IRJET- Design, Analysis & Weight Reduction of Piston of Refrigerator Compressor
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This document summarizes a research project to optimize the design of a refrigerator compressor piston to reduce weight. The current piston design and material are analyzed using CAD and FEA software. Several design iterations are performed with varying dimensions and materials to minimize weight while ensuring structural integrity under operating pressures. The optimal design was found to use a 2mm thickness aluminum alloy piston, reducing weight by 12 grams (15%) compared to the original design while maintaining a safety factor above requirements. Overall the project aims to improve refrigerator efficiency by lightweighting compressor components through design optimization.
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 966
2. LITERATURE REVIEW
[1] Ashwani Kumar, Shaik Imran Behmad, PravinPPatil
et al The main objective of this research work is to
investigate and analyse the stress distribution of piston at
actual engine condition. This research work suggests a new
type of SiC reinforced ZrB2 composite material that can
sustain at higher temperature (1680 K) and pressure (18
MPa).
[2] Jatender Datta, Dr. Sahib Sartaj Singh et al The paper
shows the behavior of piston made of Carbon Graphite and
Aluminum Alloy 2618 applied heat power valueof200Watt.
The result of Temperature distribution and resultant
temperature gradient was found and the main motive is to
find the comparison between both of materials of piston.
[3] K Ramesh Babu, G Guru Mahesh and G Harinath
Gowd et al In this paper the authors have studied the
variation of Isotherms and heat flux with respect to radius,
height of piston, liner, cylinder head and thermal analysis.
First thermal analysis was done and analyzed the
temperature distribution over the convectional engine and
copper coated convectional engine. In the second stage
structural analysis was carried out using the thermal loads
obtained in the first stage. Three different types of materials
were taken for analysis.
[4] Dilip Kumar Sonar, Madhura Chattopadhyay et al
The authors had studied a piston which is designed using
CATIA V5R20 software. Complete design is imported to
ANSYS 14.5 software then analysis is performed.Aluminium
alloy has been selected for structural andthermal analysisof
piston. Results are shown and a comparison is made to find
the most suited design.
3. PROBLEM DEFINITION AND METHODOLOGY
A. Problem Definition
We have to reduce the overall weight of the system.Theload
bearing components like piston and crank shaft are used in
refrigeration and are also heavy in assembly.TheShell ofthe
compressor is also heavy. This heavy component decreases
the overall efficiency. Due to the heavy weight components
the power consumption of systemincreasesandthusitis not
good as it increases the running cost of the system. The
material requirement also increases as the component is
heavy. Hence to overcome all this problem this system
should be redesign for optimisation.
B. Objectives
1. To study the current system in detail with its
specification and all required considerations.
2. To design & optimize the existing material for
compressor shell and piston.
3. To optimize system according to one of the following:
a) Changing dimensions of system and keeping material
same as it is.
b) Keeping same dimensions and changing material of
components.
c) Changing both material as well as dimensions of
component.
4. Modelling of new design with help of CATIA software.
5. To analyse the optimized components to study the
stress on the system.
6. To compare existing & optimized piston & shell of
compressor.
C. Methodology
The following are important steps for completion of
objectives -
1. Check design of various existing components in
compressor.
2. Creating geometric model and finite element model of
existing components of compressor using CATIA software.
3. Analysis of piston of compressor byusingANSYSsoftware.
4. Optimization of compressor assembly for weight
reduction.
5. Comparison between existing and optimized design.
4. DESIGN & ANALYSIS OF EXISTING COMPRESSOR
PISTON
Mechanical Efficiency, η = B.P / I.P
B.P = 163 W
I.P = 163 / 0.8 = 203.75 W
I.P = P × A × L × N / 2
203.75 = P × 0.112 × 0.015 × 1500/ 2 × 60
P = 203.75 × 2 × 60 / 0.112 × 0.015 × 1500
= 9.70 Mpa
Max pressure = 10 × P
= 10 × 9.70
= 97.02 MPa
Assuming piston material as Aluminum Alloy Steel
Permissible Stress of aluminum alloys is Sut = 900 Mpa
Considering uniformly distributed load & FOS as 2
We have to calculate actual FOS for pressure vessel.
Allowable Stress (σall) = Sut / Fs
= 900/2
= 450 Mpa.
