Thermo-structural Comparative Analysis of Internal Combustion Engine Piston by Finite Element Methods

The piston is often considered the "heart" of the engine, operating under some of the most challenging conditions among its components. Therefore, conducting a structural analysis of the piston is crucial. This study focuses on evaluating the piston to enhance and optimize its design. The piston is subjected to cyclic gas pressure and inertial forces, which can lead to fatigue damage, including side wear and head cracks. Research indicates that an ideal piston effectively dissipates heat from burned gases, contributing to overall engine efficiency. One key design objective is to reduce the piston structural weight, which in turn decreases fuel consumption. This has been achieved through advancements in engine design, incorporating lightweight materials such as ultrahigh tensile strength steels, aluminium, magnesium alloys, polymers, and carbon-fibre composites. In this study, the piston lifespan is extended by introducing a composite matrix of aluminium mixed with silicon carbide particulates, which enhances wear resistance while maintaining similar performance. The piston is designed and analysed using a 2:3 ratio of aluminium to silicon carbide. A parametric model and finite element analysis are conducted to assess stresses, strains, deformations, and temperature distributions, ultimately identifying the most suitable materials for internal combustion engines based on the results. The results indicated a better performance for AlSiC-12 than Al-6061, although, both models were in satisfactory performance range, the lightness of AlSiC-12 will make it the best choice.