Thermal Analysis of Diesel Engine’s Piston with Integrated Cooling System

Chin, Chee Kang (2021) Thermal Analysis of Diesel Engine’s Piston with Integrated Cooling System. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

Piston, the most important component in an engine to generate power that drives the wheels. As the automotive manufacturers are keen to crank out more power from the engine with the same bore and piston size by increasing the compression ratio, it can cause an increase in temperature and heat transfer to the piston. High mean temperature of the piston will often result in cracks or even deformation that will cause structural failure which will be costly for the owner. Therefore, it is crucial to analyse and determine the temperature distribution, heat flux, thermal stress and deformation of the piston during the design process to ensure the piston reliability. Maximum temperature found in a piston is at the piston crown region based on previous studies. In this project, the main focus is to reduce the mean temperature at the piston crown by study, investigate and compare the temperature distribution, heat flux, thermal stress and deformation between piston with cooling channel, with thermal coating and with integrated cooling system through steady-state thermal simulation carried out by using Ansys with the use of boundary condition based on previous study and 3-D model of the pistons will be drawn using Solidworks. Based on the results, the piston achieved the lowest measured temperature with the value of 227.81˚C on the piston crown and when compared with a piston with cooling channel, it was improved to as high as 134.20˚C or 45.51%. The maximum heat flux was found at the curvature of the combustion chamber with the value of 6.5903×105 W/m2. The measured heat flux on the piston crown was determined to be at 14157 W/m2 and the maximum deformation of the piston was measured with the value of 1.4108×10-4 m which was found to be at the piston top center. The thermal stress experienced by the piston crown was measured at 3.4902×10-2 Pa which is the lowest out of the other pistons. Overall, the piston with integrated cooling system showed significant improvement in reducing the heat absorption on the piston crown when compared with other 2 pistons.