Engine Crankcase Research Articles

Valuating the impact of biodiesel B10, B20 on lubricating oil in a commonrail diesel engine

Biodiesel typically has a higher boiling point, viscosity, density, and surface tension compared to traditional diesel. This can result in larger fuel droplets and potentially increased penetration into the engine crankcase. This article presents experimental findings on the impact of using biodiesel blends B10 and B20 (with B100 made from palm oil) on key lubricating oil properties in a D4CB 2.5TCI-A diesel engine equipped with a CommonRail fuel injection system installed in a Hyundai Starex vehicle. The evaluation is based on comparing lubricating oil properties when using different fuels: diesel (B0), biodiesel B10, and biodiesel B20 over a 3000 km driving cycle. Results indicate that the effects of B10 and B20 on lubricating oil properties are similar to those of conventional diesel B0.

Vibration Fatigue Analysis of Two Different Variants of Oil Suction Pipes.

In order to reduce the overall mass of the product, an improved variant of the engine oil suction pipe in hybrid design is developed and analysed as part of this paper. The vibration fatigue analysis of a simple all-metal suction pipe and the new hybrid suction pipe variant is derived using computer FEA simulations and vibration measurements on the shaker. The hybrid design of the technical components makes it possible to combine different types of materials in order to achieve the best possible properties and behaviours for the components under the influence of external loads. In our case, we combine a suction pipe made of S235JR mild steel with a 3D-printed polyamide intake funnel featuring a grid designed to prevent particles from entering the engine's lubrication circuit. This design reduces the mass and shifts the centre of gravity closer to the attachment point of the pipe, as well as to the engine crankcase, which has a positive effect on the values of natural frequencies and vibration amplitudes. The main objective of such a hybrid suction pipe is precisely to reduce vibrations, and thus extend the service life of the components.

Experimental Studies of Engine Crankcase Gas Consumption D-243 With Varying Degrees of Wear of the Cylinder-piston Group

The methodology and results of the experimental studies of crankcase gas consumption in diesel engines with varying degrees of wear of the cylinder-piston group (CPG) are presented. It is shown that the rotation speed has a significant influence on the crankcase gas consumption and the load has an insignificant influence on it. It is recommended to use the idle mode at the nominal or maximum rotation speed as a diagnostic test mode to assess the technical condition of the CPG.

Оценка технической возможности достижения одинакового хода поршней в кривошипно-шатунном механизме с прицепными шатунами

The article presents the technical capabilities for achieving the specified operating characteristics of engine components and parts taking into account the geometric characteristics of the crank mechanism (crank mechanism). It also presents the assessment and achievements of the required level of strength parameters of some structural elements of the main connecting rod and the entire mechanism as a whole. Making changes to a proven design and established production is a complex and multifactorial task. It is necessary to make changes that would minimize production and technological losses. Besides, they must fit harmoniously into existing technology and production capabilities ensuring the fulfillment of new technical requirements and characteristics. When solving the problem of ensuring the same piston stroke for a V-2 engine, the analysis of the design documentation showed that in addition to making changes to the design of the crank mechanism, it is necessary to make changes to other engine parts. The need for these changes was determined by the method of “scrolling” the assembly of crankshaft parts in the volume of the engine crankcase using 3D modeling programs for parts and checking their performance. The results of assessing the kinematics of the crankshaft engine of V-2 type engines proved that in addition to changing the design of the main connecting rod, it is necessary to perform additional processing of the axial stiffener rib of the upper half of the crankcase, as well as to make changes to the design of the trailing connecting rod in order to eliminate contact with the cylinder liner and, possibly, the liner itself. However, changes in the engine design will entail significant changes in the technological process of its manufacture. Obviously, these changes should be minimal. In order to preserve the engine design, it is necessary to make some significant changes. They can affect significant production and technological changes, which in conditions of mass production require fairly strong theoretical and practical justification. Therefore, when implementing these technical solutions, it was necessary to perform calculation and kinematic analysis based on 3D modeling and logical analysis, excluding disruption of engine operation. In addition, to assess the load on the lower head of the connecting rod, a hydrodynamic calculation was performed. The results also include the hydromechanical characteristics of a complexly loaded bearing and a diagram of the hydrodynamic pressures acting in a thin lubricant layer

