The rapid advancements in next-generation automotive engines demand engine pistons that can withstand extreme thermal and structural loads while ensuring durability, efficiency, and reduced emissions. Existing piston designs often face challenges such as thermal fatigue, stress concentration, material degradation, and reduced lifespan under high-pressure combustion environments. To address these issues, this study proposes an advanced thermal-structural optimization framework for engine pistons by integrating Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), and metaheuristic optimization techniques. The methodology involves coupling thermo-mechanical simulations with multi-objective optimization to minimize thermal stresses enhance heat dissipation and reduce mechanical deformation, while also improving fuel efficiency and emission control. The primary objective is to achieve a piston design that provides improved durability, lightweight characteristics and superior resistance to both thermal cracking and mechanical wear. Results from the optimized model indicate a significant reduction in peak thermal stress (by 18%), lower temperature gradients across the piston crown and enhanced fatigue life compared to conventional designs. These findings highlight the potential of advanced optimization-driven piston engineering to enable more durable, sustainable, and high-performance next-generation automotive engines.

Thermal-Structural Optimization; Engine Pistons; Finite Element Analysis; Computational Fluid Dynamics; Metaheuristic Optimization; Durability Enhancement; Thermal Stress Reduction; Fatigue Life Improvement; Next-Generation Automotive Engines; Lightweight