An Integrated Surface Engineering Technology Development for Improving Energy Efficiency of Engine Components

Abstract

Frictional losses are inherent in most practical mechanical systems. The ability to control friction offers many opportunities to achieve energy conservation. Over the years, materials, lubricants, and surface modifications have been used to reduce friction in automotive and diesel engines. However, in recent years, progress in friction reduction technology has slowed because many of the inefficiencies have been eliminated. A new avenue for friction reduction is needed. Designing surfaces specifically for friction reduction with concomitant enhanced durability for various engine components has emerged recently as a viable opportunity due to advances in fabrication and surface finishing techniques. Recently, laser ablated dimples on surfaces have shown friction reduction properties and have been demonstrated successfully in conformal contacts such as seals where the speed is high and the load is low. The friction reduction mechanism in this regime appears to depend on the size, patterns, and density of dimples in the contact. This report describes modeling efforts in characterizing surface textures and understanding their mechanisms for enhanced lubrication under high contact pressure conditions. A literature survey is first presented on the development of descriptors for irregular surface features. This is followed by a study of the hydrodynamic effects of individual micro-wedge dimples using the analytical solution of the 1-D Reynolds equation and the determination of individual components of the total friction resistance. The results obtained provide a better understanding of the dimple orientation effects and the approach which may be used to further compare the friction reduction provided by different texture patterns.