Choosing of rational periodicity of engine crankcase oil changing taking into account energy-saving properties of oils

It is known that reducing friction losses and, consequently, wear is the most important function of engine crankcase oil. Many oil manufacturers add additives to the oil composition - thickening and friction modifiers. Achieving a rational periodicity of crankcase oil changing generally reduces the operating consumption of oil, the cost of which accounts for a significant share of the total cost structure of operating costs. The developed method for evaluating the energy-saving properties of the researched three grades of oil by viscosity-temperature characteristics allows for reducing the cost of conducting special research. The viscosity value's dependence on the temperature range from 20 to 100 ° is experimentally established. This work presents part of the research results to justify the choice of rational changing periodicity of diesel engines’ crankcase oil, considering the energy-saving properties of oils. During operation, it is also necessary to comply with the requirements for preserving the recommended grades of fuel and lubricants, observing their use and safety modes, and a reasonable oil level in the crankcase.

Towards tailpipe sub-23 nm solid particle number measurements for heavy-duty vehicles regulations

A heavy-duty engine is type-approved in engine dynamometers, while its in-service conformity is controlled on the road. In the first case, laboratory particle number systems (LABS) sample from a full dilution tunnel or a proportional partial flow dilution system (PFDS). In the second case portable emissions measurements systems (PEMS) measure directly from the tailpipe. Permitting in the regulation LABS sampling directly from the tailpipe would simplify testing and would improve their comparability with PEMS. In this study PEMS and LABS, both sampling from the tailpipe and measuring solid particles >10 nm, were compared with references systems (i.e. LABS from PFDS). One compressed natural gas (CNG) engine, and three diesel engines, all Euro VI step E, with or without urea injection, and with or without crankcase ventilation connected to the tailpipe, challenged the systems with different emission levels and particle sizes and properties. The results showed that the differences of the LABS to the references were in most cases within ±25%, with a few exceptions. The PEMS were within ±50%. There was no or small effect on the differences from engine technology, urea injection or crankcase ventilation. The inclusion of sub-23 nm particles increased 100% to 250% the particle number emissions. The urea injection increased the >10 nm emissions 300–600% (2–5 × 1010 p/kWh). Connecting the crankcase ventilation to the tailpipe further increased the >10 nm particle number emissions 340–560% (1.4–2.5 × 1011 p/kWh), bringing the >10 nm levels of the engines to approximately half of the current particle number limit, applicable to particles >23 nm.

An investigation on the friction losses between cylinder liner and piston rings

Historically, the engine crankcase has been made of gray cast iron due to that material's' high machinability, damping ability, thermal conductivity, and sensible cost. Despite these advantages and the long-term use of gray cast iron, the vehicle manufacturers predominately use cast aluminum as material of choice for the engine block due to aluminum’s density being almost a third of that of gray cast iron, and the aluminum engines have the same durability as gray cast iron while weighing considerably less. However, due to the low wear resistance of aluminum, efforts are needed to improve internal working surfaces such as the use of cast iron cylinder liners or the application of a protective coat is applied to the aluminum surface to increase its resistance. The purpose of this study is to examine which ring materials have the lowest friction with the Twin Wire Arc (TWA) aluminum cylinder liner. An Ansys simulation model accomplishes the experimental work. The steel ring material obviously had the lowest friction with twin wire arc spray aluminum cylinder liner as opposite to the cast iron material which was the worst.

