ADVANCED COMPUTER AIDED DESIGN AND

MANUFACTURE (MEE 534)

PROF. N.A RAJI

190221073
OSHINOWO CLINTON
July 2025

PISTON

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 Simulation of Piston
generator
Date: Sunday, July 20, 2025
Designer: Solidworks
Study name: Static 1
Analysis type: Static

Table of Contents
Description .......................................... 2
Assumptions ..... Error! Bookmark not defined.
Model Information ................................ 10
Study Properties ................................... 11
Units ................................................ 11
Material Properties ............................... 12
Description Loads and Fixtures ................................ 12
No Data Connector Definitions ............................ 13
Interaction Information .......................... 13
Mesh information .................................. 14
Sensor Details ...................................... 15
Resultant Forces .................................. 16
Beams ............................................... 16
Study Results ...................................... 17
Conclusion....... Error! Bookmark not defined.

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1. INTRODUCTION
1.1 Conceptual Phase Introduction
The conceptual phase initiates the design
process for a free-piston engine generator
(FPEG), a novel energy converter that
eliminates the traditional crankshaft, offering
advantages like variable compression ratios and
compact size. This phase involves reviewing
existing literature, such as the patent by
Mikalsen and Roskilly, and exploring the
potential of FPEGs for applications like hybrid-
electric vehicles. The goal is to establish a
foundation for the design by identifying key
performance objectives, such as high efficiency
and low emissions, based on current research
and industry needs [1].
1.2 Description of the Component

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The piston generator, likely an FPEG, consists
of one or two pistons moving linearly within
cylinders, coupled with a linear electric
machine. In a dual-piston configuration, two
combustion chambers, each with a spark
electrode, piston, and poppet valves, are
connected via a linear electric machine that
operates as both a motor (for starting) and a
generator (for power production). The pistons
are linked by the mover of the linear electric
machine, which is the primary moving
component, reducing mechanical complexity
compared to traditional engines [1, 2].
1.3 Functionality of the Component
The FPEG converts chemical energy from fuel
into mechanical energy through combustion,
driving the linear motion of the pistons. This
motion is then converted into electrical energy
by the linear generator. The absence of a

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crankshaft allows for direct linear motion,
potentially increasing efficiency and enabling
precise control over piston movement. The
system typically operates in a two-stroke cycle,
with the linear generator managing timing and
motion, which can reduce emissions and
improve fuel efficiency [3].
1.4 Design Requirements and Constraints
Key design requirements include high thermal
efficiency, reliability, and the ability to operate
with various fuels. Constraints involve size and
weight limitations, particularly for automotive
applications, and the need for precise control to
ensure stable piston motion. The design must
withstand high temperatures and pressures,
necessitating robust materials and effective
thermal management. Additionally, the system
should minimize vibrations and noise, which is
critical for user acceptance [4].

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1.5 Design Alternatives
Design alternatives include single-piston versus
dual-piston configurations, with dual-piston
designs offering better balance and reduced
vibration. Different types of linear electric
machines, such as permanent magnet or
reluctance motors, can be considered. Control
strategies may vary, including variable valve
timing or different combustion chamber
geometries to optimize performance. Starting
mechanisms, such as using the linear generator
as a motor or an auxiliary system, are also
evaluated [2, 3].

2. COMPUTER DESIGN
PHASE
2.1 CAD Modeling Process

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The CAD modeling process involves creating
detailed 3D models of the piston generator’s
components, including pistons, cylinders, and
the linear electric machine. Software like
SolidWorks or CATIA is used to define precise
geometries, such as the combustion chamber
and piston rings, ensuring proper fit and
function. The linear motion requires high
precision to minimize friction and wear, and
models are validated through simulations to
confirm performance under operational
conditions [7].
2.2 Software Tools Used
Designers likely employ CAD software (e.g.,
SolidWorks, CATIA, Creo) for modeling, finite
element analysis (FEA) tools like ANSYS or
Abaqus for structural and thermal analysis, and
computational fluid dynamics (CFD) software
like STAR-CCM+ or Fluent for simulating

