The Design Optimization of an Internal Combustion Engine by using Finite Element Method

Wong, Suet Yin (2020) The Design Optimization of an Internal Combustion Engine by using Finite Element Method. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

The objective of this project is to optimize the fatigue strength of the internal combustion engine to increase the performance by changing some of its design parameter and analyse with different material. The most important part in an internal combustion engine must be piston and connecting rod. An analysis was performed on the piston with different thickness of piston head and axial thickness to analyse the deformation, von Mises stress and factor of safety. The analysis was using three different materials such as Grey Cast Iron, Aluminium 4032 and AISI 1020 Steel. From the results, AISI 1020 Steel is a better material for piston and the thickness of head is 21.57mm and axial thickness is 2.4mm. Material that made for connecting rod is very important. The connecting rod is analysed with three different materials such as Steel, Aluminium 360 and PEEK. The most suitable material for connecting rod as observed from the results is Steel. The fatigue strength of the assembly of the piston with connecting rod has been optimized due to the deformation and equivalent stress has been reduced by 80% and 9.16% respectively in addition the factor of safety for the model has been improved by 10%. In this project, two computational software are required to use to design a quality piston such as Solidworks and ANSYS. Solidworks is to design a 3D model and import the model to ANSYS to do simulation and fatigue strength testing. By using ANSYS the weakest area can be determined, therefore, the design of piston can be further improved to get a better result, as well as achieve the project objectives which improve the engine performance and efficiency. By making use of the modern tools, the results that obtained had been achieved the objective of this project.