CHAPTER 1

INTRODUCTION

1.1 BACKGROUND OF STUDY

The modern trend is to develop IC Engine of increased power capacity. One of the design criteria

is the endeavor to reduce the structures weight and thus to reduce fuel consumption. This has been

made possible by improved engine design. These improvements include increased use of

lightweight materials, such as advanced ultra-high tensile strength steels, aluminum and

magnesium alloys, polymers, and carbon-fiber reinforced composite materials. The integration of

lighter weight materials is especially important if more complex parts can be manufactured as a

single unit. In the next 10–20 years, an additional 20–40% reduction in overall weight, without

sacrificing safety, seems to be possible. Cuddy et al (1997) have reported that for every 10%

weight reduction of the vehicle, an improvement in fuel consumption of 6–8% is expected.

Improved engine design requires optimized engine components. Therefore sophisticated tools are

needed to analyze engine components. Engine piston is one of the most analyzed components

among all automotive or other industry field components. The engine can be called the heart of an

automobile and the piston may be considered the most important part of an engine. Many

sophisticated Aluminum piston analysis methods have been reported in the past years. Silva 2006

has analyzed fatigue damaged piston. Damages initiated at the crown, ring grooves, pin holes and

skirt are assessed. An analysis of both thermal fatigue and mechanical fatigue damages is

presented and analyzed in this work. A linear static stress analysis, using ‘‘cosmos works’’, is

used to determine the stress distribution during the combustion. Stresses at the piston crown and

pin holes, as well as stresses at the grooves and skirt as a function of land clearances are also

presented. We almost take our Internal Combustion Engines for granted don’t we. All we do is

buy our vehicles, hop in and drive around. There is, however, a history of development to know

about. The compact, well-tuned, powerful and surprisingly quiet engine that seems to be purr

under your vehicle’s hood just wasn’t the tame beast it seems to be now. It was loud, it used to
1
roar and it used to be rather bulky. In fact, one of the very first engines that had been conceived

wasn’t even like the engine we know so well of today. An internal combustion engine is defined

as an engine in which the chemical energy of the fuel is released inside the engine and used

directly for mechanical work, as opposed to an external combustion engine in which a separate

combustor is used to burn the fuel. The internal combustion engine was conceived and developed

in the late 1800s Internal combustion engines can deliver power in the range from 0.01 kW to

20x103 kW, depending on their displacement. The complete in the market place with electric

motors, gas turbines and steam engines. The major applications are in the vehicle (automobile and

truck), railroad, marine, aircraft, home use and stationary areas. The vast majority of internal

combustion engines are produced for vehicular applications, requiring a power output on the order

of 102 kW. Next to that internal combustion engines have become the dominant prime mover

technology in several areas. For example, in 1900 most automobiles were steam or electrically

powered, but by 1900 most automobiles were powered by gasoline engines.

Impact of Modified Piston - A Review

Source: S. Manavalan, et al (2019).

As of year 2000, in the United States alone their internal combustion engines. In 1900, steam

engines were used to power ships and railroad locomotives; today two- and four-stoke diesel

engines are used. Prior to 1950, aircraft relied almost exclusively on the pistons engines.Today

gas turbines are the power plant used in large planes, and piston engines continue to dominate the
2
market in small planes. The adoption and continued use of the internal combustion engine in

different application areas has resulted from its relatively low cost, favorable power to weight

ratio, high efficiency, and relatively simple and robust operating characteristics of compressing or

ejecting the fluid in the cylinder. In some engines, the piston also acts as a valve by covering and

uncovering ports in the cylinder wall.

1.2 Statement of the Problem

A piston is a component to reciprocating IC-engines. It is the moving component that is contained

by a cylinder and is made gas-tight by piston rings. In an engine, its purpose is to transfer force

from expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod. As an

important part in an engine, piston endures the cyclic gas pressure and the inertial forces at work,

and this working condition may cause the fatigue damage of piston, such as piston side wear,

piston head/crown cracks and so on. The investigations indicate that the greatest stress appears on

the upper end of the piston and stress concentration is one of the mainly reason for fatigue failure.

On the other hand piston over heating-seizure can only occur when something burns or scrapes

away the oil film that exists between the piston and the cylinder wall.

1.3 Scope of the Study

The study is to examine the various parts of a piston and the various fabrication and prefabrication
methods with the metal suitable for piston construction.

