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Abstract
A piston is a component of reciprocating engines, reciprocating pumps, gas compressors and pneumatic cylinders,
among other similar mechanisms. It is the moving component that is contained by a cylinder and is made gas-tight by
piston rings. The piston transforms the energy of the expanding gasses into mechanical energy. The piston rides in the
cylinder liner or sleeve. Pistons are commonly made of aluminum or cast iron alloys.
In our project a piston for 1300cc diesel engine car will be designed using empirical formulas for the material Cast
Iron. A 2D drawing is created from the calculations. The piston is modeled from 2D drawing using CREO parametric
(Pro/Engineer) software.
Validation of die will be done using structural and dynamic analysis done in Ansys.
Generally manufacturing process for pistons is casting. So we have to design a die tool for the piston manufacturing. Designing of casting tool die for four cavities will be done. Core and Cavity will be extracted and total die will be
designed as per the standards. CNC program will be generated for both core and cavity.
Modeling, core cavity extraction, die design and CNC program generation is done in CREO parametric (Pro/Engineer)
software.
*Corresponding Author:
Kola Nagarjuna
Research Scholar, Department of Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India
Published: July 22, 2014
Review Type: peer reviewed
Volume: II, Issue : IV
Citation: Kola Nagarjuna, Research Scholar (2015) MULTI
CAVITY DIE PREPARATION, ANALYSIS AND MANUFACTURING PROCESS OF DIESEL ENGINE PISTON
INTRODUCTION TO PISTON
In every engine, piston plays an important role in working
and producing results. Piston forms a guide and bearing
for the small end of connecting rod and also transmits
the force of explosion in the cylinder, to the crank shaft
through connecting rod.
The piston is the single, most active and very critical component of the automotive engine. The Piston is one of the
most crucial, but very much behind-the-stage parts of
the engine which does the critical work of passing on the
energy derived from the combustion within the combustion chamber to the crankshaft. Simply said, it carries
the force of explosion of the combustion process to the
crankshaft.
Apart from the critical job that it does above, there are
certain other functions that a piston invariably does -- It
forms a sort of a seal between the combustion chambers
formed within the cylinders and the crankcase. The pistons do not let the high pressure mixture from the com-
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Drives a gearbox through a clutch. Components of a typical, four stroke cycle, DOHC piston engine. (E) Exhaust
camshaft, (I) Intake camshaft, (S) Spark plug, (V) Valves,
(P) Piston, (R) Connecting rod, (C) Crankshaft, (W) Water
jacket for coolant flow.
Suzuki GS 150 R specifications
Engine type : air cooled 4-stroke SOHC
Bore stroke(mm)=5758.6
Displacement =149.5CC
Maximum power = 13.8bhp @8500rpm
Maximum torque = 13.4Nm @ 6000 rpm
Compression ratio =9.35/1
3D MODEL PREPARATION
SKETCHER
REVELOVED MODEL
SLOT CUTTING
INTRODUCTION TO CASTING
Casting is one of the oldest procedures done on metals.
Many products are formed using this method. Here is an
attempt to share the knowledge of casting.
Casting is one of four types: sand casting, permanent
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EXPLODED VIEW
CAVITY
CORE
166
CUTTING TOOL
VERICUT
ROUGHING PROGRAM
INTRODUCTION TO MANUFACTURING
The manufacturing of various products is done at different scales ranging from humble domestic production of
say candlesticks to the manufacturing of huge machines
including ships, aeroplanes and so forth. The word manufacturing technology is mainly used for the latter range of
the spectrum of manufacturing, and refers to the commercial industrial production of goods for sale and consumption with the help of gadgets and advanced machine
%
G71
O0001
(D:\nsr\roughing.ncl.1)
N0010T1M06
S5000M03
G00X5.Y-5.
G43Z0.H01
G01Z-5.F200.
X201.177
Y-9.914
X5.
Y-14.828
X201.177
167
Y-19.742
X5.
Y-24.656
X201.177
Y-29.57
X5.
Y-34.484
X201.177
Y-39.398
X5.
Y-44.313
Results table
STRUCTURAL ANALYSIS
Existing Model
Modified Model
Total deformation
0.010822
0.0090683
Stress
37.317
31.116
Strain
0.00034214
0.00028758
FATIGUE ANALYSIS
Existing Model
Modified Model
LIFE
1e6
1e6
Damage
1000
1000
Safety factor
2.3099
2.7703
Biaxiality indication
0.98181
0.99333
Alternating stress
37.317
31.116
graphs
Conclusion:
This project work deals with Multy cavity die preparation
and manufacturing process of diesel engine piston".
In the first step data collection and inputs are collected
for the design of piston for diesel engine.
In the next step design calculations are done using mathematical formulaes from the calculations piston dimensions are required.
A 3d model was generated using above calculations.
Tool design calculations are done to prepare the die assembly.
Core and cavity inserts are prepared using manufacturing model in pro- engineer.
Mould tool parts are prepared and assembled withdrew
set.
Structural and Fatigue Analysis is conducted on mold to
find structural and Fatigue behavior to, modifications
done for core & cavity models to increase strength by adding stress relief holes.
CNC program was generated for both core and cavity inserts.
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author
REFERENCES
1.Thermal analysis and optimization of i.C. Engine piston
using finite element method
2.Design and analysis of i.C. Engine piston and pistonring using catia and ansys software
Kola Nagarjuna
Research Scholar,
Department of Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India
Koyilakonda-Sumanth
Assistant professor
Department of Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India
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