THERMAL ANALYSIS OF DIESEL ENGINE PISTON USING 3-D FINITE ELEMENT METHOD

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1 INTERNATIONAL JOURNAL OF MANUFACTURING TECHNOLOGY AND INDUSTRIAL ENGINEERING (IJMTIE) Vol. 2, No. 2, July-December 2011, pp THERMAL ANALYSIS OF DIESEL ENGINE PISTON USING 3-D FINITE ELEMENT METHOD M. L. S. Dev Kumar Sir 1 & P. Poornima 2 ABSTRACT: In a conventional internal combustion engine the small portion of the total energy produced is converted to useful work. More than half of this energy is expelled from the system through frictional losses, cooling the engine components, exhaust, etc. The sum of these losses is termed as energy loss for the engine. The most effective way of increasing the percentage of useful work is energy to reduce the energy loss. One way of reducing the energy loss or increasing the efficiency of the engine is by using thermal barrier coatings (TBC) on the various elements of the combustion chamber like valves, piston, cylinder surfaces, and rings. Ceramic materials are most commonly used as thermal barrier coating materials. To enhance the thermal, mechanical, and corrosion strengths of automotive parts, ceramic materials are applied, either as whole part or as coatings making the whole part from ceramics has many drawbacks, like brittleness, manufacturing difficulty etc. Instead of this, coating the metallic parts of the combustion chamber with ceramic gives the design flexibility. Coating of this elements by a ceramic with low thermal conductivity keeps the heat in the chamber and hence increases the temperature. The higher temperature in the chamber increases efficiency of the engine, but requires higher temperature components. Ceramics materials have high temperature resistance and offer an excellent coating surface to reduce the amount of degradation and to extend the life. The temperature distribution in piston is crucial parameter influence the thermal stresses and deformations. In the present work the temperature distribution of piston with or without coating is carried out by using finite element method. The 3-D model of the piston is generated in the PRO/E and the analysis is carried out in the commercial software ANSYS. 1. INTRODUCTION The high costs of fuel oils have necessitated of less expensive but quality fuels for diesel engines. However, the combustion gases of these fuels are more corrosive, and this has created demands for improved corrosion and wear protection of heat loaded parts. Tadensz Hejwowski has studied the behavior of thermal barrier coatings for internal combustion engines. One way of reducing the energy loss or increasing the efficiency of the engine is by using TBC on the various elements of the combustion chamber like valves, piston, cylinder surfaces and rings. It is important to calculate the piston temperature distribution in order to control the thermal stresses and deformations within acceptable levels. The temperature distribution enables the designer to optimize the thermal aspects of the piston design at lower cost, before the first prototype is constructed. Most of the internal combustion engine pistons are made of aluminum alloy which has a thermal expansion coefficient 80% higher than the cylinder bore material made of cast iron. This leads to some differences between running and the design clearances. Therefore, analysis of the piston thermal behavior is extremely crucial in designing more efficient engines. The thermal analysis of piston is important from different point of views. First, the highest temperature of any point on piston should not exceed 66% of the melting point temperature of the alloy. This limiting temperature for the current engine piston alloy is about 370 º C. This temperature level can be increased in ceramic coating diesel engines. Ceramics have a higher thermal durability than metals; therefore it is usually not necessary to cool them as fast as metals. Low thermal conductivity ceramics can be used to control temperature distribution and heat flow in a structure. Thermal barrier coatings provide the potential for higher thermal efficiencies of the engine, improved combustion and reduced emissions. 1 Associate Professor, Dept. of Mechanical Engineering, JNTU Anantapur. 2 Dept. of Mechanical Engineering, JNTU Anantapur.

