DESIGN, OPTIMIZATION AND THERMAL ANALYSIS OF A COMPRESSION IGNITION ENGINE CYLINDER USING NANO MATERIALS

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1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 5, May 2017, pp , Article ID: IJMET_08_05_014 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed DESIGN, OPTIMIZATION AND THERMAL ANALYSIS OF A COMPRESSION IGNITION ENGINE CYLINDER USING NANO MATERIALS Kunduru Srinivasa Reddy Assistant Professor, Department of Mechanical Engineering, K L University, Andhra Pradesh, India Guttula Syam Gopal, Chennuboina Ratna Kishore, Puli Dileep, B.Tech Student, Department of Mechanical Engineering, K L University, Andhra Pradesh, India ABSTRACT In the present project an effort has been made to optimize the dimensions and weight of a compression ignition cylinder along with its thermal analysis by reducing the thickness, length and the material used to make the cylinder. Design and optimization are done by considering the dimensions of a cylinder of a normal diesel car engine. The modelling is done in CATIA V5 R20 for both the cylinders before and after optimization. The models are then imported into ANSYS WORKBENCH 2015 and are analyzed under the working conditions using static structural and steady state thermal analysis. Finally both the results are compared to judge whether the optimized cylinder works under the similar conditions and also to find out which piston cylinder has better energy efficiency. The optimization is done by the application of Nano materials. Key words: Piston cylinder, CATIA V5 R20, ANSYS WORKBENCH 2015, energy efficiency, Nano materials Cite this Article: Kunduru Srinivasa Reddy, Guttula Syam Gopal, Chennuboina Ratna Kishore, Puli Dileep and, Design, Optimization and Thermal Analysis of a Compression Ignition Engine Cylinder Using Nano Materials. International Journal of Mechanical Engineering and Technology, 8(5), 2017, pp INTRODUCTION A piston cylinder is the main component of a piston in an engine because it acts as a mechanism to transfer energy from one form to the other i.e. mostly heat energy to mechanical energy. As it is the main component in an automobile, it is common that most researchers try to optimize it in one way or the other. But most of the researchers try to editor@iaeme.com

2 Kunduru Srinivasa Reddy, Guttula Syam Gopal, Chennuboina Ratna Kishore, Puli Dileep and change the weight of the piston by using different materials. Some of them even tried to change the design parameters, which have shown significant results. These attempts prove that, changing the material and altering the design can improve the energy transfer efficiency of the engine. But the main aspect is that the piston has to withstand the temperature due to conduction and convection that occurs due to the combustion of fuel on the top land side of the piston. In the current study, an attempt has been made to change the design without changing its bore diameter along with which, a layer of Nano-coating is applied to make it be able to withstand more heat and thermal stresses produced inside the engine. The results of this piston are the compared to those of the standard one to check which produces better results. The design is done based on the standard formulae to get the piston parameters. All the modelling work is done by using CATIA V5 R20 and the analysis part is done on ANSYS WORKBENCH 2015 by taking the working conditions into consideration Design Parameters of Cylinder in a Piston The cylinder in a piston has many design parameters, but the most important of them are the length of the stroke and the bore diameter of the piston. For the sake of optimization, we may alter all the other parameters but we cannot change the bore diameter, as it is a constant for a particular engine. These are the main parameters required for the design of a cylinder are shown in the table 1. Table 1 Design parameters of a Cylinder NO Name of the Parameter Notation 1 Thickness of the cylinder head t H 2 Radial thickness of piston rings t 1 3 Axial thickness of piston rings t 2 4 Width of the top land b 1 5 Width of the other ring lands b 2 6 Heat flow through the piston head H 7 Length of the cylinder (Stroke) L 8 Bore Diameter D 9 Maximum thickness of the barrel t 3 10 Radial depth of the piston ring groove b 1.2. Material Considerations The most common materials used in the manufacturing of the cylinder of a piston are Aluminum-Silicon alloy, mild steel and cast iron. This studyis done only on the pistons made of Al-Si alloy, as they are most commonly used. An attempt has been made to optimize the weight and dimensions of a theoretically designed piston using one of the Taguchi methods. In order for the optimized piston to be able to withstand the thermal stresses and the deformation produced due to the pressure acting, conduction and convection a thin film is created around the cylinder in the modelling. This thin film is a Nano coating made of Zirconium Carbide (ZrC). The properties of the materials considered are listed in the table editor@iaeme.com