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combustion and fluid flow. Specialized tools
for linear electric machine design may also be
used to optimize electromagnetic performance,
ensuring efficient power generation [6, 7].
2.3 Parametric Design and Constraints
Parametric design enables iterative adjustments
of dimensions, such as piston mass, stroke
length, and combustion chamber size, to
optimize performance. Constraints include
maintaining specific stroke lengths for efficient
combustion, ensuring the linear generator
produces sufficient power, and managing
thermal and mechanical stresses. Parametric
studies help balance these factors to achieve
optimal efficiency and durability [4].
2.4 Design Revisions and Optimization
Design revisions are driven by simulation
results, focusing on improving efficiency,

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reducing weight, and ensuring
manufacturability. For instance, optimizing
piston mass and compression ratio can enhance
fuel efficiency, while material selection impacts
durability and cost. Iterative testing using FEA
and CFD ensures the design meets performance
goals while remaining feasible for production
[6, 8].

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Model Information

Model name: Piston generator

Current Configuration: Default
Solid Bodies
Document Name and Document Path/Date
Treated As Volumetric Properties
Reference Modified
Fillet1
Mass:0.0479059 kg
Volume:1.77429e-05 m^3 C:\Users\MSI\Documents\P
Solid Body Density:2,700 kg/m^3 iston generator.SLDPRT
Weight:0.469478 N Jul 20 15:48:10 2025

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Study Properties
Study name Static 1
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from SOLIDWORKS Off
Flow Simulation
Solver type Automatic
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Contact penalty stiffness scale factor 1
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SOLIDWORKS document (C:\Users\MSI\Documents)

Units
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2

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Material Properties
Model Reference Properties Components
Name: 1060 Alloy SolidBody 1(Fillet1)(Part1)
Model type: Linear Elastic Isotropic
Default failure Max von Mises Stress
criterion:
Yield strength: 2.75742e+07 N/m^2
Tensile strength: 6.89356e+07 N/m^2
Elastic modulus: 6.9e+10 N/m^2
Poisson's ratio: 0.33
Mass density: 2,700 kg/m^3
Shear modulus: 2.7e+10 N/m^2
Thermal expansion 2.4e-05 /Kelvin
coefficient:
Curve Data:N/A

Loads and Fixtures

Fixture name Fixture Image Fixture Details
Entities: 3 face(s)
Type: Fixed
Geometry
Fixed-1

Resultant Forces
Components X Y Z Resultant
Reaction force(N) -6.96332e-12 0.00154025 -2.10477e-10 0.00154025
Reaction Moment(N.m) 0 0 0 0

Load name Load Image Load Details

Entities: 1 face(s)
Type: Normal to
selected
face
Pressure-1 Value: 1
Units: N/m^2
Phase Angle: 0
Units: deg

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Connector Definitions
No Data

Interaction Information
No Data

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Mesh information
Mesh type Solid Mesh
Mesher Used: Blended curvature-based mesh
Jacobian points for High quality mesh 16 Points
Maximum element size 5.2183 mm
Minimum element size 0.765367 mm
Mesh Quality High

Mesh information - Details

Total Nodes 11398
Total Elements 5804
Maximum Aspect Ratio 31.342
% of elements with Aspect Ratio < 3 89.8
Percentage of elements with Aspect Ratio > 10 3.22
Percentage of distorted elements 0
Time to complete mesh(hh;mm;ss): 00:00:07
Computer name: SKIDDO

Mesh Quality Plots

Name Type Min Max
Quality1 Mesh - -

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 Piston generator-Static 1-Quality-Quality1

Sensor Details
No Data

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Resultant Forces
Reaction forces
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N -6.96332e-12 0.00154025 -2.10477e-10 0.00154025

