Internal Combustion Engine Piston Research Articles

Dynamic method of controlling friction losses in the mechanism of converting reciprocating motion into rotary inline piston internal combustion engines

The task of reducing friction in internal combustion engines is an important task of the development of transport engineering. As the analysis of literature sources shows, the problem of reducing friction losses in relation to internal combustion engines is usually solved for each individual friction pair, for example, a cylinder-skirt of a piston or a cylinder - compression ring. In this case, the measurement of friction is carried out mainly in stationary conditions. However, such approaches do not allow to identify the most critical, in terms of friction in all friction pairs of internal combustion engines, operating modes and do not allow to study and control the friction processes of all friction pairs in of the internal combustion engines. The developed dynamic methods of control of mechanical parameters of engines of rotational action and drives on their basis allow to synthesize a dynamic method of control of friction losses in the internal combustion engines, the scientific and technical justification of which is devoted to this work. Critical, from the point of view of the developed method, is the calculation of the value given to the axis of rotation of the crankshaft moment of inertia of the parts of the crank mechanism, changing during one revolution of the crankshaft.

Method of stabilizing pulsating gas flows in the intake system of a piston engine with turbocharging

Piston internal combustion engines (ICE) are the most common sources of energy among heat engines. Currently, most ICEs are equipped with a turbocharging system. Thermomechanical perfection of processes in the intake system largely determines the efficiency of engines. This article proposes a method of stabilizing the pulsating flows in the intake system by installing the leveling grid in the output channel of the turbocharger (TC) compressor. Studies were conducted on an experimental setup, which consisted of a single-cylinder engine and turbocharging system. A constant-temperature thermo-anemometer was used to determine the instantaneous values of the air flow rate and the local heat transfer coefficient. It has been established that the presence of a leveling grid in the intake system leads to a decrease in the turbulence number by up to 25% compared with the basic intake system (while maintaining the flow characteristics). It is shown that the installation of a leveling grid in the intake system of the ICE with TC also leads to a decrease in the heat transfer intensity by up to 15 % compared to the base system. The obtained data expands the knowledge base on the thermomechanics of pulsating flows in hydraulic systems of complex configuration.

MOTOR INFLUENCE RESEARCH OF HYDROGEN MICRODOSES ON THE DIESEL MIDGET OF TOXICITY INDICATORS

In this article, an analysis of paths to improve the environmental performance of internal combustion engines through the use of alternative motor fuels or by modifying regular petroleum fuels with microdoses has been presented. The experience of various researchers of the hydrogen interaction mechanism with hydrocarbon fuel and its influence on the characteristics of the air-fuel mixture combustion and the performance of the operating cycle of a piston internal combustion engine has been considered. The method of improvement characteristics of toxicity diesel midget by addition in nominal diesel fuel (DF) microdoses of the atomic and molecular Hydrogen and at the expense of it decrease in level emission of harmful substances with the exhaust gases (EG) has been offered. Receiving mix of atomic and molecular Hydrogen by its generation provides a path in the compact economic electrolyzer which is powered from a DC power source with tension of 12 V. Integration of this electrolyzer type in the fuel system of the vehicle will rid from creation of an additional hydrogen power supply system of the engine with use of the bulky and fire-hazardous equipment for storage of an onboard reserve of Hydrogen. The research of toxicity indexes of the fulfilled for diesel gases with use of regular diesel fuel was conducted at the motor stand for three modes of its loading – 0.8; 1.0; 1.2 kW. At the following stage researches for the same load conditions with addition to fuel of the Hydrogen microdoses in a fraction – 0.49 ; 1.15; 1.83% (on mass) have been executed. Motor influence research results of hydrogen microdoses on diesel midget of toxicity indicators 1Ч8,5/11 have been brought to diesel fuel. The effect consists in the composition exception of the exhaust gases of the unburnt hydrocarbons and weakening of white damp in EG practically up to 0 and concentration of nitrogen oxide for 14–26%.

Responses of Aluminium Alloy Pistons under Mechanical and Thermal Loads

A comparative study of three different aluminium alloys, Al2618, Al4032 and Al6061 made internal combustion engine pistons is done on their responses under mechanical and thermal loads using finite element methods. In this study, a 3D solid model of piston is created in CATIA and the simulations of the static structural analysis, steady-state thermal analysis and transient thermal analysis are carried out in ANSYS. Stress and temperature distributions on critical areas of piston are pointed out for appropriate modification in piston design. The temperature and heat flux variations with time are presented in transient thermal analysis. Taguchi method and topological optimization are applied to optimize the process parameters and to select the appropriate material for the piston.