According to Grashoff’s formula
Thickness of piston
Tc = D √ (3 × Pmax / 16 ×σt)
3 = 10 √3 ×97.02 / 16 × σt
σt = 289 Mpa](https://image.slidesharecdn.com/irjet-v6i6258-191118054322/85/IRJET-Design-Analysis-Weight-Reduction-of-Piston-of-Refrigerator-Compressor-2-320.jpg)
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 969
6. RESULT AND DISCUSSIONS
After studying the above system, we can have the optimum
thickness as 2 mm which is having a stress of 450 Mpa in it
and weight reduction of 12 grams. Total weight of piston is
83 grams, actually the system is small and hence the weight
of piston is less. If we think according to the % of weight
reduction then 14.67 % of weight reduction was achieved.
This weight reduction is very less but it is important
according to the total system optimization.
Thickness = 2 mm
Outer Diameter = 148 mm
Inner diameter = 144 mm
Total weight reduction of 12 grams was obtained. It means
total optimization of 14.67 % is achieved.
Comparison of Stress on basis of Theoretical and analytical
results.
Analysis of Piston was carried out with use of Ansys
Software. Results of stresswascalculatedandComparisonof
both design calculations and Ansys was tabulated below:
Dimensions Design
calculations
Results
Ansys Results
Thickness = 2
mm
Outer Diameter =
148 mm
Inner diameter =
144 mm
Stress
450 Mpa
Stress
466.5 Mpa
Table 6.1 - Theoretical & analytical comparisonofpiston
7. CONCLUSION
Optimization was achieved on pistonofcompressor.Someof
components of system like motor assembly and vents are
kept as it is due to its proper design. Design calculations,
analysis model, and optimized system are compared on
stress basis. The weight reduction achieved on piston does
not affect the load carrying capacity of system. 12 grams
weight reduction is achieved by optimize design than
existing design. 14.67 % of material was saved on
optimized system than existing system which further save
cost of system.
8. FUTURE SCOPE
The use of composite materials can be done for more
weight reduction. This weight reductioncanalsobringa
lightest compressor.
The scotch yoke mechanism is used to get rotarymotion
from the piston, this system can be optimised.
Use of heat treatments can also increase the surface
strength and thus again thickness can be reduced.
Vibration analysis of whole system can be increase
working capacity of system
9.REFERENCES
[1] Ashwani Kumar, Shaik Imran Behmad, Pravin P Patil,
Thermo-Mechanical and Vibration Analysis of the I.C.
Engine Piston made of SiC reinforced ZrB2 composite
using Finite Element Method (ANSYS), IOSR Journal of
Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN:
2278-1684, p-ISSN: 2320-334X PP 19-23
www.iosrjournals.org International Conference on
Advances in Engineering & Technology – 2014
[2] Jatender Datta*, Dr. Sahib Sartaj Singh, Heat Power
Analysis on different materials of piston using finite
element thermal analysis, International journal onrecent
researchers in science, engineering and technology,
volume 5 isssue 10.
[3] K Ramesh Babu, G Guru Mahesh and G Harinath Gowd,
Modeling and Thermal Analysis of Si Engine PistonUsing
Fem, ISSN 2278 – 0149 Vol. 3, No. 1, January 2014
[4] Dilip Kumar Sonar, Madhura Chattopadhyay, Theoretical
Analysis of Stress and Design of Piston Head usingCATIA
& ANSYS, International Journal of Engineering Science
Invention ISSN (Online): 2319 – 6734,ISSN:2319– 6726,
Volume 4 Issue 6, June 2015
[5] T Arun Kumar Reddy, M Sachidhanand , Comparision of
two Different Materials for Connecting Rod using Ansys,
IJIRST –International Journal for Innovative Research in
Science & Technology| Volume 1 | Issue 11 | April 2015
[6] Leela Krishna Vegi, Venu Gopal Vegi, DesignandAnalysis
of Connecting Rod Using Forged steel, International
Journal of Scientific & Engineering Research, Volume 4,
Issue 6, June-2013
[7] Vikrant K. Dhone, A.S. Rao, Vinaay Patil, “Comparative
study of AISI4340 and Al7068 Connecting rod”,
International Journal on Recent technologies in
Mechanical and Electrical Engineering (IJRMEE), Vol-2,
(2015), issue 7, ISSN- 2349-7947, page no. 1-4.
[8] Abhinav Gautam, K Priya Ajit “Static stress Analysis of
Connecting Rod Using Finite Element Approach”, IOSR
Journal of Mechanical and Civil Engineering, vol. 10,
(2013), issue 1, ISSN-2320-334X, page no. 47-51.