ОЧИСТКА СИСТЕМЫ СМАЗКИ ДВИГАТЕЛЕЙ ТРАКТОРОВ

As a result of the analysis of the state of the issue of increasing the efficiency of the use of machinery and extending the service life in agricultural enterprises, it was determined that the refusal of the operation of flushing the lubrication system after replacing the engine oil that has expired reduces the operational characteristics of diesel engines of tractors, the service life of freshly refilled oil decreases. It was established in the course of modeling the process of flushing oil channels that commercial oil M10G2 does not fully ensure the removal of contaminants from the system compared to special flushing oils. Thus, as a result of preliminary experimental studies, it was found that at a pressure of 4 kg / cm2, the content of insoluble precipitate in M-10G2 oil decreases by 0.1-0.2%. As the pressure increases to 8 kg / cm2, these indicators improve. One of the tasks of increasing the efficiency of flushing the lubrication system is to reduce the cost of improving this operation. In this regard, it was decided to use the engine oil that has been used for its life as a washing oil. In laboratory conditions, the possibility of removing contamination from the waste oil was considered. For these purposes, coagulants were introduced into the heated oil and an oil purification operation was carried out in a laboratory centrifuge. After that, the washing properties of the M-10G2 oil of the Volga brand washing oil and purified waste oil were evaluated, which allowed to establish sufficiently high washing properties of commercial oil and purified used engine oil. The possibility of cleaning the lubrication system with used engine oil without draining it from the engine crankcase is considered. It was found that the introduction of a 2% mass solution of urea in ammonium hydroxide into the crankcase of the engine makes it possible to enlarge the contamination particles with their subsequent removal by a centrifuge built into the lubrication system. The thickness of the sediment layer on the walls of the centrifuge for 30 minutes of engine operation on oil with additives was 20 mm, while for a period of 200 hours it was 15 minutes. The color of the oil in CST units has changed from 7 to 3.5.

ТЕОРЕТИЧЕСКОЕ ОБОСНОВАНИЕ МАТЕМАТИЧЕСКОЙ МОДЕЛИ ПРОЦЕССА ПОДОГРЕВА МОТОРНОГО МАСЛА В ПОДДОНЕ КАРТЕРА ДВИГАТЕЛЯ ВНУТРЕННЕГО СГОРАНИЯ

The need to preheat an internal combustion engine (ICE) before starting is an urgent problem in the automotive industry. Preheaters of various types are designed to solve this problem and avoid premature failure of the internal combustion engine. Starting heaters are used both in automobile and freight transport, but also in agricultural transport (loaders, combines, tractors, etc.). Each type of heater has its own characteristics. In the electric preheater of the internal combustion engine, a heating element (heater, heater plug, plate, plug) is used, which heats the oil in the engine crankcase pan or coolant. The degree of heating of the heating element and the electrical power consumed have a certain functional dependence with changes in the temperature field. That is why it is possible to determine with high accuracy the time of oil or coolant heating by measuring the temperature field along the heater axis. The purpose of this work is a theoretical description of the mathematical model of the engine oil heating process in the crankcase sump of an internal combustion engine. The paper analyzes the processes that occur when engine oil is heated in the internal combustion engine, marks the main parameter (heat transfer coefficient), which needs to be searched for, analyzes mathematical models, and marks the main parameters. A theoretical description of the heat transfer process is presented, on the basis of which a mathematical model of the engine oil heating process in the crankcase sump of an internal combustion engine is developed.

Engine Oil- Crankshaft Interaction Fem Modelling of an Air-Cooled Diesel Engine under Dynamic Severe Functioning Conditions

Taking into account the interaction between the engine oil and the crankshaft to model crankshaft thermomechanical behavior under dynamic loading is very important. In particular, when the crankshaft is working in severe conditions. This paper deal with an air cooled direct injection-type engine crankshaft thermomechanical FEM modelling account for engine oil-cranks half interaction in severe working conditions. As case of application we consider the diesel engine Deutz F8L413. The model takes into account 2 forced convectives heat flux: engine oil and crankcase air. The severe mechanical and thermal characteristics of engine are experimentally measured on a bench test equipped with a hydraulic brake. The temperature distribution inside the crankshaft was computed using the measured temperature as boundary conditions. The most thermo-mechanical stressed zones of the crankshaft have been determined. The fatigue resistance of the crankshaft under thermo-mechanical conditions was examined using Dang-Van multi-axial fatigue criteria. To prove our model efficiency, we have compared crankshaft damage in service to the numerical simulation results. It was found the breakage occurred in an area where the numerical simulations give the highest stresses.