Microstructural Characteristics, Mechanical Properties, Fracture Analysis and Corrosion Behavior of Hypereutectic Al–13.5Si Alloy

Hypereutectic Al–13.5Si alloy containing 1.47% of copper and 1.30% of magnesium was designed as a potential material for internal combustion engine pistons. The optical microscopy and scanning electron microscopy (SEM) revealed the fine dendrites of α-Al phase and significantly dispersed eutectics in as-cast specimens. Several intermetallic phases were observed indicating different crystallization velocities and alloy composition nonuniformities. The tensile testing and hardness measurements performed at room temperature have shown an excellent tensile strength and hardness of as-cast specimens, but low elongation due to a complex multiphase structure. The mechanical examinations at 250 °C and 300 °C have presented a decrease in tensile strength and an increase in elongation, while hardness was slightly changed. The fractographic analysis has shown the features of the brittle as well as ductile fracture. The areas of dimples and areas containing particles with smooth surfaces were detected. Electrochemical methods, Tafel linear polarization, cyclic voltammetry, chronoamperometric measurement and impedance spectroscopy were employed to determine the corrosion behavior of as-cast specimens in 0.5 M NaCl solution. The resistant oxide layer formed on the surface was not entirely consistent due to the appearance of intermetallic phases. SEM examinations of corroded samples did not discover severe pits on their surfaces.

Options for using solid oxide fuel cell technology in complex integrated biomass gasification cogeneration plants

The aim of this paper is to draw readers' attention to potential new technological solutions for effective utilisation of dispersed biomass resources in distributed community-scale applications. In the paper conceptual system, that consists of allothermal wood gasifier, solid oxide fuel cell (SOFC), internal combustion piston engine (ICE) and Organic Rankine Cycle (ORC) for waste heat recovery, is proposed. Configuration of such systems is nowadays possible due to availability individual small-scale energy conversion technologies that can be integrated into complex structures. In the studied case the anode exhaust gas of the syngas fired SOFC module, that still contains combustible gases, is considered a secondary fuel for a bottoming ICE. The ORC cycle module is driven by the heat recovered from process gas coolers as well as from SOFC cathode and ICE exhaust gases. The system has been theoretically evaluated in terms of energy conversion efficiency and profitability using thermodynamic and economic analysis. Relevant robust mathematical models of key components have been developed. Through the modelling the most important performance parameters are addressed. Electric power of the sample system is below 1 MW what makes it suitable for utilisation of locally available biomass. Simulations revealed potentially high value of the net biomass energy to electricity conversion efficiency of 37%–40% depending on the ORC cycle configuration. Financial analysis revealed positive values of profitability indices at current level of market prices. The results are compared with a real biomass-fired ORC cogeneration project. The system also addresses issues related to external effects of the project, such as global emission reduction and primary energy savings.

Control of mixture formation in the piston internal combustion engine with phased fuel injection

The two-phase flow of a fresh charge in the inlet bodies of a commercially available engine accompanied by a heat exchange is investigated. The design changes of the commercially produced internal combustion engine, providing the improvement of the quality of mixture formation and allowing to increase its compression ratio with the subsequent increase of thermal efficiency, are developed, investigated and justified.

Effect of Water Injection in a Spark Ignition Engine Using Kerosene

Using kerosene for an aero piston internal combustion engine can improve system safety. Constrained by the knock limit of kerosene, the indicated mean effective pressure (IMEP) of spark ignition (SI) aero piston engine using kerosene is lower than that of gasoline. In this study, an experimental study based on a four-stroke SI aero engine was carried out. The influences of water injection on the combustion process and the improvement of IMEP were evaluated. The results indicate that the knock phenomenon can be suppressed in a certain extent with an appropriate amount of water injection.

