international journal of research and innovation · s.girish v satya sai vara prasad1, k.l.kishore...

INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION

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646

Subject: Mechanical Engineering IJRIME

EFFECT OF CERAMIC COATINGS ON PISTON USING FEA

S.Girish V Satya Sai Vara Prasad1, K.L.Kishore 2.

1 Research Scholar, Department of Mechanical Engineering, Aditya Engineering College, Surampalem, Andhra Pradesh, India. 2 Associate Professor, Department of Mechanical Engineering, Aditya Engineering College, Surampalem, Andhra Pradesh, India.

Abstract

In this project work we have created a piston model for diesel engine car which is of 1300cc using empirical relations

for the material Cast Iron. With this calculations a 2D drafting is created. The piston is designed from 2D drawing using

Pro/Engineer software.

The main aim of this project work is to provide optimum material, coating and shape to improve thermal and structural

ability’s.

Firstly literature review is done to understand methodology and material adoption for the piston; data collection will be

done to determine about process, theory for calculations and process.

Coupled filed and fatigue analysis will be carried out to determine errors due to temperature and lode; same will be done

by varying material for piston and coatings; as per the obtain results model will be modified to reduce thermal and

structural errors to improve piston quality.

Conclusion will be made according to the obtain results.

*Corresponding Author:

S.Girish V Satya Sai Vara Prasad,

Research Scholar,

Department of Mechanical Engineering,

Aditya Engineering College, Surampalem,

Andhra Pradesh, India.

Email: [email protected]

Year of publication: 2017

Paper Type: Review paper

Review Type: peer reviewed

Volume: IV, Issue: I

*Citation: S.Girish V Satya Sai Vara Prasad, Research

Scholar, “Effect of Ceramic Coatings on Piston Using

Fea" International Journal of Research and Innovation

(IJRI) 4.1 (2017) 646-658.

Introduction

Internal combustion engines are the integral part of

every automotive, we come across in our day-today life.

However they are having very poor thermal efficiency. In

order to meet the rising demand for efficiency IC engines

are constantly being modified. The pollution levels

caused due to vehicular emissions also stress the need

for intense research. Nearly 15% undesirable heat loss

is observed in an IC Engine through its combustion

chamber walls and piston. Use of TBC materials reduce

this heat loss.

Ceramic coatings provides high thermal efficiency,

reduced emissions and improved combustion. This

provides increase in available energy due to low heat

reduction from combustion chamber and this in return

increase cylinder work and also ceramic materials



647

provide better wear characteristics than regular

materials.

LITERATURE SURVEY

[1] Mr.K.Kadambanathan, E.Selvan has done the

research work on “FATIGUE ANALYSIS OF A DIESEL

PISTON RING BY USING FEA” To provide the analysis

of fatigue-damaged for pistons & ring. Pistons from

different automobiles are analyzed. Thus Damages are

intiated at the pin hole sand skirt ,crown and rings . the

case studies of fatigue-damaged pistons is presented.

Both thermal and mechanical fatigue damages is

presented and analyzsis is done. And they have given

the conclusion as “the first main conclusion drawn from

this work is that even fatigue is not the responsible for

biggest slice of damaged pistons, still it remains a

problem for piston manufacturers. "And it will last a

problem for long because efforts on fuel consumption

reduction and power increase will push to the limit

weight reduction that means thinner walls and higher

stresses. To satisfy all the requirements with regard to

successful application of pistons, in particular

mechanical and high temperature mechanical fatigue

and thermal/thermal–mechanical fatigue there are

several concepts available that can be used to improve

its use, such as design, materials, and processing

technologies.”

[2] Dr.Ahmed A. Bairuti, Dr.Besim M.

Quraishi&IsamEzzulddinyousifhas done the research

work on “THERMAL EFFECTS ON DIESEL ENGINE

PISTONAND PISTON COMPRESSION RINGS” and they

have given the result as “The following can be concluded

from the results of this work The material type of high

thermal conductivity is considered better thanthe

material type of low thermal conductivity. This means

that the aluminum alloy is considered better than the

cast-iron alloy.

[3] Ch.VenkataRajam, P.V.K.Murthy, M.V.S.Murali

Krishna, G.M.PrasadaRao has done the research on

“Design Analysis and Optimization of Piston using

CATIA and ANSYS” and they have given the research

results as “The deflection due to pressure applied after

optimization is more than before optimization andthis

value is taken into consideration for design purpose.

