Background

Frictionworkvaries10%atfullloadto100%atidle(noload)
Goodenginedesignhaslowerfrictionalloss
Largepartoffrictionallossesappearasheatandremovedinthe
oilcoolerandradiatorsystems,thusinfluencethesizeofthe
cooling system
coolingsystem.
Frictionwork=Workdeliveredtothepistonwhiletheworkingfluidis
containedwithin(compressionandexpansionstroke) usableworkdelivered
tothedriveshaft

Engine friction and lubrication

Dr. Primal Fernando
primal@eng.fsu.edu
Ph: (081) 2393608
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ENGINECONSTRUCTIONOVERVIEW
LubricationSystem

Lubrication&Bearings
2/3ofenginefrictionisatthe
pistons&rings
Lossesincreasewithspeed
Frictionmostsignificantatpart
loadoperation,sinceitisaweak
functionofloadandastrong
functionofRPM

Allenginescontainmovingand
slidingpartsthatmustbekept
lubricatedtoreducewearand
friction.

Atypicallubricationsystem,showingtheoil
pan,oilpump,oilfilter,andoilpassages.

ReadInfoonViscosity
SAE10W40measuredat0oFand
210oF
Ratingslosemeaningathigh
loading

TheSocietyofAutomotiveEngineers (SAE)hasestablishedanumericalcodesystemforgradingmotor
oilsaccordingtotheirviscositycharacteristics.SAEviscositygradingincludethefollowing,fromlowto
highviscosity:0,5,10,15,20,25,30,40,50or60.Thenumbers0,5,10,15and25aresuffixedwiththe
letterW,designatingtheirwinter(notweight)orcoldstartviscosity,atlowertemperature.
3

Mean Effective Pressure, MEP Concept

Workdissipatedasheat

Actual Processes
Pumpingwork(Wp): todrawthefreshmixturetothecylinder
andtoexpeltheburngasfromthecylinder
Toovercometheresistancetorelativemotion(rubbingfriction
work Wrf): frictionbetweenpistonrings,pistonskirt,and
cylinderwall;frictioninthewristpin,bigend,crankshaftand
camshaftbearings;frictioninthevalvemechanism;frictioninthe
gears,orpulleysandbelts
Todrivetheengineaccessories(accessoryworkWa): fan,water
pump,oilpump,fuelpump,thegenerator,secondaryairpump
foremissioncontrol,powersteeringpump,andairconditioner
Note:theabsolutevalueoffrictionworkvarieswithload,andincreasesasspeed
increases
Totalfrictionwork,

Equivalent by MEP

Equivalent

Wnet

MEP

Wwork per cycle

vmin
TDC

vmax v

vmin

vmax

BDC

Wwork per cycle = (MEP) x (Displacement Volume)

= (MEP) x (Vmax-Vmin)

Wtf=Wp+ Wrf+ Wa

=(MEP)xVd
5

Power and Mean Effective Pressure

Workdissipatedasheat

Wwork per cycle = (mep) x (Displacement Volume)

Wtf(totalfriction)=Wp(intake&exhaust)+ Wrf(rubbingfriction)+ Wa(engineaccessory)

= (mep) x (Vmax-Vmin)
=(mep)xVd

P W percycle

Ptf(totalfriction)=Pp(intake&exhaust)+ Prf(rubbingfriction)+ Pa(engineaccessory)

N
nR

mep Vd

P W percycle

N
nR

N
nR

mep Vd

N
nR

nR number of revolutions per cycle,

nR number of revolutions per cycle,

1 for two - stroke cycle and 2 for four stroke cycle

1 for two - stroke cycle and 2 for four stroke cycle

Therefore,Wtf,Wp, Wrf, Wa canbedefineas,tfmep&Ptf,pmep&Pp,

rfmep&Prf,amep&Pa

tfmep(totalfriction)=pmep(intake&exhaust)+ rfmep(rubbingfriction)+ amep

(engineaccessory)

Someterms

Measurements

Brakepower(Pb):Measureenginepower(bythedynamometer).
Thisistheusablepowerdeliveredbytheenginetotheload
Netindicatedpower(Pn):Theworkdeliveredtothepistonover
theentirecycle
Grossindicatedpower(Pg):Theworkdeliveredtothecycle
duringthecompressingandexpansionstrokes

Brakepower:bythedynamometer
Grossindicatedpower:when
accuraterecordofcylinderpressure
throughoutthecycleisavailable
Netindicatedpower:whenaccurate
recordofcylinderpressure
th
throughoutthecycleisavailablepdV
h t th
l i
il bl dV
overthewholecycle

Pg=Pn+Pp

Pg=Pn+Pp
imepg=imepn+pmep
bmep=imepg tfmep
tfmep=pmep+ rfmep+ amep

bmep=imepn rfmepamep

imepg=imepn+pmep
bmep=imepg tfmep
tfmep=pmep+ rfmep+ amep

bmep=imepn rfmep amep

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10

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12

Frictionallossescanbeclassifiedintotwogroups
dependingondissipation

Operationconditionsoftwocommongeometriesfor
lubricatedparts
oil

1. Frictionbetweentwometalsinrelativemotion,withalubricant
inbetween

journal
bearing

2. Turbulentdissipationpartofthetotalfrictionworkisspentin
pu pi g fluids th ough flo est ictio s P
pumpingfluidsthroughflowrestrictions
P v2.
Lubricatedsliderbearing
load

supporting oil film

Lubricatedjournalbearing

Note:Aprimaryprobleminunderstanding
frictionbetweenlubricatedsurfacesin
enginesisthewidevariationinthe
magnitudeoftheforcesinvolved.

