Design and Analysis of Al-6081 T6 Piston

IJIRST –International Journal for Innovative Research in Science & Technology| Volume 3 | Issue 11 | April 2017 ISSN (online): 2349-6010

Design and Analysis of Piston by Aluminium 6081-T6 Alloy Smedha Mohanlal UG Student Department of Mechanical Engineering SASTRA University, Thanjavur, India

Rishika Chatterjee UG Student Department of Mechanical Engineering SASTRA University, Thanjavur, India

Abstract Piston is the integral part of the engine where combustion occurs and maximum heat is produced. Hence it is necessary to choose an appropriate material to serve this purpose. The material chosen should withstand the heat and the shear stress that is produced during the process. Aluminium is chosen as the material to serve this purpose as it can withstand the above said properties.

Number of alloys of aluminium has been discovered that serves the need. In this paper, comparative study of the structural and thermal behaviour of the piston that is designed with Al-6081 t6 alloy. The results are convincing to choose Al-6081 as the piston materials than other conventional alloys of aluminium. To serve this purpose the piston was modelled in Solidworks 14 and analysed in Ansys 15.

Keywords: Al 6082-T6, Aluminium, Piston, Structural Analysis, Thermal Analysis _______________________________________________________________________________________________________ I.

INTRODUCTION

Piston serves as a reciprocating component in engines, gas compressors and pneumatic cylinders. It is an important component in IC engine as the reciprocating motion of the piston is transferred to the crankshaft to serve its purpose. The performance of an engine can be improved by the effective design of the piston. For this the material should posses light weight, high thermal conductivity, high strength and module. Aluminium alloys satisfies all the above said qualities.

Among aluminium alloys there are number of variants with optimum properties. Among them Al-6081 serves the best with optimum property values. Among them  High tensile strength  Good thermal conductivity  High strength II. ANALYTICAL METHOD Body design

Fig. 1: Engineering drawing of a piston

The structural analysis of the piston was made using solidworks 14. It helps in designing the body of the piston. solidworks software by Dassault systems SOLIDWORKS corp, helps in providing 3D structure of the piston body. It provides a friendly environment where the design can be made and it can be viewed in 2D and 3D structures

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Design and Analysis of Piston by Aluminium 6081-T6 Alloy (IJIRST/ Volume 3 / Issue 11/ 047)

Since we already had a hands on in Pro-E, working in Solidworks wasn’t a big deal. Just like the way in Pro-E we created our piston model in Solidworks using simple commands and completed the model. After the completion of 3D model it allows to print out in two ways. They are:  2D engineering drawing (Fig 1)  3D model (Fig 2) and orthographic view (Fig 3)

Fig. 2: 3D end model using Solidworks

Fig. 3: Orthographic view of modelled piston Engineering Data  

Aluminium Al 6081-T6 Aluminium It is a white silvery metal that belongs to the boron group with atomic number 13. It is soft, non-magnetic and ductile metal. It is the most abundant metal in the earth’s crust. It is third most abundant element after oxygen and silicon. It has wide range of applications because of its properties. The chief ore of aluminium is bauxite.

Table – 1 Aluminium properties Density 2.7e-003 kg m-3 Thermal Conductivity- 0.237 KW m-1 C-1 Young's Modulus 70000 MPa Poisson's Ratio 0.35 Bulk Modulus 77778 MPa Shear Modulus 25926 MPa

Al 6082-T6 Al 6081- t6, they are further classified under AA 6000 series (aluminium-magnesium-silicon wrought alloy). They are prepared by casting and forging. Their composition consists of Al (96.3-98.6%), silicon(0.7-1.1%),magnesium(0.6-1%),manganese(0.10.45%) along with traces of iron,copper and titanium. They have undergone multistage heat treatment process for hardening and to attain fracture toughness..