The stress distribution on the pistonmainly depends on

the deformation of piston crown. Therefore, the piston

crown should have enough stiffness to reduce the

deformation.All the phases in this project given can be

extended to the piston design with reduction ofmaterial

at bottom. The material is removed to reduce the weight

of the piston so as to improvethe efficiency. It is

essential to obtain the optimized results for new piston

with reducedmaterial.

[4]P.C. Mishra,Prakhardeep has done the work on

"coating strength on compression ring in contact with

cylinder liner using FEA" and they have provided the

conclusion on coationgs as “The paper presented the co-

relation between the tribodynamic issues and the

coating substrate strength. The forces computed in

addressing the former study are used as input to the

FEM model. The highest tilting angle during

compression ring is found to be 30 and the maximum

von-Misses stress developed at the highest combustion

chamber pressure is 128 MPa and much below the yield

strength of the coating and the substrate. The strain

calculated using von-Misses criteria is near to 0.3 %.

Temperature stability analysis of coating in a rapid

sliding environment in presence of elevated heat

transfer will be a step further in this research.”

[5] ErdincVural work ed on “Thermal Analysis of a

Piston Coated with Silicon carbide and MgOZrO2

Thermal Barrier Materials” and he has given the results

as “In this study, it was determined as the result of

thermal analyses that the highest temperature value

had occurred by the piston bowl coated with MgOZrO2.

Temperature increase compared to standard piston was

determined at a rate of 26.36%. By decreasing the heat

transmission on piston coated with MgOZrO2, less

temperature effect on the main piston material was

caused. Thus, less temperature was determined on the

pins and skirts of pistons coated with MgOZrO2. And in

the piston coated with SiC, the temperature increase

compared to piston coated with MgOZrO2 was less by

5.19%, and it was higher by 21.17% compared to

standard piston. In the direction of the obtained results,

in pistons coated with SiC and MgOZrO2 having

NiCoCrAlYintercoating layer, it is being considered that

the lower temperature affecting the AlSi material will

increase the operation life of the material, and that

lower temperature of piston’s skirt parts will increase

the life of motor's oil and will decrease the load of the

cooling system of motor [23-25].”

[6] Lokesh Singh and Suneer Singh Rawat has done the

research work on “FINITE ELEMENT ANALYSIS OF

PISTON IN ANSYS” they have given the conclusion as

“The following conclusion can be drawn from analysis

conducted in this study:It was found that the design

parameter of the piston with modification gives the

sufficientImprovement in the existing results.

Problem description and methodology

According to the previous researches maximum of

researchers worked on materials and coatings even

shape optimization but they have done individually on

different fieldsthis thesis work is to provide optimum

solution for piston by analyzing step by step to provide

suitable material, coatings and shape for the pristine.



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Procedure Steps for the Project

Designing the piston for Cast Iron material

using empirical formulas.

Creating 2D drawings from the design.

Modeling the piston from 2D drawing in

Pro/Engineer.

Perform Structural,Thermal and fatigue

Analysis on the Piston for given pressure and

temperatures for materials Cast Iron and

Aluminum alloy A360.


Analysis on the Piston by applying thermal

barrior coatings on suitable material.

Remodeling of the piston according to the

obtain results to reduce thermal errors.


Analysis on the Piston modified models to

suggest optimum shape.

Preparation of charts and graphs for easy

comparison of results to provide conclusion.

DESIGN CALCULATIONS

Density of diesel = 0.00000095 kg/mm³

Molecular weight of C15H28 =208g/mole

Mass =density × volume

m = 0.00000095× 312000

m =0.2964 kg

R = 8.3143 J/mol K

PV = m R T

P = m R T

V =

0.2964× 8.3143× 288

0.208× 0.000312

= 709.73525

0.000064896

= 10936502.2495 J /m³

P = 10.936 N/mm²

1. Piston Head

Thickness of piston based on the strength of

material

t1= √( 3p × D²)

16 stp

P = 10.936 N/mm²

stp= 35-40 N/mm² for cast iron

= √3×10.936×69.62

16×40 =√

158927.2013

640

= √248.32= 15.75mm

Thickness of rib =(0.3 to 0.5) t1

t2 = 5.25 (or) 7.875 mm

2. Piston Ring

Radial thickness of the ring

t3 = D × √3 × Pc

𝑠𝑏𝑟

Pc = 0.025 to 0.042 N/mm²(pressure of gas on

the cylinder wall)