1.4 Aim of the project

The purpose of this project is to construct a piston

1.5 Objectives of Study

(i) Use aluminum alloy to produce a piston which has the ability to withstand heat or high
temperature

3
1.6 Significance of the study
It seals the combustion chamber

It guides the connecting rod (in trunk piston engines)

It dissipates the heat generated in the combustion chamber

It supports gas exchange (by means of gas suction and emission)

1.7 Limitation of the study

The major limitation encountered in the course of study is the limited access to materials and

machineries for construction.

4
 CHAPTER 2

LITERATURE REVIEW

2.1 History of Piston

The earliest piston engines were steam driven engine which evolved during the 18 th century but

modern internal combustion engine are based on development at the end of the 19 th century. The

two main types are the spark ignition engine and the compression engine. A piston tells a story of

the engine in which it resides the crown can reveal the bore the number of valves and whether or

not the fuel is directly injected into the cylinder. Yet a piston’s design and technology can say a

lot about the wider trends and challenges facing the auto industry. Piston accounts for at least 60%

of the engine friction, and improvements here have a direct impact on fuel consumption. The

internal-combustion engine’s lasting relevance is due to the continuous evolution of its

components. Yet after more than a century of automotive progress reciprocating pistons continue

to produce most of the power that moves us.

Piston plays a main role in energy conversation. Failure of piston due to various thermal and

mechanical stresses. The working condition of the piston is so worst in comparison of other parts

of the internal combustion engine. The main objective of this work is to investigate and analyze

the stress distribution of piston. Design and analysis of an IC engine piston using three different

materials that are used in this project. We are taking pulsar 220cc piston dimensions different

materials (grey cast iron, aluminum alloy, al-sic) have been selected for structural and thermal

analysis of piston and piston rings.

There are lots of research works proposing, for engine pistons, new geometries, materials and

manufacturing techniques, and this evolution has undergone with a continuous improvement over

the last decades and required thorough examination of the smallest details. Notwithstanding all

these studies, there are a huge number of damaged pistons. Damage mechanisms have different

origins and are mainly wear, temperature, and fatigue related. Among the fatigue damages,

5
thermal fatigue and mechanical fatigue, either at room or at high temperature, play a prominent

role

In this present work a piston and piston ring are designed for a single cylinder four stroke petrol

engine using Computer Aided Three-dimensional Interactive Application (CATIA) software.

2.2 Review of related construction analysis

According to Gadde anilkumar, Piston plays a main role in energy conversation. Failure of piston

due to various thermal and mechanical stresses. The working condition of the piston is so worst in

comparison of other parts of the internal combustion engine. The main objective of this work is to

investigate and analyze the stress distribution of piston. Design and analysis of an IC engine

piston using three different materials that are used in this project. We are taking pulsar 220cc

piston dimensions different materials (grey cast iron, aluminum alloy, al-sic) have been selected

for structural and thermal analysis of piston and piston rings.

According to Ajeet Kumar Rai In this present work a piston and piston ring are designed for a

single cylinder four stroke petrol engine using CATIA V5R20 software. Complete design is

imported to ANSYS 14.5 software then analysis is performed. Three different materials have been

selected for structural and thermal analysis of piston. For piston ring two different materials are

selected and structural and thermal analysis is performed using ANSYS 14.5 software. Results are

shown and a comparison is made to find the most suited design.

According to Aditya Kumar Gupta In this study work there are two steps of analysis of the piston

they are designing and Analysis. Firstly design the model of the piston in giving design

specification on the modelling software like INVENTOR. Then giving it the constraints which are

act on the working condition of the piston after import the model of the piston into the analysis

software ANSYS in IGES format. Then the analysis becomes completed on the different

parameters (temperature, stress, deformation) and easily analysis the result. In this work the piston

become optimized after the reducing the material of the piston. The mass and volume of the piston
6
become reduced. The deformation also increased after the optimization which is responsible for

the stress distribution on the piston head or piston crown.

2.3 How it works

When the engine is running, the piston moves up and down in the cylinder. When the piston

reaches the turning point, it slows down and then accelerates again suddenly. This produces

inertia forces that act on the piston. When considered together with the forces generated by the

gas pressure, this forms the piston force, which is transferred to the connecting rod and crankshaft.

Connecting rods are only perfectly vertical at the upper and lower turning points. The angle of the

connecting rod presses the piston against the side of the cylinder wall. The amount and direction

of this force makes the crankshaft rotate hereby producing energy.