Improving the technical and environmental performance of piston engines by upgrading the fuel system

The article presents the results of an experimental study of the dispersion of superheated water through cylindrical channels and nozzles of piston internal combustion engines under different initial conditions. The advantages and disadvantages of modern diesel engine fuel systems are discussed in the article. The process of explosive boiling in relation to the fuel system of a piston engine is formulated and briefly described. A description of the laboratory setup and methods of conducting experiments is given in the article. The results of the visualization of sprayed superheated water through a cylindrical channel and through a diesel engine nozzle of 21/21 dimension are presented. The original scheme of the fuel system for a diesel engine using the effect of explosive boiling is proposed. Preliminary estimates have shown that the use of such a fuel system will increase the reliability of the combustion chamber elements of a piston engine, reduce specific fuel consumption (up to 2%) and reduce the amount of harmful substances in exhaust gases (an average of 12% compared with traditional fuel systems).

Numerical Analysis of the Effect of Piston Cooling Gallery Design on Heat Transfer in an Internal Combustion Engine

Internal combustion engines are important machines that make human life easier. Internal combustion engines are developing day by day and higher power density engines are produced. Besides, strict standards of emission and fuel economy are forcing automotive manufacturers to produce environment-friendly engines. While manufacturers produce engines in accordance with these standards, they also do various studies in order not to reduce performance. One of the most important of these studies is the development of thermal management. Good cooling of internal combustion engine pistons, which are exposed to high pressures and temperatures during the combustion process, is an important consideration for the development of the thermal management. In this study; it is aimed to investigate the effect of design differences on piston cooling by using different designs for the cooling gallery located in the head region of an internal combustion engine piston. For this purpose, thermal analysis of an internal combustion engine piston was performed for different cooling gallery designs and the results of the analysis of each design were compared. In addition, the results of the analysis were compared with the heat transfer rates in the literature.

TOPOLOGY OPTIMIZATION OF INTEGRATED COMBUSTION ENGINE PISTON USING FEA METHOD (CAE TOOLS)

Topology optimization is a numerical approach that optimizes material arrangement within a given design space, for a given set of loads and periphery conditions such that the resulting layout meets a approved set of concert targets. Using topology optimization, engineers can find the best perception design that meets the design necessities. Topology optimization has been developed through the use of finite element methods of the analysis, and optimization techniques based on the method of moving asymptotes, genetic algorithms, optimality criteria method, level sets, and derivatives. Topology optimization is used at the idea level of the design process to appear at an intangible design plan that is then fine-tuned for concert and manufacturability. This thesis work correlated to the lay out optimization of internal combustion engine piston. Piston is one of the significant apparatus of engine. The multiple type of piston using through the automobile sectors. The various different type of piston is i) Equivalents lands thickness piston ii) Without crown piston (flat piston), iii) Without undercut piston, iv) With skirt land piston v) Dissimilar land thickness the analyzed this research work the Computer Aided Designing model initially created by CATIA, then Finite Element Analysis done by ANSYS.

Energy and exergy analysis of hydraulic free-piston engines

A hydraulic free-piston engine is an unconventional reciprocating piston internal combustion engine in which the piston assembly motion is determined by in-cylinder gas pressure and load force. Fuel combustion energy is directly converted into hydraulic energy. These affect the work process of cylinder and efficiency of energy conversion. In order to study the energy utilization efficiency and to explore the recovery potential of waste heat energy of hydraulic free-piston engine, in this paper, the energy distribution and waste heat energy characteristics of hydraulic free-piston engine have been studied by combining energy and exergy analysis. The thermal efficiency was analyzed by the first law of thermodynamics, and exergy balance was analyzed by the second law. The effect of the characteristic parameters on the thermal and exergy efficiency was studied through the simulation analysis comparing the energy utilization of hydraulic free-piston engine and conventional engines. The results show that control of the injection timing parameter is effective for optimizing efficiency because the cycle characteristic parameters can be controlled by changing the injection timing. The experimental results show that the thermal efficiency is 40.8% and the exergy efficiency is 46.3%. The simulation result show that the thermal efficiency of hydraulic free-piston engine is 38.0% and the conventional diesel engine is 33.0%.

