industry is to hire a designer to create a design based on
their specifications. This operation takes a long time and is very expensive. The traditional method works well for
producing new ideas, but it fails miserably when it comes to making revisions to old designs that require dimension
changes. As a result, design automation must be developed.

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 Design Automation
Design automation is the use of a preset set of codes to do automatic design activities that would otherwise take a
lengthy time to accomplish in a human design process. The usage of conventional CAD techniques can make the
development of such apps go more smoothly. CAD methods preserve previous modifications and conditions in the
cloud or on local devices so they may be reprocessed as needed [5]. Design automation, in general, refers to the use
of a computer to automate a human design process. The data for the automation might originate from standard design
techniques, past experience, manuals, charts, and so on, and it will be recorded in a computer database to be utilised
as needed [6]. Figure 3 depicts a typical design automation process.

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FIGURE 3. The process of design automation.

Application Programming Interface (API)

API is for Application Programming Interface, and it is a software development approach that allows two separate
applications to communicate with one other. An API may be used to generate bespoke distinct Windows executable
files. The languages VB.NET, C#, and Visual C++ may be used to create APIs [3]. In addition to API flexibility,
almost all CAD software has a macro feature. SolidWorks has an API that may be used to automate and personalise
the programme. CAD automation may be made easier with the API's hundreds of functions.

Visual Basic (VB)

In 1991, Microsoft released Visual Basic (VB) as a third-generation programming language. It's a user-friendly
programming language that lets us construct GUI (Graphical User Interface) windows apps easily. The most
significant, easiest, and best programming language for creating macros is Visual Basic. VB has shown to be an
extremely valuable tool for writing a wide range of computer codes for a wide range of applications. Engineers may
integrate Visual Basic with multiple Windows programmes and develop new user interfaces using ActiveX dynamic
link libraries, or DLLs [3]. With the use of API and VBA, the CAD programme SolidWorks automates modelling
(Visual Basic for Application). In addition, VB may be used to construct a customised GUI.

Macros
In computer science, a macro is a rule or pattern that describes how a particular input sequence should be translated
to an output sequence according to a procedure [7]. Engagement with the model environment is crucial for improving
the design automation process [8, 9]. API interfaces in CAD systems allow users to utilise macros to communicate
with the model environment. And, with the requirement for data exchange across disciplines in order to tackle real-

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world challenges. In some cases, a sophisticated algorithm must be built to do a computation that is not accessible in
commercial software. It also helps to construct geometrical entities and actions using a computer approach [10].

IC engine piston material

Gray Cast Iron, Aluminum Alloy, Structural Steel, Magnesium Alloy (AZ91D), Al-GHS1300, A2618, A4032,
A6061, and A7075 are some of the materials that should be used for the IC piston, according to ISO 6621-5:2020
requirements. Table 1 lists the important mechanical and thermal parameters of various materials taken from the
literature [11-16].

TABLE 1. The Properties of different materials of IC engine piston

Type of material

Magnesium Alloy
Aluminium Alloy

Structural Steel
Gray Cast Iron

Al-GHS-1300
(AZ91D)

A2618

A4032

A6061

A7075

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Material Property

Density (kg/m3) 7200 2700 7860 1800 2780 2767 2684 2700 2810
Youngs Modulus 110 71 200 44.8 98 73.7 79 68.9 71.7
(GPa)
Poison’s Ratio 0.27 0.33 0.266 0.35 0.3 0.33 0.33 0.33 0.33
Ultimate Tensile 100 225 460 255 1300 480 380 310 276
strength (MPa)
Thermal conductivity 46.6 175 51.25 72.7 120 147 154 167 173
(W/m/C)
Coefficient of thermal 1.0× 0.3× 1.17× 2.6× 18×1 25.9× 79.2× 2.36× 2.81×
expansion (1/K) 10-5 10-5 10-5 10-5 0-6 10-6 10-6 10-5 10-6