2 98 International Journal of Manufacturing Technology and Industrial Engineering (IJMTIE) Lower heat rejection from the combustion chamber through thermally insulated components causes an increase in available energy that would increase the in-cylinder work and the amount of energy carried by the exhaust gases which could be also utilized. Pier z (1993) studied the performance of plasma sprayed zirconia and mullite coated pistons and indicated comparatively higher surface temperatures and larger thermal strains are observed for Zirconia coatings than Mullite. Due to large thermal strains Mullite coatings are more durable than Zirconia coating. Lyubimov et al, (1992) indicated that Physical Vapor deposited (PVD) multilayer Ti/Tin coated piston rings have high wear resistance than chromium electroplated piston rings. Ceramics materials have high temperature resistance and offer an excellent coating surface to reduce the amount of degradation and to extend the life. The temperature distribution in piston is crucial parameter influence the thermal stresses and deformation. Thermal barrier coatings used in research and development and in commercial heat engine applications are commonly deposited by air plasma spraying. Partially stabilized ZrO2 coatings produced by this technique consist of a complex m-lange of platelet shaped particles, porosity and micro cracks. The ceramic layer is generally deposited on a plasma-sprayed metallic bond layer of the material. One of the development trends for heat engines is improvement of their efficiency. In the case of internal combustion engines, one of the ways to achieve this aim is engine adiabatization. To create suitable conditions for the thermodynamics cycle in the internal combustion engine, it is essential to construct the elements of the combustion chamber from low thermal conductivity. It is known that the lifetime of thermal barrier coatings (TBCS) is limited by two basic failure mechanisms: thermal expansion mismatch between bond coat and top coat, and oxidation of the bond coat. One of the possible methods to adiabatize an engine is to cover the surface of the combustion chamber with a TBC. The thermal insulation thus obtained is supposed to lead, according to the second law of thermodynamics. To an improvement in the engine s heat efficiency and a reduction in consumption. The exhaust energy rise that accompanies this can be wed effectively to turbo charger an engine. Higher temperatures in the combustion chamber can also have a positive effect in diesel engines, due to the reduction in delay and hardness of engine operation, although an increase in the emission of nitrogen oxides (NO1) may be expected as well. The typical thermal efficiency of most commercially available diesel engines ranges from 38% to 42%. Therefore, between 58% and 62% of the energy content of the fuel is lost in the form of waste heat. Approximately 30% is retained in the exhaust gas and the remainder is removed by cooling, etc. More than 55% of the energy that is produced during the combustion process is removed by cooling water/air and through the exhaust gas. In order to save energy, it is an advantage to protect the hot parts by a thermally insulating layer. This will reduce the heat transfer through the engine walls and a greater part of the energy produced can be utilized, involving an increased efficiency. In the present paper the temperature distribution of piston with or without coating is carried out by using finite element method. The 3-D model of the piston is generated in the PRO/E and the analysis is carried out in the commercial software ANSYS. 2. MODELING OF THE POSTON In the present work single cylinder 5 BHP kirloskar diesel engine piston is considered for study. The different stages in modeling of the piston are shown in Figure 1. The Zirconia based ceramic coatings are used as thermal barrier coatings owing to their low thermal conductivity and their relatively high coefficients of thermal expansion, which reduce interfacial, stresses (Ekrem Buyukkaya, 2007, 2008). In this work NiCrAl and MgZrO 3 as the coating materials and AlSi and steel pistons are considered for the study. Figure 1: Coated Piston Model

