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    Friction in IC Engines

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    Robinson Prabu
    The document discusses piston rings and lubrication in internal combustion engines. It provides three key points: 1) Piston rings act as seals between the piston and cylinder wall, preventing combustion gases from escaping and distributing oil. They are needed to maintain a minimum clearance as engines require higher power and temperatures. 2) Proper lubrication is essential for engines. There are different regimes including hydrodynamic, mixed and boundary lubrication depending on oil film thickness. Additives help reduce friction and wear under extreme conditions. 3) Testing methods are used to analyze tribological performance and determine factors like coefficient of friction and wear rate. Design approaches like thinner rings and offset wrist pins can help reduce engine friction. Lubricating

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    Friction in IC Engines

    Uploaded by

    Robinson Prabu
    252 views27 pages
    The document discusses piston rings and lubrication in internal combustion engines. It provides three key points: 1) Piston rings act as seals between the piston and cylinder wall, preventing combustion gases from escaping and distributing oil. They are needed to maintain a minimum clearance as engines require higher power and temperatures. 2) Proper lubrication is essential for engines. There are different regimes including hydrodynamic, mixed and boundary lubrication depending on oil film thickness. Additives help reduce friction and wear under extreme conditions. 3) Testing methods are used to analyze tribological performance and determine factors like coefficient of friction and wear rate. Design approaches like thinner rings and offset wrist pins can help reduce engine friction. Lubricating

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    The document discusses piston rings and lubrication in internal combustion engines. It provides three key points: 1) Piston rings act as seals between the piston and cylinder wall, preventing combustion gases from escaping and distributing oil. They are needed to maintain a minimum clearance as engines require higher power and temperatures. 2) Proper lubrication is essential for engines. There are different regimes including hydrodynamic, mixed and boundary lubrication depending on oil film thickness. Additives help reduce friction and wear under extreme conditions. 3) Testing methods are used to analyze tribological performance and determine factors like coefficient of friction and wear rate. Design approaches like thinner rings and offset wrist pins can help reduce engine friction. Lubricating

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    252 views27 pages

    Friction in IC Engines

    Uploaded by

    Robinson Prabu
    The document discusses piston rings and lubrication in internal combustion engines. It provides three key points: 1) Piston rings act as seals between the piston and cylinder wall, preventing combustion gases from escaping and distributing oil. They are needed to maintain a minimum clearance as engines require higher power and temperatures. 2) Proper lubrication is essential for engines. There are different regimes including hydrodynamic, mixed and boundary lubrication depending on oil film thickness. Additives help reduce friction and wear under extreme conditions. 3) Testing methods are used to analyze tribological performance and determine factors like coefficient of friction and wear rate. Design approaches like thinner rings and offset wrist pins can help reduce engine friction. Lubricating

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    of 27

    AMALRAJ A ARUNKUMAR S

    M.E.,CAD (V SEM) CEG, ANNA UNIVERSITY

    Internal Combustion Engine

    Piston and Piston Rings

    Compression Rings The compression ring acts as a gas seal between the piston and the liner wall, preventing the combustion gases from trailing down to the crankcase. The rings have a certain pretension, i.e. they have a larger free diameter than the cylinder liner, which assists the ring in conforming to the liner. Oil control ring to distribute the oil evenly onto the liner

    Why Piston Rings are needed?


    Increasing power demands required higher temperatures, which caused stronger heat expansion of the piston material. It is necessary to use a sealant between the piston and the cylinder liner to allow a decrease in the clearance in cold conditions, i.e. when the clearances were at their maximum. Keeping the clearance between the piston and liner wall at a minimum considerably reduces the combustion gas flow from the combustion chamber past the piston.

    Requirements of Piston Rings


    Low friction, for supporting a high power efficiency rate Low wear of the ring, for ensuring a long operational lifetime

    Low wear of the cylinder liner, for retaining the desired surface texture of the liner
    Emission suppression, by limiting the flow of engine oil to the combustion chamber Good sealing capability and low blow-by for supporting the power efficiency rate Good resistance against mechano-thermal fatigue, chemical attacks and hot erosion Reliable operation and cost effectiveness for a significantly long time

    Tribological Analysis
    The frictional behavior of the piston, piston ring and cylinder liner can be expressed in several different ways, the most detailed analyses comprise friction curves, in which the
    (i) coefficient of friction, or (i) the friction force is plotted with respect to either - the piston stroke, or - the angular position of the crankshaft.