Dwaipayan Roy Chowdhury et al. [10] showed how or when to automate the design of a cube using SolidWorks
and VB.net. Macro scripts were used to automate the cube design process. The SolidWorks API allows us to generate
a cube with the size, material, and colour we choose. Balachandar Krishnamurty et al. [5] have developed a programme
that automates the design of pistons and connecting rods using the SolidWorks API and macro scripts. Making
adjustments to an established design using traditional methods will take a lot of time and money. With the aid of the
unique user interface, the piston and connecting rod may be easily designed and produced. This will save a significant
amount of time and money, as well as eliminating the need to hire a design engineer. Jayakiran Reddy et al. [4]
suggested a spur gear design approach using a knowledge-based system and SolidWorks API together with macro
codes. For knowledge base systems, graphical user interfaces, inference engines, and knowledge base systems are
created. The Graphical User Interface contains all of the information that the user need. Designers contribute their
knowledge to the knowledge base, which is subsequently utilised to standardise components. As a result, the client or
user may now get the component they need in a shorter amount of time. Andrijana Bocevska et al. [7] developed a
CAD system for the application design of automotive rims. The user interface of a CAD system makes use of macros
to allow the user to interact with the system. It will aid engineers in offering a whole new degree of possibilities for
modelling better items faster and more accurately. Using the SolidWorks API architecture, Reddy et al. [3] automated
the development of a CAD model of a universal coupling. A knowledge base system is built to reduce the time it takes
to model an existing part by making modest design modifications. When compared to a humans, parametric modelling
of the part may be recreated in a fraction of the time utilising knowledge base systems. Joshi et al. [9] shown how
mechanical component CAD modelling may be automated. Design automation, as well as time and labour savings,
result in increased productivity, resilience, and quality. The automation of cotter joint design saves time and produces
better results than traditional modelling. To build a safe design and minimise modelling mistakes, the calculations are
done in the software's backend. Rui Lyu et al. [17] used the SolidWorks API to automate the simulation of an
automobile chassis frame construction. SolidWorks' material selection software is written in Visual Basic Language,

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and material properties may be directly modified using macro codes. Abhishek et al. [6] designed the design
automation of a winding machine using SolidWorks. The CAD model is developed in less than two hours as a
consequence of design automation. It can help you save up to 25% on total costs and up to 80% on the time it takes to
finish the design process. Similarly, a few additional design automation techniques [18-23] have been published in
the literature with the goal of reducing design time.
According to the literature study, several researchers attempted to build an automation tool for design automation,
but none of them were successful at the industrial level. Automation is accessible for conventional components, but
not for the particular parts that are sorely needed in the business. It takes a lot of money and effort because there isn't
any design automation. It puts a lot of pressure on the engineer, and the need for competent workers has skyrocketed.
The design automation of the IC engine piston component is selected to overcome this gap in the vehicle businesses.
It is expected to save a significant amount of time and money, as well as make the work of R&D engineers and
individuals easier.

METHODOLOGY
Presently, most commercial CAD software developers are aiming to create software that can construct or recreate

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any commercial component's part model utilising text input data as well as traditional methods. In order to draw a line
on the screen, input data such as beginning and ending points do not need to be entered using the mouse; instead, they
may be entered as text by typing the 3-dimensional coordinates of the starting and finishing points. These input
messages can also be delivered using a computer application. As a result, any design system's automation needs may
be accomplished through the use of a computer programme by leveraging existing CAD software. Only a few
programming languages, such as Visual Basic for Applications (VBA), may be used to programme. VBA is a strong
and easy-to-use programming language. For commercial CAD software like SolidWorks, VBA is the programming
editor. As a consequence, the current KBS for CAD modelling of IC engine pistons was created using SolidWorks
software. To finish the design calculations, you'll need a database with data connected to piston materials. The database
has been created in such a manner that it has all of the essential data for design calculations, and the software may use
it anytime the present system is required. This database contains information on the design of the IC engine piston as
well as material characteristics.

Developing a generic 3D model

To begin, a traditional piston model is manually produced in CAD, with all of the model's characteristics and
limitations in mind when recording the macro file. The equations for the producing CAD model should be established
based on the piston's important characteristics. For parameterization and integration with SolidWorks API, the
recorded macro file must be modified. In the future, the same method will be used to produce a 3D CAD model of an
IC engine piston. The developed macro code in the proposed system is 64 KB in size.

Design Calculations
To begin, the user's input data such as bore diameter, length of stroke, maximum gas pressure, speed, indicated
mean effective pressure, fuel consumption, and piston material choices were to be collected using the designed GUI
(see figure 4). In SolidWorks, VB was used to create this GUI. The created method will perform all design calculations
using conventional empirical formulae based on the given data.

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 FIGURE 4. GUI for feeding the IC engine piston design requirements.