[9] A. Prem Kumar “Design and analysisofconnectingrod by
composite material”, IJRDO- Journal of Mechanical and
Civil Engineering, vol. 1, (2015)](https://image.slidesharecdn.com/irjet-v6i6258-191118054322/85/IRJET-Design-Analysis-Weight-Reduction-of-Piston-of-Refrigerator-Compressor-5-320.jpg)
IRJET- Design, Analysis & Weight Reduction of Piston of Refrigerator Compressor
- 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 965 Design, Analysis & Weight Reduction of Piston of Refrigerator Compressor Mr. Nadim Sajid Tamboli1, Prof. A. S. Darur2 1M. Tech. (CAD-CAM-CAE) Department of Mechanical Engineering, KITCOEK, Kolhapur, Maharashtra, India. 2Professor, Department of Mechanical Engineering, KITCOEK, Kolhapur, Maharashtra, India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - The refrigerator is a device used for cooling purpose. It is one of the home appliances using mechanical vapour compression cycle in its process. Performance of the systems become the main issue and many researches are still ongoing to evaluate and improve the efficiency of any used system. Refrigerator consist of various importantpartsuchas, compressor, condenser and evaporator. These all components play main role in efficiency of refrigerator. If suchcomponents are having the heavy system then it may decrease the overall efficiency of refrigerator as they consume the more amount of power. Hence in this project we are working on the piston of compressor in refrigerator. As we known that the compressor used in refrigerator is a reciprocating type. Connecting rod is the intermediate link between the piston and the crank shaft. And is responsible to transmit the push and pull from the piston pin to crank pin, thus converting the reciprocating motion of the piston to rotary motion of the crank. The loads acting on this piston and crank shaft are cyclic in nature. Further in this project we will use the modelling and analysis software and ensure the weight reduction and optimisation of piston. The modelling software is CATIA and analysissoftware is ANSYS. Key Words: Optimisation, Pressure vessel, Compressor, Efficiency, Piston 1.INTRODUCTION The refrigerator is used for cooling purpose. The domestic refrigerator contains the sealed compressor. This compressor is sealed because to avoid the noise. It also consists of crank shaft, connecting rod, piston, etc. In this project the optimization of piston and will be done. This will decrease the weight ofthesystemandalsoincreasethe efficiency of the system. Due to the low weight of system like Shell, piston and crank shaft the power consumption of system will be decrease and it will conclude on the increaseintheefficiencyofthesystem. This project is unique andvery less work is being done on refrigerator compressor. 1.1 Technical Specifications of compressor shell used for study Thus, Specification of the compressor shell are tabulated below: Sr No. Parameters Values 1 Length 15 mm 2 Diameter 10 mm 3 Thickness 3 mm 4 Power (For the same model in Refrigerator) 163 W Material Specifications Al Alloys 5 Density 2800 kg/m3 6 Tensile strength, Ultimate 900 MPa 7 Tensile Strength, Yield 600 MPa 8 Melting Point 1370‐1430°C Table 1.1 – Specifications of existing piston Fig. 1.1 – Photographic view of existing piston
- 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 966 2. LITERATURE REVIEW [1] Ashwani Kumar, Shaik Imran Behmad, PravinPPatil et al The main objective of this research work is to investigate and analyse the stress distribution of piston at actual engine condition. This research work suggests a new type of SiC reinforced ZrB2 composite material that can sustain at higher temperature (1680 K) and pressure (18 MPa). [2] Jatender Datta, Dr. Sahib Sartaj Singh et al The paper shows the behavior of piston made of Carbon Graphite and Aluminum Alloy 2618 applied heat power valueof200Watt. The result of Temperature distribution and resultant temperature gradient was found and the main motive is to find the comparison between both of materials of piston. [3] K Ramesh Babu, G Guru Mahesh and G Harinath Gowd et al In this paper the authors have studied the variation of Isotherms and heat flux with respect to radius, height of piston, liner, cylinder head and thermal analysis. First thermal analysis was done and analyzed the temperature distribution over the convectional engine and copper coated convectional engine. In the second stage structural analysis was carried out using the thermal loads obtained in the first stage. Three different types of materials were taken for analysis. [4] Dilip Kumar Sonar, Madhura Chattopadhyay et al The authors had studied a piston which is designed using CATIA V5R20 software. Complete design is imported to ANSYS 14.5 software then analysis is performed.Aluminium alloy has been selected for structural andthermal analysisof piston. Results are shown and a comparison is made to find the most suited design. 