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Automated CAD modelling approach and FEM analysis for an IC engine piston

Conference Paper  in  AIP Conference Proceedings · November 2022

DOI: 10.1063/5.0114358

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RESEARCH ARTICLE | NOVEMBER 29 2022

Automated CAD modelling approach and FEM analysis for

an IC engine piston
Bill Christopher Sirigiri  ; Jayakiran Reddy Esanakula

AIP Conference Proceedings 2648, 020029 (2022)

https://doi.org/10.1063/5.0114358

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 Automated CAD Modelling Approach and FEM Analysis
for an IC Engine Piston
Bill Christopher Sirigiri a) and Jayakiran Reddy Esanakula b)

Department of Mechanical Engineering, Sreenidhi Institute of Science and Technology, Hyderabad, India.

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Corresponding author: a)[email protected]
b)
[email protected]

Abstract. Internal combustion engines have been widely employed in the automobile industry since their introduction. As
a result, the efficiency of the IC engine is constantly in need of improvement. The piston is one of the most important
components in the operation of an IC engine. The approach for improving the performance of IC engine pistons is crucial
in today's business. Because of the complexity of geometry and design calculations, traditional CAD modelling
methodologies for IC engine pistons are time-consuming. A little change in the size or shape of the IC engine assembly
will result in a massive chain reaction in computing the associated modifications due to many connected plan
considerations. As a result, the CAD model for the piston should be changed to match the changes in the IC engine (s).
These issues can be solved by using CAD modelling approaches like parametric modelling to automate the process. This
paper lays the groundwork for using SolidWorks to create a CAD model of an IC engine piston. In the CAD application, a
customised GUI was created to assist the design engineers in feeding the input data. The offered method makes use of
design data reuse. The suggested technique can reduce the modelling and design time for the IC engine piston. In this study,
the proposed technique is illustrated and its stability is tested using FEM analysis.

INTRODUCTION
In terms of total revenues and demand, the automobile industry is one of the most profitable and in-demand sectors
on the planet. The engine of a car is one of the most important components of the vehicle. A mechanism that turns
chemical energy into mechanical energy is known as an engine. An internal combustion engine (IC engine) burns the
fuel to produce heat, which is then used to do labour. In these engines, a piston is essential because it guides the
connecting rod's movement while simultaneously delivering gas pressure forces to change the volume inside the
cylinder. The forward and backward moving components are enclosed in a cylinder, and piston rings maintain them
gastight. The piston and connecting rod transfer the force of expanding gas to the crankshaft. The efficiency of the IC
engine is dependent on the piston function. If the piston fails to perform properly, the IC engine will come to a
standstill. The main causes of piston failure are mechanical and thermal stresses [1]. In order to avoid self-failure, a
superior IC engine piston design is always required. Furthermore, if the new design is available at a faster rate, it is
undoubtedly beneficial to automakers. A number of tools are available to assist with the design process [2]. Figure 1
shows the IC engine piston and its components.

Fourth International Congress on Advances in Mechanical Sciences

AIP Conf. Proc. 2648, 020029-1–020029-11; https://doi.org/10.1063/5.0114358
Published by AIP Publishing. 978-0-7354-4242-9/$30.00

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FIGURE 1. An IC engine piston and its parts as 1. Piston head, 2. Piston rings, 3. Piston pin.

Knowledge-Based Engineering (KBE)

KBE is an automation methodology that shows how AI methodologies can be used in conjunction with CAD
technology to provide customised or alternative design automation solutions [2]. The introduction of Knowledge-
Based Systems (KBS) has drastically decreased the time required for design [2]. Thanks to the use of simulation
technologies, KBS has also become a useful tool for visualising and evaluating the design process. KBE is one of
KBS' technology-based solutions in the design, manufacturing, and production fields. Because KBE is one of the best
quick design technologies, it's frequently utilised for mass customization [3]. The ultimate goal of the KBE system
should be to create a corporate knowledge base that incorporates the finest design approaches and engineering skills.
Figure 2 depicts the KBS's architecture.

FIGURE 2. Knowledge-Based System architecture [4].

Need of CAD-Modeling in the Modern Era

Most businesses seek to save money when it comes to CAD modelling because it is a time-consuming and labor-
intensive procedure. In most industries, hiring a designer to produce a design based on their demands is standard
practise. This procedure takes a long time and is highly costly. The traditional method is great for coming up with
fresh concepts, but it falls short when it comes to making improvements to existing designs that require dimension
changes. As a result, design automation will need to be created.