    Effect of additives in lubricating oil on cylinder liner friction :


    Glidewell and Korcek have presented results obtained in reciprocating tests with a molybdenum-coated cast-iron piston ring sliding against a cast-iron cylinder liner sample. In the measurements, which were carried out with different oils at 100C temperature weighted average coefficients of friction in the range of = 0.10...0.11 = 0.04...0.05 - for oils not containing a friction modifier *, - obtained with oils containing a molybdenum dialkylthiocarbamate (MoDTC) friction modifier *.

    * is measured against crankshaft angle

    Effect of cylinder liner surface finishing and coating


    According to the work by Galligan and co-authors, the coefficient of friction = 0.13 - Cylinder liner standard surface finish. = 0.10 - Cylinder liner with highly polished surface finish. Chromia (Cr2O3) coating applied on both sliding surfaces and lubricated with a polyalphaolefine oil can give a coefficient of friction in the range of = 0.05...0.08 at 260C temperature. Plasma-sprayed coatings, gave lower coefficients of friction than the honed cast-iron cylinder liners under identical test conditions

    Test method of determining wear and co-efficient of friction

    Test Rig: Piezo-electric transducer attached to the non-moving support plate measures the friction force. Resistive coils embedded in heater block heats the specimen thru conduction, for tests at elevated temperature. Data Acquisition System collects and stores the frictional force periodically

    Test method of determining wear and co-efficient of friction


    Wear Analysis: Wear Factor, K = V / (N * X); Where, V Volume of the material removed, N normal load at the sliding contact, X Sliding distance

    Test method of determining wear and co-efficient of friction

    How to reduce engine friction?


    To reduce engine friction Using piston with less mass lowers the piston inertia and reduce acceleration shorter skirt Shorter piston skirts reduce rubbing friction because of the smaller surface contact area. Shorter skirts require closer tolerance between the piston and cylinder wall to keep piston from cocking in the cylinder. Using fewer and thinner piston rings but require closer tolerances. Using offset wrist pin from the center towards the minor thrust side of the piston. To reduce the side thrust force and resulting wear on the major thrust side. Using the shorter stroke. This, for a given displacement requires a larger bore which results in greater heat losses due to larger cylinder surface area, Greater knock tendency due to longer flame travelling distance.

    IC Engine Lubrication
    According to Mr.Richard Stribeck (1861-1950), based on oil film thickness the lubrication is separated into three regions: - Hydrodynamic lubrication - Mixed lubrication - Boundary lubrication Hydrodynamic Lubrication The two bearing surfaces are completely separated by oil film Mixed Lubrication The oil film thickness drops into the range of roughness of the bearing surfaces. The peaks of the surface which give it its roughness are called asperities and the asperities are begin to contact. Boundary Lubrication The interaction of the asperities between the two bearing surfaces increasingly the cause of friction

    IC Engine Lubrication
    Elasto-Hydrodynamic Lubrication In rolling element bearings, the elastic deformation of the bearing (flattening) as it rolls under load in the bearing race. This momentary flattening improves the hydrodynamic lubrication properties by converting point or line contact to surface-surface contact.

    System
    Crankshaft Bearing Crankpin Bearing

    Mode of Lubrication
    Hydrodynamic Hydrodynamic

    Wristpin
    Cam/Lifter contact

    Sliding Hydrodynamic
    Elasto-Hydrodynamic/Boundary

    Hydrodynamic Lubrication A system of lubrication in which the shape and relative motion of the sliding surfaces causes the formation of a fluid film having sufficient pressure to separate the surfaces.

    Factors which determine Hydrodynamic Oil Film thickness:


    Oil Viscosity HD oil film thickness is directly proportional to the oil viscosity. The choice of oil viscosity is determined by design load, bearing clearance and rpm range of the engine. Temperature of the oil During cold, the residual oil in the bearing will have a much greater viscosity than it will at the engines full operating temperature, which lowers the chance of bearing damage. A hot restart of an engine poses more of a risk of bearing damage , due to the fact the oil film will be thinner than a cold oil film, and may not adequately separate the journal and bearing until proper oil system pressure is re-established.

