>Design and Structural Analysis with Thermal Analysis of IC Engine Piston Head with Top Surface Modification

Design and Structural Analysis with Thermal Analysis of IC Engine Piston Head with Top Surface Modification

Authors -P.Vijayan, Assistant Professor Nagarajan S

Abstract- – This research focuses on the design and structural analysis of internal combustion (IC) engine piston heads with top surface modifications, emphasizing improved thermal and mechanical performance. Given the piston’s critical role in enduring high pressure and temperature cycles, this study investigates the influence of advanced materials, optimized geometry, and surface modifications on its structural integrity and thermal behavior. Aluminum alloys and composite materials were evaluated for their heat dissipation and strength characteristics, while ceramic and catalytic coatings were considered for emission control and thermal resistance. Finite Element Analysis (FEA) was performed using ANSYS to simulate stress distribution, deformation, and temperature gradients under various loading conditions. The study also assesses the effect of different piston head geometries—flat, bowl, square bowl, and dome—on performance, revealing that bowl-type pistons offer optimal stress and thermal resistance. Surface modifications were found to enhance air-fuel mixing through improved swirl and squish effects, contributing to reduced NOx and PM emissions. The findings underscore the significance of geometrical optimization and advanced materials in extending piston life and achieving high-performance engine design.

DOI: /10.61463/ijset.vol.10.issue2.221