Piston Ring Wear Research Articles

Simplified Wear Model for Power Cylinder under Engine Operating Conditions

A simple numerical approach is developed to predict the wear and friction of piston ring pack and cylinder liner during the break-in period and under transient speed conditions. In the model, a solution of mixed lubrications using the load-shearing concept is presented based on the selected elastic-plastic equations of asperity contacts in conjunction with well-established elastohydrodynamic equations. The model takes shear-thinning, thermal effects in elastohydrodynamic lubrication (EHL) and lubricant starvation effects into account. Modified Archard’s wear coefficient to describe the piston ring against cylinder liner wear is introduced. The approach is valid for the calculations of the asperity pressure at low values of the ratio of oil film thickness to combined roughness of the interacting surfaces, that is, less than 0.5. Applications are discussed, including association of piston side thrust force on wear and friction characteristics of piston ring/cylinder bore, gas blowby through the ring pack on the cylinder liner wear, a strong coating dependence for the piston ring wear, and wear distribution across the stroke under engine operating conditions. A good agreement between the experimental and analytical data indicates that the proposed model can be used to predict the wear and friction of the piston ring pack sliding against cylinder liner.

Стендовые испытания нового уплотнения деталей цилиндропоршневой группы судового ДВС

The engine consists of a large number of parts, each of which is responsible for a specific function of its efficient operation. The reliability of a marine diesel engine is largely determined by the resource of its individual components and parts. Therefore, in order to increase the engine life, it is necessary to allocate the most responsible parts in it, which are subject to greater wear and find solutions to increase their durability. Such details include piston rings, which affect not only the technical and economic performance of the engine, but also its reliability and environmental performance. Of the entire set of sealing parts of the cylinder-piston group, the upper piston compression ring should be distinguished as the most loaded. The main function of piston rings is noted – the creation of tightness of the combustion chamber. The passage of exhaust gases is inevitable due to the presence of a “lock” in the structure, and during operation, the wear of the piston rings leads to an increase in it, which affects fuel consumption, oil, and a decrease in engine power. One of the most negative consequences of piston ring wear is the appearance of “flutter” type vibration, which leads to the destruction of not only the ring, but also the edges of the piston grooves, especially on aluminum pistons. Worn grooves are not repaired by resorting to replacing pistons. A method for extending the service life is proposed, which consists in the use of a new sealing unit for cylinder piston group parts. The new sealing unit allows you to extend the piston's operability by boring the upper piston groove of the piston until all chips are eliminated. The operability of this node and the effectiveness of the seal was confirmed by an experiment that was conducted on the stand in conditions close to real ones. A technology for restoring the operability of pistons made of aluminum alloys is proposed.

Peculiarities of ship power plant diagnostics using the ERS-500 TechSim TRANSAS MIP LTD simulator complex in the process of ship engineers' training

This paper presents an analysis of the results obtained using the ERS 5000 TechSim Engine Room Simulator software. The software simulates remote control from the ship's central control station using virtual equipment panels, which are dedicated hardware combined into a separate console. The simulator covers the main areas of training in accordance with the International Convention on Standards of Training, Certification and Watchkeeping for Seafarers with the Manila Amendments of 2010 and meets the requirements of IMO Conventions and Resolutions and IEC standards. The simulator is certified by the Norwegian classification society DNV/GL. Main engine diagnostics are performed using the Cylinder Combustion Quality diagnostic panel and the Indicator Diagram Comparison panel. Analysis of changes in gas turbine engine parameters and the indicator diagrams themselves at different levels of piston ring wear showed a decrease in compression pressure, mean indicated pressure and maximum combustion pressure, as well as an increase in the return oil temperature of the piston cooling system and the consumption of lubricating oil in the cylinder. The advantages of using simulators in the training process include the ability to perform laboratory work in a frontal method, which significantly improves the learning experience

Bionic Design and Optimization of the Wear-Resistant Structure of Piston Rings in Internal Combustion Engines

