Aluminum Piston Head Design And Reliability Analysis

With the power improving of internal combustion engine, the work condition of piston becomes more and more rigorous. Heavy mechanical load and thermal load often lead to breakage such as the piston pin hoss split, ring groove wear and tear, piston peak burn out, combustion chamber throat rim thermal fatigue crack, etc. So, FEA analysis should be done in order to find the distribution rule of thermal stress and mechanical stress of the piston, and provide reference to improving design. Though the piston design technique is more and more maturing, yet with the developing of whole society, many new advanced design methods, test methods and technics appear ceaseless, for example, the FEA technique can improve the piston design strength greatly, the temperature field experiment of piston can test the actual working temperature exactly. Now, the internal combustion engine is facing more and more strict request, especially in exhaust, reliability and efficiency, how to design and analyze the piston structure( especially the head structure), insure the capability and stability under high temperature and improve the reliability become the key problem in piston design.This paper concluded the design rules of piston head; Based on the typical piston temperature field experiment, the thermal fatigue test-heat and cold cycles with temperature controlled, has been completed by the "Piston Thermal Fatigue Test System" to simulate the piston truth crack, The relation between the heat temperature and the thermal fatigue life has been studied; 3D model of the piston has been established using the FEA software and the elastic FEA analysis technology, refer to the temperature test, the temperature field and the stress field has been calculated for researching the relation between the fatigue life and the stress, and the numerical value analog computation has been performed. In the paper, the temperature distinction of the different structure has been studied, too. The method using cold oil way to strengthen the cooling effect of piston head has been discussed; Much more, the structure improvement of oil inlet and outlet holes of the piston has been done to improve the reliability.As an example, piston of 4110 engine, has been studied and talked about for the...