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Optimisation of Cylinder Liner Surface Finish by Slide Honing
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.ORCID iD: 0000-0002-9447-9635
Halmstad University, School of Business and Engineering (SET), Mechanical Engineering and Industrial Design (MTEK), Functional Surfaces.ORCID iD: 0000-0003-0292-893X
Volvo Cars.
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2012 (English)In: Proceedings of the Institution of mechanical engineers. Part B, journal of engineering manufacture, ISSN 0954-4054, Vol. 226, no 4, 575-584 p.Article in journal (Refereed) Published
Abstract [en]

Cylinder liner surface finish controls the frictional losses, oil consumption, and emissions of internal combustion engines to a large extent. In order to minimize such losses, it is important to optimize the liner surface topography by a consistent and more productive finishing process such as slide honing. This process employs diamond abrasives and has been recently introduced in the automotive industry. In this study, its potentials are explored, especially the winning combination of its key process parameters: the base honing pressure and plateau honing time that would yield an optimal liner surface finish. A number of truck engine liners were slide-honed by using different process parameters, samples of the liners were cut, and three-dimensional (3D) surface measurements were taken on a white light interferometer. Then, among others, the (deep honing) groove parameters, specific for liner surfaces, were computed from the measurements for building a large database for comparison and correlation. By simulating the contact and fluid mechanics between the measured liner topographies and a twin land oil control ring under mixed lubrication conditions, the friction mean effective pressure and oil passage rate for a range of engine speeds were calculated. These two parameters represent the liner's function associated with the engine's friction and oil consumption respectively. The results show that the lowest friction and oil flow are highly correlated with surfaces having smoother plateaus and smaller valleys, finished by using lower base honing pressure and longer plateau honing time. High correlations between the 3D roughness parameters were also found, enabling the selection and use of more stable and robust parameters in the quality control of the liner's surface finish. © IMechE 2012.

Place, publisher, year, edition, pages
London: Mechanical Engineering Publ. , 2012. Vol. 226, no 4, 575-584 p.
Keyword [en]
3D characterization, diamond honing, liner surface finish, mixed lubrication simulation
National Category
Manufacturing, Surface and Joining Technology
Identifiers
URN: urn:nbn:se:hh:diva-14645DOI: 10.1177/0954405410396154ISI: 000305481600001Scopus ID: 2-s2.0-84860231449OAI: oai:DiVA.org:hh-14645DiVA: diva2:406501
Available from: 2011-03-25 Created: 2011-03-25 Last updated: 2016-08-15Bibliographically 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
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Available from: 2011-03-28 Created: 2011-03-25 Last updated: 2014-03-05Bibliographically approved

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Dimkovski, ZlateCabanettes, FrédéricLöfgren, HansAnderberg, CeciliaRosén, Bengt-Göran
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