Internal combustion engines, during their operation, subject the piston to high-temperature and high-pressure conditions, requiring it to endure intense, continuous reciprocating motion. This strenuous process leads to significant wear and tear. Among the engine’s crucial components, the piston ring plays a pivotal role but is particularly susceptible to wear. Therefore, extensive research has been devoted to investigating the wear of piston rings, a critical sealing component within internal combustion engines. To address the high cost of existing coating methods, which hinders widespread application, we propose a bionic design approach inspired by groove structures observed on earthworm bodies, aimed at enhancing the wear resistance of piston rings. Bionic piston rings featuring optimally designed groove structures inspired by the earthworm’s anatomy were designed. These rings exhibited varying groove depths (1 mm, 2 mm, and 3 mm), groove widths (0.1 mm, 0.3 mm, and 0.5 mm), and groove spacings (0.1 mm, 0.2 mm, and 0.3 mm). We conducted thermal–structural coupling analyses on both standard piston rings and these bionic counterparts. The results revealed that the maximum stress was concentrated at the first piston ring, precisely at the opposing region of the end gap. Thus, the initial piston ring endured the primary frictional losses. Moreover, a comparison of stress levels between bionic rings and the standard ring revealed that the bionic groove structure substantially reduced stress and minimized stress concentration, thus enhancing wear resistance. Groove width had the most notable influence on wear performance, followed by groove depth and groove spacing. Optimal wear resistance was achieved when the groove depth was 3 mm, groove width was 0.1 mm, and groove spacing was 0.1 mm. Subsequently, we constructed a piston ring friction test bench to validate the wear resistance of the most effective piston ring. The results indicated that the wear resistance of the bionic piston ring exceeded that of the standard piston ring by up to 19.627%. Therefore, incorporating a bionic groove structure within the piston ring can effectively reduce surface friction and enhance wear resistance. This, in turn, can enhance the operational lifespan of internal combustion engines under favorable working conditions.

Possibility of Marine Low-Speed Engine Piston Ring Wear Prediction during Real Operational Conditions

A long-stroke, low-speed marine engine is used as the prime mover of a ship. During the operation of such engines, the excessive wear of the cylinder liners and piston rings frequently occurs. The breakdown of cylinder liners or piston rings is very dangerous for the safety of a vessel, the environment, and the people on board. The reliability of engine components is an extremely important topic, as it influences the efficient operation of the vessel. Therefore, to prevent such undesired events, it is essential that the condition of the cylinder liners and piston rings is frequently assessed. This paper presents research that finds prediction models for the rate of piston ring wear. The compiled prediction models are verified using verification tests. The models can be implemented to evaluate the tendency of piston rings to wear, and can be used to evaluate the quality of cylinder liner lubrication. Our findings will help to obtain the required optimal piston ring wear rates, maintain the good operational condition of the engine, reduce the costs of engine maintenance, and reduce the total consumption of lubricating oil and the emission of noxious substances into the atmosphere. All the mentioned benefits are related to a reduction in the ship’s operational costs and are directly related to energy efficiency.

An Examination of Effect of Impact on Four Stroke 4 Cylinder Petrol Engine using Different Engine Oil

In the gas powered motor not practically everything moved to the cylinder from the gases contained inside the chamber the Demonstrated work is accessible at the drive shaft for real work.. The grinding delivered because of PRA(piston ring assembly) has a significant commitment altogether frictional misfortunes of the motor. The piston ring gathering is predominant wellsprings of the motor scouring force. This work endeavors to assess the frictional power at the piston ring liner gathering by utilizing different motor oil. To assess the frictional power a model ready by the YUKIO is thought of. The exploratory work was led on a four stroke 4-chamber SI motor from speed range from 1500 rpm to 3000 rpm. It is seen that the greatest worth of the frictional power is higher for the ointment SAE30W which might reason for higher wear of the rings. The utilization of grease SAE15W in the given arrangement would make less wear of piston rings due diminish frictional powers. Key words:- Piston Ring Assembly, Gas powered cycle, friction, wear, SAE.

Service life predicting of the piston ring with laser-hardened cylinder liner

The article considers the issues associated with the evaluation of hardening treatments influence on the service life of the piston ring in the cylinder of a heavy-duty diesel engine. The statement about the high efficiency of laser hardening of cylinder liners made of cast iron is substantiated. Model experiments on a laboratory friction machine investigate the wear resistance of the friction surfaces of the coupling piston ring-cylinder liner. The effect of piston ring wear on the loss of elasticity and the service life of the coupling is analyzed. The calculation method determines the service life of the coupling and analyzes the efficiency factor of the laser hardening treatment. On the basis of the study, it was found that laser hardening of the friction surfaces of cast-iron cylinder liners has a positive effect on the coupling wear resistance, but increases the wear of the piston rings. To eliminate the increase in wear resistance of piston rings, it is proposed to make them from steel and apply laser treatment of a wear-resistant coating from a high-entropy alloy of the Fe-Cr-W-Mo-Co-Ni system, which can significantly increase the service life of the piston ring-cylinder liner coupling in heavy diesel engines.

