The minimum volume design of I. C. engine pistons is considered with constraints on temperature and stresses developed in the piston. The interior penalty function method, coupled with the Davidon-Fletcher-Powell method of unconstrained minimization and the cubic interpolation method of one-dimensional search, is used for solving the constrained optimization problems. The temperature and stresses developed in the piston are determined by using the classic as well as the finite element methods of analysis. A sensitivity analysis is conducted to find the influence of changes in design variables on the objective function and the response parameters.

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