Investigation on topology-optimized compressor piston by metal additive manufacturing technique: Analytical and numeric computational modeling using finite element analysis in ANSYS

Air compressors are widely used in factories to power automation systems and store energy. Several studies have been conducted on the performance of reciprocating and screw compressors. Advancements in design and manufacturing techniques, such as generative design and topology optimization, are leading to improved performance and turbomachinery growth. This work presents a methodology to design and manufacture air compressor pistons using topology optimization and metal additive manufacturing. The existing piston is converted to 3D CAD data and topology optimization is conducted to reduce material in stress concentration regions. Thermal and mechanical loads are considered in boundary conditions. The results show reduced material and improved efficiency, which is validated using ANSYS fluent. The optimized 3D model of the piston is too complex for conventional subtractive manufacturing, so laser sintering 3D printing is proposed. Honeycomb pattern infill patterns are used in 3D printing. This investigation is a step toward researching similar methods in other reciprocating compressor components such as cylinder, cylinder head, piston pins, crankshaft, and connecting rods, which will ultimately lead to improved compressor efficiency.