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44 (2001), 3, 359-366
TRIBOLOGY TRANSACTIONS
Automotive Components
AVIRAM RONEN and IZHAK ETSION (Fellow, STLE)
Faculty of Mechanical Engineering
Technion
Haifa, 32000, Israel
and
YURI KLIGERMAN
Surface Technologies Ltd.
Nesher, 36601, Israel
A model is presented to study the potential use of micro-surface structure in the form of micro pores to improve tribological
properties of reciprocating automotive components. The Reynolds
equation and the equation of motion are solved simultaneously for
a simplified piston/cylinder system with surface texturing. The
solution provides the time behavior of both the clearance and the
friction force between the piston ring and cylinder liner surfaces. It is shown that surface texturing can efficiently be used to
maintain hydrodynamic effects even with nominally parallel surfaces. It is also shown that optimum surface texturing may substantially reduce the friction losses in reciprocating automotive
components.
KEY WORDS
Automotive; Friction; Hydrodynamic Lubrication; Piston
Rings; Surface Texturing
INTRODUCTION
NOMENCLATURE
A
c
C
Fe
Ff(t)
Ff
Fh
F
h
hp
H
Lc
L
m
Np
p
pa
pt
pb
P
rp
r1
rc
Sp
t
U
W
L
x
X
z
Z
P
1
2
= contact area
= nominal clearance between mating surfaces
= dimensionless clearance, c/hp
= external force acting on the stationary specimen
= instantaneous friction force between the sliding table and
the specimen
= average friction force
= hydrodynamic opening force acting between the sliding
table and the specimen
= dimensionless force, F/(paA)
= instantaneous local film thickness
= pore depth
= dimensionless instantaneous local film thickness, h/hp
= connecting rod length
= axial length of specimen
= specimen mass
= number of pores
= pressure
= ambient pressure
= pressure above ring
= pressure below ring
359
360
contribute to the friction losses the piston and piston ring system
accounts for about 50-60 percent. It is not surprising therefore that
engine friction in general and the friction of the piston/cylinder
system in particular was the focus of many research work, e.g. (2)(4).
Proper lubrication and surface roughness are key issues in
reducing friction in the piston/cylinder system and, hence,
received great deal of attention in the relevant literature. Some of
the previous studies (5) and (6), which predicted the oil film thickness between a piston ring and cylinder liner, assumed that the
liner and the ring surfaces were smooth. The first to develop a piston ring lubrication model, which included surface roughness
effect, was Rohde (7), in 1980. Sanda and Someya (8) examined
theoretically and experimentally the effect of surface roughness
on lubrication between a piston ring and a cylinder liner regarding
four different magnitudes and directions of roughness. It was
found that the effect of the roughness is significant only near the
top and bottom dead centers when the oil film is thinner. Higher
friction peaks were observed in the case of larger (high RMS) and
longitudinal roughness (asperities ridges parallel to the sliding
direction) than in the case of smaller (low RMS) and transverse
roughness.
Michail and Barber (9), (10) developed a theoretical piston
ring/cylinder wall model, based on the average Reynolds equation
developed by Patir and Cheng (11), to study the effects of cylinder wall roughness, crosshatched angle and plateau honing on the
oil film thickness between a piston ring and a cylinder wall. It was
found that for a given set of operating parameters, the oil film
thickness is largest for transversely oriented surfaces. This corresponds to crosshatch angles of less than 45 degrees for the honed
surface considered. It was also found that for equal roughness, the
oil film thickness is largest for unskewed surfaces. From the
rp
2
Sp
[1]
[2]
sin 2
pa
( ) = sin
+
pa
2 1 2 sin 2
pa
[3]
361
X=
Fig. 2bGeometrical model of laser textured surface. Longitudinal
pores column with its system of coordinates and boundary
conditions.
