In order to avoid copper bushing shedding and reduce the maximum stress on the surface of a piston pin bore

nine groups of experiments and a comparison scheme of inserted copper bushing were designed by using orthogonal experiment method L9(34). A piston was simulated by using the ANSYS

and an optimal solution to the thermal and mechanical loads of the piston was obtained by using the range analysis. The results show that the three factors which affect the thermo mechanical stress of the piston pin bore are ranked according to their importance: the pin bore profile equation coming first

the clearance between the pin bore and the piston pin next

and the thickness of the reinforcing material last. The optimal solution makes the coupled stress on the piston pin bore surface reduce up to 28.8%

the piston bore temperature increase by 3% to 4%

and the piston coupled deformation decrease by 2.9% to 3.8%.