Performance indices of a common rail-system CI engine powered by diesel oil and biofuel blends

Conventional fuels used for supplying internal combustion piston engines include petrols and diesel oils produced from petroleum. These are a non-renewable energy source. The environmental policy of the European Union is geared towards increasing the share of renewable fuels in the overall energy consumption. An alternative fuel originating from a renewable source, which could be used for feeding self-ignition internal combustion engines are the fatty acid methyl esters (FAME) of plant oils. The paper reports selected results of testing a 1.3 MULTIJET SDE 90 PS self-ignition engine with the Common Rail reservoir feed system supplied with mixtures of diesel oil and rape oil fatty acid methyl esters (FAME). Tests were carried out on an engine test bed equipped with an eddy-current brake. The purpose of the tests was to determine the economic–energy and ecological indices of engine operation. The concentrations of exhaust gas gaseous components were measured using a MEXA-1600DEGR analyzer, while the particulate concentrations, with a MEXA-1230PM analyzer. In addition, the variations of working medium pressures in the engine chamber and of fuel pressure upstream the injector were recorded as a function of crankshaft rotation angle using the AVL IndiSmart 612 indication system for this purpose. The physicochemical properties of fuels used in the tests were determined using a fuel analyzer. The obtained testing results made it possible to determine and assess the operation indices of the engine fed with mixtures of diesel oil and rape oil fatty acid methyl esters (FAME) with slightly higher ester contents than the requirements of the currently applicable diesel oil standard.

Wear Evaluation of Engine Piston Rings Coated With Dual Layer Hard and Soft Coatings

The main objective of this investigation is the evaluation of the performance of hard diamond-like-carbon (DLC) or tungsten carbide (WC) and soft (epoxy composite) dual-coatings on the internal combustion (IC) engine piston rings as a protective coating to reduce their wear. The rings were coated with DLC or WC by physical vapor deposition (PVD) method and then soft polymeric composite coating (epoxy/graphene/base oil SN150) was applied on the hard coating. The tribological tests of the dual-coated piston rings were conducted for 3.6 × 105 cycles at 1500 rpm engine speed and 50% rated load of a diesel engine in order to evaluate the wear performance of the piston rings. Scuffing of cylinder liner and piston rings interface was prevented by the application of polymer composites over the hard-coated rings. DLC hard and soft polymer composite dual coating over the top piston ring was found to have the lowest wear rate 1.69 × 10−12 mm3/N·m compared with the wear rate of dual coatings on the middle and lower rings.

Design Optimization Study of a Nonlinear Energy Absorber for Internal Combustion Engine Pistons

Piston impacts against the cylinder liner are the most significant sources of mechanical noise in internal combustion (IC) engines. Traditionally, the severity of impacts is reduced through the modification of physical and geometrical characteristics of components in the piston assembly. These methods effectively reduce power losses at certain engine operating conditions. Frictional losses and piston impact noise are inversely proportional. Hence, the reduction in power loss leads to louder piston impact noise. An alternative method that is robust to fluctuations in the engine operating conditions is anticipated to improve the engine's noise, vibration and harshness (NVH) performance, while exacerbation in power loss remains within the limits of conventional methods. The concept of targeted energy transfer (TET) through the use of nonlinear energy sink (NES) is relatively new and its application in automotive powertrains has not been demonstrated yet. In this paper, a TET device is conceptually designed and optimized through a series of parametric studies. The dynamic response and power loss of a piston model equipped with this nonlinear energy sink is investigated. Numerical studies have shown a potential in reducing the severity of impact dynamics by controlling the piston's secondary motion.

Optimization of Internal Combustion Engine Piston

Optimization of Internal Combustion Engine Piston

INCREASING THE RELIABILITY OF PISTON ENGINES BY THE IMPROVEMENT OF THE MIXING PROCESS

The article presents the results of an experimental study of the spraying of superheated water through channels (holes in the nozzle), characteristic of piston internal combustion engines, under different initial conditions. The paper briefly discusses the advantages and disadvantages of modern fuel systems of diesel engines. The process of explosive boiling is briefly described with reference to the diesel fuel system. The results of spraying superheated water through a cylindrical channel and through a nozzle of an operating diesel of dimension 21/21 are presented. The scheme for the implementation of the diesel fuel system with the use of the explosive boiling effect is proposed. Preliminary estimates have shown that the use of such a fuel system will lead to an increase in the reliability of the elements forming the combustion chamber of the engine, reducing the specific fuel consumption to 2 % and reducing the amount of harmful substances in the exhaust gases by an average of 12 %.

