Piston Head
This tutorial explains the step-by-step working process of modelling the piston, piston crown, piston skirt, and piston pin boss which is available in the model section of my profile. There are a total of 4 parts in this model, which physically cannot be separated as all parts are connected.
Patrick Ray Samperuru - 2106718306
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Step 1: Base of Piston
After creating a new drawing using mm dimensions, start a 2D sketch of a circle with a diameter of 85mm in the XZ plane.
Extrude the 2D sketch of the circle by 90mm to create the piston into a 3D model. Finally, change the material of the object into "Aluminum 5052" located on the top middle.
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Step 2: Setting Up Compression Ring Land
Select "offset from plane" on the piston crown (top) with a depth of -7.3mm to create Work Plane 1. View the working plane on "half section view" to eliminate the top from perspective.
Start a 2D sketch on Work Plane 1 and create a circle with a diameter of 79mm. Finally, select "project geometry" on the outer circle to project it for extruding in the next step.
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Step 3: Compression Ring Land and Gap
Extrude the outer circle that has been selected for project geometry with a distance of 4.3mm and a Boolean of cut which will automatically move the direction into flipped.
Turn the view back into "end section view" to return the top part of the piston (piston crown). Select the "rectangle pattern" command on "Extrusion 2" with the direction of the Y-axis, selecting flip, 2 repeated patterns, and a spacing of 11.6mm. This will create 2 identical piston ring lands along with its gaps.
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Step 4: Setting Up Oil Control Ring Land
Select "offset from plane" on bottom compression ring land with a depth of -7.3mm to create Work Plane 2. View the working plane on "half section view" to eliminate the top from perspective.
Start a 2D sketch on Work Plane 2 and create a circle with a diameter of 79mm. Finally, select "project geometry" on the outer circle to project it for extruding in the next step.
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Step 5: Oil Control Ring Land and Gap
Extrude the outer circle that has been selected for project geometry with a distance of 6mm and a Boolean of cut which will automatically move the direction into flipped. Turn the view back into "end section view" to return the top part of the piston (piston crown and the two compression ring lands and gaps).
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Step 6: Piston Crown
Start a 2D sketch on the origin of the YZ plane and slice graphics (F7) to hide the previous geometric changes in order to have a clear perspective. Draw a vertical line in the middle of the top with a height of 5mm. Next to it, draw an arc from the top of said vertical line to the side of the piston crown top and change the dimension to 300mm.
Revolve the created arc using the "revolve" command on the top left of the 3D model ribbon with flipped directions and a 360 degree angle. This will create a curve surface on the piston crown.
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Step 7: Depth in Piston
To create depth in the piston, a hole must be extruded from the piston skirt (bottom of the piston). Create a 2D sketch of a circle with a diameter of 76mm following the piston dimensions.
With the 2D sketch of the circle, select the "extrude" command on the 3D model section. Input a depth of 85mm and select "cut" for the Boolean.
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Step 8: Holes for Piston Wrist Pin
In order to have a connecting pin (piston pin) joining the piston and connecting rod, a hole in the piston must be created. To do this, create a 2D sketch in the YZ plane and slice graphics (F7). Draw a circle in the middle of the piston with a diameter of 33.8mm and add a dimension between the middle of the circle and the bottom of the piston with a height of 27mm.
Extrude the produced 2D circle, selecting "cut" for the Boolean, "symmetrical" for the direction, and "through all". This will create identical holes that are in a straight line.
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Step 9: Piston Skirt
This step focuses on trimming the piston skirt by creating a manual arc-like shape. Create a 2D sketch with an origin of the XY plane. Start by drawing a line in the middle and right clicking it to select "construction". Next, create one line on the left and one on the right, selecting "symmetrical" on all three of the created lines and equal on the side lines. With this, connect the two side lines with an arc on the top. Add dimensions of 50mm for the distance between the two side lines, 12mm for the height of the side lines, and 40mm for the arc. Finally, add a line on the bottom connecting the two side lines from beneath.
Extrude the created shape and select "cut" for the Boolean, "symmetrical" for the direction, and through all. The distance should be automatically 85mm.
Next, smoothen the edges of the created hole to become a curved arc. To do this, select "fillet" command and input 10mm while selecting 4 edges of the piston skirt trims as seen on the image below.
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Step 10: Piston Pin Boss Base
The first part of creating the piston pin boss is to start a 2D sketch in the YZ plane. Select "project geometry" on the already existing circle from step 6. Next, create a circle from the end point of the said existing circle with a diameter of 45mm.
Extrude the circle created by selecting the bigger circle (on the inside) and selecting a direction of "default" with "to next".
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Step 11: Piston Pin Boss Finishing
To finish the piston pin boss, start a 2D sketch and select "project geometry" on the two circles created in step 8, as seen highlighted in yellow on the image below.
Extrude the circles by selecting them and clicking the "extrude" command. Input a distance of 25mm, a Boolean of "cut", and a direction of flipped. This will trim the piston pin boss.
Finally, click on the "mirror" pattern and select both Extrusion6 and Extrusion7. Select the YZ plane on the mirror tab and the piston pin boss will duplicate to be identical on each side.
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Step 12: Model Review
Top isometric view of the piston head
Bottom isometric view of the piston head
Side (right) profile of the piston
