Details
| Original language | English |
|---|---|
| Article number | 03-16-04-0027 |
| Journal | SAE International Journal of Engines |
| Volume | 16 |
| Issue number | 4 |
| Publication status | Published - 1 Sept 2022 |
Abstract
Reducing the friction of the internal combustion engine (ICE) is of major interest to reduce fuel consumption and greenhouse gas (GHG) emissions. A huge potential for friction reduction is seen in the piston ring-cylinder liner (PRCL) coupling. Approaching the cylindrical liner shape in the hot operation state will enhance the PRCL conformation. Recently, newly developed freeform honing techniques can help to achieve this perfect cylinder shape. This article presents a numerical study of the effect of freeform honing on the geometrical performance of the liner in the hot operation state. The freeform honed liner (TR) concept is based on the approach of reversing the local deformation of a conventional circular liner. A validated computational model for a gasoline engine is used to compare the geometrical performance of those TR cases with circular, elliptical (EL), and conical elliptical liners (NEL) at different operational points. It was found that the TR concept can reduce the roundness error by 92-95% and the straightness error by 70-75% when the reference load equals the operational one. Quite a good compromise is found to be the initial NEL shape, which probably would be easier for the manufacturing process. In this study, the influence of the reference load on the shape, and with that on friction, is also investigated at different operational loads. It was found that the reference load should be selected at a medium level since commonly the deviations at higher operational loads are less problematic for friction than vice versa. The numerical studies with optimal freeform-shaped cylinder liners - or with the compromise of NEL shapes - show a promising approach to enhance the PRCL conformation and reduce engine friction.
Keywords
- Conical liner, Cylinder liner, Engine design, Freeform honed liner, Non-circular liner, Piston ring-cylinder liner conformation, Tapered bore liner, Thermal deformation
ASJC Scopus subject areas
- Engineering(all)
- Automotive Engineering
- Energy(all)
- Fuel Technology
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In: SAE International Journal of Engines, Vol. 16, No. 4, 03-16-04-0027, 01.09.2022.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Effect of Freeform Honing on the Geometrical Performance of the Cylinder Liner - Numerical Study
AU - Alshwawra, Ahmad
AU - Pohlmann-Tasche, Florian
AU - Stelljes, Frederik
AU - Dinkelacker, Friedrich
N1 - Funding Information: A partial fund for this work was provided by the German Federal Ministry for Economic Affairs and Energy (BMWi) within the cooperation project “Energieeffiziente Prozessketten zur Herstellung eines reibungs-, gewichts-und lebendsdaueroptimierten Antriebsstrangs” (Antriebsstrang 2025). The German Jordanian University (GJU) funded another part through a research scholarship. 1
PY - 2022/9/1
Y1 - 2022/9/1
N2 - Reducing the friction of the internal combustion engine (ICE) is of major interest to reduce fuel consumption and greenhouse gas (GHG) emissions. A huge potential for friction reduction is seen in the piston ring-cylinder liner (PRCL) coupling. Approaching the cylindrical liner shape in the hot operation state will enhance the PRCL conformation. Recently, newly developed freeform honing techniques can help to achieve this perfect cylinder shape. This article presents a numerical study of the effect of freeform honing on the geometrical performance of the liner in the hot operation state. The freeform honed liner (TR) concept is based on the approach of reversing the local deformation of a conventional circular liner. A validated computational model for a gasoline engine is used to compare the geometrical performance of those TR cases with circular, elliptical (EL), and conical elliptical liners (NEL) at different operational points. It was found that the TR concept can reduce the roundness error by 92-95% and the straightness error by 70-75% when the reference load equals the operational one. Quite a good compromise is found to be the initial NEL shape, which probably would be easier for the manufacturing process. In this study, the influence of the reference load on the shape, and with that on friction, is also investigated at different operational loads. It was found that the reference load should be selected at a medium level since commonly the deviations at higher operational loads are less problematic for friction than vice versa. The numerical studies with optimal freeform-shaped cylinder liners - or with the compromise of NEL shapes - show a promising approach to enhance the PRCL conformation and reduce engine friction.
AB - Reducing the friction of the internal combustion engine (ICE) is of major interest to reduce fuel consumption and greenhouse gas (GHG) emissions. A huge potential for friction reduction is seen in the piston ring-cylinder liner (PRCL) coupling. Approaching the cylindrical liner shape in the hot operation state will enhance the PRCL conformation. Recently, newly developed freeform honing techniques can help to achieve this perfect cylinder shape. This article presents a numerical study of the effect of freeform honing on the geometrical performance of the liner in the hot operation state. The freeform honed liner (TR) concept is based on the approach of reversing the local deformation of a conventional circular liner. A validated computational model for a gasoline engine is used to compare the geometrical performance of those TR cases with circular, elliptical (EL), and conical elliptical liners (NEL) at different operational points. It was found that the TR concept can reduce the roundness error by 92-95% and the straightness error by 70-75% when the reference load equals the operational one. Quite a good compromise is found to be the initial NEL shape, which probably would be easier for the manufacturing process. In this study, the influence of the reference load on the shape, and with that on friction, is also investigated at different operational loads. It was found that the reference load should be selected at a medium level since commonly the deviations at higher operational loads are less problematic for friction than vice versa. The numerical studies with optimal freeform-shaped cylinder liners - or with the compromise of NEL shapes - show a promising approach to enhance the PRCL conformation and reduce engine friction.
KW - Conical liner
KW - Cylinder liner
KW - Engine design
KW - Freeform honed liner
KW - Non-circular liner
KW - Piston ring-cylinder liner conformation
KW - Tapered bore liner
KW - Thermal deformation
UR - http://www.scopus.com/inward/record.url?scp=85139201840&partnerID=8YFLogxK
U2 - 10.4271/03-16-04-0027
DO - 10.4271/03-16-04-0027
M3 - Article
AN - SCOPUS:85139201840
VL - 16
JO - SAE International Journal of Engines
JF - SAE International Journal of Engines
SN - 1946-3936
IS - 4
M1 - 03-16-04-0027
ER -