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 Design Automation
Design automation is the application of a pre-programmed set of codes to do design tasks that would otherwise
take a long time to complete in a human design process. Traditional CAD procedures can help to speed up the creation
of such apps. Previous adjustments and conditions are stored in the cloud or on local devices through CAD techniques,
allowing them to be reprocessed as needed [5]. The use of a computer to automate a human design process is referred
to as design automation. The data for the automation might come from conventional design procedures, previous
experience, manuals, charts, and other sources, and it will be stored in a computer database to be used as needed [6].
The design automation process is depicted in Figure 3.

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FIGURE 3. The process of design automation.

Application Programming Interface (API)

API is for Application Programming Interface, and it is a software development technique that allows two different
apps to interact with one another. To create customised separate Windows executable files, an API can be utilised.
APIs can be written in the languages VB.NET, C#, and Visual C++ [3]. Almost all CAD software has a macro function
in addition to API freedom. SolidWorks provides a programming interface (API) that may be used to automate and
customise the application. The API's hundreds of capabilities may make CAD automation easier.

Visual Basic (VB)

Visual Basic (VB) was launched by Microsoft in 1991 as a third-generation programming language. It's a simple
programming language that allows us to quickly create GUI (Graphical User Interface) Windows programmes. Visual
Basic is the most important, easiest, and finest programming language for writing macros. VB has shown to be an
incredibly useful tool for building a variety of computer programmes for a variety of purposes. Engineers may utilise
ActiveX dynamic link libraries, or DLLs, to combine Visual Basic with numerous Windows programmes and create
new user interfaces [4]. SolidWorks is a CAD application that automates modelling using API and VBA (Visual Basic
for Application). In addition, VB may be utilised to create a customised user interface.

Macros
A macro is a rule or pattern in computer science that outlines how an input sequence should be transformed into
an output sequence according to a method [7]. The model environment must be engaged in order to improve the design
automation process [8, 9]. API interfaces in CAD systems allow users to connect with the model environment via
macros. In addition, in order to address real-world difficulties, data must be shared across disciplines. A complicated

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algorithm may be required in some circumstances to do a computation that is not available in commercial software. It
also aids in the computer-assisted construction of geometrical entities and operations [10].

IC Engine Piston Material

According to ISO 6621-5:2020, Gray Cast Iron, Aluminum Alloy, Structural Steel, Magnesium Alloy (AZ91D),
Al-GHS1300, A2618, A4032, A6061, and A7075 are some of the materials that should be utilised for the IC piston.
Table 1 summarises the key mechanical and thermal properties of several materials based on research [11-16].

TABLE 1. The Properties of different materials of IC engine piston

Type of material

Magnesium Alloy
Aluminium Alloy

Structural Steel
Gray Cast Iron

Al-GHS-1300
(AZ91D)

A2618

A4032

A6061

A7075
Material Property

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Density (kg/m3) 7200 2700 7860 1800 2780 2767 2684 2700 2810
Youngs Modulus 110 71 200 44.8 98 73.7 79 68.9 71.7
(GPa)
Poison’s Ratio 0.27 0.33 0.266 0.35 0.3 0.33 0.33 0.33 0.33
Ultimate Tensile 100 225 460 255 1300 480 380 310 276
strength (MPa)
Thermal conductivity 46.6 175 51.25 72.7 120 147 154 167 173
(W/m/C)
Coefficient of thermal 1.0× 0.3× 1.17× 2.6× 18×1 25.9× 79.2× 2.36× 2.81×
expansion (1/K) 10-5 10-5 10-5 10-5 0-6 10-6 10-6 10-5 10-6