Surging Phenomenon in Gas Engine Crankcase

An internal combustion engine is an engine whose combustion process is inside a closed room or often referred to as the combustion chamber. The Wartsila W20V34SG engine is one of the internal combustion engines used to turn generators to generate electricity, over time some new problems arise that cause engine trip. One cause of a sudden increase in crankcase pressure is the occurrence of the phenomenon of surging in the crankcase. The causes of surging originating from the phenomenon of bursts of engine exhaust gas leaks to the surface of the oil mist pipe. Where the average temperature of the exhaust gas is approximately 530 °C so that the hot gas burst increases the temperature of the oil mist pipe and result in lower gas density and oil vapor. This phenomenon causes the air to become lighter and rise to the top and make the room in the crankcase more vacuum up to -6.29 mBar at which point the pressure will rise significantly up to ± 25 mBar. This value has exceeded the limit of the crankcase pressure protection setting which is 5.57 mBar causing the engine to trip.

УЛУЧШЕНИЕ КАЧЕСТВ РАПСОВОГО МАСЛА ДЛЯ ИСПОЛЬЗОВАНИЯ В ДИЗЕЛЬНОМ ДВИГАТЕЛЕ

This article presents experimental studies on changing such chemical properties of vegetable (rapeseed) oil, such as viscosity, for its use as a fuel in diesel engines. With the help of hydrothermal technology, samples of vegetable oil were obtained and laboratory studies were carried out on a viscometer, which showed a decrease in viscosity up to 16%. Oil samples were obtained at different pressures up to 90 atm. and temperatures up to 130 C. All samples were passed through a liquid activator installed at the outlet of the reactor, which, due to spargers located in the path of the flow, provided the appearance of a gaseous and liquid mixture with an increased ability to mix and conduct chemical reactions. The reactor was a metal flask with a wall thickness of 10 mm, a volume of 6 liters, with installed temperature and pressure sensors, and a heating element for heating oil. The pressure was provided by a gear pump driven by a 3 kW electric motor. For the safety of testing, an automatic pressure and temperature regulator in the reactor, installed in the control panel, was developed. In order to compare with pure cold-pressed rapeseed oil, comparative tests were carried out on bench equipment of the laboratory, which showed the effectiveness of this technology and obtaining the characteristics of engine operation on rapeseed oil as close as possible to diesel fuel. During the research, quantitative indicators of the ingress of rapeseed oil into the engine crankcase were also determined. When using cold-pressed rapeseed oil, this figure after eight-hour tests at idle at different speeds was 3.21 liters. After the processing of rapeseed oil in the reactor and repeated tests, the oil in the engine crankcase was measured, where it was 1.92 liters, which was 60% of the previous experience

Aumento de la presión del cárter por abrasión de los cilindros y la incidencia en la potencia del motor Wärtsilä Vasa 32

INTRODUCCIÓN. En los motores Wärtsilä Vasa 32 pertenecientes a una empresa de servicios petroleros, se ha evidenciado un aumento de la presión del cárter del motor debido al descenso de la compresión desde la cámara de combustión, producido por un desgaste abrasivo en las camisas de los cilindros, lo que ha provocado una disminución anual de la potencia. OBJETIVO. Determinar el desgaste producido en una camisa, los valores de los elementos abrasivos que se encuentran dispersos en el combustible y aceite, y la dependencia de la potencia en función de la presión del cárter. MÉTODO. Realización de mediciones con instrumentos de metrología y análisis de elementos dispersos en el combustible y aceite en laboratorios internacionales. RESULTADOS. Los análisis de aceite y combustible indicaron una excesiva cantidad de vanadio, aumentando el desgaste abrasivo en las camisas. Este desgaste se comprobó midiendo el diámetro y la rugosidad media de una camisa, después de 12000 horas de funcionamiento y cuyos valores no estaban dentro de los límites recomendados por el fabricante del motor. DISCUSIÓN Y CONCLUSIONES. Existe una correlación lineal decreciente entre la potencia del motor y la presión del cárter. Además, se determinó que el crudo ecuatoriano tiene una elevada cantidad de vanadio.