3 Thermal Analysis of Diesel Engine Piston Using 3-D Finite Element Method 99 The modeling and assembly of the piston using PRO/E is presented. Next by applying thermal analysis using ANSYS is presented in the next chapter. 3. THERMAL ANALYSIS BY FINITE ELEMENT METHOD In this work numerical analysis is carried out in both uncoated and single layer coated piston the finite element mesh of the piston model using ANSYS is shown in Figure 2. For thermal analysis 10 node solid 87 is selected for meshing. Piston thermal boundary conditions are considered from earlier work done by Ekrem Buyukkaya, (2007, 2008), the various boundary conditions on the piston are given in table. Figure 2: Piston Model and Meshing Table 1 Material Properties of Piston, Rings and Coating Materials Materials Thermal conductivity Density Specific heat (w/m 0 c) (kg/m 3 ) (J/kg 0 c) AlSi steel NiCrAl MgZrO Oil rings _ Compression rings _ Table 2 Boundary Conditions Thermal boundary conditions Temperature ( 0 C) Convective heat transfer coefficient (W/mm 2 K) Combustion chamber A * e -6 The region between piston crown &liner B* e -6 Rings C ** e -6 The region between rings D** e -6 Skirt inside E ** e -6 Piston crown underside F ** e -6 Piston skirt outside G * 85 60e -6 Now by applying the thermal boundary conditions are selected based on the literature. The variation in temperature over the surface of the piston is presented as shown in Figure 3.

4 100 International Journal of Manufacturing Technology and Industrial Engineering (IJMTIE) 3.1.Temperature Distribution in Uncoated Piston Figure 3: Thermal Boundary Conditions Hence compare the temperature distribution in uncoated AlSi alloy and steel piston for the given boundary conditions are shown in above figures. The result showed the maximum temperature is observed uncoated steel piston than AlSi alloy piston for same given boundary conditions. The heat loss with steel piston is less compare to AlSi alloy piston. AlSi piston Steel piston

5 Thermal Analysis of Diesel Engine Piston Using 3-D Finite Element Method Temperature Distribution in Single Layer Coated Piston Temperature Distribution of the NiCrAl Coated AlSi Piston Temperature Distribution of the NiCrAl Coated Steel Piston Temperature Distribution of the MgZrO3 Coated AlSi Piston Temperature Distribution of the MgZrO 3 Coated Steel Piston 4. RESULTS AND DISCUSSIONS The finite element results show that steel piston is showing maximum surface temperature than AlSi alloy piston for selected boundary conditions and coatings. It is due to lower thermal conductivity of steel material than AlSi material. It is also observed from the results the surface in uncoated piston. The coatings act as thermal barrier on the surface of piston which resulting in lesser heat loss to the piston and maintaining higher temperature on the top surface of the piston. The comparison of maximum temperature observed on the top surface of the various single layer coated and uncoated piston for the same thermal boundary conditions are given in Table 3. Table 3 Temperature Distributions in Different Types of Coatings Piston Material Uncoated NiCrAl MgZrO 3 AlSi Maximum Minimum Steel Maximum Minimum

6 102 International Journal of Manufacturing Technology and Industrial Engineering (IJMTIE) 5. CONCLUSIONS In this work a comparative evaluation was made between the temperature distributions on the uncoated piston and single layer coated AlSi alloy and steel piston surfaces. According to the simulation results conducted in this study, it has been concluded that steel is having maximum temperature distribution than AlSi alloy piston. The temperature values of single layer coating piston surface are higher than uncoated piston surface. REFERENCES Ekrem Buyukkaya (2008), Thermal Analysis of Functionally Graded Coating AlSi Alloy and Steel Pistons Surface & Coatings Technology, 202, Imdat Taymaz (2007), The Effect of Thermal Barrier Coatings on Diesel Engine Performance, Surface & Coatings Technology, 20, E.Buyukkaya and M. Cerit (2007), Thermal Analysis of a Ceramic Coating Diesel Engine Piston Using 3-D Finite Element Method, Surface & Coatings Technology, Imdat Taymaz (2006), An Experimental Study of Energy Balance in Low Heat Rejection Diesel Engine, Energy, 31 (2006) Ekrem Buyukkaya, Tahsin Engine, Muhammet Cerit, (2006), Effects of Thermal Barrier Coating on Gas Emissions and Performance of a LHR Engine with Different Injection Timings and Valve Adjustments, Energy Conversion and Management, 47, Taymaz, I., K. Cakvr, A. Mimaroglu (2005), Experimental Study of Effective Efficiency in a Ceramic Coated Diesel Engine, Surface & Coatings Technology, 200,

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