3 Design, Optimization and Thermal Analysis of a Compression Ignition Engine Cylinder Using Nano Materials Table 2 Material used and their properties NO Property Aluminum Alloy Zirconium 1 Young s Modulus (E) 70 GPa 440 GPa 2 Poisson s Ratio Thermal Conductivity (K) 234 W/mK 25 W/mK 4 Coefficient of thermal expansion 23e -6 /K 1e -6 /K 5 Density 2.72g/cm g/cm 3 6 Tensile Strength 280 MPa MPa 2. DESIGN OF CYLINDER The design of the piston cylinder is done by following the standard formulae that are shown below. 1. Grashoff s formula for calculation of thickness of cylinder head is = ( ) where P is maximum pressure in N/mm 2 and σ t is the allowable tensile stress of the material. 2. = ( ) / WhereT c is the temperature at centre of cylinder head in C and T e = temperature at edges of piston head in C. 3. = ( )Where P w is the fuel pressure on cylinder. 4. = = = = Where b is the radial depth of the ring groove. The cylinder is designed by taking Al-Si alloy into consideration. After the necessary calculations the parameters that are obtained are listed in table 3. Table 3 Dimensions of the cylinder NO Parameter Dimensions (in mm) 1 Stroke (L) 93 2 Bore Diameter (D) Thickness of piston head (t H ) Radial thickness of ring (t 1 ) Axial thickness of ring (t 2 ) Width of top land (b 1 ) Width of other ring lands (b 2 ) Maximum thickness of Barrel (t 3 ) editor@iaeme.com

4 Kunduru Srinivasa Reddy, Guttula Syam Gopal, Chennuboina Ratna Kishore, Puli Dileep and The heat flow through the piston head (H) is KJ/s. The volume of the cylinder is m 3. The mass of the cylinder is kg. 3. OPTIMIZATION OF CYLINDER After the design of the cylinder, a strategy of optimization is defined based on Taguchi method with the target to reduce the mass of the cylinder with the constraints as Von mises stress with factor of safety as 1.2. After the removal of material in the areas with the scope of removal, the final dimensions are listed in the table 4. Table 4 Dimensions of the cylinder NO Parameter Dimensions (in mm) 1 Stroke (L) 93 2 Bore Diameter (D) Thickness of piston head (t H ) Radial thickness of ring (t 1 ) Axial thickness of ring (t 2 ) Width of top land (b 1 ) Width of other ring lands (b 2 ) Maximum thickness of Barrel (t 3 ) 9.77 The heat flow through the piston head (H) is KJ/s. The volume of the cylinder is m 3. The mass of the cylinder is kg. The optimized cylinder is coated with ZrC of10 micro meter thickness with the help of sheet metal. 4. MODELLING Modelling is done on the computer aided design software CATIA V5 R20 for both the cylinders Before Optimization The required profile is obtained using sketch command in CATIA V5 R20. The profile before optimization is show in figure editor@iaeme.com

5 Design, Optimization and Thermal Analysis of a Compression Ignition Engine Cylinder Using Nano Materials Figure 1 Profile of the cylinder before optimization The cylinder shown in figure 2 is obtained by revolving the profile along the axis shown in figure 1. Figure 2 Cylinder before optimization 4.2. After Optimization The required profile is obtained using sketch command in CATIA V5 R20. The profile before optimization is show in figure editor@iaeme.com

