Author : G Gopal, L Suresh Kumar, D Gopinath and Uma Maheshwara Rao

The present aim of the project is to study the effect of the materials being used for the Piston, Connecting rod and Crank Shaft assembly for an engine of a four wheeler vehicle. The material selected for the piston is Cast Iron, Manganese steel for the connecting rod and High Carbon Steel for the crank shaft. The engine speed was desired to be increased. The effect of the materials used for the assembly and its behavior was required to be studied. The parts piston, connecting rod and crankshaft are designed using theoretical calculations. The designed parts are modeled and assembled in 3D modeling software Pro/Engineer. The meshing is done in Hypermesh. The Finite Element Analysis is done in Ansys. The FE Analysis involves structural and analysis of the assembly. The parts of the assembly should be rigid. And, when they are connected together, they should perform as a mechanism. This requires calculation of the forces acting on the components and the dynamic stresses. As the assembly will be working under high temperatures, thermal analysis also has to be done. From the results, it is observed that a change in the piston material will allow the engine to operate at the new high speed.

Keywords: Engine displacement, Piston skirt, Under square, Crank web, HyperMesh, Ansys.

Article published in International Journal of Current Engineering and Technology, Vol.6, No.1 (Feb-2016)