Marine Slow-Speed Engines’ Cylinder Oil Lubrication Feed Rate Optimization in Real Operational Conditions

The paper presents results of research performed to find the most suitable cylinder-liner-lubricating-oil feed rates for lubrication of long-stroke, slow-speed marine engines to reduce cylinder oil consumption and reduce engines’ maintenance costs. Obtained research data can be used to increase engines’ reliability, reduce operational costs of the vessels, and improve energy efficiency on board ships. Using analysis of under-piston scavenge drain oil, research has been performed to find the relationship between various engines’ operational factors and the wear intensity of cylinder liners and piston rings. Prediction models of the most suitable cylinder oil feed rates depend on the brand of cylinder oil and fuel actually in use, and the sulfur content in the fuel oil Verified in operation, the presented practical model can be used by engines’ operators to set up cylinder oil feed rates with satisfactory cylinder liner and piston ring wear rates and cylinder oil consumption. It is underlined that analysis of scavenge drain oil properties gives an answer whether reduction of the cylinder oil lubricating feed rate is possible, information about the quality of lubrication of cylinder liners and piston rings, and can be used as a maintenance tool to maintain the serviceability and reliability of marine slow-speed engines.

A Review of the External and Internal Residual Exhaust Gas in the Internal Combustion Engine

Efficiency and emission reduction are the primary targets of internal combustion engine research due the large number of vehicles in operation and the impact of emissions-related pollution on human and ecosystem health. Harmful components of engine exhaust gases include nitrous oxides (NOx), carbon dioxide, hydrocarbons, and particulate matter. NOx emissions in particular are associated with significant health threats. The recirculation of exhaust gases can reduce NOx emissions and improve engine efficiency when combined with other advanced techniques. On the other hand, the residual exhaust gas also effects on the quality of lubricating engine oil and therefore causes an increase in engine piston ring wear. In this review paper, the effects of external and internal exhaust gas recirculation on the performance and emission characteristics of diesel, gasoline, and alternative fuel engines are summarized and discussed in detail. Because it is difficult to estimate the internal residual exhaust gas in the combustion engine by doing experiments. This review paper introduces control strategies and prediction methods for internal and external exhaust gas recirculation.

Investigation of piston ring wear engines by the mathematical statistics method

Improving the reliability and durability of internal combustion engines makes it possible to increase productivity and reduce the cost of operation. The study of nature and magnitude of piston rings wear is relevant and represents a scientific novelty. During the operation of internal combustion engines, it is almost impossible to determine the influence of various factors on the wear rate and the resource of piston rings. One of the most accurate ways to study the wear intensity and the service life values of internal combustion engines piston rings during operation is the statistical method. The method of mathematical statistics allows us to study the nature and magnitude of individual parts wear with a sufficient degree of accuracy, to determine the main causes of wear, to outline ways of increasing the parts wear resistance, to establish durability criteria, to reasonably assign standard service life of parts and plan the parts need for any period with a given probability, with climatic conditions being taking into account. The article presents the collected statistical material on the internal combustion engines piston rings wear of construction and road vehicles operated at construction sites of Rostov region. It has been processed according to the normal Gauss law and data on the wear and service life of piston rings are obtained. The obtained experimental data on the wear of piston rings in height are reliable to the distribution law and can be used to determine the intensity of engines piston rings wear at repair enterprises.

Wear Test of Cylinder Liner and Piston Ring of Marine Diesel Engine Based on Computer Simulation Technology

With the development of computer technology, computer simulation has become a powerful tool to carry out liner - piston ring wear experiment of Marine diesel engines. Turbocharged diesel engine is a typical multi-system and multi-level complex power plant. There are many factors that affect the piston change and wear speed of diesel engine in practical operation, and many factors are interrelated and influence each other. Marine diesel engine is the most important mechanical equipment in Marine engine room, which has a complex system structure. If the diesel engine fails, it will seriously affect the navigation safety of the ship. In order to reduce the loss of Marine diesel engine piston ring wear, it is necessary to rely on fault diagnosis technology for timely and reliable diagnosis and maintenance.