3. PROBLEM DEFINITION AND METHODOLOGY A. Problem Definition We have to reduce the overall weight of the system.Theload bearing components like piston and crank shaft are used in refrigeration and are also heavy in assembly.TheShell ofthe compressor is also heavy. This heavy component decreases the overall efficiency. Due to the heavy weight components the power consumption of systemincreasesandthusitis not good as it increases the running cost of the system. The material requirement also increases as the component is heavy. Hence to overcome all this problem this system should be redesign for optimisation. B. Objectives 1. To study the current system in detail with its specification and all required considerations. 2. To design & optimize the existing material for compressor shell and piston. 3. To optimize system according to one of the following: a) Changing dimensions of system and keeping material same as it is. b) Keeping same dimensions and changing material of components. c) Changing both material as well as dimensions of component. 4. Modelling of new design with help of CATIA software. 5. To analyse the optimized components to study the stress on the system. 6. To compare existing & optimized piston & shell of compressor. C. Methodology The following are important steps for completion of objectives - 1. Check design of various existing components in compressor. 2. Creating geometric model and finite element model of existing components of compressor using CATIA software. 3. Analysis of piston of compressor byusingANSYSsoftware. 4. Optimization of compressor assembly for weight reduction. 5. Comparison between existing and optimized design. 4. DESIGN & ANALYSIS OF EXISTING COMPRESSOR PISTON Mechanical Efficiency, η = B.P / I.P B.P = 163 W I.P = 163 / 0.8 = 203.75 W I.P = P × A × L × N / 2 203.75 = P × 0.112 × 0.015 × 1500/ 2 × 60 P = 203.75 × 2 × 60 / 0.112 × 0.015 × 1500 = 9.70 Mpa Max pressure = 10 × P = 10 × 9.70 = 97.02 MPa Assuming piston material as Aluminum Alloy Steel Permissible Stress of aluminum alloys is Sut = 900 Mpa Considering uniformly distributed load & FOS as 2 We have to calculate actual FOS for pressure vessel. Allowable Stress (σall) = Sut / Fs = 900/2 = 450 Mpa. According to Grashoff’s formula Thickness of piston Tc = D √ (3 × Pmax / 16 ×σt) 3 = 10 √3 ×97.02 / 16 × σt σt = 289 Mpa
- 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 967 Thus, there is scope to change the material and optimize the system. Density = Mass/ Volume Volume of piston = ∏ × h ( r1 2 – r2 2) + ∏ × r2 × t = ∏ × 0.015 (0.0052 – 0.00375 2 ) + ∏ × 0.00375 × 0.0025 = 2.99527E-05 m3 mass of piston = V × ρ = 0.083 Kg Fig. 4.1 – Geometric model of piston Fig. 4.2 – Meshing of piston Fig. 4.3 – Boundary conditions for piston Fig. 4.4 – Stress analysis of piston 5. DESIGN & ANALYSIS OF OPTIMIZED SHELL Mechanical Efficiency, η = B.P / I.P B.P = 163 W I.P = 163 / 0.8 = 203.75 W I.P = P × A × L × N / 2 203.75 = P × 0.112 × 0.015 × 1500/ 2 × 60 P = 203.75 × 2 × 60 / 0.112 × 0.015 × 1500 = 9.70 Mpa Max pressure = 10 × P = 10 × 9.70 = 97.02 Mpa Assuming piston material as Aluminum Alloy Steel Permissible Stress of aluminum alloys is Sut = 900 Mpa Considering uniformly distributed load & FOS as 2 We have to calculate actual FOS for pressure vessel. Allowable Stress (σall) = Syt / Fs = 900/2 = 450 Mpa. According to Grashoff’s formula Iteration 1:
- 4. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 968 Consider the thickness of the piston as 2 mm, Thus, the calculations are as follow Thickness of piston Tc = D √(3 × Pmax / 16 ×σt) 2 = 10 √3 ×97.02 / 16 × σt σt = 450 Mpa thus, if we compare the actual stress with allowable stress then the above design is safe. Weight of Piston Density = Mass/ Volume Volume of piston = ∏ × h ( r1 2 – r2 2) + ∏ × r2 × t = ∏ × 0.015 (0.0052 – 0.004 2 ) + ∏ × 0.004 × 0.002 = 2.55439E-05 m3 Mass of piston = V × ρ = 0.071523 Kg If we compare the weight reduction of above design with existing one then we are achieving weight reduction. It is up to 12 grams and 15 % weight reduced. Same like above 3 such iterations are carried on. The following table shows the iterations: Thick D2 D1 Stress Weight Diff. 0.0025 0.0075 0.01 291.06 Safe 0.0838 0 0.002 0.008 0.01 450.78 Safe 0.0715 0.0123 0.0015 0.0085 0.01 808.5 Not Safe 0.0569 0.0269 0.001 0.009 0.01 1819.12 Not Safe 0.0401 0.0436 Table 5.1 - Iteration table for optimized piston After studying the above system, we can have the optimum thickness as 2 mm which is having a stress of 450 Mpa in it and weight reduction of 12 grams. Fig. 5.1 – Geometric model of optimized piston Fig. 5.2 – Meshing of optimized piston Fig. 5.3 – Boundary conditions for optimized piston Fig. 5.4 – Stress analysis of optimized piston Fig. 5.5 – Deformation analysis of optimized piston