Dwaipayan Roy Chowdhury et al. [10] used SolidWorks and VB.net to demonstrate how and when to automate
the design of a cube. The cube design process was automated using macro scripts. We can generate a cube with the
size, material, and colour we want using the SolidWorks API. Balachandar Krishnamurty et al. [5] have created a tool
that uses the SolidWorks API and macro scripts to automate the design of pistons and connecting rods. Traditional
techniques for making changes to an established design will take a long time and cost a lot of money. The piston and
connecting rod may be readily developed and manufactured with the help of the unique user interface. This will save
a lot of time and money, and it will also eliminate the need for a design engineer. Jayakiran Reddy et al. [4] proposed
a spur gear design method based on a knowledge-based system, SolidWorks API, and macro codes. Graphical user
interfaces, inference engines, and knowledge base systems are all developed for knowledge base systems. All of the
information that the user need is contained in the Graphical User Interface. Designers contribute their expertise to a
knowledge base that is then used to standardise components. As a result, the client or user may now be able to obtain
the component they want in less time. Andrijana Bocevska et al. [7] created a CAD system for designing automobile
rim applications. Macros are used in the user interface of a CAD system to allow the user to interact with the system.
Engineers will benefit from it since it will open up a whole new world of possibilities for modelling better objects
faster and more precisely. Reddy et al. [3] used the SolidWorks API framework to automate the creation of a CAD
model of a universal connection. By making minor design changes, a knowledge base system can minimise the time
it takes to model an existing item. When compared to people, knowledge base systems can reproduce parametric
modelling of a part in a fraction of the time. Joshi et al. [9] shown how to automate mechanical component CAD
modelling. Increased productivity, resilience, and quality are the results of design automation, as well as time and
labour savings. Cotter joint design automation saves time and yields better results than conventional modelling. The
computations are done in the software's backend to create a safe design and reduce modelling errors. The SolidWorks
API was utilised by Rui Lyu et al. [17] to automate the simulation of a car chassis frame manufacturing. Material
properties may be directly adjusted using macro codes in SolidWorks' material selection programme, which is written
in Visual Basic Language. Using SolidWorks, Abhishek et al. [6] built the design automation of a winding machine.

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As a result of design automation, the CAD model is created in less than two hours. It can save you up to 25% on
overall expenditures and up to 80% on the time it takes to complete the design process. A few other design automation
strategies [18-23] have also been published in the literature with the purpose of lowering design time.
Atul Jain et al. [13] did a comparative research and static analysis of pistons using SolidWorks and Ansys. In this
investigation, four different kinds of aluminium alloys were employed. The piston was a Bajaj pulsar 220cc, and the
materials used in the experiment were A2618, A4032, Al-GHS1300, Ti-6AL-4V. SolidWorks was used to create the
pistons, which were made of a variety of aluminium alloys, and Ansys Workbench R15.0 was utilised for static
analysis. A static structural study of the piston is performed using Finite Element Methods (FEM), and the results of
maximum and minimum deformation, stress, and strain are analysed. Based on the results, Al-GHS1300 was chosen
as the best piston material. Raghuveer Chandra and his colleagues [14] The static and thermal study of an IC engine
piston was performed using Autodesk Fusion 360 in this work. The analysis used Aluminum7075, Aluminum6061,
Titanium Alloy, and Gray Cast Iron A48. The examination of four different materials is carried out under two different
load conditions (Mechanical loads and Thermal loads). Titanium, when compared to other materials, is more resistant
to deformation, has the highest safety characteristics, and can dissipate more heat. The paper by Yash Dhamecha et
al. [15] used Finite Element Methods to build and analyse pistons constructed of diverse materials (FEM). A Bajaj
pulsar 220cc motorbike piston was utilised in the case study. The materials used include A2618, Al-GHS-1300, and

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Ti-Al-6V. The piston's 3-D model was created using Creo3.0 software. For static structural and thermal stress analysis,
Ansys 16.0 is utilised. Al-GHS-1300 is the best of the three materials, according to the findings of the analysis. [1]
Satyanarayana et al. The stress analysis of a range of variable compression ratio diesel engine pistons was studied
using Finite Element Methods (FEM). The piston was manufactured by Kirloskar and is constructed of Al6061, Ti-
6Al-4V, and INCONEL Nickel-Chromium alloy-625. The piston is made with flat head crown and hemispherical
crown piston heads. The piston model was created in SolidWorks. Thermal and structural studies for the piston are
handled by Ansys. The thermo-structural study was completed, which meant that the thermal analysis was completed
first, followed by the static analysis, and it was determined that the hemispherical piston with Al6061 was the most
suited piston design among the piston designs. A study by Valentin Mereuta et al. [12] employed FEM analysis to
perform static and thermal analysis on a piston. The piston is designed in Autodesk Inventor, and the analysis is done
in SolidWorks. The materials utilised are Gray Cast Iron and Aluminum6061 alloy. Ravikiran et al., MSSR Ravikiran
et al., MSSR Ravikiran et al., MSSR The weight of the piston has been reduced thanks to the use of CREO and ANSYS
to optimise it. The piston is designed using standard design equations, then optimised for weight reductions. The two
pistons are static and thermally tested using three different materials: grey cast iron, aluminium alloy, and aluminium
silicon carbide. The optimised piston outperformed the regular piston in the analysis, while Aluminium Silicon
Carbide outperformed the other three materials examined. Anup Kumar Shetty and colleagues [16] The results of the
static analysis of the piston using various Aluminum alloys were provided in the article. The piston in this article is a
Bajaj Pulsar 220cc. The CATIA software used to simulate the piston is based on the analytical design of the piston.
The materials employed were A2618, A4032, Al-GHS1300, and Ti-6Al-4V. ANSYS software was used to compute
the equivalent (von-mises) stress and equivalent elastic strain of the piston in various materials, and it was determined
that A4032 alloy outperforms the others, while Al-GHS-1300 is the least recommended alloy owing to its high yield
strength for the particular piston.
Several academics worked to create a software application for design automation, and none of those were effective
at the industry level, according to the literature review. Automation is available for standard components, but not for
the specialty parts that are critical to the business. Because there is no design automation, it costs a lot of money and
time. It puts a lot of strain on the engineer, and the need for qualified professionals has risen dramatically. To bridge
this gap in the automotive industry, the design automation of the IC engine piston component was chosen. It is
projected to save R&D engineers and individuals a substantial amount of time and money, as well as make their work
easier.