2.4 Types of a piston

Truncated piston: Trunk pistons are long relative to their diameter. They act both as a piston and

cylindrical crosshead. As the connecting rod is angled for much of its rotation, there is also a side

force that reacts along the side of the piston against the cylinder wall. A longer piston helps to

support this. Trunk pistons have a common design of piston since the early days of the

reciprocating internal combustion engine. They were used for both petrol and diesel engines

although high speed engines have now adopted light weight. They do have a groove for an oil ring

below the gudgeon pin, in addition to the ring between the gudgeon pin and crown.

Cross head piston: Large slow-speed Diesel engines use crosshead pistons. The main pistons has

a large piston rod extending downwards from the piston to what is effectively a second smaller

diameter piston. The main piston is responsible for gas sealing and carries the piston rings. The

smaller piston is purely a mechanical guide. I runs within a small cylinder as a trunk guide and

also carries the gudgeon pin.

Slipper piston: This is a piston for a petrol engine that has been reduced in size and weight as

much as possible. In the extreme case, they are reduced to the piston crown, support for the piston

7
rings and just enough of the piston skirt remaining to leave two lands so as to stop the piston

rocking in the bore. The sides of the piston skirt around the gudgeon pin are reduced away from

the cylinder walls. The purpose is mostly to reduce the reciprocating mass thus making it easier to

balance the engine and so to permit high speeds.

Deflector piston: These pistons are used in two-stroke engines with crankcase compression where

the gas flow within the cylinder must be carefully directed in order to provide efficient

scavenging. With the cross scavenging the transfer (inlet to the cylinder) and exhaust ports are on

the directly facing sides of the cylindrical walls. To prevent the incoming mixture passing straight

across from one port to the other the piston has a raised rib on its crown. This is intended to

deflect the incoming mixture upwards around the combustion chamber.

Racing pistons: In racing engines piston strength and stiffness is typically much higher than that

of a passenger car engine while the weight is much less to achieve the high engine RPM necessary

in racing.

2.5 Features of a piston

Piston head, piston ring, piston skirt, piston pin

Piston head
Piston head is the top surface (closest to the cylinder head) of the piston which is subjected to

tremendous forces and heat during normal engine operation. In some pistons which come quite

close to the valves, the head is provided valve relief. In some other engines the piston may be

dished to form a desired shape of combustion chamber, jointly with cylinder head. The top of the

piston is called head or crown. Generally low cost low energy combustion in its crown,

compression ratio can be controlled very accurately but the disadvantage is that in this case much

larger amount of heat has to be dissipated through the pistons and rings.

There are two types of piston heads-flat plate type and cup type. The selection of the type

depends upon the required volume for combustion chamber and the arrangement of valves.
8
Source: Design of a piston, Muslim Alli, 2020.

Piston Rings
Piston rings are made to maintain the cylinder and combustion pressure of the automobile. They

prevent any oil from seeping into the combustion chamber as well as sealing in the air and fuel to

be able to compress them. There are typically three piston rings to every piston. Towards the top

of the piston of a few grooves are cut to house the piston rings. The bands left between the

grooves are known as lands. These lands support the rings against the gas pressure and guide them

so that they may flux freely in the radial direction. The supporting webs transmit the force of

explosion directly from the crown to the piston pin bosses thereby relieving the groove portion of

the large load and thus by preventing the deformation of the ring grooves

9
The first ring (the top ring) also known as the compression ring. This ring helps the piston work,

because during the combustion process it doesn’t allow it to lose any pressure.

The second ring is known as the secondary compression ring. This ring is a back up compression

ring with a slightly tighter tolerance to help the top compression ring in sealing the combustion

chamber.

The last ring is called the oil ring. These work with the piston in the engine to lubricate the

cylinder, walls, pistons, rings, and wrist pins. This ring keeps the oil out of the combustion

process. The oil rings also help the thermal control because it cools the piston by directing oil

around it.

Piston Skirt
The part of the piston below the rings is called skirt. It is the side of the piston below the last ring.

Without a skirt the piston could tip and jam. It`s function is to form a guide suitable for absorbing

side thrust due to gas pressure. The skirt is provided with the bosses on the inside of the piston

pin. It must be of sufficient length to resist tilting of the piston under load. It is kept quite close

fitting in the cylinder but even then it is separated from the cylinder walls by means of lubricating

oil film for smooth running. The bosses form a bearing surface for the rocking motion of the

connecting rod. The thick-sectioned webs also form heat paths from the piston crown to the pin

bosses and the skirt and thus have to be designed so as to avoid expansion problems.

Piston Pin

The piston pin is a connecting pin also known as the gudgeon pin which connects the piston to the

connecting rod and provides a bearing for the connecting rod to pivot upon as the piston moves.

