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Characterisation of worn cylinder liner surfaces by segmentation of honing and wear scratches
Halmstad University, School of Business and Engineering (SET), Mechanical Engineering and Industrial Design (MTEK), Functional Surfaces.ORCID iD: 0000-0003-3149-4296
Halmstad University, School of Business and Engineering (SET), Mechanical Engineering and Industrial Design (MTEK), Functional Surfaces.
Volvo Powertrain Corp., Volvo Group, Göteborg, Sweden.
Halmstad University, School of Business and Engineering (SET), Mechanical Engineering and Industrial Design (MTEK), Functional Surfaces.ORCID iD: 0000-0001-8058-1252
2011 (English)In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, Vol. 271, 548-552 p.Article in journal (Refereed) Published
Abstract [en]

The presence of the honing scratches/grooves in cylinder liner surfaces is intended and desired as they improve the lubrication and retain the debris reducing the piston assembly/liner friction and consequently improve the fuel economy and longevity of the internal combustion (IC) engines. Axial scratches caused by the abrasive wear between the tribological partners and/or entrained wear particles are undesired since they are correlated with increased oil consumption and noxious emissions of the IC engines. Due to the imperfection of the manufacturing process, the honing grooves, especially the deep ones, are smeared and interrupted by folds. A portion of the folds would eventually detach during the running process and act as abrasive particles increasing the wear in the cylinder. To closely examine the influence of all these features on the liner's function, it emerges a need to objectively quantify the axial wear scratches, plateau honing grooves, deep honing grooves and their interrupts. The existing techniques fail to segment a groove containing interrupts as they usually appear as summits at several locations in the course of the groove. Combining the profile and image analyses, the deep grooves and their interrupts were successfully identified and quantified in earlier works of the authors. In this paper those algorithms are extended, so that the deep honing grooves, plateau honing grooves and axial scratches crossing different depth levels are sequentially segmented in three levels/steps in an immersing way. A number of parameters derived from this method were utilised to compare 3D interference measurements from the top dead centre, middle and bottom region of a liner run in a truck engine test whereas the three regions represent different wear regimes due to the different running conditions. The results show that: (i) the axial scratches are densest in the top dead centre and about the same size as the plateau grooves in all three regions, while in the bottom region there are only few scratches; (ii) the presence of plateau grooves in the top region clearly decreases, (iii) the deep groove interrupt and coverage are lowest in the top region, and (iv) the groove height and distance between grooves spread mostly.

Place, publisher, year, edition, pages
Amsterdam: Elsevier, 2011. Vol. 271, 548-552 p.
Keyword [en]
Honing, Abrasives, Automobile testing, Debris, Fuel economy, Image analysis
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:hh:diva-14247DOI: 10.1016/j.wear.2010.04.024ISI: 000292678600011Scopus ID: 2-s2.0-77952190501OAI: oai:DiVA.org:hh-14247DiVA: diva2:392671
Projects
Linersurf2
Available from: 2011-01-27 Created: 2011-01-27 Last updated: 2014-03-05Bibliographically approved
In thesis
1. Surfaces of Honed Cylinder Liners
Open this publication in new window or tab >>Surfaces of Honed Cylinder Liners
2011 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Cylinder liner surfaces are often on the agenda of engine developers because of their large influence on the frictional losses, oil consumption and emissions of internal combustion engines. Improving the liner function involves not only manufacturing new surfaces and checking their function but also characterising them as a necessary intermediate step for better understanding of the changes made. In the manufacturing of the liners, honing is a well adapted and widely used finishing process and along with the characterisation and function has been the subject of studies in this thesis. Regarding the liner’s function, three phenomena were monitored: wear, friction and oil passage rate (correlated with engine’s oil consumption). The first one was studied experimentally while the other two were simulated. Only the interactions with the twin land oil control ring were simulated as it has the greatest influence on the control of friction and oil consumption of all other rings. In the mid-stroke region of truck engine liners, the presence of axial wear scratches was observed and their relation with the removal of the cold worked material (“Blechmantel”) folded inside the deep honing grooves was investigated. Algorithms were developed for estimating the extent of Blechmantel, revealing that most of it remained on the surface whereas the engines still performed well. Other algorithms for characterising honing angle, balance of honing texture, width, height, distance between honing grooves/axial wear scratches, etc were developed for quicker and more objective inspection of unworn and worn surfaces from 3D interference measurements. Based on such 3D measurements, the algorithms were incorporated in a characterisation tool enabling rating of the surfaces and determining the number of measurements necessary to achieve stable roughness parameter values. In addition, it was found that interference measurements are more suitable for quantification of the deposits on the worn truck liner surfaces compared with scanning electron microscope measurements. The lubrication and friction of flat oil control ring lands and differently slide honed surfaces of truck liners were simulated. Friction mean effective pressure and oil passage rate were calculated for each surface showing in each case a reduction for the surfaces with smoother plateaus and smaller valleys. Such a liner surface was finished by using a low base honing pressure and a longer plateau honing time. In a car engine, the influence of different liner surfaces, ring land widths and tensions was examined by running simulations. The results suggest that a considerably improved function can be achieved if the ring land width and tension are reduced whereby the differences between the liner surfaces would reduce.

Place, publisher, year, edition, pages
Göteborg: Chalmers University of Technology, 2011. 75 p.
Series
Doktorsavhandlingar vid Chalmers tekniska högskola. Ny serie, ISSN 0346-718X ; 3186
Keyword
Honing, Characterisation, Blechmantel, Groove Parameters, Quality Control, Oil Consumption, Wear, Friction, Mixed Lubrication Simulation
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:hh:diva-14649 (URN)978-91-7385-505-1 (ISBN)
Public defence
2011-03-18, EA, Hörsalsv. 11, Göteborg, 10:00 (English)
Opponent
Supervisors
Available from: 2011-03-28 Created: 2011-03-25 Last updated: 2014-03-05Bibliographically approved

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