In this analysis, Ford Motor Company’s, modular engine series piston was selected for the analysis purposes. The engine has a capacity of 4.6 liter, V-8 cylinder and with 2 valves. The piston is made of aluminum alloy material Z-16-T6. A three-dimensional finite element model was created to analyze the piston. The model, which contains only the quarter section of the piston due to loading symmetry and geometry, was used to calculate operating temperatures and the corresponding thermal expansion. Operating stresses due to thermal and mechanical loads were also calculated. The accuracy of the model was verified by material data published in the literature, as well as from the data provided by Ford Motor Company. The obtained results are very useful in the designing and developing the existing piston to increase wear resistance capacity. These results are also useful for design and development that will absorb more heat load, and reduce noise by proper barrel planning of the skirt from the deformation data of the piston. Additionally, it helps in reducing the piston weight and inertia forces through optimization.

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