International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 07 Issue: 12 | Dec 2020
p-ISSN: 2395-0072
www.irjet.net
compare the analysis results, find the best material amongst them and figure out whether the titanium alloy is a suitable option.
3.2 Analytical Design Calculations
3. METHODOLOGY
Thickness of the Piston Head According to Grashoff’s formula the thickness of the piston head is given by: th = D√(3pmax/16σt) where σt = σut/2.5 = 480/2.5 = 192 MPa and D = cylinder bore diameter
For A2618 alloy
Analytical design of pistons based on design formulae and empirical relations. 3-D piston models are created in CREO 3.0. Meshing and analysis of piston is done in ANSYS Workbench 16.0. Various stresses are determined by individually performing structural analysis, thermal analysis and thermomechanical analysis. Various zones or regions where chances of damage in piston are possible are analyzed. Comparison is made between the three materials in terms of stresses, deformation, strain, volume, weight, inertia force and factor of safety.
Therefore th = 67*√((3*13.65)/(16*192)) = 7.735 mm Empirical formula: th = 0.032 D + 1.5 = 3.644 mm The maximum thickness from the above formula (th) is 7.735 mm. Piston Rings The radial width of the ring is given by: b = D√(3*pw/σp) = 67*√(3*0.025/100) = 1.834 mm
3.1 Design of Piston
Axial thickness of the piston ring is given by: h = (0.7 b to b) = 0.7*1.834 = 1.284 mm
Engine: Bajaj Pulsar 220 cc petrol engine. Table-1: Engine Specifications
PARAMETERS Engine type Induction No. of cylinders Bore (D) Stroke (L) Length of connecting rod Displacement volume Compression ratio Maximum power Maximum torque (T) No. of revolutions/cycle
Width of Top Land and Ring Lands Width of top land: h1 = (th to 1.2 th) = 7.735 mm
VALUES Four stroke, petrol engine Air cooled type Single cylinder 67 mm 62.4 mm 124.8 mm 220 cm3 9.5+/-0.5:1 15.51 kW at 8500 rpm 19.12 N-m at 7000 rpm (N) 2
Width of ring land: h2 = (0.75 h to h) = 0.75*1.284 = 0.963 mm Piston Barrel Thickness of piston barrel at the top end: t1 = 0.03 D + b + 4.9 Therefore t1 = 0.03*67 + 1.834 + 4.9 = 8.744 mm Thickness of piston barrel at the open end: t2 = (0.25 t1 to 0.35 t1) Therefore t2 = 0.25*8.744 = 2.186 mm
Mechanical efficiency of the engine (η) = 80 %.
Length of the skirt Ls = (0.6 D to 0.8 D) = 0.6*67 = 40.2 mm
η = Brake power (B.P.)/Indicating power (I.P.) B.P. = 2πNT/60 = 2π*7000*19.12/(60*1000) = 14.015 kW
Length of piston pin in the connecting rod bushing L1 = 45% of the piston diameter = 0.45*67 = 30.15 mm
Therefore, I.P. = B.P./η = 14.015/0.8 = 17.518 kW
Piston pin diameter do = (0.28 D to 0.38 D) = 0.3*67 = 20.1 mm
Also, I.P. = P*A*L*N/2 = P*π/4*D2*L*N/2 17.518*1000 = P*π/4*(0.067)2*(0.0624)*(7000)/(2*60)
The center of piston pin should be 0.02 D to 0.04 D above center of the skirt = 0.03*67 = 2.01 mm above skirt center.
So, P = 13.65*105 N/m2 or P = 1.365 MPa
Similarly, analytical design for Al-GHS 1300 and Ti-6Al-4V alloy is also carried out and the dimensions of the three pistons are presented in the table below:
Maximum Pressure (pmax) = 10*P = 10*1.365 = 13.65 MPa
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