TY - JOUR

T1 - Structural Performance of Additively Manufactured Cylinder Liner

T2 - A Numerical Study

AU - Alshwawra, Ahmad

AU - Abo Swerih, Ahmad

AU - Sakhrieh, Ahmad

AU - Dinkelacker, Friedrich

N1 - Funding Information: This publication was made possible with the support and within the interdisciplinary setting of the Arab–German Young Academy of Sciences and Humanities (AGYA). AGYA is supported by the German Federal Ministry of Education and Research (BMBF). The authors also would like to thank F. Pohlmann-Tasche and F. Stelljes for sharing their experiences and fruitful discussions. Funding Information: Partial fund is given from Leibniz University Hannover. The study is based on earlier funded research work from German Federal Ministry for Economic Affairs and Energy (BMWi) within the cooperation project (Antriebsstrang 2025). The study is intended as a preparation for a new research project in conjunction with additive manufacturing. The publication of this article was funded by the Open Access Fund of the Leibniz Universität Hannover.

PY - 2022/12

Y1 - 2022/12

N2 - Climate change is exacerbated by vehicle emissions. Furthermore, vehicle pollution contributes to respiratory and cardiopulmonary diseases, as well as lung cancer. This requires a drastic reduction in global greenhouse gas emissions for the automobile industry. To address this issue, researchers are required to reduce friction, which is one of the most important aspects of improving the efficiency of internal combustion engines. One of the most important parts of an engine that contributes to friction is the piston ring cylinder liner (PRCL) coupling. Controlling the linear deformation enhances the performance of the engine and, as a result, contributes positively to its performance. The majority of the tests to study the conformability between cylinder liner and piston were carried out on cylinder liners made of cast iron. It is possible to improve the performance of piston ring cylinder liner couplings by implementing new and advanced manufacturing techniques. In this work, a validated finite element model was used to simulate the performance when advanced manufactured materials were adapted. The deformation of the cylinder liner due to thermal and mechanical loads is simulated with five different additive manufactured materials (Inconel 625, Inconel 718, 17-4PH stainless steel, AlSi10Mg, Ti6Al4V). Simulated roundness and straightness errors, as well as maximum deformation, are compared with conventional grey cast iron liner deformation. Some additive manufactured materials, especially Ti6Al4V, show a significant reduction in deformation compared to grey cast iron, both in bore and circumferential deformation. Results show that Ti6Al4V can reduce maximum liner deformation by 36%. In addition, the roundness improved by 36%. The straightness error when Ti6Al4V was used also improved by 44% on one side, with an average of 20% over the four sides. Numerical results indicate that additive manufactured materials have the potential to reduce friction within the piston liner arrangement of internal combustion engines.

AB - Climate change is exacerbated by vehicle emissions. Furthermore, vehicle pollution contributes to respiratory and cardiopulmonary diseases, as well as lung cancer. This requires a drastic reduction in global greenhouse gas emissions for the automobile industry. To address this issue, researchers are required to reduce friction, which is one of the most important aspects of improving the efficiency of internal combustion engines. One of the most important parts of an engine that contributes to friction is the piston ring cylinder liner (PRCL) coupling. Controlling the linear deformation enhances the performance of the engine and, as a result, contributes positively to its performance. The majority of the tests to study the conformability between cylinder liner and piston were carried out on cylinder liners made of cast iron. It is possible to improve the performance of piston ring cylinder liner couplings by implementing new and advanced manufacturing techniques. In this work, a validated finite element model was used to simulate the performance when advanced manufactured materials were adapted. The deformation of the cylinder liner due to thermal and mechanical loads is simulated with five different additive manufactured materials (Inconel 625, Inconel 718, 17-4PH stainless steel, AlSi10Mg, Ti6Al4V). Simulated roundness and straightness errors, as well as maximum deformation, are compared with conventional grey cast iron liner deformation. Some additive manufactured materials, especially Ti6Al4V, show a significant reduction in deformation compared to grey cast iron, both in bore and circumferential deformation. Results show that Ti6Al4V can reduce maximum liner deformation by 36%. In addition, the roundness improved by 36%. The straightness error when Ti6Al4V was used also improved by 44% on one side, with an average of 20% over the four sides. Numerical results indicate that additive manufactured materials have the potential to reduce friction within the piston liner arrangement of internal combustion engines.

KW - additive manufacturing

KW - additively manufactured cylinder liner

KW - cylinder liner

KW - engine design

KW - finite element method

KW - internal combustion engine

KW - thermal deformation

UR - http://www.scopus.com/inward/record.url?scp=85143838365&partnerID=8YFLogxK

U2 - 10.3390/en15238926

DO - 10.3390/en15238926

M3 - Article

AN - SCOPUS:85143838365

VL - 15

JO - ENERGIES

JF - ENERGIES

SN - 1996-1073

IS - 23

M1 - 8926

ER -