In order to improve the lifetime of arc surface bushing piston pin and reduce the stress concentration of piston pin seat, the arc surface bushing piston pin was optimized with the finite element analysis method and orthogonal test method. The orthogonal experiment was established with the piston pin step bore d and cylindrical hole length l as variables and the largest stress value of piston pin as the goal. By considering the contact and thermal stress, the optimal parameters of arc surface bushing piston pin structure were acquired with d=14.5 mm and l=8 mm. In addition, the common materials of piston pin were further studied and the optimized results were verified with the finite element method. It was found that the material had little effect on the bushing piston. Accordingly, the optimized piston pin reduced the stress concentration of piston pin seat and piston pin, which improved the lifetime of piston pin greatly.