    Factors which determine Hydrodynamic Oil Film thickness:


    Polarity of the oil It directly affects its adhesion to the parts it is supposed to lubricate. The amount of adhesion can be determined by the resulting angle at the junction of the drop as it wets the surface.

    Cam, follower, crankshaft and bearing insert are made of high polar metals.
    Polyol ester, Polyalkaline glycol are highly polar.

    Boundary Lubrication
    It is a form of lubrication between two wearing surfaces without the existence of a full-fluid lubricating film. Eg. Cam/Follower contact Wide variety of additives can be added to the primary lubricating oil to alter the lubricating characteristics. For mild conditions, oiliness agents can be added. Oiliness agents can reduce friction and abrasion under some conditions that are too severe for straight petroleum oils. The most severe cases of boundary lubrication are defined as extreme pressure conditions; they are met with lubricants containing Extreme Pressure additives that prevent wearing surfaces from actually fusing together at high local temperatures and high pressures. ET-50 is an Extreme Pressure (EP) additive. It is an advanced boundary lubrication technology developed by Greenecotek

    Boundary Lubrication
    EP additives typically contain organic sulfur, phosphorus, zinc compounds which attempt to produce a chemical reaction with the metal surface under these high pressure and high temperature conditions. ET-50 functions by addressing the condition whereby at the high local temperatures associated with the metal-to-metal contact,

    the EP agents in ET-50 disassociate from the product and combine chemically with the metal surface to form a surface film that prevents the welding of opposing asperities (rough surfaces), and the consequent abrasion and scoring that is destructive to these wearing surfaces under these extreme conditions.
    ET-50 forms a molecular bond that chemically reacts with the metal compound to create a remarkably strong surface that serves to drastically reduce friction,

    Boundary Lubrication
    Benefits of ET-50 Compatible with all petroleum and synthetic oils, greases, hydraulic fluids. Chemical reaction reduces friction, heat, wear, corrosion, rust and chemical attack. Reduces acidic formations in internal combustion engines. High temperature operating range. Constant viscosity reduces dry start-ups. Keeps metal surfaces free of contaminants and solid particulates. Easier cold weather starts in internal combustion engines. General Applications ET-50 is a surface metal conditioner for use wherever any conventional lubricants can be used.

    Lubricating Oil Functions


    to reduce friction and wear Coolant Removal of contaminants Piston ring pressure seal Slow rust and corrosion Stable over operating temperature Long life and low cost

    Lubricating Oil Additives


    Antifoam agents Oxidation inhibitors Pour-Point depressant Antirust agents Antiwear agents Friction reducers Viscosity index improvers.

    Types of Lubrication System


    1. Pressure Lubrication System 2. Splash Lubrication System Pressure Lubrication In a pressure lubrication system, a mechanical pump supplies oil under pressure to the bearings
    Oil flows into the inlet of the pump through the pump and into an oil manifold which distributes it to the crankshaft bearings

    Types of Lubrication System


    Splash Lubrication In the splash lubricating system , oil is splashed up from the oil pan or oil trays in the lower part of the crankcase.
    The oil is thrown upward as droplets or fine mist and provides adequate lubrication to valve mechanisms, piston pins, cylinder walls, and piston rings In the engine, dippers on the connecting-rod bearing caps enter the oil pan with each crankshaft revolution to produce the oil splash. A passage is drilled in each connecting rod from the dipper to the bearing to ensure lubrication.

    Types of Lubrication System


    Combination of Splash and Pressure Feed

    Purpose of Lubrication of engine bearings: Significant decrease of the co-efficient of friction Extraction of the heat generated by friction Removal of foreign particles from the rubbing surface

    References
    S.NO
    1

    Description
    Peter Andersson, Jaana Tamminen & Carl-Erik Sandstrm Piston Ring Tribology Test Method to Evaluate Cylinder Liner Piston Ring Coatings for Advanced Heat Engines Internal Combustion Engine Lubrication A Study of Friction and Lubrication Behavior for Gasoline Piston Skirt Profile Concepts Boundary Lubrication by Greenecotek

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