Analytical study regarding the topological optimization of an internal combustion engine piston

Abstract

Continuous progress in the automotive field involves the use of new working methods in the calculation and optimization of the internal combustion engine parts. On this occasion, in this paper, the impact of a topological optimization on the piston in the combustion engine of the conventional or hybrid electric car was studied. Starting from the simulation of the Otto cycle, the dimensional calculation is reached, after which a classical FEA analysis is carried out in order to establish the reference values. In the last part, the data of the classical analysis are compared with those of the topological analysis in order to perform a comparison of their results. The purpose of this study is to reduce the volume of the optimized part and to increase its rigidity.

Analytical study regarding topological optimisation of an internal combustion engine cylinder block

“…With the help of specialised calculation toolsets, the optimum engine block shape was determined whilst respecting the user imposed constraints. The base of these algorithms underlies genetic algorithms, optimal criterion methods, topological derivatives, and many more mathematical modelling relationships [2,5].…”

Contributions towards improving the displacement and strain responses of an internal combustion engine piston through topology optimisation

“…B is the piston's bore, p is the gas pressure in the cylinder that for this scenario is equal to 9 [MPa], and pcart is the gas pressure inside the engine bay [3]. pcart usually has a value of 1 [bar], which is equal to 0.1 [MPa].…”

“…The optimized engine piston has the following mechanical characteristics: piston bore B = 70 [mm], piston stroke S = 64 [mm], and the nominal speed n = 6000 [rpm]. The aforementioned data was used to determine the piston's forces to withstand during workload [3].…”

Geometry design and optimization of piston by using finite element method

“…4 𝑃 = 𝑃 𝑏 × 𝑑 𝑜 × 𝑙 1 (10) where Pb is bearing pressure at small end of connecting rod (25 MPa). 3.189 Length of piston pin at the bush of small end, l1 (mm) 39.375 Outer diameter of piston pin, do (mm) 30.54…”

“…The target percentage of mass reduction can be set in TO. A study about TO of piston has been conducted by Gaidur et al [10]. In this study, there is 1 % of reduction in piston mass and 17% reduction in Von Mises stress on optimized piston compared to original piston.…”