Engine durability and lubricating oil tribology study of a biodiesel fuelled common rail direct injection medium-duty transportation diesel engine

Biodiesel has emerged as a viable alternative to mineral diesel in the transport sector to replace fossil fuels partially. However, long-term compatibility with engine hardware must be evaluated to ensure a smooth transition. Long-term material compatibility studies of Karanja oil methyl ester (biodiesel) blends with the hardware of a modern common rail direct injection system equipped diesel engine used in sports utility vehicles have been carried out in this investigation. A long-term endurance test was carried out in two phases, each lasting 274 h and utilizing (i) baseline mineral diesel and (ii) a 20% v/v Karanja biodiesel blended with mineral diesel (KB20). After completing the first phase, the engine was dismantled, and essential engine components were investigated for carbon deposits and physical wear using several techniques. Before proceeding with the next phase of the endurance test KB20, new engine components were installed in the engine, and then the test was executed. The KB20-fuelled engine exhibited lower wear on the valves and crankpins but higher wear of liners, piston rings, pistons, gudgeon pin, small and big end bearings of the connecting rod, and the main bearings. Fuel chemistry affected the lubricating oil efficacy and its residual useful life. Lubricating oil from the KB20-fuelled engine exhibited a higher increase in density and ash content. KB20 fuelled engine's lubricating oil underwent higher oxidation and polymerization. The surface roughness characteristics of the cylinder liner were measured before and after the endurance test for comparative wear evaluation during both phases of the endurance test. Carbon deposits on the cylinder head, piston top, and injectors were compared, and the pistons of the KB20 fuelled engine exhibited higher carbonaceous deposits. Biodiesel blends harmed the CRDI engine's fuel injection system. Biodiesel harms the fuel injection equipment (FIE) of the CRDI engine. Various tribological tests were performed on the lubricating oil samples collected regularly to examine the compatibility of KB20 vis-à-vis mineral diesel. This series of tribological tests on the lubricating oil samples assessed the effect of fuel chemistry on the lubricating oil's performance and residual useful life. Tests included variations in lubricant density, viscosity, flash point temperature, moisture content, pentane and toluene insoluble, and copper corrosion with time. The study summarily concluded that Biodiesel blends could be utilized in a CRDI engine without causing major engine durability or lubricating oil degradation issues.

Team durability test of a 1.3 MW locomotive diesel engine with prototype piston rings

Objective of this work was to realize a test of durability of railway engine EMD645 with power about 1300 kW. Within the framework of this test were investigated a prototyped piston’s rings with diamond embankment. Piston rings are made of chromium layer with including of diamond powders technology with a porous chromium coating, where in pores is deposited on said diamond powder with a grain size about 1 micron. The work will be carried out of an analysis of collaboration piston – piston rings – cylinder unit in internal combustion engine and an analysis of the use of hard materials (diamond powder) in friction pairs. During work of this unit we can observe wear of piston rings, precisely - of coating which is deposited on ring to prolong service life. After testing of the locomotive engine EMD645 on the basis of the collected results are developed conclusions of the wearing intensity on piston ring and relating them to the requirements for coatings. The work aims to show the possibilities and benefits of the application of new protective coatings on structural elements of the internal combustion engine in order to reduce their wearing, which is consistent with the observed trend of technology development.

An experimental study on fuel energy saving in gasoline engines using GNP as a lubricant additive

This study concentrates on enhancing the performance of the gasoline engine through nano-lubrication. The effect of Graphene nano-platelets (GNP) as lubricant additives in SAE 15W40 oil on the fuel energy consumption and piston ring wear is investigated. GNP-filled lubricating oil boosted the brake strength, engine torque, and mechanical efficiency, whereas the gasoline engine’s brake specific fuel consumption (BSFC) decreased by 5.3%–6.5% due to a 1.7%–3.46% improvement in engine mechanical efficiency. Further, emission results showed that the GNP-filled lubricating oil reduced the emissions of the engine by approximately 3%–6% as compared to the virgin lubricating oil. Furthermore, the piston ring wear was found to reduce by using GNP-filled nano-lubricant. The characterization of the worn piston ring surfaces showed that the tribo-film formed on wear tracks resulted in the improved performance of the engine thereby reducing abrasive wear and surface roughness. From these studies, an attempt has been made to co-relate engine performance characteristics with tribological perception to contribute in the direction of energy savings and fuel economy.

Potential applications of thermal spray coating for I.C. engine tribology: A Review

The IC engine has been a conventional source of producing mechanical energy for various applications. The tribopair of piston ring and cylinder liner has to work in adverse tribological conditions such as high temperature, speed and load. The wear of piston ring not only reduce the performance of the tribopair but also cause the failure of the system. The insufficient lubrication at the interface increases the tribological losses drastically. The tribological losses can be minimized by coating of some material which has superior tribological performance. The thermal spray coating can be used for providing a stable coating over the tribological surfaces. The versatile operating conditions and process parameters assist the deposition of required material to a desired thickness over the various substrate materials. The process can be used for producing the stable coating over at a faster deposition rate. The environmental friendly coating material can be used as a bled with the conventional coating material for making the process sustainable.

