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

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.