METHODOLOGY
Most commercial CAD software developers are now working on software that can build or reproduce any
commercial component's part model using text input data as well as traditional ways. In order to draw a line on the
screen, input data such as starting and ending points do not need to be inputted using the mouse; instead, they may be
typed in as text using the 3-dimensional coordinates of the starting and finishing points. A computer programme can
also offer these input messages. As a consequence, any design system's automation requirements may be met using a
computer programme and current CAD software. Only a few programming languages are available, such as Visual

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Basic for Applications (VBA). VBA is a powerful and simple programming language. VBA is the programming editor
for commercial CAD applications such as SolidWorks. As a result, SolidWorks software was used to develop the
current KBS for CAD modelling of IC engine pistons. You'll need a database containing data related to piston materials
to complete the design calculations. The database was built in such a way that it has all of the necessary data for design
calculations, and the programme may access it at any moment the current system is needed. This database offers
information on the IC engine piston's design as well as material properties.

Developing a Generic 3D Model

To start, a typical piston model is created manually in CAD, taking into account all of the model's qualities and
restrictions while recording the macro file. Based on the piston's key properties, the equations for the generating CAD
model should be constructed. The recorded macro file needs be changed for parameterization and interaction with
SolidWorks API. The same technology will be utilised in the future to create a 3D CAD model of an IC engine piston.
The suggested system's created macro code is 64 KB in size.

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Design Calculations
To begin, the user's input data had to be collected using the proposed GUI, which included bore diameter, length
of stroke, maximum gas pressure, speed, suggested mean effective pressure, fuel consumption, and piston material
selections (see figure 4). This GUI was created in SolidWorks using VB. Based on the provided data, the generated
method will execute all design calculations using typical empirical equations.

FIGURE 4. GUI for feeding the IC engine piston design requirements.

Creating GUI
Users may create and design their own graphical user interfaces using SolidWorks' built-in VBA (Visual Basic for
Application). This user interface was used to collect input from the user so that a CAD model of the piston could be
created. The user interface was built using conventional Visual Basic tools such as text boxes, combo boxes, and
buttons, and it was designed to collect all of the necessary data from the user and send it to an algorithm for design
calculations. Figure 5 depicts the flowchart for the design calculations algorithm. Figure 6 depicts a button/icon created
in the SolidWorks environment to display the GUI on the screen.
After hitting the submit button, all of the design calculations will be completed. The GUI will not allow the process
to advance to design calculations if the user does not give the minimum basic input data required for design
calculations.

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 Start

Collection of the
design inputs

Enough data No
obtained?

Yes

Developed KBS gathers all of the standards, empirical relationships

and procedure(s) for design computations based on input data

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Design computation for critical dimensions
of IC engine piston

Display of results as message

box for user reference

Using developed macro code, the proposed system generates the

CAD model of the IC engine piston as output of the system

End
FIGURE 5. Flowchart of the design calculations algorithm.

FIGURE 6. Developed IC engine piston button in the GUI of SolidWorks.

Program Development for Design Calculations

Calculating the allowable dimensions using typical empirical methodologies is exceedingly difficult and time-
consuming when done manually. To solve this challenge, a computer programme is developed to do design
calculations and predict the piston's geometrical dimensions. As previously indicated, the newly developed KBS will
calculate the design using a specialised algorithm made exclusively for this purpose. This application's output data
will be submitted to the SolidWorks programme, which will create a 3D CAD model based on the computed
geometrical parameters. As a result, the design and modelling of the task are automated.

