Design and Failure Analysis of Piston

Abstract: A piston is a component of reciprocating engines. The purpose of piston is to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and a connecting rod. It is one of the most complex components of an automobile. In This project we are describes the structural analysis of five different aluminum alloy pistons, by using finite element method (FEM). The specifications used for designing the piston belong to four stroke single cylinder engine of Bajaj Pulsar 220cc. Modeling of various aluminium alloy piston are done using SOLID EDGE. Static structural, thermal and fatigue analysis is performed by using ANSYS WORKBENCH 2022 R1. The parameters used for the simulation are operating gas pressure, material properties of piston. The results predict the maximum stress and strain on different aluminium alloy pistons using FEA. The best aluminum alloy material is selected based on static structural, thermal and fatigue analysis. The analysis results are used to optimize piston geometry of best aluminum alloy.