"Project ScopeThe purpose of this project is to demonstrate the capability of designing andperforming calculations, FEM and computer simulations on a mechanical component(car piston) using commercial software. The project scope will be to investigate anengine piston for a Toyota. The first part will involve doing the geometry of the engineposition i.e. using the measurements of a real Toyota piston. Only one piston will beinvestigated. Hypermesh or Ansys software will be used for the engine piston’sgeometry and the Finite Element Modelling. The piston will be calculated with the use of Finite Element Modelling and Computersimulations. The desired outcomes are having a piston model and FEA results formodal, thermal, fatigue analysis, closed form solution (bending and torsion) and adetailed discussions on the results will be discussed in detail in the project.1 | P a g e Introduction:In the recent years, industries, especially in field of mechanical design, there has beenextensive research, development and optimization technology invented for easy use, reliableapplication, cost saving, time management and product aesthetic appearance. Software toolsfor Finite Element Analysis (FEA) and Finite Element Modelling (FEM) and very helpful fordesigners, production purposes, as well as for researching novel techniques and products.There are many engineering applications which are solved by software tools.Generally mechanical components are design and finalized by three different techniques. Iftwo techniques are satisfied within a given condition and require application, then the designis finalized for production. Before the production, the first design of piston or any mechanical component are prepared inan analytical solution. The analytical solution is solved with the design fundamental andformula of standards geometry and parts. The result of analytical solution get further softwaretool is use for analysis purpose and finalizes the design of particular component which giveresult of analytical solution. For software analysis generally Ansys and Hypermesh softwaretools are used for analysis and optimization and finalize the product design. The Ansys workbatch tool can give same environment which have to work in practical condition. Ansys toolcan give result before the failure occurs or can estimate require mechanical input anddesirable output. For optimization Hypermesh is generally use for different optimizationtechnique use and different parameter can get by using Hypermesh designing software.Keywords: Piston design, FE analysis, Hypermesh, Optimization. Finite element analysis: it is numerical method and multiphysics technique which is usefulfor solve engineering problem. In FEA simulation process first create mathematical model ofproduct with boundary condition and loading condition. After that it divide in to domain to2 | P a g e subdomain is called element. Element have different size and different geometry with node.In specific model elements are connect with node and all elements connect with the nodesand create complete model with finite element size. (Al-Momani,2008)The meaning of finiteelement method is to divide entire volume of product into define size of element. The entiregeometry divide into small size of element and elements are connecting with nodes. Withapplying loading of particular product, stress induces with consideration of each and everyelement of product. The result shows the maximum stress induce at particular region andminimum stress at particular region. Forms that result are useful for design optimization anddesign modification. Finite element analysis can perform by analytical approach as well but itis difficult for complex geometry analysis with analytical approach of FEA. For complexgeometry it is good for use software tool like Ansys, Hypermesh, ABAQUS, and Nastran etc.Piston is a heart of I C engine which is important for design as well as working purpose in I Cengine. The function of piston is to concert heat energy into pressure energy and kineticenergy for the combustion and for mechanical works. The designing of piston is mostcomplex and tough among the other component of I C engine because need for piston designis that it should be optimum weight, sufficient to carry high thrust and impact load, strongenough for all directional load, optimum cost. For the all require properties of piston there arenecessary to analysis by the software tool Ansys work batch or Ansys APDL. There arevarious analysis tool available Ansyswork batch module like static structural analysis,thermal analysis, vibration analysis, transient analysis, fatigue analysis, optimizationtechnique like design of experiment method, sensitive analysis. For the piston analysis anddesign for finding stress distribution, deformation, life cycle etc. there are need part modelwhich create in Computer aided designing tool cro-o parametric or solid works softwarewhich easy to create part like piston. After that piston part import into Ansys work batch toolfor analysis purpose. it also easy to create part file in Ansys work batch tool but rather than3 | P a g e create part into Ansys it is easy to create in modelling software like solid works, cre-oparametric. ANSYS work batch is the platform where industrial engineer use software for deep suit ofengineering simulation technology built. (Kongari, 2015) This is an advance technology projectschematic version which builds bridge between advance simulation and existing designapproach. By using Ansys workbench tool it guide for metaphysics analysis for complex partand simulation which is not easy task for analytical designin Ansys.Thereis connectivity withCAD modelling tool by creating bridge between modelling and analysis in software. Thereare great technique with auto mashing which give define element size of part for accurate anddesirable result. The produce for FEA analysis in Ansys work batch tool: ? Create geometry in solid modelling software like solid edge or solid works etc.? There is availability to build bridge between solid model and Ansys work batchanalysis.? Import geometry form CAD model into Ansys work batch. ? Assign specific material properties to model in Ansys geometry modular. Generallycast iron use in production of piston. ? Apply mashing to part model in designer module file. The function of mashing is todivide whole component into finite part. Therefore assign appropriate mashing to partmodel. There are various options available in Ansys file to assign mash properties liketri element, tetra element, and quad, hex element etc.And another purpose ofmashing is for accurate result after simulation and analysis. ? Assign boundary condition and loading condition to part model. In this case staticanalysis, thermal analysis, dynamic analysis and vibration analysis should perform todesign output and complete design.4 | P a g e Find the result form designer module of Ansys example like In static analysis deformationand stress is a considerable factor for design outcome. For thermal analysis