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Piston is one of the key components in an Internal Combustion Engine and it closely
relates to the machine performance, carbon emissions and the economy. With the
higher speed of engines and strength development, higher pressure ratio and higher
power improvements work conditions of pistons have become more and more bad, so
its reliability now relies on the key factors. Structure and working environments of
pistons are very complex. In the working environment, the pistons will produce stress
and deformation because of the periodic load effect, which are from high gas pressure,
high speed reciprocating motion from the inertia force, lateral pressure, friction and so
on. Burning of the high pressure gas produces high temperature, which makes piston
move out due to expansion thus its interior produces thermal stress and thermal
deformation. The thermal deformation and mechanical deformation will cause piston
cracks, tortuosity, etc. Therefore, it is essential to analyse the stress field, temperature
field, heat transfer, thermal load and mechanical load coupling of piston, etc. in order
to lower the heat load and improve the thermal stress distribution and improve its
working reliability during operation. Analysis method of the finite element provides a
powerful calculation tool, which is better than test and theory analysis method and has
become an important means for internal combustion engine performance study.
By analysis of the piston working process, we find that stress and deformation of the
piston is most serious under the steady speed conditions when the gas-fired pressure
is the maximum. At the same time, the strength of piston has a limit. Therefore, it is
essential to choose the piston under the rated power and we only analyse distribution
force in the axis of the force, including the maximum explosion pressure and
reciprocating inertia force. Pressure load of piston is that gas pressure affects piston
top surface due to high pressure in the cylinder. For simplified analysis, we can use
the steady state process, but cannot ignore the effect that combustion power stroke
produces, i.e. impact load for piston.
Piston is affected by gas explosion pressure and the reciprocating inertia force and
their common feature is that they have line of effect along the axis direction of the
piston, so the axis direction of piston bears the bigger load. The maximum stress
appears the centre of piston pin top, which is accordance to engine design manual.
Piston pin top is the part most susceptible to fracture.
When Pistons are operating, they directly touch the high temperature gas and their
transient temperature can reach more than 2500K and generates the 18KW power.
Piston is heated seriously and its heat transfer coefficient is 167 W/(mC) and its heat
dissipation coefficient is poor, so the piston temperature can reach 600 ~ 700 K
approximately and the temperature distributes unevenly. On the basis of these
conditions, we will make thermal analysis for the piston.
1. Thermodynamic Aspects:
2. Mechanical Aspects:
a. Radial type.
b. Bore diameter (d).
c. Speed of the engine (N).
d. Fuel volume/displacement (V).
Type of engine:
I.
V type.
II.
W type.
Design of Cylinder:
1. Thickness of wall:
Longitudinal Stress:
Radial Stress:
Net longitudinal stress:
The thickness of the flange should be 1.2t - 1.4t. The diameter of the studs
can be found by equation:
Piston
Element that moves inside the cylinder by receiving the impulse from the
expanding gas and transmits energy to crankshaft through connecting
rod.
Design Considerations:
It should have enormous strength. (Pressures & Forces)
Minimum mass. (inertia forces)
Form effective gas and oil sealing.
Provide bearing area. (prevent wear)
Disperse the heat quickly.
High speed reciprocation. (without noise)
PISTON MATERIALS
Cast Iron
Cast Aluminium
Forged Aluminium
Cast Steel
Forged Steel
P.T.O.
(in mm)