Abstract
Reducing friction is an important aspect to increase the efficiency of internal combustion engines (ICE). The majority of frictional losses in engines are related to both the piston skirt and piston ring–cylinder liner (PRCL) arrangement. We studied the enhancement of the conformation of the PRCL arrangement based on the assumption that a suitable conical liner in its cold state may deform into a liner with nearly straight parallel walls in the fired state due to the impact of mechanical and thermal stresses. Combining the initially conical shape with a noncircular cross section will bring the liner even closer to the perfect cylindrical shape in the fired state. Hence, a significant friction reduction can be expected. For the investigation, the numerical method was first developed to simulate the liner deformation with advanced finite element methods. This was validated with given experimental data of the deformation for a gasoline engine in its fired state. In the next step, initially conically and/or elliptically shaped liners were investigated for their deformation between the cold and fired state. It was found that, for liners being both conical and elliptical in their cold state, a significant increase of straightness, parallelism, and roundness was reached in the fired state. The combined elliptical-conical liner led to a reduced straightness error by more than 50% compared to the cylindrical liner. The parallelism error was reduced by 60% to 70% and the roundness error was reduced between 70% and 80% at different liner positions. These numerical results show interesting potential for the friction reduction in the piston-liner arrangement within internal combustion engines.
Highlights
The piston ring–cylinder liner (PRCL) assembly contributes to 20% to 50% of the total mechanical energy loss of internal combustion engine (ICE) [1]
Approximately 4%–7.5% of fuel energy is used to overcome the frictional losses by the piston assembly, and the oil control ring alone corresponds to 0.23% to 2.8% of the fuel energy in the diesel engine [2]
High piston ring tension leads to increased friction losses, which means more fuel consumption and greenhouse gas (GHG) emissions [3,4]
Summary
The piston ring–cylinder liner (PRCL) assembly contributes to 20% to 50% of the total mechanical energy loss of internal combustion engine (ICE) [1]. Increasing the roundness of the deformed liner in the fired state provides a significant opportunity for improving the PRCL performance [12,13]. There are many reasons which cause the liner to deform from its ideal circular shape This includes manufacturing inaccuracies, the assembly process, thermal expansion variations between different engine components, temperature gradients during the fired state, and mechanical load during fired operations [16,17]. The aim of this article was to find a defined methodology to reduce the engine friction and achieve better PRCL conformation through increasing the liner’s straightness, roundness, and parallelism during the fired operation state. The main hypothesis in this work is that a suitable formed conical liner will be deformed to a more cylindrical shape in the fired state, such that the friction will decrease. A combined conical-elliptical shaped liner has not been published
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