Design and Structural Analysis of a Hydraulic Piston Rod Assembly Using Finite Element Method Use In Orange Peel Grab

Author(s)	Sonu Rajeshvar More
Country	India
Abstract	Hydraulic cylinders are widely used in industrial machinery, construction systems, and material-handling equipment. The piston–rod assembly is the most critical load-bearing component, directly transmitting hydraulic force into mechanical work. This study presents the design, analytical calculations, and Finite Element Analysis (FEA) of a steel piston–rod system subjected to 25 MPa operating pressure. Three commonly used materials—EN8 & EN19 were evaluated to determine their structural suitability. Theoretical axial stress and deformation were calculated and validated through static simulation. The FEA results illustrate that EN19 provides the highest strength and lowest deformation, while EN8 demonstrates marginal safety under overload. The study concludes with material recommendations, comparative safety factors, and guidelines for future optimization. The findings serve as a reference for safe piston design in medium-pressure hydraulic applications.
Keywords	Hydraulic cylinder, piston design, piston rod, Finite Element Analysis, EN8 steel, EN19 steel, static loading, 25 MPa pressure.
Field	Engineering
Published In	Volume 7, Issue 6, November-December 2025
Published On	2025-12-18
DOI	https://doi.org/10.36948/ijfmr.2025.v07i06.64106

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