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Creating GUI
The built-in VBA in SolidWorks allows users to construct and develop their own graphical user interfaces (Visual
Basic for Application). This user interface was used to collect data from the user in order to produce a CAD model of
the piston. The GUI was constructed using standard Visual Basic tools including text boxes, combo boxes, and buttons,
and it was designed in such a manner that it could collect all of the essential data from the user and transmit it to an
algorithm for design calculations. The flowchart for the design calculations algorithm is shown in figure 5. Figure 6
shows a button/icon that was generated in the SolidWorks environment to cause the GUI to appear on the screen.
All of the design calculations will be done after you click the submit button. If the user does not provide the
minimum essential input data required for design calculations, the GUI will not enable the process to proceed to design
calculations.

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 Start

Collection of the
design inputs

Enough data No
obtained?

Yes

Developed KBS gathers all of the standards, empirical relationships

and procedure(s) for design computations based on input data

Design computation for critical dimensions

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of IC engine piston

Display of results as message

box for user reference

Using developed macro code, the proposed system generates the

CAD model of the IC engine piston as output of the system

End
FIGURE 5. Flowchart of the design calculations algorithm.

FIGURE 6. Developed IC engine piston button in the GUI of SolidWorks.

Program development for design calculations

When done manually, calculating the allowed dimensions using traditional empirical approaches is extremely
complex and time-consuming. To overcome this obstacle, a computer programme is created to do design calculations
and estimate the geometrical dimensions of the piston. As previously stated, the created KBS will perform the design
calculation using a specialised algorithm designed specifically for this purpose. The output data from this application
will be sent to the SolidWorks software, which will construct the matching 3D CAD model based on the computed
geometrical parameters. As a result, the work's design and modelling are automated.

RESULT AND DISCUSSION

Table 2 lists some sample inputs for designing an IC engine piston. The created programme used common
empirical formulae to generate the design calculations based on this input data. After computation, the obtained piston

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dimensions are shown in a message box for the user's reference. Figure 7 shows the computed dimensions. The created
KBS built a CAD model of the IC engine piston using these specifications, as illustrated in figure 8. When executed
on a machine that meets the SolidWorks 2020 minimal hardware requirements, the designed system takes 54 seconds
to complete the full procedure.

TABLE 2. The Properties of different materials of IC engine piston

Design Considerations Corresponding Values
Material Gray Cast Iron
Cylinder bore (mm) 300
Stroke (mm) 450
Speed (rpm) 300
Indicated mean effective pressure (MPa) 0.85
Max gas pressure (MPa) 5
Fuel Consumption (Kg per BP per hr) 0.3

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FIGURE 7. Dimensions of Gray Cast Iron IC engine.

FIGURE 8. An automated generation of IC engine CAD model.

A knowledge-based method is outlined in this work. KBE techniques can make more dramatic geometric topology
adjustments than the usual CAD approach, making this methodology more adaptable than previous approaches. The

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KBE methodologies can also be utilised because they were created in an object-oriented framework. Macros may be
used to initialise KBE approaches, and the same Macros can be used to drastically modify KBE approaches. The
proposed method was shown to be beneficial in creating early IC engine piston CAD models. The suggested system
will be used in the industry where the design and/or production of IC engine pistons is done. This method is very
useful in the design sector, when early design is being considered.

CONCLUSIONS
Using a knowledge-based parametric modelling methodology, this work provides a preliminary method for
creating a CAD model of an IC engine piston. The main goal of the approach's creation is to reduce the piston's CAD
modelling time by accepting design input from an inexperienced user. This system was created using Visual Basic
and SolidWorks. The system development process is described using an appropriate example. This system is easy to
use, trouble-free, and convenient, and it may aid in the improvement of design quality and efficiency. The technology
was able to minimise turn-around time by automating the process and removing human tasks. This system not only
has extensive features and a user interface that is easy to use, but it also makes it simple for a novice to operate. This
system may also be reused because it was created in an object-oriented setting.

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Automobile businesses can use the present IC engine design technique to complete the preliminary design process.
By including piston assembly concepts and expertise into the knowledge base, the approach may also be used for
engine block design. This flexibility, on the other hand, can only be acquired by making appropriate changes to the
macro file.
When a system has to be upgraded, it cannot do it on its own; instead, it requires the assistance of a skilled
developer. This is a system issue that can be remedied by enhancing the knowledge base system that was established
so that it can update its knowledge as new information becomes available. Although the suggested technique is
confined to SolidWorks software, it may be adapted to other CAD software to make piston design more accessible to
everyone. The only additional effort necessary is to convert the SolidWorks macro file format to the supported format
of the target CAD software.

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