6 Kunduru Srinivasa Reddy, Guttula Syam Gopal, Chennuboina Ratna Kishore, Puli Dileep and Figure 3 Profile of cylinder before optimization The cylinder shown in figure 4 is obtained by revolving the profile along the axis shown in figure 2. But a sheet metal is created around the outer surface of the cylinder profile of 10 micro meter. Figure 4 Cylinder after optimization with a sheet metal applied around it editor@iaeme.com

7 Design, Optimization and Thermal Analysis of a Compression Ignition Engine Cylinder Using Nano Materials 5. ANALYSIS The analysis of theses pistons are done on ANSYS WORKBENCH 2015 by applying the following working conditions shown in table 5. Table 5 Working Conditions NO Parameter Value 1 Pressure acting on top land 2 MPa 2 Surrounding Temperature 27ºC 3 Conduction Temperature 240ºC 4 Convection Coefficient 1884 W/mK After applying these conditions on both models, the deformations, thermal stresses and von mises stresses are compared. The model from the CATIA V5 R20 software is saved in igs format and is imported into ANSYS WORKBENCH 2015 for analysis Before Optimization The imported model is the cylinder before optimization which is fine meshed into small elements and nodes for finite element analysis to obtain better results. Now the material is applied to the body i.e. Aluminum alloy. Finally the surrounding conditions are applied and the analysis is done. The number of nodes are The number of elements are After Optimization The imported model is the cylinder after optimization which is fine meshed into small elements and nodes for finite element analysis to obtain better results. Now the material is applied to the body i.e. Aluminum alloy and ZrC Nano material is applied to the 10 micro meter thick sheet metal which acts as a thin film around the cylinder. Finally the surrounding conditions are applied and the analysis is done. The number of nodes are The number of elements are RESULTS AND DISCUSSION The results and the comparison of the temperature, deformation and equivalent stress and heat flux parameters are as shown in figures 5 to editor@iaeme.com

8 Kunduru Srinivasa Reddy, Guttula Syam Gopal, Chennuboina Ratna Kishore, Puli Dileep and 6.1. Temperature Figure 5 Temperature distribution in the cylinder before optimization Figure 6 Temperature distribution in the cylinder after optimization The temperature is more evenly distributed in the cylinder after optimization because the minimum temperature is ºC which is less compared to the 27ºC even when the thickness and other dimensions are reduced as it has a Nano coating on it Deformation Figure 7 Total deformation in the cylinder before optimization editor@iaeme.com

9 Design, Optimization and Thermal Analysis of a Compression Ignition Engine Cylinder Using Nano Materials Figure 8 Total deformation in the cylinder before optimization The deformation in the cylinder dimensions is a lot less in the optimized cylinder due to the Nano coating when compared to the standard cylinder i.e mm is less than that of the maximum displacement in the designed cylinder i.e mm Equivalent Stress Figure 9 Equivalent Stress in the cylinder before optimization Figure 10 Equivalent Stress in the cylinder after optimization The equivalent stress in the cylinder after optimization is slightly increased but it is a lot less than the yield stress of Zirconium Carbide i.e MPa is a lost less than MPa even when 1.2 factor of safety is considered editor@iaeme.com

10 Kunduru Srinivasa Reddy, Guttula Syam Gopal, Chennuboina Ratna Kishore, Puli Dileep and 6.4. Heat Flux Figure 11 Heat flux in the cylinder before optimization Figure 12 Heat flux in the cylinder after optimization The heat flux generated in the cylinder is a lot less in the optimized cylinder due to the 10 micro meter Nano coating which is due to the very low thermal conductivity coefficient of Zirconium Carbide i.e MW/m 2 is less than MW/m CONCLUSION From the above results we can conclude that Nano coating on the material are obtains a lot better results in almost every aspect and also allows weight optimization of the piston. The process of practical Nano coating can be done by a process developed by U.Keiderling, A.Wiedenmann, V.Srdic, M.Winterer and H.Hahn which can withstand rough usage. The stress developed in the analysis of the optimized cylinder is MPa with a factor of safety of 1.2 which is far less than the tensile strength of ZrC i.e MPa i.e. there is a scope for more aggressive optimization for future research. The weight is reduced from kg to kg due to optimization i.e. nearly 40 grams of material is removed. This automatically increases the performance of the engine by increasing its energy efficiency. In the future research the piston can be further optimized by changing the material of the coating and also by more aggressive optimization of von mises stress. ACKNOWLEDGEMENTS The authors thank all the faculty of the Department of Mechanical Engineering in K L University and also the college and department libraries for providing the materials required for the research. The authors are also grateful to Dassault Systemes and Ansys for providing their fabulous software for this research. The authors also are grateful to U.Keiderling, editor@iaeme.com

