DESIGN, MODELING AND ANALYSIS OF REAL TIME PISTON WITH DIFFERENT MATERIALS

  • Unique Paper ID: 186888
  • Volume: 12
  • Issue: 6
  • PageNo: 3246-3256
  • Abstract:
  • This paper focuses on the design, material selection, and thermal-structural analysis of an internal combustion engine piston to determine the most efficient combination of strength, heat dissipation, and deformation resistance. Fourteen piston diameters were analyzed using three materials Aluminum Alloy 2618, Aluminum Alloy 4032, and AISI 4340 Steel to evaluate the influence of geometry and material on performance. Using ANSYS Workbench, both steady-state thermal and static structural analyses were performed to assess temperature distribution, heat flux, stress concentration, and deformation under realistic loading. The results revealed that Aluminum Alloy 2618 offers the best balance between lightweight design and effective heat dissipation, Aluminum Alloy 4032 provides improved wear resistance, and AISI 4340 steel ensures superior strength with minimal deformation but higher weight. The study concludes that optimized piston design significantly enhances engine efficiency, durability, and thermal stability, and recommends future work on transient thermal, fatigue life, CFD-based analysis, experimental validation, and topology optimization for developing advanced lightweight and high-performance pistons.

Copyright & License

Copyright © 2025 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

BibTeX

@article{186888,
        author = {GORIPARTHI GOPI CHAND and PUTTI SRINIVASA RAO},
        title = {DESIGN, MODELING AND ANALYSIS OF REAL TIME PISTON WITH DIFFERENT MATERIALS},
        journal = {International Journal of Innovative Research in Technology},
        year = {2025},
        volume = {12},
        number = {6},
        pages = {3246-3256},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=186888},
        abstract = {This paper focuses on the design, material selection, and thermal-structural analysis of an internal combustion engine piston to determine the most efficient combination of strength, heat dissipation, and deformation resistance. Fourteen piston diameters were analyzed using three materials Aluminum Alloy 2618, Aluminum Alloy 4032, and AISI 4340 Steel to evaluate the influence of geometry and material on performance. Using ANSYS Workbench, both steady-state thermal and static structural analyses were performed to assess temperature distribution, heat flux, stress concentration, and deformation under realistic loading. The results revealed that Aluminum Alloy 2618 offers the best balance between lightweight design and effective heat dissipation, Aluminum Alloy 4032 provides improved wear resistance, and AISI 4340 steel ensures superior strength with minimal deformation but higher weight. The study concludes that optimized piston design significantly enhances engine efficiency, durability, and thermal stability, and recommends future work on transient thermal, fatigue life, CFD-based analysis, experimental validation, and topology optimization for developing advanced lightweight and high-performance pistons.},
        keywords = {Internal Combustion Engine, Piston, Aluminum Alloy, Finite Element Method (FEM), ANSYS Workbench, Catia V5},
        month = {November},
        }

Cite This Article

  • ISSN: 2349-6002
  • Volume: 12
  • Issue: 6
  • PageNo: 3246-3256

DESIGN, MODELING AND ANALYSIS OF REAL TIME PISTON WITH DIFFERENT MATERIALS

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