Mechanical stresses analysis of a partially ceramic coated cylinder liners using finite element analysis

Abstract

Cylinder liners are an essential component of an automotive engine, and their performance has a direct impact on the engine's performance. High-temperature composite materials are being used to replace traditional cylinder liners. The cylinder liner's primary roles are to provide a sliding surface for the piston to provide a smooth reciprocating motion, to prevent wear from the piston and piston rings, and to maintain high pressure and temperature. Continuous exposure to high thermal stress, mechanical stress, and friction inside the combustion chamber, on the other hand, may induce failure and shorten the life cycle of the cylinder liner. As a result, the primary goal of this study is to investigate the stresses caused by gas pressure, the principal thrust force of the piston, and thermal load in the cylinder liner of a genuine Kirloskar diesel engine. This study examines the thermal barrier coated liner or uncoated liner of a diesel engine, employing NiCrAl as the bond coat with a thickness of 0.15 mm and CaZrO3 as the coating material with a thickness of 0.35 mm, and the outcomes are contrasted. ANSYS 15 is used to determine the mechanical stress along the cylinder liner in terms of radial, longitudinal, and hoop stresses. The variation in the von misses stress, normal stress (x axis) are identified for selected ceramic materials. Mechanical equivalent elastic strain, normal equivalent elastic strain (x axis) and total deformation are also identified. With mechanical stress analysis for ceramic materials, the current study is used to effectively design cylinder liners.