11 Design, Optimization and Thermal Analysis of a Compression Ignition Engine Cylinder Using Nano Materials A.Wiedenmann, V.Srdic, M.Winterer and H.Hahnwhose research proved that Nano and Ceramic coatings can be applied to any kind of metals and can withstand high wear and tear. REFERENCES [1] S. Srikanth Reddy, Dr. B. Sudheer Prem Kumar, Thermal Analysis and optimization of I.C. Engine Piston Using Finite Element Method, International Journal of Innovative Research in Science, Engineering and Technology, Vol.2, Issue 12, December 2013, ISSN: [2] Ch. Venkata Rajam, P.V.K. Murthy, M.V.S. Murali Krishna, G.M.Prasada, Design Analysis and Optimization of Piston using CATIA and ANSYS, International Journal of Innovative Research in Engineering & Science, Vol.1, Issue 2, January 2013, ISSN: [3] Deovrat Vibandik, Ameya Pradhan, SampadaMhaskar, Nikita Sukthankar, Atul Dhale, Design Analysis and Optimization of Piston and Determination of tits Thermal Stresses Using CAE Tools,International Journal of Engineering Sciences & Research Technology, Vol.3, Issue 5, May 2014, ISSN: [4] Bhaumik Patel, Ashwin Bhabhor, Design and Prediction of Temperature Distribution of Piston of Reciprocating Engine, International Journal of Advanced Engineering Research and Studies, Vol.1, Issue 3, April-June 2012, ISSN: [5] Aditya Kumar Gupta, Vinay Kumar Tripathi, Design Analysis and Optimization of Internal Combustion Engine using CAE tools ANSYS, International Journal of Engineering Research and Applications, Vol.4, Issue 11, November 2014, ISSN: [6] R. Silambarasan, S. Balakrishnan, A. Selvarasu, Design and Thermal Analysis of Partial Ceramic Coated Piston of Spark Ignition (SI) Engine, International Advanced Research Journal in Science, Engineering and Technology, Vol.2, Issue 4, April 2016, ISSN: [7] Vivek Zolekar, Dr. L. N. Wankhade, Finite Element Analysis and Optimization of I.C. Engine Piston using RADIOSS and OptiStruct, Altair Technology Conference. [8] Vinay V. Kuppast, Dr. S. N. Kurbet, H. D. Umeshkumar, Adarsh B.C, Thermal Analysis of Piston for the Influence on Secondary Motion, International Journal of Engineering Research and Applications, Vol.3, Issue 3. May-Jun 2013, pp , ISSN: [9] B. S. Seong, Y. R. Cho, E. J. Shin, S. I. Choi, H. R. Kim, Y. J. Kim, Study of the Effect of Nano-sized Precipitates on the Mechanical Properties of Boron-added, Low-Carbon Steels by Neutron Scattering Techniques, Journal of Applied Crystallography, Vol.41, Issue 5, October 2008, ISSN: [10] Uwe Keiderling, Albrecht Wiedenmann, Vladimir Srdic, Markus Winterer and Horst Hahn, Nano-sized Ceramics of Coated Alumina and Zirconia Analyzed with SANS, Journal of Applied Crystallography, Vol.2000, Issue 33, ISSN: [11] P. Sai Kishore, P. Mariya Kunar, Design & Thermal Analysis of Ceramic Layered Piston, Anveshana s International Journal of Research in Engineering and Applied Sciences, Vol.1, Issue 2, ISSN: editor@iaeme.com