Design and Analysis of a Spark?Ignition (SI) Engine Piston Made of Aluminum Alloy 7475 T761

A piston is a critical component used in reciprocating engines, pumps, gas compressors, and pneumatic cylinders. It is the moving part contained within a cylinder, sealed gas-tight using piston rings. The primary function of the piston is to convert the energy from expanding gases into mechanical work. It moves within the cylinder liner or sleeve, typically made from highstrength materials to withstand combustion forces and wear. Pistons are commonly manufactured using aluminum alloys or cast iron due to their favorable strength-to-weight ratios and thermal properties. The main aim of this project is to design and analyze a piston for a two-wheeler engine, considering three different materials: Cast Iron, Aluminum Alloy 7475-T761, Aluminum Metal Matrix Composite (MMC). The piston designs are modeled using Pro/ENGINEER (PRO-E) 3D CAD software. Finite Element Analysis (FEA) and performance simulations are carried out using SolidWorks Simulation. n mechanical design, design evaluation is crucial for verifying performance, safety, and efficiency. In this project, the evaluation is performed through Design Optimization, using the following criteria: Constraints: Maximum allowable stress and deformation. Variables: Piston head thickness, Goal: Minimization of piston mass without compromising strength or functionality. By evaluating multiple design iterations under the defined constraints and objectives, the optimal piston design will be identified. This design will offer the best balance between strength, weight, and material performance, suitable for application in a two-wheeler engine.