FEM Analysis of Combined Paired Effect on Piston & Connecting Rod using ANSYS

Transcription

1 FEM Analysis of Combined Paired Effect on Piston & Connecting Rod using ANSYS Kunal Saurabh Assistant Professor, Mechanical Department IEC Group of Institutions, Greater Noida - India kunalsaurabh.me@ieccollege.com Anand Tiwari IEC Group of Institutions, Greater Noida India anandtiwari2395@gmail.com Abhishek Pandey 6abhishekpandey@gmail.com, Abhijeet Raj abhijeet51096@gmail.com, Amit Kumar B.Tech Student, Mechanical Department ak277581@gmail.com Abstract: This paper reveals simulation of combined effect paired of finite element analysis on piston and connecting Rod. When combustion of fuel takes place inside cylinder the major portion of stress and temperature load applied on piston which will further travel through connection rod. Firstly, the model of piston, pin and connecting rod has modeled and then the stress and thermal analysis has been done. The material aluminum alloy has used through ANSYS software. In this paper the range stress and thermal analysis has achieved on piston first. Then, stress and thermal analysis has done on combined effect of piston and connecting rod. The stress range has achieved to 85MPa from 55MPa on piston which has validated with previous research and observation about deformation has observed by ( ) mm. The simulation of these components explains about the combined effect of stresses and temperature distribution of each component and also with combined paired effect. This paper emphasizes on the totally value of stress and thermal distribution on these components of IC Engines. I. INTRODUCTION An Internal Combustion Engine is a heat engine where the combustion of a fuel occurs with an oxidiser as air in a combustion chamber which is an integral part of the working fluid flow circuit. In working fluid flow circuit, the piston plays vital role. It has wide range to bear the maximum combined effect of stress and thermal load which has been developed by oxidation of fuel. The piston transfers these combined loads to connecting rod. A piston is a component of reciprocating IC-engines which is moving component of cylinder. Its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a connecting rod. The piston endures the cyclic gas pressure and inertial forces at work, and this working condition may cause occurs. 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 overheating-seizure can only occur when something burns or scrapes away the oil film that exists between the piston and the cylinder wall. The connecting rod connects the piston with crank or crankshaft. With the togetherness by crank, they have ability to form a simple mechanism which converts reciprocating motion into rotating motion. As a connecting rod is rigid, it m have ability to transmit either a push or a pull and also the rod have ability to rotate the crank through both halves of a revolution, i.e. piston pushing and piston pulling. FEM Analysis on piston and connecting rod explains about mechanisms of stress and thermal distribution. These distributions explain about loading bearing capacity on the various components of internal combustion engine.

