Optimization of a Piaggio 150cc Engine Piston: A Simulation-Driven Approach in the Advanced Machine Design Course at the University of Rome Tor Vergata

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Optimization of a Piaggio 150cc Engine Piston: A Simulation-Driven Approach in the Advanced Machine Design Course at the University of Rome Tor Vergata

The Advanced Machine Design course at the University of Rome Tor Vergata, led by Professor Marco Evangelos Biancolini, provided students with the opportunity to apply cutting-edge engineering tools to a real-world structural and fatigue optimization project. The focus was on the optimization of a Piaggio 150cc engine piston, a complex task that required an interdisciplinary approach combining numerical simulation, computational optimization, and advanced engineering methodologies.

Through the use of Ansys software, students engaged in a rigorous analysis that encompassed multiple phases. The project began with the definition of critical load conditions at three different RPM levels (6500, 8000, and 9000), ensuring a comprehensive understanding of the mechanical stresses involved. Finite Element Analysis (FEA) was conducted using Ansys Workbench, providing detailed insights into the structural behavior of the piston under operational loads. Additionally, fatigue analysis was implemented in MATLAB, allowing for precise assessment of durability and performance.

Optimization played a central role in the study, with students exploring various approaches to enhance piston design. Topology optimization was employed to achieve weight reduction while maintaining structural integrity, followed by shape optimization using FEM-based methods to refine geometrical features. A significant aspect of the project was the application of mesh morphing techniques, integrating RBF Morph and the Biological Growth Method (BGM) to further improve structural efficiency.

The culmination of this work was presented in a final review session attended by Fabio Pavia and Stefano Rota from Ansys, who recognized the students’ efforts and the high level of technical competence demonstrated. The results highlighted substantial advancements in stress distribution optimization and mass reduction, with a comparative analysis of different optimization strategies, including topology optimization, shape optimization, and RBF Morph techniques.

This project exemplifies the integration of digital tools in tackling real-world engineering challenges, reinforcing the importance of simulation-driven design in modern mechanical engineering. The invaluable support provided by Piaggio Group, Ansys, and RBF Morph contributed to an engaging and educational experience, equipping students with the expertise needed to address complex design problems in industry.

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rbfLAB

rbfLAB is a research group located in Rome, at the University of Rome 'Tor Vergata'.

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