P.D. King

Tribology of the ring–bore conjunction subject to a mixed regime of lubrication

Abstract This paper provides a detailed analysis of the compression ring—bore/liner conjunction. The analysis includes ring—bore conformability and global in-plane deformation of ring fitted in situ. The analysis for fitted ring in an out-of-round bore shows very good agreement with precise measurements, using a coordinate measuring machine. The analysis also includes the lubricated conjunction under a transient regime of lubrication, taking into account combined elastohydrodynamics and asperity interactions. The transient nature of the tribological conjunction has been demonstrated, particularly the prevalent mixed/boundary regime of lubrication at the top and bottom dead centres. The analysis is applied to a high performance motorbike engine subjected to very high impact loads and engine speeds of the order of 13 000 r/min. Furthermore, the predictions of the model show good conformance to the measurements of friction reported by other research workers.

In-Cylinder Friction Reduction Using a Surface Finish Optimization Technique

Abstract The paper describes the importance of reducing frictional losses in internal combustion (IC) engines, thereby improving engine efficiency. One of the main sources contributing significantly to engine friction is the interaction between the piston compression and oil rings and the cylinder bore/liner. Improving the tribological performance in these conjunctions has the greatest potential for performance improvement in the IC engine. Traditionally, the approaches used to tackle this problem have relied heavily on empirical engineering judgement. These have resulted in many inconclusive studies, involving a large number of alternatives, including the introduction of cylinder liners with surface modification work and/or with special coatings. This paper highlights a fundamental investigation of surface modification and coating and its impact on frictional performance. The study combines numerical and experimental approaches. Very good agreement is found between the conclusions of numerical predictions and those of engine test bed work.

The influence of piston ring geometry and topography on friction

This article provides solution for isothermal mixed hydrodynamic conjunction of the compression ring to cylinder liner. This is obtained using the average flow model representation of Reynolds equation based on pressure- and shear-induced flow factors. In particular, the effects of compression ring axial profile along its face-width and surface topography of contiguous solids are investigated. It is shown that ring geometry may be optimized to improve lubrication, whilst care should be taken in order to avoid oil loss or degradation resulting from any loss of sealing. In predicting friction, it is shown that appropriate surface parameters should be used in-line with the state of wear of the ring. For a new ring against a plateau honed liner, boundary friction contribution during the initial running-in wear phase should be predicted according to the average asperity peak heights protruding above the plateau, whilst the plateau height also takes into account the valleys within the surface roughness or grooves created by any cross-hatch honing would be the appropriate measure of topography for worn rings. The main contributions of the article are in providing an analytic solution as well investigation of ring face-width geometry and effect of wear upon friction. However, it is acknowledged that generated heat, inlet boundary starvation and circumferential non-conformity of ring to the bore surface would affect the film thickness and exacerbate generated friction accordingly. These further considerations would require a numerical solution, rather than an analytical one presented here.

Thermo-Mixed Hydrodynamics of Piston Compression Ring Conjunction

A new method, comprising Navier–Stokes equations, Rayleigh–Plesset volume fraction equation, an analytical control-volume thermal-mixed approach and asperity interactions, is reported. The method is employed for prediction of lubricant flow and assessment of friction in the compression ring–cylinder liner conjunction. The results are compared with Reynolds-based laminar flow with Elrod cavitation algorithm. Good conformance is observed for medium load intensity part of the engine cycle. At lighter loads and higher sliding velocity, the new method shows more complex fluid flow, possessing layered flow characteristics on the account of pressure and temperature gradient into the depth of the lubricant film, which leads to a cavitation region with vapour content at varied volume fractions. Predictions also conform well to experimental measurements reported by other authors.

Direct measurement of piston friction of internal-combustion engines using the floating-liner principle

Piston–cylinder interactions account for a significant portion of frictional losses in an internal-combustion engine. This is mainly as the result of significant changes in the operating conditions (the load, the speed and the temperature) as well as the contact geometry and the encountered topography during a typical engine cycle. These changes alter the regime of lubrication which underlies the mechanisms of friction generation. The multi-variate interactive nature of the problem requires quite complex analyses which do not fully replicate the actual in-situ conditions. Therefore, there is a need for direct measurement of cyclic friction under controlled conditions. The paper describes the use of a novel floating-liner arrangement which is capable of direct measurement of friction, its transitory mechanisms, as well as determination of the regime of lubrication.