2 II. LITERATURE SURVEY There are numerous of research analysis that has been carried out on individual components of internal combustion engine. The combined effect of IC components gives the well defined structural and temperature effect on internal combustion system. In analysis of piston, S Srikanth Reddy and Dr. B Sudheer Prem Kumar [1] have analyzed the thermal analysis and optimization of IC engine Piston components using FEM method. In their paper they have observed that the maximum stress changed to 85MPa from 55MPa and they have also observed that the deformation has been reduced by ( ) mm. Lokesh Singh, Suneer Singh Rawat, Taufeeque Hasan and Upendra Kumar [2] have focused on the finite analysis of piston in ANSYS. In this paper they been observed that it was found maximum stress 207 MPa and they have also observed that the maximum tensile stress (650 MPa) and yield stress (480 MPa) of the material at maximum temperature having factor of safety Vivek Zolikar and Dr. L.N Wankhade [3] have on the finite analysis and optimization of IC engine piston using radius. In this paper they have observed that the FEA able to find critical area of failure of model and they have also observed that simple concept of FEA at the piston rod is useful for generating new concept design in less time. In connecting rod analysis, Professor Vivek C. Pathade and Dr. Dilip S Ingole [4] did analysis on stress analysis of IC engine by FEM and photoelastic. In this paper they have been observed that the stress induced in the small end of the connecting rod are greater than the stresses induced at the big end and they also observed that the chances of failure of the connecting rod may occur at the fillet section of both end. Mr. J D Ramani, Prof. Sunil Shukla and Dr. Puspendra Kumar Sharma [5] did analysis on connecting rod of IC engine by using ANSYS for the purpose of material optimization. In this paper they have been observed that the connecting rod can be designed at optimized under a load range(compressive load) as one extreme load and they have also observed that it can be replaced by optimization with a new connecting rod (approx.15%). Prateek Joshi and Mohammad Umair Zaki [6] have on the analysis on connecting rod of different material using ANSYS. In this research paper, they have observed that displacement, stress and strain in the connecting rod of carbon fiber is greater than compared to connecting rod and they have also observed that the connecting rod made up of alloy has higher intensity of stress and strain. Puran Singh, Debasis Pramanik and Ram Vijay Singh [7] have analyzed fatigue and structural analysis of connecting rod due to using FEA. In their paper, they have observed that the maximum principal stress comes out to be MPa which is less than yield compressive stress(530 MPa) of connecting rod hence design is safe. In this paper ANSYS software is used to analysis stress and thermal analysis of piston, pin and connecting rod. The components have modeled, meshed and then analysis of stress and thermal have obtained. III. FINITE ELEMENT METHOD The design of the piston, pin and connecting rod starts with the definition of the geometry using 3D CAD software. This 3D CAD geometric model is created and analyzed under the predicted condition of service after meshing is created. This speeds up design and testing process which reduces the lead time to create pistons, pin and connecting rod designs. The idea behind finite elements analysis is to divide these models into a fixed number of finite elements. Design software, ANSYS generates and predicts the overall stiffness of the entire piston. Analyzing the data with previous results show better possible predicts how the piston has behaved in a real engine and how the engineer has allowed seeing where the stresses and temperatures has to be the greatest and how the combined effect of piston and connecting rod has behaved [1]. Analysis of the piston and connecting rod are done to obtain the stresses and thermal effects using ANSYS. Firstly, the mathematical model of analyzer is established and then FEA is carried out by using the ANSYS software. Based on the analysis of result, the stress and thermal concentrates on the piston and connecting rod have become evaluate, which provides a better reference for redesign of piston.

3 A. Modelling mechanical and thermal properties to do couple thermomechanical calculations. The temperature load is applied on different areas and pressure applied on given model. IV. RESULTS AND DISCUSSIONS Finite element analysis is the process of differentiation of complex structure into smaller element to gain a better understanding of each sub components. The meshed model is undergoes into stress and thermal analysis followed by coupled field analysis. The component is subjected to the influence of heat conduction at the top of the piston and heat convection to side lands etc. The following images are shown for resulted von misses stresses and thermal analysis. Fig 1. Assemble Modeling of Piston, Pin and Connecting Rod The dimensions for the piston are taken from previous research work [1] and the dimension of pin and connecting rod are corresponding taken from design data book. In the above procedure of modeling the piston pin is contact body which is used to incorporate between target body as connecting rod and piston. The modeling of piston, pin and connecting rod has built in CATIA. This model is assembled and calls on ANSYS for preprocessor which is shown in Figure 1. Figure 2 show the distribution of maximum von mosses stresses induced within the piston is MPa. The previous result of von misses was obtained on piston with value of 85 MPa [1]. This shows that the result is almost same having minor error of 4.4%. Hence the entire procedure of design is validated. B. Geometric Properties and Meshing The selections of material are defined in properties of aluminium alloy. For both stress and thermal analysis, the values of these properties as density, Young modulus, Poisson s Ratio, Coefficient of Thermal Expansion, Specific Heat are 2770 kg/ m 3, 220E3 MPa, 0.35, 7 W/mK, 10E-6 /K respectively. In meshing of assemble geometric, the number of element used in pin, piston and connecting rod are 110, 4075 and 1668 respectively. The nodes having number of 622, 8184 and 3509 are used in pin, piston and connecting rod respectively. Fig 2. Von-Misses Stress Distribution on Piston In thermal analysis of piston shows that the value of maximum temperature is same for materials at the top edge surface of the piston crown, but minimum value of temperature in the piston at bottom level. The highest value of maximum temperature is C which is shown in Fig. 3. C. Applying Temperatures, Convections and Loads The entire components are assembled into the areas defined by combination of piston, pin and connecting rod. The boundary conditions for this mechanical simulation are defined by the pressure acting on the entire piston head surface i.e. maximum pressure bear on piston. It is necessary to load given data on material which refer to both its