The piston pin transfers the entire power out of the combustion process from the piston via the

connecting rod to the crankshaft and its one of the most stressed part of an engine. Therefore the

pin as to be checked for wear and tear carefully on a regular basis.

10
It serves as a link between the piston and the connecting rod and is also called the wrist pin which

allows the piston to swing on the connecting rod. The pin fits through the hole in the piston and

the connecting rod small end.

Functions of a piston

1. To form a seal so that the high pressure gases in the combustion chamber do not escape

into the crankcase.

2. To serve as a guide and a bearing for small end of the connecting rod. Apart from its

capability to perform the above functions efficiently the pistons must have some other

desirable characteristics.

3. The design should be such that the seizure does not occur.

4. It should offer sufficient resistance to corrosion due to some other products of

combustion.

5. It should have the shortest possible length so as to decrease overall engine size.

6. It should be lighter in weight so that inertia forces created by its reciprocating motion are

minimum.

7. It must have a long life.

8. To transmit the force of explosion in the crankshaft.

11
 CHAPTER 3

3.0 MATERIALS AND METHODOLOGY

The piston is a reciprocating part of IC engine that performs a number of functions. The main

functions of the piston are as follows:

(1) It transmits the force due to gas pressure inside the cylinder to the crankshaft through the

connecting rod.

(2) It compresses the gas during the compression stroke.

(3) It seals the inside portion of the cylinder from the crankcase by means of piston rings.

(4) It dissipates large amount of heat from the combustion chamber to the cylinder wall.

TABLE 1.0: Piston Dimension

S/N DESCRIPTION NOTATION UNIT VALUE USED (mm)

1 Length of piston L Mm 100

2 Height of piston L Mm 120

3 Outside diameter of piston L Mm 105

4 Length of skirt Ls Mm 66.2

5 Thickness of piston head tH Mm 15

6 Radial thickness of the ring T1 Mm 2

groove

7 Axial thickness of the ring T2 Mm 2

groove.
8 Maximum thickness of the T3 Mm 13
piston skirt.
9 Width of the top land. B1 Mm 2

12
3.1 THE DESIGN REQUIREMENTS FOR THE PISTON ARE AS FOLLOWS:

(i) It should have sufficient strength to withstand the force due to combustion of fuel and also

the inertia forces due to reciprocating parts.

(ii) It should have sufficient rigidity to withstand thermal and mechanical distortions.

(iii) It should have adequate capacity to dissipate the heat from the crown to the cylinder wall

through the piston rings and the skirt.

(iv) It should have minimum weight to reduce the inertia force due to reciprocating motion.

(v) It should form an efficient seal to prevent leakage of flue gases from combustion chamber to

the crankcase past the piston.

(vi) It should also prevent leakage of lubricating oil into the combustion chamber past the piston.

(vii) It should have sufficient bearing area to take the side thrust and prevent undue wear.

(viii) It should result in noiseless operation.

(ix) It should provide adequate support for the piston pin, which connects the small end of the

connecting rod.

3.2 PISTON MATERIALS

Piston materials commonly used materials for IC engine pistons are cast iron, cast steel, forged

steel, cast aluminum alloys and forged aluminum alloy.

Compared with cast iron, aluminum alloy pistons have the following advantages:

(i) The thermal conductivity of aluminum alloys is approximately three times that of cast iron.

Therefore, an aluminum alloy piston has less variation in temperature from the crown to the piston

rings.

(ii) The density of aluminum alloy is about one third that of cast iron. This result in light weight

construction and reduces inertia forces.

(iii) Aluminum has faster thermal conductivity so its cooling performance is good.

13
(iv) It’s also easier to manufacture

(v) The density is one-third of that of a cast iron

(vi) Higher thermal efficiency can be secured by means of higher compression.

(vii) It has a simple net shape fabrication technique.

3.3 Material properties

The material used is aluminum. Aluminum is widely and commonly used in engineering

structures and components where light weight or corrosion resistance is required.

FIG.3. SKELETAL VIEW OF A CUP HEAD PISTON.

Source: Design of a piston, Muslim Alli April, 2020.

14
FIG.4 SIDE VIEW OF A PISTON.

Source: Design and thermal analysis of piston, Tumpala uma santhosh, 2016.

3.4 THE PROCEDURES IN THE MAKING OF A PISTON

Aluminum Alloys are the preferred materials for pistons both in gasoline and diesel engines due

to their specific characteristics: low density, high thermal conductivity, easy machinability etc.