ススによって発生するシリンダボア・ピストンリング摩耗の解析(2) ―ディーゼルエンジンのEGR摩耗に対する表面分析からの解析―

ススによって発生するシリンダボア・ピストンリング摩耗の解析(2) ―ディーゼルエンジンのEGR摩耗に対する表面分析からの解析―

ススによって発生するシリンダボア・ピストンリング摩耗の解析(1):―ディーゼルエンジンのEGR 摩耗に対するピストン摩擦力からの解析―

ススによって発生するシリンダボア・ピストンリング摩耗の解析(1):―ディーゼルエンジンのEGR 摩耗に対するピストン摩擦力からの解析―

The Vibration Characteristics of Diesel Engine Cylinder Piston Rings Under Different Wear

In this paper, Through the experimental research on the wear of cylinder liner and piston ring of diesel engine under different forms, The purpose is to study the vibration law of piston ring of cylinder liner of diesel engine under different wear conditions, and obtain the vibration law through vibration signal analysis, which provides theoretical support for the design of diesel engine. The relevant laws are obtained, which provides good technical support for the follow-up design and research. to explore the use of vibration signals to monitor the cylinder piston ring wear state of the feasibility of starting, summed up the vibration signal of diesel engine piston ring and cylinder liner wear contact the specific state, According to the wear state of multiple sets of cylinder liner piston rings and the change trend of each characteristic parameters of vibration signal: As the wear of the piston ring increases, the vibration signal increases and the vibration characteristic parameters increases; The variation trend of each vibration characteristic quantity with the cylinder liner piston ring is basically the same, and it increases with the increase of wear quantity; When the amount of cylinder liner piston ring is large, the gap between them is also large. The increase of clearance causes the change of characteristic parameters greatly, otherwise it is smaller. Therefore, the larger the gap, the more reliable the diagnosis will be the vibration signal analysis cylinder piston ring wear state of the specific program for diesel engine maintenance and provides the basis for maintenance.

Numerical calculation and experimental study on friction and lubrication of Stirling engine piston ring

To solve the practical problem of Stirling engine piston ring, numerical model on friction and lubrication were established based on average Reynolds equation theory. Numerical calculation results show: piston rings are in the mixed lubrication state which gas lubrication film and micro-convex body contact existing simultaneously; contact pressure is 2 orders of magnitude less than gas film pressure; contact pressure is approximately linearly related to mean gas pressure. Simulated test rig was built and experimental results show: high-pressure working gas leak to intermediate chamber through piston rings, and the pressure of intermediate chamber drops sharply at lowest pressure of circulation; piston ring wear increases when rotational speed or working pressure increase. The accuracy of numerical model was proved by experimental phenomena and test data.

Field-Testing of Biodiesel (B100) and Diesel-Fueled Vehicles: Part 3—Wear Assessment of Liner and Piston Rings, Engine Deposits, and Operational Issues

AbstractThis study investigated the use of biodiesel (B100) and baseline mineral diesel in two identical unmodified vehicles to realistically assess different aspects of biodiesel’s compatibility and durability issues with modern common rail direct injection (CRDI) engine-powered vehicles. Two identical vehicles were operated for 30,000 km under identical operating conditions during a field-trial using biodiesel (B100) and mineral diesel. Exhaustive experimental results from this series of tests are divided into four sections, and this is the third paper of this series of four papers, which covers comparative feasibility and wear analyses, underlining the effect of long-term use of biodiesel on wear of cylinder liner and piston rings compared to baseline mineral diesel-fueled vehicle. Surface microstructures at three locations of the cylinder liner were evaluated using scanning electron microscopy (SEM). Wear was found to be relatively lower at all locations of liners from biodiesel-fueled vehicle compared to diesel-fueled vehicle. Surface roughness of cylinder liners measured at different locations showed that it reduced by ∼30–40% at top dead center (TDC), ∼10–20% at mid-stroke, and ∼20–30% at bottom dead center (BDC) for both vehicles, showing higher wear close to TDC compared to mid-stroke and BDC locations. Loss of piston-ring weight was significantly lower for biodiesel-fueled vehicle. Engine tear-down observations and carbon deposits on various engine components were recorded after the conclusion of the field trials. During these field-trials, engine durability-related issues such as fuel-filter plugging, injector coking, piston-ring sticking, carbon deposits in the combustion chamber, and contamination of lubricating oils were found to be relatively lower in biodiesel-fueled vehicle. Overall, no noticeable durability issues were recorded because of the use of biodiesel in CRDI engine-powered vehicle.