Diagnosis of EMD645 diesel engine connection rod failure through modal testing and finite element modeling

Abstract Connection rods are best known through their use in internal combustion piston engines. GM-GT26 locomotive uses a 3300 horse power V type engine with 16 cylinders that works at maximum crank speed of 900 RPM. The present study is concerned with the failure of a 645E3B engine connection rod with a reported catastrophic deformation due to unknown reasons. This rod has suffered from simultaneous bends in two surfaces with obvious marks of failure. A theoretical procedure, an experimental modal analysis technique and simulation by using finite element engineering softwares are used for this study. It includes finding the natural frequencies and the corresponding mode shapes for a new connection rod. This is then used to validate the FEM simulated model. The critical loads and the buckling forces on the connection rod are then calculated. The maximum loads are calculated by using the classical approaches and are verified by simulation in ADAMS-Engine software. The dynamic modeling includes rigid and flexible beam models and the torsional modes of vibrations are also considered. It is concluded that the connection rod failure is due to buckling at the presence of hydrolock phenomenon. The outcome of this research provides vital information for the proper operation and maintenance of heavy duty Diesel engines.

Gimazetdinov R.R., Malozemov A.A., Kukis V.S. Diesel-generator plant with the recovery of waste heat of the piston engine

The subject of the investigation was the waste heat recovery system of a small-scale heat electropower station that can be used as stationary and primary, reserve or additional source of electrical and thermal energy. The object of the investigation was the waste heat recovery system of the diesel engine D 180 and the small-scale heat electropower station on the basis of the diesel generator plant DGU-100C produced by JSC «ChTZ». The aim of the investigation was an experimental estimation of the efficient use of the diesel engine’s waste heat recovery system. The recovery system was consisted of an original heat exchanger for the recovery of the waste heat of the diesel engine’s cooling system, the waste heat of the lubricating system, the centers of which is made in a common housing, and the heat exchanger for the recovery of the exhaust gases waste heat from the diesel engine (pre-heater boiler PZD-600). The article presents the small-scale heat electropower station’s arrangement with the waste heat recovery system, the original heat exchanger arrangement and a scheme of the small-scale heat electropower station with the waste heat recovery system. The principle of operation of the proposed system is described. In comparison with the known constructions, in the proposed cogeneration power plant there is no need to separately regulate the temperature of the cooling liquid and the lubricating oil at the inlet to the piston internal combustion engine and the necessity to use an additional liquid-oil heat exchanger or oil cooler in the operation of the cogeneration plant without thermal load. Collectively, it was ensured a reduction of the complexity, material consumption and overall dimensions of the recovery system and the cogeneration power plant in general. The absolute economic effect from the using of the waste heat recovery system is 240…300 thousand rubles for the engine life, specific - 22…28 rubles/h. The payback period of the waste heat recovery system is less than a year. The obtained results convincingly indicate the economic feasibility of implementing the proposed system of waste heat recovery of the diesel engine D 180 of a small-scale heat electropower station based on the DGU-100S.

Effect of adding 2-ethylhexyl nitrate cetane improver on the autoignition properties of ethanol–diesel fuel blend – Investigation at various ambient gas temperatures

One of the alternative fuels considered for powering piston internal combustion engines is ethanol. In some countries, ethanol has been successfully used for many years as a self-contained fuel in positive-ignition engines after relatively minor technical modifications. Due, among other things, to a very low cetane number, this fuel cannot be used in pure form in diesel engines. Consideration is being given to fuels that are blends of diesel fuel with some ethanol fraction. Diesel fuel containing up to 15% (v/v) of ethanol is sometimes referred to as e-diesel or oxygenated diesel. However, it is necessary to improve the autoignition properties of such a blend. Improvement of the autoignition properties of an ethanol–diesel fuel blend (EDB) can be accomplished by introducing an additive that improves the propensity for autoignition. One such additive may be 2-ethylhexyl nitrate (2-EHN), which is commonly used to improve the autoignition properties of diesel fuels. This study determined the effect of the addition of 2-EHN (up to 10,000 ppm [m/m]) on the autoignition properties of an EDB with an ethanol fraction of 15% (v/v). The study was carried out by using a device with a constant volume combustion chamber, which additionally enabled determination of the effect of the ambient gas temperature (in the range 550–650 °C) on the period of ignition delay and the period of combustion delay, as well as the derived cetane number. The average and maximum pressure rise rates in the combustion chamber were also analysed. Studies have shown that, with an increase of the 2-EHN fraction in an EDB, the periods of ignition and combustion delay decrease, and the increase in the temperature of ambient gas into which the fuel is injected shortens these periods to a varying extent.