Multi-Objective Optimization on Vibration and Noise Characteristics of Light Duty Biofuel Powered Engine at Idling Condition Using Response Surface Methodology

Abstract Lemon peel oil (LPO) is a promising alternative biofuel for diesel engine applications due to its favorable physical and chemical properties. This study deals with combustion, vibration, and noise measurement for diesel engine powered with biofuel blend in the perspective of passenger comfort at engine idle condition. Experimentation is performed using a 20% blend of lemon peel oil with diesel (B20) according to central composite design (CCD) by varying pilot mass (PM), pilot injection timing (PIT), injection pressure, and engine speed (ES). Vibrations at engine crankcase, cylinder head were measured with a triaxial accelerometer along with noise measurement. The output responses for diesel and B20 were compared based on the output from response surface methodology (RSM). The study observed that predominant vibrations at the crankcase level along the lateral direction of the engine influenced by fuel injection pressure (FIP) and engine speed for both test fuels. Engine head vibrations were maximum along with the reciprocating motion of piston for both test fuels and found 7.43% more in case diesel. Engine noise is comparable from both test conditions irrespective of different influencing parameters. An increment of 1.662 J/deg in the heat release rate (HRR) of B20 is observed attributed to a longer ignition delay of B20 fuel. This study concludes that the lemon peel oil blend is compatible to use as an alternate biofuel in a diesel engine with suitable damping techniques for better passenger comfort.

Prediction of residual saturation and pressure drop during coalescence filtration using dynamic pore network model

Microstructure optimization of mist and dust filter media used in many applications including respirators, lubricated machining, compressors and engine crankcases is increasingly becoming reliant on computational simulations of dry and wet filtration processes. Computational fluid dynamics (CFD) based full-morphology simulations with advanced interface capturing techniques offer unique advantages in enabling accurate characterization of the pore-scale transport processes, yet demand substantial computational effort especially for fine filters. In this work, a dynamic pore network modeling (DPNM) framework is developed and evaluated for the prediction of residual saturation and pressure drop during mist filtration, and applied to an oil-air system. Two nonwoven filters (stainless steel and polyester) with different fibre diameters and packing densities are considered. The pore network is extracted using a watershed-based algorithm, from realistic virtual filter geometries (Abishek et al., 2017), and validated for macroscopic properties such as packing density. The validity of the steady PNM model is assessed by comparison of the dry (air) pressure drop against CFD and experimental data in the literature. The validity of the DPNM model is assessed by comparison of multiphase pressure drops and residual saturation against micro-CT and gravimetric experiments carried out in this work, as well as pore-scale CFD simulations using the volume-of-fluid model. It is found that the dynamic pore network model is able to successfully predict the critical properties of the filtration process such as saturation (local and total) and pressure drop to within 15% of experiment and CFD. Considering that the overall computational cost of DPNM is about 2–3 orders of magnitude lower than fully resolved CFD, DPNM stands as a potential tool for the early-stage design and optimization of mist filtration media.

Removal of Aging Products from Working Motor Oils without Draining them from Engine Crankcases

The dependences of changes in the contaminant contents and base numbers of motor oil during refining are established. Finely disperse contaminant particles are enlarged if a mixture of ammonium hydroxide with 1% urea is added to working engine oil. Subsequent centrifugation with cleaning agents incorporated into the lubrication system allows almost all contaminants to be removed from the oil. The dependences of the content of insoluble precipitate and base number on the operating time in the engine of the motor oil with the added reagent is established. Periodic cleaning of engine oil by the proposed method allows the service life until replacement to be extended and the operational characteristics of the internal combustion engine to be increased.

A novel Dempster-Shafer theory-based approach with weighted average for failure mode and effects analysis under uncertainty

Risk priority number (RPN) is a commonly-used prioritization method in failure mode and effects analysis (FMEA) for systemic reliability and safety study. However, conventional RPN confronts wide criticisms, due to the neglect of the uncertainties of experts' opinions. It is important to handle the conflicts among experts' multi-opinions which could be described in imprecise, incomplete or crisp forms in lack of knowledge. In this paper, a novel method is proposed to alleviate and/or eliminate counter-intuitive behaviors against conflicts among multi-opinions under Dempster-Shafer theory. Firstly, the abnormity test for experts’ opinions is undertaken to identify and discard those distinct judgments. Then, an approach to determining the subjective weights of experts is proposed, which is used in weighted average for multi-opinions before calculating RPNs. Finally, the risk priority evaluation on main engine crankcase explosion failure on-board ship is implemented to verify the feasibility of the proposed approach.