4 Fig 3. Temperature Distribution on Piston Fig 6. Total heat flux distribution on piston & connecting rod In figures 4, 5 and 6 shows the FEM analysis on combined effect of piston and connecting rod to obtain von-misses stresses distribution, total deformation distribution and heat flux distribution respectively. Fig 4. Von-Misses distribution on piston & connecting Rod Fig.4 shows about von-misses stress distribution on combined effect of piston & connecting rod. The maximum value of stress distribution is allocated at connection rod bearing insert area which is transferred by piston. Fig. 5 explains about the total deformation factor which is obtained maximum region at piston head. This deformation future helps in the motion of connecting rods. Fig. 6 discusses about the flow of heat flux. As the combustion take place in cylinder, the major portion of piston and piston head is taken for flow of heat transfer. Fig 5. Total deformation distribution on piston & connecting Rod V. CONCLUSION It is concluded from above work that stress and thermal analysis on combined effect on piston, pin and connecting rods give the better condition of FEM analysis. The stress on individual piston components is obtained with MPa. This obtained result has compared with previous a result [1] which shows minor error of 4.4%. This process helps in further analysis on combined effect of piston, pin and connecting rods. And, also thermal analysis of individual component of piston is obtained with maximum temperature is C. This is better heat generation inside combustion chamber. Further, von-misses stress, total deformation and total heat flux has obtained on combined effect of piston, pin and connecting rods. It is found that exerted pressure on piston play vital role to move load from combustion chamber i.e. cylinder inside to crankshaft via connecting rod. The

5 deformation has shown on piston head and heat flux can be flow through piston ring area. References [1] S. Srikanth Reddy and Dr. B. Sudheer Prem Kumar, Thermal Analysis And Optimization Of I.C. Engine Piston Using Finite Element Method, International Journal Of Innovative Research In Science, Engineering And Technology, vol. 12(2), pp , December [2] L Singh, S S Rawat, T Hasan and Upendra Kumar, Finite Element Analysis 0f Piston In Ansys, International Journal Of Modern Trends In Engineering And Research, vol.2(4), pp , April [3] Vivek Zolekar and Dr. L.N. Wankhade, Finite Element Analysis And Optimization Of I.C. Engine Piston Using Radioss And Optistruct, pp. 1-8, year [4] Professor Vivek C. Pathade and Dr. Dilip S Ingole, Stress Analysis of I.C.Engine Connecting Rod by FEM and Photoelasticity, IOSR Journal of Mechanical and Civil Engineering, vol. 6(1), pp , Mar. - Apr [5] J.D.Ramani, Sunil Shukla and Dr. Pushpendra Kumar Sharma, FE-Analysis of Connecting Rod of I.C.Engine by Using Ansys for Material Optimization, Journal of Engineering Research and Applications, vol. 4(3), pp , March [6] Prateek Joshi and Mohammad UmairZaki, FEM Analysis of Connecting Rod of different materials using ANSYS. International Journal of Engineering and Techniques, vol.1(3), pp , May - June [7] P Singh, D Pramanik and R V Singh, Fatigue and Structural Analysis of Connecting Rod s Material Due to (C.I) Using FEA, International Journal of Automotive engineering and Technologies, vol. 4 (4), pp , December 2015.