t need maximumtemperature induce at the top surface and outer surface of piston, for vibration analysis itshould be nature frequency of piston at extreme position considering the working conditionof piston in I C engine. For fatigue analysis it should get result of life span of piston after theapproximate year of working. (Montazersadgh, 2007)Mashing of piston for analysis and optimization:Generally mashing is done in FEA for close and accurate result. The purpose of mashing inFE analysis is for create arbitrarily volume element with divide part modal equal size indefine elements size. Static structure analysis of piston by using Ansys work batch: ? It is easy to perform analysis by CAD interface and FE analysis. First import modelform CAD model to Ansys work batch. ? Assign aluminium alloy material specification to model.? Generate model in geometry interface in Ansys work batch. ? Assign mashing with specific element size. Mashing create for divide element intospecific size for entire volume of model. The advantage of mashing is that we canidentify sacrifice region where most of effect are generate and modified according tosafe design consideration. ? Applying loading condition and boundary condition for piston. For static structuralanalysis the boundary condition is a volume of cylinder where piston travel and thetravelling path where piston travel top dead centre to bottom dead centre.? Loading condition defined by the how much amount of outcome require form I Cengine and life span of piston and cylinder. Also depends on the input applied formoving reciprocating of piston. ? Find the result of deformation and stresses of piston design. Deformationconsideration form friction losses, stresses are generating due to wear and tear ofpiston due to reciprocating motion of piston. Stress is von –missis stress, normalstresses and axial thrust stresses. (Norberg et.all.,201)5 | P a g e ? Finally compare result with analytical approach. All kind of analysis cannot perform with analytical approach and cannot perform before thefinalize product in terms of practical approach. For this reason Finite element analysis isuseful for design, development and optimization purpose.Thermal and geometric properties: For prepare product design of piston it is important to consideration of thermal stressdistribution over the top surface of piston head. Therefore it should be thermal analysis forobtain intensity of head which produce during combustion in I C engine. The deformationand stress produce over the surface of piston head should be within acceptable limits. Formthe result of temperature distribution over the piston which give conclusion that how muchamount of heat generate and how much amount of temperature can sustain by piston beforemanufacturing. Another reason for thermal analysis using Finite analysis in Ansys workbatch is that mainly during working condition the chance of failure of piston ring is more dueto wear and tear over the surface of cylinder. For that lubrication film fills between thesurface of piston and cylinder. During analysis first identify material selection for particulardesign product. Here,for prepare model or prototype of piston it should be good for usingaluminium alloy because aluminium have great amount of thermal expansion co efferentwhich is more the cylinder bore. Therefore it can operate at high temperature for infinite lifeconsideration. In practical thermal analysis is a difficult task to identify the temperature anddeformation due to heat over the surface of piston. So form the Finite element analysis wecan conclude that we can find certain temperature and heating capacity sustain by piston fromthe result of Finite element analysis.6 | P a g e Optimization of Product design:Optimization is a technique which give result at optimum condition with design constrain. Indesign of piston the mass of piston, area cover due to heat over the surface of piston, pistonring thickness, width can optimize with constrain and boundary condition. (Sonar,2015)The final product design and analysis in finite element analysis the product have to optimizeat certain level. The purpose of optimization is to reduce the mass of material and resize theproduct at optimum condition. From the result which get form ansys work batch module withrequire analysis perform we get constrain and loading condition for optimization. Hear we setminimization technique for optimize the mass of piston. The result of von –missis stress andfactor of safety which get from ansys are constrained of optimization tool. The objectivefunction of the piston design is to reduce mass. Form Hypermesh tool software use. Providemedium for CAD system and Finite element analysis. The advantage of Hypermesh is to obtain any optimization which is not possible in Ansys orother software. Example like topology optimization, topography optimization, sizeoptimization, shape optimization, etc. for product design like piston our objective function isto reduce mass or optimize mass with stress and factor of safety constrain. The fundamentalwork of Hypermesh tool reduces or maximizes the particular term up to 80 % of refinementof product. Procedure of optimization in Hypermesh as following:? Import CAD model into Hypermesh software? Firstcreate folder of material properties of piston.? Mash component and assign properties. ? Define constrain. ? Applied loading condition by load collector. ? Define specified output by cart image 7 | P a g e ? Define load step.? Define output like size optimization, shape optimization, topology optimization. Application of Hypermesh:Hypermesh have advance geometry and mashing capabilities by the providingenvironment for quick model generation. From hyper mash work it has properties whichgive high quality mash with great extent. It is one of great properties for using Hypermeshfor design requirement and research development. in recent year there are many researchabout the different material with different properties. To assign material and properties toproduct is easy by using Hypermesh. Hypermesh is capable to support complex geometryfor optimization. For composite material specification Hypermesh tool is use for finiteelement analysis which cannot done in Ansys work batch tool. Nonlinear properties ofmaterial also support in Hypermesh tool. Modelling of laminated composite with complexgeometry also supported in Hypermesh tool technology. Designing change andmodification done by mash properties and result of optimization.Mashing advantage of Hypermesh:? It is compatible for both CAD model and FE analysis. ? Highly mashing can generate like surface mashing, CFD mashing, SPH mashing,hex mash, tetra mash etc. ? Fast and high quality mash generate with large assembling model. ? Auto mashing adding advantage for time saving and value added engineeringprocess activity.? CAD interface advantage: support IGES, step file, JT file, UG, solid works,CATIA etc. modelling software are support for interface between CAD designingand Finite element analysis.8 | P a g e "