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Coefficientoffrictionf (Tangentialforce/Normalforce)fora
journalbearingisplottedagainstdimensionlessdutyparameter

Coefficientoffrictionf (Tangentialforce/Normalforce)
Thecoefficientoffrictioncanbeexpressedas

Foraslidingsurface
dutyparameter=U/(b)

Mixed lubrication

fs ismetaltometalcoefficientofdryfriction,frictioniscalledboundary,
i.e.,closetosolidfriction.Lubricatingfilmisreducedtooneorafew
molecularlayersandcannotpreventmetaltometalcontactbetween
surface asperities
surfaceasperities
fL ishydrodynamiccoefficientoffrictionorviscousorthickfilmfriction.
Lubricationfilmcompletelyseparatesthesurfacesofrelativemotion( =0).

Coefficie
ent of friction, f

f f s (1 ) f L

Hydrodynamic lubrication

0.1
-Lubricant dynamic viscosity

0.01

0.001
Boundary lubrication

Betweenfs andfL ismixedorpartiallubricationregime

f f s (1 ) f L

-Loading force per unit area

N-rotational speed

D t parameter =N/
Duty
N/
Hydrodynamic friction, (1- )fL
Solid friction, fs

ismetaltometalcontactconstant,variesbetween0and1
Stribeckdiagram:ProfessorRichardStribeck(1861 1950)wasperformed
inBerlinattheRoyalPrussianTechnicalTestingInstitute
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Coefficientoffrictionf (Tangentialforce/Normalforce)fora
slidingsurfaceisplottedagainstdimensionlessdutyparameter

STRIBECKCURVE

Full Fluid

Boundarybad
forbearings!
BoundaryOK
forcams/lifters/
rockers

WearRegion

Safe Region
SafeRegion
Friction

theoretical optimum range

boundary
metal
to
metal
contact

16

friction
increase due
to fluid shear
IncreasingFilmThickness

Z=f(Speed*Viscosity)/(Load*Finish)
17

18

Boundarylubrication

Realcontactarea

(duringstartandstoppingprocess,betweenslowmovingparts valve
stemrockerarms,heavilyloadedparts,crankshaft,timinggears,chains)
Ar

Surfacepropertiesinrelative
motion
Roughness,hardness,
elasticity,plasticity,
shearingstrength,thermal
conductivityandwetability
withrespecttothelubricant
Lubricantproperties
Surfacepropertiesor
chemicalproperties,which
governsthelubricantsto
attachthemselvestotheto
thesolidsurfaces

Normal load Fn

yield stress m

Ft real area shear strength Ar m

Thecoefficientoffrictionf is,
f

Ft

m
FN m

Note:fordissimilarmaterials,thepropertiesofweakermaterials
dominatesthefrictionbehavior

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Hydrodynamiclubrication

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Turbulentdissipation

(bearings,pistonskirtandcylinderliner,athighspeed,pistonringsand
linersathighspeeds)
Hydrodynamiclubricationconditionsoccurwhentheshapeandrelative
motionoftheslidingsurfacesformaliquidfilminwhichthereisa
sufficientpressuretokeepthesurfacesseparated.Resistancetomotion
resultsfromtheshearforceswithintheliquidfilm
dv

dy
dv

dy

dv
U

f
(straight line on the Stribeck diagram)

dy
Note:viscousfrictionisindependentofmaterialproperties,onlydepends
onthefluidsviscosity.Hydrodynamiclubricationbreaksdownwhenthe
thicknessofthefluidfilmbecomesaboutthesameassurfaceasperities.
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Totalfriction

22

Measurementmethods

work per cycle per each component i friction force displacement

W f ,i F f ,i ( )dx
friction components either indipendent of speed (boundary friction)
proportional to speed (hydrodynamic friction)
proportional to speed squred (turbulent friction)

Truemeasurementoffrictioninafiringenginecanonlybe
obtainedbysubtractingthebrakepowerfromtheindicated
powerdeterminedfromaccuratemeasurementsofcylinder
pressurethroughoutthecycle.Thisisnoteasytouseinmulti
cylinderengine:cylindertocylinderdifferencesanddifficultyof
obtainingsufficientlyaccuratepressuredata.

