基于有限元分析的活塞型面设计
孙琛媛1，2，封晓晶1，2，原文涛1，2，顾鼎峰3
1.滨州渤海活塞有限公司，山东 滨州 256602；2.山东省先进发动机活塞组件重点实验室（筹），山东 滨州 256602；
3.北汽福田康明斯发动机有限公司，北京 102206
摘要：针对某柴油机铝活塞裙部型面及销孔型面接触压力分布不均匀问题，采用拓扑优化设计方法对活塞裙部横向截面椭圆度与销孔型线轮廓通过有限元分析进行协同优化，经优化迭代后重新进行数值仿真计算。仿真结果表明：当活塞裙部横向截面采用叠加修正椭圆，同时基于销孔内外侧直线段长度调控与直径收缩量优化构建双喇叭形销孔结构时，活塞裙部接触压力及销孔接触压力峰值比优化前下降约6%，同时接触区域面积增大。经台架试验验证，优化后活塞裙部和销孔接触等关键配合部位接触良好，循环载荷作用下活塞表面未出现剥落等异常磨损现象，满足发动机耐久性要求。
关键词：活塞；型线；椭圆度；接触压力；有限元分析
Design of a piston profile based on finite element analysis
SUN Chenyuan1,2, FENG Xiaojing1,2, YUAN Wentao1,2, GU Dingfeng3
1. Binzhou Bohai Piston Co., Ltd., Binzhou 256602, China;
2. Shandong Provincial Key Laboratory of Advanced Engine Piston Components (Under Preparation), Binzhou 256602, China;
3.Beijing Foton Cummins Engine Company Limited, Beijing 102206, China
Abstract: To address the uneven contact pressure distribution on the skirt and pin bore profiles of an aluminum piston in a diesel engine, a topology optimization design method is employed to collaboratively optimize the oval parameters of the skirt′s transverse cross-section and the pin bore contour. Numerical simulations are conducted after iterative optimization. The results show that when the skirt′s transverse cross-section adopts a superimposed corrected ellipse, combined with a double tapered pin bore structure optimized by adjusting the length of inner and outer linear segments and diameter recess, the contact pressure of the piston skirt and the peak contact pressure of the pin hole both decrease by 6%, and the contact area increases. After bench testing verification, the optimized key mating parts such as the piston skirt and pin hole have good contact, and there are no abnormal wear phenomena such as peeling on the piston surface under cyclic loading.The piston meets the durability requirements of the engine.
Keywords: piston; profile; ovality; contact pressure; finite element analysis
