Development of New Two-stroke Engine’s Piston

Lee, Wei Le (2025) Development of New Two-stroke Engine’s Piston. Final Year Project (Diploma), Tunku Abdul Rahman University of Management and Technology.

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Abstract

This project presents the design and development of a new two-stroke engine piston aimed at improving combustion efficiency and sealing performance. The proposed design addresses crankcase pressure leakage by concealing the pinhole that typically overlaps the transfer and auxiliary exhaust ports in traditional designs. Inspired by Formula 1 piston geometry and twopiece diesel engine structures, the new piston integrates a single piston ring to reduce friction and mass. The design process involved CAD modeling, 3D printing, sand casting, machining, and performance testing. A comparison between the stock and prototype pistons was conducted using compression tests and simulation analyses. While the theoretical compression ratio of the prototype was higher, the experimental compression result was lower due to sealing limitations and fabrication tolerances. The findings highlight the potential for further optimization in both design and manufacturing to achieve better performance and durability.