bmep=imepg tfmep

or combination of above 3

tfmep=pmep+ rfmep+ amep

bmep=imepn rfmepamep

Wtf (or tfmep) C1 C2 N C3 N 2

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Measurementoffmepfromimep

Directmotoringtest

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Morsetest

Williansline

Morsetestisdoneona4strokemulticylinderengine.Theobjectiveistofindthebrakepower(power
availableatthecrankshaft)oftheengine.Youcanalsofindtorque,mech.efficiencyetc...
Letusconsidera4cylindersparkignition(petrolengine)engineforanexample.
Thefollowingstepsaretobeperformed
1.Theengineisstartedandisrunattheratedspeed.
2.Themaximumloadoftheengineiscalculatedandisconnectedtotheengine.Theengineisnowbrought
toitsratedspeed.
3.Thefirstcylinderiscutoffbyshortingthesparkplug.
4.Nowbecausethecylinderiscutofftheenginespeedisreduced.
5.Hencetheloadistobevariedsuchthattheenginecomesbacktoitsratedspeed.
6.Thenthefirstcylinderisagainstartedandthesameisrepeatedforalltheothercylinders.
Theenginecanbeloadedusingadynamometer(hydraulicoreddycurrent)
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MORSETEST

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#THEORY:
MorseTestisapplicabletomulticylinderengines.Theengineisrunat
desiredspeedandoutputisnoted.Thenoneofthecylindersiscutout
byshortcircuitingsparkplug.Underthisconditionothercylinders
motorthiscutcylinder.Theoutputismeasuredbykeepingspeed
constanttooriginalvalue.Thedifferenceinoutputismeasureofthe
indicatedpowerofcutoutcylinder.Thusforeachcylinderindicated
powerisobtainedtofindouttotalindicatedpower.
Let,
BP=BrakePowerwhenallcylindersareinworkingcondition.
BP1=BrakePowerwhenfirstcylindercutoff.
BP2=BrakePowerwhensecondcylindercutoff.
BP3=BrakePowerwhenthirdcylindercutoff.
IP=IndicatedPowerofEngine
IP1=IndicatedPoweroffirstcylinder
IP2=IndicatedPowerofsecondcylinder
IP3=IndicatedPowerofthirdcylinder
FP1,FP2,FP3=Frictionpowerofeachcylinder

MORSETEST
#AIM:
TostudyandconductMorseTestonthreecylinderfourstrokePetrol
Engineandtodetermine:
i) I di t d P
i)IndicatedPowerofIndividualCylinders
f I di id l C li d
ii)IndicatedPowerofEngine
iii)FrictionalPowerofEngine
iv)MechanicalEfficiency

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When,
Allcylindersinworkingcondition,
IP=(IP1+IP2+IP3)(i)
BP=(IP1+IP2+IP3) (FP1+FP2+FP3)..(ii)
FirstCylinderCutoff,
BP1=(IP2+IP3) (FP1+FP2+FP3).(iii)
Where,(FP1+FP2+FP3)inabovebotheqs.(ii)&(iii)remainsalmostconstantatconstant
speed.
SubtractingEq.(iii)fromEq.(ii),Weget,
IndicatedPoweroffirstcylinder,
IP1=(BP BP1).(iv)
Similarly,
y,
IndicatedPowerofsecondcylinder
IP2=(BP BP2)..(v)
IndicatedPowerofthirdcylinder
IP3=(BP BP3).(vi)
PuttingthevaluesofIP1,IP2,IP3ineq.(i),weget,
IP=(BP BP1)+(BP BP2)+(BP BP3).(vii)
FrictionalPower,
FP=(IP BP)(viii)
MechanicalEfficiency,
?m=(BP/IP)(ix)

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EnginefrictiondataSIengine

33

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Enginefrictiondata CIengine

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36

Enginefrictioncomponents

Pumpingfriction

moredetailedanalysisofenginefriction

37

Pumpingfriction

38

Pumpingfriction

39

Lubricationsystem
Thelubricationsystem
providesoiltoappropriate
areasoftheengineto
maintainafilmofoilto
separatebearingsurfaces.
Oilalsotransferscombustion
heattothecrankcase.
Animportantcharacteristic
ofoilistheviscosity.
Viscosityistheinternal
resistancetoflowofafluid.

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OilStandards

TheSAEratestheviscosity
ofoils.
Lowviscositymeansahigh
volumeofoilflowsthrough
aspecificorificeata
specifiedtemperature,
atmosphericpressure,and
time period.
timeperiod.
Multiviscosityoilsare
popularbecausetheyoffer
lowviscositycharacteristics
inlowtemperaturesand
highviscositycharacteristics
withhighertemperatures.

ServiceCategories
GasolineEngines
SA,SB,SC,SD,SE,
SF,SG,SHare
obsolete.
SJ:2001andolder
automotiveengines.
SL:Allautomotive
enginesmanufactured
afterJuly2001.

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ServiceCategoriesDieselEngines
CA,CB,CD,CEareobsolete.
CF:Offroad,indirectinjected
manufacturedafter1994andwith
fuelsover0.5%sulfur.
CF2:Severeduty,twocycleengines.
CF 4: High speed four cycle engines
CF4:Highspeed,fourcycleengines.
CG4:Severeduty,highspeed,four
stroke,withfuelslessthan0.5%
sulfur.
CH4:Highspeed,fourstroke
enginesdesignedtomeet1998exhaust
standards.
CI4:Highspeed,fourstrokeengines
designedtomeet2002exhaust
standards.
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