FEM Analysis of IC Engine Piston

The FEM study was performed using Ansys Inc. software to determine the stability of the suggested system
produced IC engine piston. Using FEM analysis, it is possible to predict how the piston would behave in a real engine,

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as well as see where the most deformation and stress will occur. The present model is subjected to a static structural
examination. In a static study, the maximum pressure load given to the piston's top surface is 5 MPa. For static-
structural analysis, ANSYS Workbench 2020 is utilised to import the 3D model of the piston from SolidWorks 2020.
The three phases for completing this analysis are as follows:
Material Selection: Grey Cast Iron was chosen for the study because the pistons' materials must fulfil specific
stress resistance standards.
Mesh Generation: The mesh was constructed with tetrahedral pieces using an automated generation approach.
There were 36560 nodes and 14328 components in the solid model.
Boundary Conditions: Boundary conditions such as pressure and fixed supports are used in static structural
analysis. The maximum pressure is delivered to the piston's head (5 MPa). The piston pin is supported by a permanent
support.

RESULT AND DISCUSSION

Table 2 shows the sample of inputs for IC engine piston design. Based on this input data, the built application

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employed conventional empirical equations to make design calculations. The calculated piston dimensions are shown
in a message box for the user's convenience. The calculated dimensions are shown in Figure 7. Using these specs, the
KBS constructed a CAD model of the IC engine piston, as seen in figure 8. The developed system takes 54 seconds
to perform the whole operation when run on a machine that fulfils the SolidWorks 2020 minimum hardware
requirements. Later, this CAD model has been imported to the Ansys to carryout the FEM analysis part. The overall
deformation and equivalent (Von-Mises) stress are computed using a static structural analysis of the Gray Cast Iron
piston. Figure 9 and 10 shows the deformation and Von-Mises stress in the IC engine piston.

TABLE 2. The Properties of different materials of IC engine piston

Design Considerations Corresponding Values
Material Gray Cast Iron
Cylinder bore (mm) 300
Stroke (mm) 450
Speed (rpm) 300
Indicated mean effective pressure (MPa) 0.85
Max gas pressure (MPa) 5
Fuel Consumption (Kg per BP per hr) 0.3

FIGURE 7. Dimensions of Gray Cast Iron IC engine piston.

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FIGURE 8. An automated generation of IC engine CAD model.

FIGURE 9. Total Deformation of Gray Cast Iron IC engine piston.

FIGURE 10. Equivalent (Von-Mises) stress of Gray Cast Iron IC engine piston.

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 This paper outlines a knowledge-based technique. KBE techniques may make more drastic geometric topology
changes than traditional CAD procedures, making this methodology more versatile than earlier methods. Because the
KBE techniques were developed in an object-oriented environment, they may also be used. KBE approaches can be
initialised with macros, and the same macros may be used to dramatically alter KBE approaches. Early IC engine
piston CAD models were successfully created using the described approach. The proposed technology will be
employed in the industry where IC engine pistons are designed and/or manufactured. When early design is being
considered in the design industry, this strategy is quite valuable.
The suggested system's capabilities are limited to the SolidWorks software suite. Furthermore, it is not dynamic
to have industry standards added. It's possible that human intervention will be required to upgrade its knowledge-
based system, which will be a time-consuming and costly procedure. Because the proposed approach is limited to
SolidWorks software, it might be expanded to other CAD systems, making IC engine piston design more accessible
to inexperienced designers. However, converting the SolidWorks macro file to the suitable CAD programme format
is an additional process.

CONCLUSIONS

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This study presents a preliminary technique for building a CAD model of an IC engine piston using a knowledge-
based parametric modelling methodology. The approach's major purpose is to minimise CAD modelling time for the
piston by accepting design input from an untrained user. Visual Basic and SolidWorks were used to construct this
system. An suitable example is used to explain the system development process. This system is simple to operate,
trouble-free, and convenient, and it has the potential to increase design quality and efficiency. By automating the
process and eliminating human duties, the technology was able to reduce turn-around time. This system not only
includes a lot of features and an easy-to-use user interface, but it's also straightforward to use for a beginner. Because
it was designed in an object-oriented environment, this system may also be reused.
Automobile manufacturers may finish the preliminary design process using the current IC engine design approach.
The technique may also be utilised for engine block design by including piston assembly concepts and experience into
the knowledge base. On the other hand, this flexibility can only be obtained by making necessary adjustments to the
macro file.
When a system has to be improved, it can't accomplish it alone; instead, it needs the help of a knowledgeable
developer. This is a system problem that can be solved by improving the knowledge base system that was put in place
so that it can keep up with new information as it becomes available. Although the approach proposed is limited to
SolidWorks software, it might be modified to other CAD tools to make piston design more accessible to everyone.
The only additional work required is to convert the SolidWorks macro file format to the destination CAD software's
supported format.

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