The standard material for piston is Al-12% Si alloy containing in addition approximately 1% each

of Cu, Ni, and Mg.

Process Of Manufacture:

The aluminum alloy is formed into roughly shaped piston blanket either by casting or forging.

Thereafter, piston blanks are machined to final specification.

Cast Piston: They are the most common due to the simpler and less expensive manufacturing

processes involved. The majority of pistons are produced by gravity die casting process.

Forged pistons: They are made from higher strength aluminum alloy billets which are pressed

into their various shapes rather than poured. Forged pistons have a finer microstructure than cast

pistons with the same alloy composition.

15
3.5 DETAILS OF PROCESSES INVOLVED IN MANUFACTURE OF PISTON BY

CASTING PROCESS:-

MATERIAL: ALUMINUM

TOOLS: Rammer, Piston pattern, Sand, Water, Sieve, Vent pipe, Die.

1. Foundry: This is the beginning of piston manufacturing. At the foundry, a mold is made

to collect molten aluminum alloy by heating it to operating temperature. The mold used here is a

sand produced mold.

The production of the mold entails in some processes:

(i) Sieving of the sand: This sand is a combination of green sand, sea sand. The sand will be

sieved to remove bigger particles. To produce a good mixture.

(ii) Marring of the sand: The sand is wetted and marred to make the sand have light

moisture.

(iii) Striking: The marred sand is then introduced to a wooded die called “The drag” and “The

cope”. The drag is the lower die and it is where the marred sand is introduced to for striking. A

rammer is used for the striking of the sand mold in the drag it is stroked to the level of the drag.

The process of striking should not be too intense so as to allow the easy penetration of the pattern

to be introduced.

(iv) Application of patting powder: Patting powder is the powder used to prevent the pattern

from sticking to the sand. It is applied after the marred sand has been properly rammed into the

mold.

(v) Pattern: The piston pattern is a piston divided into two equal halves from the top of the

piston head to the piston skirt giving it an equal cavity in both sides. A part of the piston pattern is

gently tapped into the mold with a mallet in the drag making the cavity be on the same level with

the drag and the mold. The other half of the pattern is placed on the inserted pattern in the drag

then the cope is placed aligned on top of the drag. Then the vent pipe is introduced for production

16
of: Pouring gate, Escape gate and Rising gate. The marred sand is then poured into the cope and

stroked till it gets to the level of the cope.

(vi) Production of cavity: The vent pipe is gently removed, then the cope is also removed to be

able to extract the pattern and the pattern is also removed from the drag to create a piston cavity.

The process starts by heating the aluminum alloy well above the melting point but below its

boiling point, i.e., up to 700°C. Molten aluminum alloy is then poured into the sand mold through

the pouring gate the molten aluminum fills the provided cavity to form the piston shape. After

allowed to cool, the mold is then broken to remove the casted piston.

2 Pin hole boring: At this stage the gudgeon pin hole is created with the use of a drilling

spindle where the piston is clamped to allow the drilling spindle penetrate the piston and create

the gudgeon pin.

3 Turning: Turning of the piston casting is carried out on pricision lathe machines. The

casting are placed in the lathe on a bung and held in place by a solid rod through the gudgeon pin

hole. A draw bolt is activated in the chuck which draws the rod towards chuck and holds the

piston in place. The piston is now ready for finishing processes.

4 Finishing processes:

(a) The first stage of finishing processes include drilling oil holes in gudgeon pin bosses and oil

ring grooves, cutting slots in the skirt, valve relieving and crank relieving.

(b) Grinding : This process involves the final size being machined on the piston. The process

involved is cam grinding which machines the skirt of the piston only.

(c) Reaming : This is the final machining process which involves the piston being placed in a

bath of oil and reamed to reach the final size required.

17
 CHAPTER 4

4.0 RESULT AND DISCUSSION

4.1 EFFICIENCY OF A PISTON

The two types of piston engines are regularly used for power generation, diesel engines and spark

ignition gas engines. The former are the most efficient and can operate up to 50% fuel to electrical

conversion efficiency. Spark ignition gas engines achieve around 42% efficiency at best.

4.2 PRECAUTIONS AND MAINTENANACE OF A PISTON

To prevent piston damage and failure, whether diesel piston rings or other specific engine piston

parts:

1. Ensure you are using the correct engine oil and the engine oil filters are changed at the

recommended intervals by the manufacturer.

2. Piston rings do wear out and there is little you can do to prevent this so piston rings should be

changed routinely before they wear it will play a great part in preventing damage to the engine.

