Thermal-Stress State of the Piston During Transient Diesel Operation, Synthesis of the Piston Profile

This paper deals with simulating the thermal and stress states of the piston and cylinder of a two-stroke diesel engine type D100 for a locomotive using two different methods. The methods are based on the use of various models of piston-cylinder arrangement: one of them uses assembly of the piston-cylinder arrangement and includes all components, but the other uses two models separately: the cylinder and the piston and rings assembly. It was shown that for both methods, the piston temperature fields differ slightly both in zone of the combustion chamber and on the inner surface, and the maximum difference was 8 K in the zone of the first piston ring, but the difference in the cylinder temperature fields is significant, especially in the middle section where the difference reaches 35 K. Transient thermal-stress states of the piston were determined for three programs of engine starting from the cold state (with various initial temperatures equal to 20 ℃; 0 ℃; −20 ℃) and heating it up to its maximum operating mode, and for one program with cooling from maximum mode to idling, every time with stepped loading. Warming up of oil and antifreeze were taken into account. It is shown that temperatures and stresses reach their peaks and then drop in some zones of the piston. The stress reaches a maximum level of 380 MPa at the center of the piston surface from the combustion chamber side when heated with an initial temperature −20 ℃, which is two times more than the stress at steady-state maximum operating mode (192 MPa). The profile of the piston side surface was synthesized taking into account the heating rate. The piston design with different materials of the piston head – VCh60-2, 25H2G2FL, 12DH1MFL – was proposed for D49 and D80 engines. The mean temperature of the piston hottest zone drops by about 40 K in proposed design. The stress also decreased.