where = pat/ is a dimensionless form of the time. The twodimensional, time dependent form of the Reynolds equation for an
incompressible Newtonian fluid in laminar flow is given by:
3 p 3 p
h
h
+ 12
h
+ h
= 6 U
x x z z
x
t
[4]
2 + 2 rp2
2
h2 + r 2
r 2 hp2
h = c(t ) + p p ( 2 + 2 ) p
2 hp
2 hp
2 + 2 < rp2
x
z
h
p
; Z= ; H= ; P= ;
rp
rp
hp
pa
[5]
After substituting Eqs. [2] and [5] into Eq. [4] the Reynolds
equation in its nondimensional form becomes:
3 P 3 P 1
H 3 H
( )
+
H
+
H
=
X
X Z
Z 2
X 2
[6]
362
2c
= Fh Fe
t 2
[10]
[8]
L
P( Z , X = 0) = Pt ; P Z , X = = Pb ;
rp
[11]
After substitution of Eq. [11] into Eq. [10] the dynamic equation in its nondimensional form becomes:
P
P
r
( Z = 0, X ) = Z = 1 , X = 0
Z
Z
rp
Fh
F
; Fe = e ;
pa A
pa A
[9]
2C
= Fh Fe
2
[12]
where the dimensionless clearance, C, is c/hp and the nondimensional inertia parameter 2 is given as follows:
2 =
2 mrp pa
2 A
[13]
dA
h
[14]
Ff ( ) =
1 ( )
3 H ( )
[15]
where
1 1 dA
=
H A A H ( )
363
0
Fig. 7Dimensionless clearance, C, variation with crank angle.
364
TABLE 1VALUES OF DIMENSIONLESS PARAMETERS OF THE PROBLEM CONSIDERED FOR THE ANALYTICAL
INVESTIGATION
DIMENSIONLESS
PARAMETER
Np
Sp
Fe
1
2
LOWER LIMIT
6
5%
2.5
5.0E-4
5.0E+5
0.001
RANGE OF VARIATION
REFERENCE CASE
12
10%
5
1.0E-3
1.0E+6
0.002
UPPER LIMIT
24
20%
10
2.0E-3
2.0E+6
0.004
365
366
Topography and Oil Film Thickness, Trib. Trans., 38, pp 173-177, (1995).
(11) Patir, N. and Cheng, H. S., An Average Flow Model of Determining Effects of
Three-Dimensional Roughness on Partial Hydrodynamic Lubrication, Trans.
ASME Jour. of Lubr. Tech., 100, pp 12-16, (1978).
(12) Anno, J. N., Walowit, J. A. and Allen, C. M., Microasperity Lubrication,
Trans. ASME Jour. of Lubr. Tech., 91, pp 351-355, (1968).
(13) Anno, J. N., Walowit, J. A. and Allen, C. M., Load Support and Leakage from
Microasperity-Lubricated Face Seals, Trans. ASME Jour. of Lubr. Tech., 90, pp
726-731, (1969).
(14) Hamilton, D. B., Walowit, J. A. and Allen, C. M., A Theory of Lubrication by
Microirregularities, Trans. ASME Jour. of Basic Eng., 88, pp 177-185, (1966).
(15) Etsion, I., Kligerman Y. and Halperin, G., Analytical and Experimental
Investigation of Laser-Textured Mechanical Seal Faces, Trib. Trans., 42, pp
511-516, (1999).
(16) Burstein, L. and Ingman, D., Pore Ensemble Statistics in Application to
Lubrication Under Reciprocating Motion, Trib. Trans., 43, pp 205-212,
(2000).
(17) Mabie, H. H. and Ocvirk, F. W., Mechanisms and Dynamics of Machinery, 3rd
Ed., John Wiley and Sons Inc., New York, pp 19-20, (1975).
(18) Dowson, D. and Taylor, C. M., Cavitation in Bearings, Ann. Rev. Fluid Mech.,
11, pp 35-66, (1979).
(19) Gerald, C. F. and Wheately P. O., Applied Numerical Analysis, 5th ed., AddisonWesley Publishing Co., New York, pp 157-159, (1994).
(20) Cho, S. -W., Choi, S. -M. and Bae, C. -S., Frictional Modes of Barrel Shaped
Piston Rings Under Flooded Lubrication, Trib. Intl., 33, pp 545-551, (2000).