Reaction Moments
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 0 0

Free body forces

Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N 4.39684e-11 -1.84457e-10 3.32747e-11 1.92522e-10

Free body moments

Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 0 1e-33

Beams
No Data

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Study Results

Name Type Min Max

Stress1 VON: von Mises Stress 7.951e-08N/m^2 2.614e+01N/m^2
Node: 9606 Node: 59

Piston generator-Static 1-Stress-Stress1

Name Type Min Max

Displacement1 URES: Resultant Displacement 0.000e+00mm 2.066e-08mm
Node: 3 Node: 5158

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 Piston generator-Static 1-Displacement-Displacement1

Name Type Min Max

Strain1 ESTRN: Equivalent Strain 1.179e-18 2.367e-10
Element: 2946 Element: 3757

Piston generator-Static 1-Strain-Strain1

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3. CAPP & CAM PHASE
3.1 Process Planning (CAPP)
Computer-Aided Process Planning (CAPP)
outlines the manufacturing sequence for the
piston generator’s components. This includes
machining operations like turning, milling, and
grinding for pistons and cylinders, as well as
assembly processes for integrating the linear
generator. CAPP optimizes the process by
considering material removal rates, tool life,
and machine capabilities to ensure efficiency
and quality [9].
3.2 Manufacturing Method Selection
Manufacturing methods are chosen based on
component materials and complexity. Pistons
are typically cast from aluminum alloys and

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then machined to precise tolerances. The linear
generator may require precision machining of
steel or magnetic materials. Additive
manufacturing could be used for prototyping
complex geometries, while traditional
machining is preferred for high-volume
production due to cost and reliability [9].
3.3 CNC and CAM Toolpath Planning
Computer-Aided Manufacturing (CAM)
generates toolpaths for CNC machines to
produce components with high precision. For
the piston generator, CAM programming
ensures tight tolerances for linear motion
components to minimize friction. Toolpaths
are optimized to reduce machining time and
tool wear, with simulations verifying the
accuracy of the produced parts [9].
3.4 Estimated Production Time and Cost

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Production time and cost estimation involve
calculating the duration of each manufacturing
operation and the associated costs, including
materials, labor, and overhead. For the piston
generator, high-quality materials for pistons
and the linear generator, along with precision
machining, contribute to costs. Accurate
estimation ensures the design is economically
viable for mass production [9].

4. MFORMAT &
MACHINING PHASE
4.1 Documentation Format (MFORMAT)
MFORMAT refers to the standardized
documentation for manufacturing, including
engineering drawings, bill of materials
(BOM), process sheets, and inspection reports.
These documents, often in PDF or CAD-

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compatible formats, ensure clear
communication of design intent to the
manufacturing team. They include detailed
specifications for tolerances, materials, and
quality control procedures to maintain
consistency during production [9].

5. Conclusion
The design and manufacturing of the piston
generator involve a structured process from
conceptual design to production. The FPEG’s
unique linear motion and integrated linear
generator offer advantages in efficiency and
compactness, making it suitable for hybrid-
electric vehicles and other applications. By
leveraging CAD, CAPP, and CAM, the design
is optimized for performance and
manufacturability, with detailed
documentation ensuring successful production.

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The project highlights the potential of FPEGs
to contribute to low-carbon technologies,
aligning with global sustainability goals.
References
Reference Source
Realization of a Novel Free-Piston
[1] Engine Generator for Hybrid-
Electric Vehicle Applications
[2] Free-piston engine - Wikipedia
Free-piston linear generator -
[3]
Wikipedia
A Decoupled Design Parameter
[4] Analysis for Free-Piston Engine
Generators
[5] Piston and cylinder geometry [15]
A Review of the Design and
[6] Control of Free-Piston Linear
Generator

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[7] Labeled Image of a Piston
Piston Bowl Design Optimization
[8] and Meshing for CFD - GridPro
Blog
[9] [Piston manufacturing process

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