&aaged or .ro/en arts are generall too eensie to rela4e, or are no longer aaila.le and this is
arti4larl releant to the atoo.ile indstr owing to the eer-in4reasing a44idents .
!eerse ngineering !7 has .een s44essfll eloed to for ossi.le re4oer of a daaged or .ro/en
art8
'sing this ethod ! we generate a CA& odel of a daaged internal 4o.stion #C7 engine iston and
then se the state-of-the-art AN(+( finite eleent analsis a4/age to erfor a linear stati4 and a 4oled theral-str4tral analsis of the 4oonent8
Ne4essar .ondar 4onditions were alied for the art odel in Anss to o.tain s44essfl reslts of the
str4tral and theral analsis8
rther, a araeteri4 ealation of the aterial roerties is-:-is oerating 4onditions is 4arried ot to
generate a relational data.ase for the iston to arrie at otial design soltions nder different oerating 4onditions8
Anss 4an .e sed in 4on;n4tion with finite eleent analsis to odel o.solete rod4t geoetries and
aterial odels to redesign and generate new odels to sit eisting 4linders and other asse.lies8
DESIGN AND IMPLEMENTATION Reverse Engineering: #t
of an eisting art, re4oer of a daaged or .ro/en art, iroeent of odel re4ision and inse4tion of a neri4al odel8 Adantages of the te4hni=e in4lde iediate feed.a4/, data red4tion, dire4t generation of geoetr and
higher re4ision of the final rod4t8
Digiti!ti"n# &igiti>ation is the ro4ess of 4atring the data of the hsi4al odel and 4onerting it into digital for8
The iston is odeled fro 4lod oints o.tained . laser .ea s4anning8 The oints are ;oined . lines and then 4reating .onding areas and filling the ole8 $ater the geoetri4 solid odel is iorted to P!"- a4/age8
M"$%&ing# The s4anned at4hes are transfored into a 4losed se4tion Piston odel sing P!"- software8 CA& odel has the flei.ilit of in4ororating 4hanges and interfa4ing with CAM whi4h in4reases the rod4tion
rates8 The art odel 4reated is saed in #%( forat and is eorted to AN(+(8
An!&'sis# A new Anss wor/.en4h is oened and the solid art odel that is generated in Pro- is iorted into this
wor/.en4h8 Theral and (tr4tral tes hae .een sele4ted in referen4e and eleent te is sele4ted to .e solid 20 node 90 The theral and str4tral .ondar 4onditions hae .een alied to the solid Piston odel and are eshed sing
esh tools8 Teeratres and loads hae .een alied in the areas of the odel8 The generated esh is soled and lotted8 The nodal soltions and on ises stress atterns are 4reated and
reslts are re4orded and saed8 The generated iages 4learl elain arios roerties of the iston s4h as its defle4tion at arios load
4onditions, .ending oents, stress ales et48
&ata
Str()t(r!& !n!&'sis @713103 NB2 Poisson
T*%r+!& !n!&'sis Theral 4ond4tiitD@7*0 )BD leent tesolid .ri4/ node *5 solid*57 Mesh area set i4/ all7 Mesh shae tetrahedral Mesh te free esh Te at to area600 Te at .otto area 500
PRINT SCREEN DRA,INGS -PROE AND ANSYS/
PISTON SOLID PART GENERATED IN PROE
PISTON IMPORTED TO ANSYS WORKBENCH
PISTON AFTER MESHING
PISTON AFTER LOADING AND APPLIED BOUNDARY CONDITIONS (STRUCTURAL ANALYSIS
DEFORMED PISTON AFTER STRUCTURAL LOADING
PISTON DOF AND DISPLACEMENT !ECTOR SUM
!ON MISES STRESS
PISTON AFTER THERMAL LOADING (THERMAL ANALYSIS
PISTON"THERMAL GRADIENT !ECTOR SUM
PISTON"THERMAL NODAL TEMPERATURES
MODULE DESCRIPTION It is a well known fact that 60E of the total engine e4hani4al ower lost is generated . iston ring
asse.l8The iston s/irt srfa4e slides on the 4linder .ore8 A l.ri4ant fil fills the 4learan4e .etween the srfa4es8 The sall ales of the 4learan4e in4rease the fri4tional losses and the high ales in4rease the se4ondar otion of the iston8 This #nternal Co.stion #C7 engine iston is ade of an alin allo whi4h has a theral eansion
4oeffi4ient, 0E higher than the 4linder .ore aterial ade of 4ast iron8 This leads to soe differen4es .etween rnning and the design 4learan4es8 Therefore, analsis of the iston
theral .ehaior is etreel 4r4ial in designing ore effi4ient engine8 Here the iston erforan4e was ealated for different 4lasses of Alini allos s4h as MAH$ series ot
of whi4h MAH$ 1*2 aterial odel is .est sited for the range of oerating 4onditions for the iston nder 4onsideration8 The load was aried fro 50E to 225E of the ean 4al4lated load with a target ale of the ind4ed stress .eing
e=al to the 4oressie ield strength of the aterial8 The MAH$ 1*2 is safe for to a ea/ oerating load of 200E the ean load or a.ot 6 MPa7 a4ting on the iston head8
CONCLUSION
The reslts of this analsis show that reerse engineering 4an .e sed in 4on;n4tion with finite
eleent analsis to odel o.solete rod4t geoetries and aterial odels to redesign and generate new odels to sit eisting 4linders and other asse.lies8
#t is also seen that the &esign@lorer within the AN(+( )or/.en4h enironent 4an .e sed
er effe4tiel to reali>e an araetri4 otii>ation8
