Design and Analysis of a Single-cylinder Petrol Engine Piston Using Forged Aluminium Alloys

Design and Analysis of a Single-cylinder Petrol Engine Piston Using Forged Aluminium Alloys | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Design and Analysis of a Single-cylinder Petrol Engine Piston Using Forged Aluminium Alloys RENUKAPRASAD K Y This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8496676/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract The piston is a highly stressed component in an internal combustion engine, operating under severe thermal and mechanical loading conditions. The efficiency, durability, and reliability of an engine are strongly influenced by piston design and material selection. With increasing demands for higher power density and improved fuel efficiency, conventional design approaches must be supplemented with analytical and numerical methods. This paper presents a comprehensive design, modeling, and analysis of a single-cylinder four-stroke petrol engine piston using forged aluminium alloys. Analytical calculations are performed to determine piston dimensions such as crown thickness, skirt length, piston pin diameter, and piston ring geometry based on engine operating parameters. A detailed three-dimensional CAD model is developed and analyzed using finite element techniques to evaluate stress distribution, deformation, and temperature variation under realistic loading conditions. Aluminium alloys 4032, 2618 Forged, A2618, and 2618-T6 are investigated and compared. The results demonstrate that 2618-T6 forged aluminium alloy offers superior mechanical strength, thermal stability, and fatigue resistance. The close correlation between analytical and numerical results validates the adopted design methodology and confirms the suitability of the selected material for high-speed petrol engines. Materials Engineering Keywords—Piston design forged aluminium alloy finite element analysis IC engine thermal-structural analysis Full Text Additional Declarations The authors declare potential competing interests as follows: Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8496676","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":568111566,"identity":"68b9f1d3-08e4-4846-b2a0-d1d5488e01e5","order_by":0,"name":"RENUKAPRASAD K Y","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA00lEQVRIiWNgGAWjYPACZgMG9gYgbWBBihaeAyAtEqRokUgAMYjQYj679+HHHzXWxgY3n1/d8KNAgoG/vTsBrxaZO8eNpXmOpZsZ3M4pu9kDdJjEmbMb8GqRkEhjkGZgO2wD1JJ2gweoxUAil6AW5p8//gG13DyTdvMPkVrYJHjbDpsZ3GA/dps4W2SOsVnz9qUbS57JYbstYyDBQ9gv0m3MN398szbsO3782c03f2zk+Nt78WuBR4TCAR4DEM2DXzmyFvkG9geEVY+CUTAKRsGIBACK+kVuWiKolwAAAABJRU5ErkJggg==","orcid":"","institution":"UNIVERSITY OF VISVESVARAYA COLLEGE OF ENGINEERING","correspondingAuthor":true,"prefix":"","firstName":"RENUKAPRASAD","middleName":"K","lastName":"Y","suffix":""}],"badges":[],"createdAt":"2026-01-01 18:27:51","currentVersionCode":1,"declarations":{"humanSubjects":false,"vertebrateSubjects":true,"conflictsOfInterestStatement":true,"humanSubjectEthicalGuidelines":false,"humanSubjectConsent":false,"humanSubjectClinicalTrial":false,"humanSubjectCaseReport":false,"vertebrateSubjectEthicalGuidelines":true},"doi":"10.21203/rs.3.rs-8496676/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-8496676/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":99790640,"identity":"f6aef4ae-9494-4d30-949a-a1cb13234b72","added_by":"auto","created_at":"2026-01-08 12:58:29","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":734009,"visible":true,"origin":"","legend":"","description":"","filename":"IEEEPAPER1.pdf","url":"https://assets-eu.researchsquare.com/files/rs-8496676/v1_covered_f761d53e-bd85-4a31-8fc4-7d9acb68c7ed.pdf"}],"financialInterests":"The authors declare potential competing interests as follows: ","formattedTitle":"\u003cp\u003eDesign and Analysis of a Single-cylinder Petrol Engine Piston Using Forged Aluminium Alloys\u003c/p\u003e","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":true,"hideJournal":true,"highlight":"","institution":"UNIVERSITY OF VISVESVARAYA COLLEGE OF ENGINEERING BANGALORE","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Keywords—Piston design, forged aluminium alloy, finite element analysis, IC engine, thermal-structural analysis","lastPublishedDoi":"10.21203/rs.3.rs-8496676/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8496676/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe piston is a highly stressed component in an internal combustion engine, operating under severe thermal and mechanical loading conditions. 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