OPTIMAL DESIGN AND ANALYSIS OF RECIPROCATING COMPRESSOR PISTON

Abstract

Reciprocating compressors are widely used in industrial applications because they can deliver gases at high pressure with reliable performance. The piston is one of the most important components of a reciprocating compressor, as it is subjected to high gas pressure, thermal stresses, friction, and cyclic loading during operation. Due to these conditions, piston failures mainly occur because of fatigue, deformation, wear, and excessive thermal stress. Therefore, proper design and analysis of the piston are essential to improve compressor efficiency, durability, and operational life. This project presents the optimal design and analysis of a reciprocating compressor piston using aluminum alloy material. Aluminum alloys are preferred because of their low weight, high thermal conductivity, and good strength-to-weight ratio. The piston dimensions are calculated using standard design equations by considering parameters such as gas pressure, permissible tensile stress, piston head thickness, ring dimensions, and barrel thickness. A three-dimensional piston model is developed using CATIA software, and Finite Element Analysis (FEA) is carried out in ANSYS software to evaluate stress distribution, deformation, and thermal behavior. The analysis helps identify critical stress regions and improves the piston design by reducing weight while maintaining sufficient strength and thermal resistance. The optimized piston design provides better fatigue life, reduced vibration, improved heat dissipation, and enhanced compressor performance. The study concludes that the use of Finite Element Analysis significantly improves piston reliability, reduces design time, and minimizes manufacturing and maintenance costs in reciprocating compressor applications.