- 5. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 969 6. RESULT AND DISCUSSIONS After studying the above system, we can have the optimum thickness as 2 mm which is having a stress of 450 Mpa in it and weight reduction of 12 grams. Total weight of piston is 83 grams, actually the system is small and hence the weight of piston is less. If we think according to the % of weight reduction then 14.67 % of weight reduction was achieved. This weight reduction is very less but it is important according to the total system optimization. Thickness = 2 mm Outer Diameter = 148 mm Inner diameter = 144 mm Total weight reduction of 12 grams was obtained. It means total optimization of 14.67 % is achieved. Comparison of Stress on basis of Theoretical and analytical results. Analysis of Piston was carried out with use of Ansys Software. Results of stresswascalculatedandComparisonof both design calculations and Ansys was tabulated below: Dimensions Design calculations Results Ansys Results Thickness = 2 mm Outer Diameter = 148 mm Inner diameter = 144 mm Stress 450 Mpa Stress 466.5 Mpa Table 6.1 - Theoretical & analytical comparisonofpiston 7. CONCLUSION Optimization was achieved on pistonofcompressor.Someof components of system like motor assembly and vents are kept as it is due to its proper design. Design calculations, analysis model, and optimized system are compared on stress basis. The weight reduction achieved on piston does not affect the load carrying capacity of system. 12 grams weight reduction is achieved by optimize design than existing design. 14.67 % of material was saved on optimized system than existing system which further save cost of system. 8. FUTURE SCOPE The use of composite materials can be done for more weight reduction. This weight reductioncanalsobringa lightest compressor. The scotch yoke mechanism is used to get rotarymotion from the piston, this system can be optimised. Use of heat treatments can also increase the surface strength and thus again thickness can be reduced. Vibration analysis of whole system can be increase working capacity of system 9.REFERENCES [1] Ashwani Kumar, Shaik Imran Behmad, Pravin P Patil, Thermo-Mechanical and Vibration Analysis of the I.C. Engine Piston made of SiC reinforced ZrB2 composite using Finite Element Method (ANSYS), IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684, p-ISSN: 2320-334X PP 19-23 www.iosrjournals.org International Conference on Advances in Engineering & Technology – 2014 [2] Jatender Datta*, Dr. Sahib Sartaj Singh, Heat Power Analysis on different materials of piston using finite element thermal analysis, International journal onrecent researchers in science, engineering and technology, volume 5 isssue 10. [3] K Ramesh Babu, G Guru Mahesh and G Harinath Gowd, Modeling and Thermal Analysis of Si Engine PistonUsing Fem, ISSN 2278 – 0149 Vol. 3, No. 1, January 2014 [4] Dilip Kumar Sonar, Madhura Chattopadhyay, Theoretical Analysis of Stress and Design of Piston Head usingCATIA & ANSYS, International Journal of Engineering Science Invention ISSN (Online): 2319 – 6734,ISSN:2319– 6726, Volume 4 Issue 6, June 2015 [5] T Arun Kumar Reddy, M Sachidhanand , Comparision of two Different Materials for Connecting Rod using Ansys, IJIRST –International Journal for Innovative Research in Science & Technology| Volume 1 | Issue 11 | April 2015 [6] Leela Krishna Vegi, Venu Gopal Vegi, DesignandAnalysis of Connecting Rod Using Forged steel, International Journal of Scientific & Engineering Research, Volume 4, Issue 6, June-2013 [7] Vikrant K. Dhone, A.S. Rao, Vinaay Patil, “Comparative study of AISI4340 and Al7068 Connecting rod”, International Journal on Recent technologies in Mechanical and Electrical Engineering (IJRMEE), Vol-2, (2015), issue 7, ISSN- 2349-7947, page no. 1-4. [8] Abhinav Gautam, K Priya Ajit “Static stress Analysis of Connecting Rod Using Finite Element Approach”, IOSR Journal of Mechanical and Civil Engineering, vol. 10, (2013), issue 1, ISSN-2320-334X, page no. 47-51. [9] A. Prem Kumar “Design and analysisofconnectingrod by composite material”, IJRDO- Journal of Mechanical and Civil Engineering, vol. 1, (2015)