𝑠𝑏𝑟 = 85 to 112 N/mm² for Cast-iron

t3 =69.6 × √3× .042

110 = 2.35mm

axial thickness t4 = (.7 to 1)t3

=1.645 or 2.35

3. Piston Barrel (Cylindrical portion of the Piston)

radial depth of ring groove b=t3+0.4mm

=2.75mm

thickness of barrel near to piston head=

t5=0.03D+b+4.5mm=9.338mm

thickness of barrel at the open end of piston

t6=(0.25 to 0.35)t5 = 3.2683mm

4. Piston Skirt

length of skirt LS= 0.65 TO 0.8 D = 55.68mm

Length of ring section LR= 7× b=16.24mm

Length of piston =1 to 1.5 D

=90mm

5. Piston pin

d0 = outside diameter of the piston pin

d0 = p

𝑝𝑏1 × l1

Bearing pressure of tin bronze =50MPa

d0 = 41585.951

50× 31.32 = 26.55mm

The mean diameter of the piston bosses = 1.4

d0

= 37.17mm

2D DRAWINGS

MODEL OF PISTON



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Material properties and boundary conditions

CAST IRON

Density 7.81 g/cc

Ultimate Tensile strength 90-1650 MPa

Modulus of elasticity 150 GPa

Poisson ratio 0.370

Specific heat 506J/kg-k

Thermal conductivity 45W/m-K

MILD STEEL

Density 7.75 g/cc

Ultimate Tensile strength 550Mpa

Modulus of elasticity 183Gpa

Poisson ratio 0.250

Specific heat 486j/kg-K

Thermal conductivity 90 w/m-K

ALUMIMUM ALLOY A360

Density 2.65 g/cc

Ultimate Tensile strength 317MPa

Modulus of elasticity 71GPa

Poisson ratio 0.33

Specific heat 963j/kg-K

Thermal conductivity 113 W/m-K

Coating material AL2O3

Density 3.96g/cc Ultimate Tensile strength 300Mpa Modulus of elasticity 370Gpa Poisson ratio 0.22 Specific heat 800j/kg-K Thermal conductivity 12w/m-k

Zirconium Oxide, Zirconia,

Density 5.68g/cc Ultimate Tensile strength 500Mpa Modulus of elasticity 210Gpa Poisson ratio 0.30 Specific heat 400j/kg-K Thermal conductivity 3w/m-K

Boundary condition

Temperature 4500C at top of the piston

Pressure 10.9 N\mm2at top of the piston

All DOF at piston pin holes

WORK AND ANALYSIS

COUPLE FIELD ANALYSIS USING CAST IRON

THERMAL ANALYSIS



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STRUCTURAL ANALYSIS

FATIGUE ANALYSIS



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COUPLE FIELD ANALYSIS MILD STEEL