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Design and Analysis of Piston by Aluminium 6081-T6 Alloy (IJIRST/ Volume 3 / Issue 11/ 047)

Table – 2 Properties of amc225xe Elastic Modulus 71 GPa Ultimate Tensile Strength 320 MPa Yield strength 280 MPa Strain to Fail 9.2% Poisson’s Ratio 0.33 Density 2.70 g/cm3

III. RESULTS AND DISCUSSIONS

Fig. 5: Piston imported to ANSYS 15 from solid works 14

Fig. 6: Piston is auto meshed in ANSYS 15

ANSYS is an analysis software belonging to the category of finite element analysis(FEA). Hence the model is divided into number of finite elements, this is called as meshing.

Thermal Analysis Thermal analysis is a group of techniques in which the variation of a physical property of a substance is measured as a function of temperature. The most commonly used techniques are those which measure changes of mass or changes in energy of a sample of a substance

Fig. 7: Initial assumptions for thermal analysis

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Design and Analysis of Piston by Aluminium 6081-T6 Alloy (IJIRST/ Volume 3 / Issue 11/ 047)

Fig. 8: Steady state thermal analysis for Al 6081-T6

Fig. 9: Steady state thermal analysis for Aluminium

Fig. 10: Total heat flux in Al 6081-T6

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Design and Analysis of Piston by Aluminium 6081-T6 Alloy (IJIRST/ Volume 3 / Issue 11/ 047)

Fig. 11: Total heat flux in Aluminium

Static Structural Analysis A static structural analysis determines the displacements, stresses, strains, and forces in structures or components caused by loads that do not induce significant inertia and damping effects. Steady loading and response conditions are assumed; that is, the loads and the structure's response are assumed to vary slowly with respect to time. A static structural load can be performed using the ANSYS. The types of loading that can be applied in a static analysis include:  Externally applied forces and pressures  Steady-state inertial forces (such as gravity or rotational velocity)  Imposed (nonzero) displacements  Temperatures (for thermal strain)

Fig 12: Initial assumptions for structural analysis

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Design and Analysis of Piston by Aluminium 6081-T6 Alloy (IJIRST/ Volume 3 / Issue 11/ 047)

Fig. 13: Total deformation of Al 6081-T6

Fig 14: Total deformation of Aluminium

Fig. 15: Equivalent stress of Al 6081-T6

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Design and Analysis of Piston by Aluminium 6081-T6 Alloy (IJIRST/ Volume 3 / Issue 11/ 047)

Fig. 16: Equivalent stress of Aluminium

Fig. 17: Normal stress of Al 6081-T6

Fig. 18: Normal stress of Aluminium

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Design and Analysis of Piston by Aluminium 6081-T6 Alloy (IJIRST/ Volume 3 / Issue 11/ 047)

Fig. 19: Shear stress of Al 6081-T6

Fig. 20: Shear stress of Aluminium

IV. COMPARISON

Material Aluminium Al 6081-T6

Material Aluminium Al 6081-T6

Table – 3 Comparison of Thermal properties Temperature (.c) Total Heat flux(w/m2) Maximum Minimum 450 322.71 1.1688*106 450 233.8 0.5735*106 Table – 4 Comparison of Structural properties Total deformation(m) Equivalent stress(Pa) 0.014067 8.4564*109 0.0007288 2.2519*109

V. CONCLUSION It is concluded that the piston designed and analysed with material Al-6081 showed very good results. It has good temperature distribution and low thermal stress. Thus, aluminium proved to serve as an ideal material to meet the needs.

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Design and Analysis of Piston by Aluminium 6081-T6 Alloy (IJIRST/ Volume 3 / Issue 11/ 047)

ACKNOWLEDGEMENT We would like to thank Mr Panner.R, SAP of School of Mechanical Engineering of SASTRA University.

REFERENCES [1] [2] [3] [4] [5]

http://www.sciencedirect.com https://www.matweb.com http://www.makeitfrom.com Piston and engine testing by Mahle Gambh Design and Analysis of Piston by amc225xe alloy- IJIRST –International Journal for Innovative Research in Science & Technology Volume 3- Issue 09-3

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