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DESIGN AND THERMAL ANALYSIS OF CERAMIC COATED DIESEL ENGINE PISTON (MgZrO3 & NiCrAl)

Abstract

It is important to calculate the piston temperature distribution. In order to control the thermal stresses and deformations within acceptable levels. The temperature distribution enables the designer to optimize the thermal aspects of the piston design at lower cost, before the first prototype is constructed. As much as 60% of the total engine mechanical power lost is generated by piston ring assembly. Most of the internal combustion (IC) Engine pistons are made of aluminum alloy which has a thermal expansion coefficient 80% higher than the cylinder bore material made of cast iron. This leads to some differences between running and the design clearances. Therefore, analysis of the piston thermal behavior is extremely crucial in designing more efficient engines. The thermal analysis of piston is important from different point of views. First, the highest temperature of any point on piston should not exceed 66% of the melting point temperature of the alloy. This limiting temperature for the current engine piston alloy is about 370°C.This temperature level can be increased in ceramic coating diesel engines. Thermal analyses are investigated on a conventional (uncoated) diesel piston, made of aluminium silicon alloy and steel. Secondly, thermal analyses are performed on pistons, coated With MgO–ZrO2 material by means of using a commercial code, namely ANSYS. Finally, the results of four different pistons are compared with each other. The effects of coatings on the thermal behaviors of the pistons are investigated. It has been shown that the maximum surface temperature of the coated piston with material which has low thermal conductivity is improved approximately 48% for the AlSi alloy and 35% for the steel. 

Author

M.Mathanbabu P.Mohanraj ,S.Navaneetha Krishnan,T.Naveen Kumarb,S.Vijay
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