3. Ensure the engine coolant is in good condition which can be checked by opening the radiator

cap or the water in the coolant reservoir should be checked.

4.3 PISTON TEST

Piston is pressure tested to test for any leakage at contact surface and also between sealing rings.

--For pressure testing of piston, it is to be turned 180°e foot of piston should be at our neck level

remove lifting bracket from piston rod foot fill piston and piston rod with lubricating oil i.e,

complete line including telescopic pipe and area under piston crown, attach Pressure Testing Tool

at the foot or base of the piston, on the gauge attached to the piston testing tool you can see the

pressure inside the piston, now start supplying air at 7bar to the connection attach air hose to the

air connection nozzle on the pressure testing tool, pressure test the piston at pressure stated in the

manual when gauge show the stated pressure (around 7 bar), then stop supplying air, check the

18
contact surfaces. Wait for at least 30 minutes, if there is no leakage for 30 minutes, then

everything seems to be fine, release the pressure. Remove the pressure testing tool.

TENSILE TEST

The piston is clamped by tension grips then an extensometer is attached to the piston and the

tensile grips is separated slowly at a constant speed at 0.05-20 inches per minute until the piston

fractures then stop the test.

COMPRESSION TEST

The water the piston took to fill the cylinder at the bottom dead center should be measured and

then divided by the amount of water needed to fill the piston at the top dead center.

To know if the piston is functional it should be sent out for Rockwell or Brinnell hardness test,

which can be expensive. Suyenaga suggests that careful inspection of the backside of the piston

crown is a great indicator of piston condition.

19
 CHAPTER 5

5.0 SUMMARY, CONCLUSION AND RECOMMENDATION

5.1 SUMMARY

The piston is one of the most loaded parts of the engine. It is acted upon by changes in pressure of

hot gases and inertia forces. That is why the piston must have sufficient strength at increased

temperature and be as light as possible. The pistons of fast running engines are usually made of

light aluminum alloys. The pistons of large diesels are made of steel but sometimes they are made

of cast iron. There is a great variety of different types of piston engine constructions including the

form of bottom surface, the number of piston rings, the form of side surface of the piston case, the

method of piston cooling and others.

5.2 CONCLUSION

Compared results based on AL Alloy and cast iron (Al-2618, Cast Iron). AL alloy gives best

results. . Because the stresses induced in the piston reduced. Hence the prepared piston with AL-

Alloy specimen show better results than the normal Cast Iron. The following discussed about

piston has shown the basic parts of a piston, the functions, roles and how it works in an internal

combustion engine. Pistons are commonly made of a cast aluminium alloy for excellent and light

weight thermal conductivity and thermal conductivity is the ability of a material to conduct and

transfer heat. Aluminium expands when heated, and proper clearance must be provided to

maintain free piston movement in the cylinder bore, insufficient clearance can cause the piston to

seize in the cylinder, excessive clearance can cause a loss of compression and an increase in

piston noise, piston should have enormous strength to withstand high gas pressure and inertia

forces in addition to disperse the heat of combustion quickly to the cylinder walls, it should

provide sufficient bearing area to prevent undue wear in addition to having sufficient support for

the piston pin, and also it should have sufficient rigid construction to withstand thermal and

20
mechanical distortion in addition to it acts as effective sealing to the gases not to escaping from

combustion chamber.

From then analyses it has been shown that although thermal stress is not responsible for biggest

slice of damaged pistons, it remains a problem on engine pistons and its solution remains a goal

for manufacturing robust piston for marine diesel engine application. The problem of thermal

stress on pistons will remain a problem for a while. This is because efforts in reducing fuel

consumption and quest for power increase will push to limit weight reduction unavoidably leading

to thinner walls and higher thermal stresses. In satisfying all the critical requirements for robust

piston design suitable for marine application knowledge on piston behavior will bring an intense

modification on a piston to produce a very perfect piston without any defect. Analytically, the

stress distribution on the piston basically depends on the piston deformation. The FEM prove to

be a very veritable tool in proffering the solutions to mitigate the effect of these stressed and

deformations during piston design and manufacturing.

5.3 RECOMMENDATION

A recommendation for future work on a piston is to create better combustion efficiency in the

engine by using maximum oxygen inside the cylinder. We can make use of the available oxygen

and improve the uniformity inside the cylinder by digitizing the combustion chamber and using

that has a map to create the piston top combustion surface. The scan is then used to direct the

shape of the piston top to create the desired compression ratio while minimizing obstructions to

the combustion process.

21
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