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A set of methods is described to calculate boundary conditions for thermal and mechanical finite element (FE) analyses and to assess and present the results of those analyses in a clear and understandable way. The approach utilizes a combination of engine simulation programs and an empirical database of engine measurements developed over many years. The methodology relies on the use of specialized FE pre- and post-processors dedicated to the analyses of engine components. Gas-side thermal boundary conditions for combustion chamber components are calculated using an engine simulation code for standalone FE analyses or for FE analyses directly coupled to the engine simulation code itself. Coolant side boundary conditions are calculated using multidimensional flow analysis (computational fluid dynamics). Boundary conditions in intake and exhaust manifolds are calculated using a one-dimensional gas dynamics code.

Selective reinforcement of squeeze-cast aluminum pistons by fiber matrix inserts is a method of improving high temperature strength in piston zones subject to severe thermal and mechanical loads in highly loaded diesel engines. An investigation was carried out into the effects of selective fiber-matrix reinforcement on the thermal and stress state of an aluminum piston for a heavy-duty truck diesel engine application. Specifically, effects of geometry of the reinforced zone (fiber matrix), fiber density in the matrix, fiber orientation and piston combustion bowl shape were sought. Thermal and structural finite element analysis of the configurations were carried out. Thermal analyses were fully coupled to a simulation of a highly rated heavy-duty diesel.