Reducing in-cylinder parasitic losses through surface modification and coating

Friction constitutes nearly one fifth of all engine losses. The main contributory source of frictional losses in most engines is the piston–cylinder system, accounting for nearly half of all the parasitic losses. Minimisation of this is essential for improved fuel efficiency and reduced emissions, which are the main driving forces in engine development. The tribology of piston–cylinder conjunctions is, however, transient in nature. This means that various palliative actions need to be undertaken to suit certain instances during the engine cycle. In general, formation of a coherent film of lubricant of suitable viscosity reduces the chance of boundary interactions for most of the piston cycle. Plateau honing of the cylinder bore surface reduces the ‘peakiness’ of the surface topography. Furthermore, if regularly spaced grooves are provided on the contacting surface, these grooves can act as reservoirs of lubricant. However, at low sliding speeds, which are typically found during piston motion reversals, lubricant entrainment into the contact either ceases or is significantly reduced. Therefore, at the end of the piston strokes, there is a greater chance of boundary interactions, resulting in increased friction. There is a need to engineer the surface topography in these low-relative-speed regions in a manner conducive to the retention of a lubricant film. Surface texturing by means of laser processing or mechanical indentation at the dead centres are used to produce local reservoirs of lubricant as well as to encourage and direct the flow of lubricant into the contact conjunction. The paper shows that such surface-modifying features improve the engine’s output power by as much as 4% over that of the standard cylinder bore surface. To reduce wear and scuffing, particularly at the top dead centre, hard coatings can also be used. However, smooth surfaces and the generally oleophobic nature of hard coatings can increase the chance of adhesion, particularly at low sliding speeds. This means that prevention of wear does not necessarily lead to improved fuel efficiency. Furthermore, it is necessary to determine the geometry of the textured patterns in order to avoid the leakage of oil from the ring-pack conjunctions, which can result in increased emissions as well as lubricant degradation and depletion.

Analysis of the transient handling properties of a tyre, based on the coupling of a flexible carcass—belt model with a separate tread incorporating transient viscoelastic frictional properties

The behaviour of tyres under transient handling manoeuvres is studied with the aid of a newly developed model. The model consists of a discretized flexible belt with damping and inertia, connected to the rim by viscoelastic elements representing the carcass. In the neighbourhood of the contact patch, the belt is connected to a separate discretized viscoelastic tread with inertia. A separate algorithm taking into account the radial deflection of the carcass elements is used for the calculation of the contact pressure distribution along the contact patch. Friction follows a stick—slip law taking into consideration the velocity of tread elements, the normal force and the unequal coefficients of friction in the lateral and longitudinal directions. The model seems capable of generating transient forces and moments including the phase lags observed under time-varying kinematic excitations.

Transient analysis of tyre friction generation using a brush model with interconnected viscoelastic bristles

Abstract An analysis of the mechanism of tyre contact force generation under transient conditions is presented. For this purpose, two different versions of a brush model are used, both with inertial and viscoelastic properties. The first model consists of independent bristles, while the second, with a more realistic scenario, introduces viscoelastic circumferential connections between the sequential bristles, which affect the lateral degrees of freedom. Friction between the tyre and the ground follows an experimentally verified stick-slip law. For the model with independent bristles, the state of each bristle at any instant of time depends only on the state of the same bristle at a previous time step. In the second model, the instantaneous state depends on the state of the same bristle at the preceding time step, as well as on the state of the two adjacent bristles at the same time. Simulation results reveal the differences between the two models and most importantly show how transient friction force generation may differ substantially from steady state predictions. The findings suggest that transient tyre behaviour should not be attributed solely to the contributions of the flexible belt and carcass. On the contrary, the observed transience in the neighbourhood of the contact patch should also be taken into account.

The Measurement of Liner - Piston Skirt Oil Film Thickness by an Ultrasonic Means

The paper presents a novel method for the measurement of lubricant film thickness in the piston-liner contact. Direct measurement of the film in this conjunction has always posed a problem, particularly under fired conditions. The principle is based on capturing and analysing the reflection of an ultrasonic pulse at the oil film. The proportion of the wave amplitude reflected can be related to the thickness of the oil film. A single cylinder 4-stroke engine on a dyno test platform was used for evaluation of the method. A piezo-electric transducer was bonded to the outside of the cylinder liner and used to emit high frequency short duration ultrasonic pulses. These pulses were used to determine the oil film thickness as the piston skirt passed over the sensor location. Oil films in the range 2 to 21 μm were recorded varying with engine speeds. The results have been shown to be in agreement with detailed numerical predictions.

Combined bounce, pitch, and roll dynamics of vehicles negotiating single speed bump events

Abstract This paper investigates vehicle dynamic response for the increasingly common manoeuvre over single speed bumps, which is a non-trivial complex motion. One major aim of the study is to investigate the effect of the anti-roll bar upon vehicle body dynamics, while negotiating such traffic calming features. Numerical predictions are made with an intermediate vehicle model, whose results conform well to the actual vehicle tests. These results seem to suggest that events caused by truncated speed bumps can have implications for design of anti-roll bars from a ride comfort viewpoint, over and above the usual requirements dictated by safe vehicle handling.