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Cylinder Liners and Consequences of Improved Honing
Halmstad University, School of Business and Engineering (SET), Mechanical Engineering and Industrial Design (MTEK), Functional Surfaces.
Halmstad University, School of Business and Engineering (SET), Mechanical Engineering and Industrial Design (MTEK), Functional Surfaces.ORCID iD: 0000-0002-9447-9635
Halmstad University, School of Business and Engineering (SET), Mechanical Engineering and Industrial Design (MTEK), Functional Surfaces.ORCID iD: 0000-0003-3149-4296
Volvo Power Train Corp., Volvo Group, Göteborg, Sweden.
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2006 (English)Conference paper, (Refereed)
Abstract [en]

The demands on decreased environmental impact from vehicles are resulting in a strong push for decreased engine oil and fuel consumption. Engine oil and fuel consumption are to a great extent controlled by the topography of the cylinder liner surface.

Recent engine tests have shown a promising reduction in oil consumption when using cylinder liners with a smoother finish than the current plateau honing.

One approach to produce smoother liner surfaces is to replace SiC ceramic honing stones with diamond tools. However, event though the diamond honing process results in higher productivity, improved demands of quality control is needed to monitor the degree of cold worked material - “blechmantel” (German), and the resulting risk of increased wear and scuffing.

A number of petrol and diesel engine cylinder liners have been mapped to be able to verify the quality and consequences, in terms of wear and function, of the honing process. A new mapping method, combining SEM images and quantitative image analysis with traditional 2D profilometry has been developed and tested in this study. The liners where tested in a reciprocating rig of 8 mm stroke and with a frequency of 10 Hz, simulating the top-dead center conditions in a running engine.

The tests where carried out in high- and low pressure conditions with smooth respectively rough liner roughnesses against PVD coated piston rings. The developed surface mapping method was employed before and after the test to study effect of running-in wear on the surface, features characterized with the SEM- and the 2D profilometer.

The results show that combining SEM- and profilometric methods gives a good picture of the effects of varying the cylinder liner pressure and roughness. The core roughness decrease more for diesel liners than for petrol liners. In average (rough and smooth liners) the diesel core roughness decrease 265% while the petrol liners average on a 60% decrease. Blechmantel- and Irregularities ratio show a high sensitivity to varying conditions and decrease 1180% to 100% for the diesel liners while the parameters increase between 106% to 18% for all the petrol liners. A probable cause is the more severe diesel high pressure run-in conditions are able to effectively “truncate” the plateaux and remove residing plastically deformed un-cut honing residues while the less severe petrol liner conditions not manage to remove the blechmantel and irregularities in an important extent.

Place, publisher, year, edition, pages
2006. 13- p.
Keyword [en]
cylinder liner, surface topography, quality control, wear, honing
National Category
Engineering and Technology
Identifiers
URN: urn:nbn:se:hh:diva-1888Local ID: 2082/2283OAI: oai:DiVA.org:hh-1888DiVA: diva2:239106
Note

The 12th Nordic Symposium on Tribology, NORDTRIB'06.

Available from: 2008-09-11 Created: 2008-09-11 Last updated: 2015-02-18Bibliographically approved
In thesis
1. On Surface Topography of Cylinder Liners
Open this publication in new window or tab >>On Surface Topography of Cylinder Liners
2008 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The frictional losses, oil consumption and emissions in internal combustion engines are in great extent controlled by the cylinder liner surface topography. This emphasises the importance of: investigating the liner’s topography by objectively characterising it, investigating its effects on the tribological function to gain a better understanding and improving its manufacturing. As a first attempt in this study to objectively characterise the liner surface, a traditional combination of Scanning Electron Microscope (SEM) images and roughness profiles was used. The groove and image parameters characteristic for liner topographies were extracted by applying specially developed algorithms and together with the standard parameters served to study wear on liners of diesel and petrol engines. An experiment was designed to improve the liners’ manufacturing by varying of the honing process parameters and oil flow simulations were run to study the influence of the characteristics of the manufactured surfaces on their function. The results suggested that reducing the base honing pressure and increasing the plateau honing time gave the best surface with smoother plateaux, summits of higher density and milder slopes, more but smaller islands and shallower valleys. The potentials of fast acquiring and containing 3D data of the interference measurements were utilised to overcome the encountered problems in the usage of the combination of profile and SEM measurements and to enable automatic quality control of the cylinder liner surfaces. In the efforts to examine the influence of the surface properties on liner’s function, the extent of blechmantel (cold work material) removal was estimated from 3D measurements of run liners in engine tests. For characterising this feature, algorithms were developed and implemented and it was found that the most of the blechmantel is still left on the liner pointing that it plays a minor role on wear.

Place, publisher, year, edition, pages
Göteborg: Chalmers University of Technology, 2008. 64 p.
Series
Report / Department of Materials and Manufacturing Technology, Chalmers University of Technology, ISSN 1652-8891 ; 37
Keyword
Cylinder liner, Surface Roughness, Characterisation, Honing, Wear, Blechmantel, Groove Parameters, Quality Control, Flow Simulation
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:hh:diva-14648 (URN)
Presentation
Delta-Gamma, Hörsalsvägen 7 Chalmers, Göteborg
Opponent
Available from: 2011-03-28 Created: 2011-03-25 Last updated: 2014-03-05Bibliographically approved

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