THERMAL ANALYSIS

STRUCTURAL ANALYSIS

FATIGUE ANALYSIS



652

COUPLE FIELD ANALYSIS USING ALUMIMUM ALLOY

THERMAL ANALYSIS

STRUCTURAL ANALYSIS



653

FATIGUE ANALYSIS


WITH AL2O3 COATING

THERMAL ANALYSIS

STRUCTURAL ANALYSIS



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WITH ZIRCONIA COATING

THERMAL ANALYSIS

STRUCTURAL ANALYSIS

FATIGUE ANALYSIS



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WITH AL2O3 COATING

MODIFIED MODEL 2, THERMAL ANALYSIS

STRUCTURAL ANALYSIS

FATIGUE ANALYSIS



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RESULTS

COUPLE FIELD ANALYSIS

Temperature oc

450 0c 450 450

Total heat flux

w/mm2

3.0816 4.1368 8.0366

Thermal error

21837 4.6523e-

9

4.6523e-

6

STRUCTURAL ANALYSIS

Cast iron

Mild

steel

ALA360

Total

deformation

mm

0.79786 0.27199 0.24753

Equivalent

stress Mpa

4524.3 3028.1 1147.7

Equivalent

elastic strain

0.044667 0.016576 0.018132

FATIGUE ANALYSIS

Cast

iron

Mild

steel

ALA360

Life 1 cycle equals to

17.434 17.434 167.64

Safety factor

11.779 15 15

Equivalent

alternating stress

Mpa

4524.3 3028.1 1147.7

COATING MATERIALSTHERMAL ANALYSIS

AL2O3 Zirconia

Temperature oc

450 450

Total heat flux w/mm2

2.9105 2.2365

Thermal error

15146 1.1274e5

STRUCTURAL ANALYSIS

AL2O3 Zirconia

Total deformation mm

17.613 0.13861

Equivalent stress Mpa

436.17 436.1

Equivalent elastic strain

27.398 0.031417

FATIGUE ANALYSIS

AL2O3 Zirconia

Life

2069.2 2070.2

Safety factor 15 15

Equivalent alternating stress

Mpa

436.17 436.1

THERMAL ANALYSIS for modified models with

zirconia coating

Modified

model 1

Modified

model 2

Temperature oc

450 450

Total heat flux

w/mm2

2.1972 3.7713

Thermal error

67264 1.329e5

STRUCTURAL ANALYSIS

Modified

model 1

Modified

model 2

Total deformation

mm

19.534 19.537

Equivalent stress

Mpa

247.6 223.25

Equivalent elastic

strain

29.135 29.123



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FATIGUE ANALYSIS

Modified

model 1

Modified

model 2

Life

12137 17301

Safety factor

15 15

Equivalent

alternating stress

Mpa

247.6 223.25

GRAPHS

COUPLE FIELD ANALYSIS

THERMAL ANALYSIS

STRUCTURAL ANALYSIS



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Conclusion

This theses work is done on optimization of piston to

suggest optimum material, coating and geometry;

Initially data collection and literacher was done to

understand modeling and analysis approach and also

to select materials.

Theoretical calculations are done and 2d model was

prepared according to the obtain results from the 2d; 3d

model was prepared using creo for further study.

Couple field analysis combination of structural and

thermal loads was carried out to determine thermal and

structural ability’s like flux, error, stress, strain and

deformation by varying materials mild steel and

aluminum a360; fatigue analysis also done to study life

and safety.

According to the obtained results aluminum is better in

thermal error and stress aspects; also aluminum is a

low weight material with this property engine will have

higher mechanical efficiency.

Al2o3 and zirconia (ysz)Coating was applied and analysed

to find the best one; as per the analysis results al2o3 is

good in thermal behavior but it will not lost longer due

to heavy displacement and stress values so better to use

zirconia instead of al2o3 even its thermal abilities are

low.

Model was geometrically modified to improve quality

and also to reduce some more weight.

As per the analysis results of new models modified 2

model will be the best model to improve efficiency/

quality.

References

[1] Mr.K.Kadambanathan, E.Selvan “FATIGUE

ANALYSIS OF A DIESEL PISTON RING BY USING FEA”

[2] Dr.Ahmed A. Beiruti, Dr.Basim M.

Quraishi&IsamEzzulddinyousif“THERMAL EFFECTS

ON DIESEL ENGINE PISTON AND PISTON

COMPRESSION RINGS”

[3]Ch.VenkataRajam, P.V.K.Murthy, M.V.S.Murali

Krishna, G.M.PrasadaRao

Design Analysis and Optimization of Piston using CATIA

and ANSYS

International Journal of Innovative Research in

Engineering & Science

[4] Vural E, Ozel S, Ozdalyan B (2014). The investigation

of microstructure and mechanical properties of oxide

powders coated on engine pistons surface,

Optoelectronıcs And Advanced Materials – Rapid

Communications,

[5] Alkidas AC (1989). Performance and emissions

achievements with an uncooledheavy duty, single

cylinder diesel engine, SAE, vol. 890141.

[6] Uzun A, Effects of thermal barrier coating material

on a turbocharged diesel engine performance, Surface

Coating Technology, 505, 116–119 .

[7] Shackelford J, Al FE (2001). Materials Science and

EngineeringHandbook, Ed. James F. Shackelford & W.

Alexander Boca Raton: CRC Press LLC, paper 68-123.

[8]EkremBuyukkaya, (2008) Thermal analysis of coated

Al-Si alloy and steel pistons

[9] Access Date: June 8, 2015

http://accuratus.com/zirc.html.

[10] Sroka ZJ ( 2012 ). Thermal load of tuned piston,

Archives of Civil and Mechanical Engineering, 12, 342 –

347.

[11] 3. S. Alphiine, Derrien , Thermal Barrier Coatings

for turbine

AUTHORS

S.Girish V Satya Sai Vara Prasad, Research Scholar,

Department of Mechanical Engineering, Aditya Engineering College, Surampalem, Andhra Pradesh, India.

K.L.Kishore ,

Associate Professor,

Department of Mechanical Engineering, Aditya Engineering College, Surampalem, Andhra Pradesh, India.

international journal of research and innovation · s.girish v satya sai vara prasad1, k.l.kishore...

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