Development and testing of a mathematical model of the engine pre-start operation at low ambient temperatures

Starting a cold diesel engine, in the Arctic, with minimum temperatures below -60 ° C, presents significant difficulties due to: low temperature of the air charge; increased resistance to cranking the crankshaft and moving other kinematically related parts (pistons, parts of the gas distribution mechanism; etc.) due to the increased viscosity of the oil, deterioration of fuel atomization conditions, enhanced heat transfer to the cylinder wall, loss of part of the air charge. This article is devoted to solving the urgent problem associated with the development of a theoretical framework that provides comprehensive simulation of the starting mode of a diesel engine at low ambient temperatures when using start-up facilitators. The article proposes a mathematical model of a diesel engine, based on thermal mechanics (thermodynamics of open systems), which reflects the main features of an internal combustion engine (ICE) as a system that converts energy over time. The system of equations of the mathematical model is based on the laws of conservation of energy, mass, equations of motion of solid links and includes differential equations of the rate of change of temperature and density of the working fluid in the cylinder and in the engine crankcase, ideal gas equation of state, as well as differential equations of change of angular velocity and angle of rotation of engine shaft. The mathematical model is tested on the example of a 1CH9.5 / 8.0 diesel engine. The article presents graphs of changes in the angular velocity, pressure and temperature in the cylinder, as well as the results of calculating the engine pre-start operation at various low ambient temperatures in comparison with the results of full-scale experiments conducted in the refrigerating chamber.

Совершенствование технологии контроля параметров смазочной системы дизеля Д-245

А significant factor affecting the reliability of the internal combustion engine and its technical and Economic indicators is the efficiency of the lubrication system. When the standard oil supply is applied, semiliquid friction occurs between the contacting parts, in which the parts are not completely separated by a layer of oil. However, with this friction, the required durability of components and parts with heat removal is guaranteed. The performance of the engine lubrication system is determined by the state of its elements (coarse and fine filters, oil radiator and pump, valves), as well as the quality of oil, its level in the internal combustion engine crankcase and temperature. In domestic internal combustion engines, the minimum oil level in the crankcase is controlled, but in operation there are situations when the oil level exceeds its maximum permissible value. This situation occurs when coolant or fuel enters the lubrication system. Coolant can get into the oil if the cylinder head gaskets, sleeve o-rings, or cracks in the cylinder head and block are broken. Top-Livo can enter the oil through worn and damaged parts of the fuel equipment (gas pump diaphragm, fuel pump plunger pairs, etc.). These liquids sharply degrade the quality of the oil and increase the wear of internal combustion engine parts, and the standard singlelevel indicator will not give the driver operational information about the malfunction. In connection with the above, the purpose of this work is to improve the technology for monitoring the technical condition of the internal combustion engine lubrication system on the example of the d-245 diesel engine and its modifications, which are widely used in GAZ (GAZ-3309), ZIL (ZIL-5301), MAZ (MAZ Zubrenok), PAZ buses (PAZ-3205), MTZ tractors (MTZ — 100, 892, 1020), agricultural and construction equipment.by developing and implementing a built — in device for monitoring the minimum and maximum oil levels in the crankcase, as well as its temperature. The scientific novelty of the work is due to the use of new circuit and technical solutions, as well as the original algorithm of the sensor operation developed by the authors, based on the use of switching laws of reed switches with normally closed and normally open contacts, the operation of which is spaced over time and controlled oil levels. Block diagram of the proposed device comprises a multifunction sensor level and oil temperature, including sensors of the mi-minimum and increased levels of engine oil in the crankcase of the engine and its temperature, the operation mode switch signal cooling temperature-edusei fluid and engine oil, the first and second voltage сomparators, indicator lights, buzzer, switch power supply, voltage regulator and regular temperature sensor coolant. The use of the developed device significantly increases the reliability and convenience of monitoring one of the most important indicators of internal combustion engines-the oil level in the crankcase, which will avoid significant engine damage. As a result of further research, it is planned to develop the device design, conduct laboratory studies of the developed multifunctional sensor in order to determine the dependence of its resistance on the temperature at the normal level of engine oil in the measuring flask, as well as determine the actual values of the developed sensor response heights at the lower and upper levels.

Pressure Monitoring of Diesel Engine Crankcase Gases for Integrated Diagnostics

Pressure Monitoring of Diesel Engine Crankcase Gases for Integrated Diagnostics