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EN
The paper describes the results of the wear test of innovative sets of piston rings intended, among others, to drive diesel locomotives operated in North America, including the USA. The main subject of research is an innovative set of piston rings, the first sealing ring containing a synthetic diamond embedded in a porous chrome coating. The developed multilayer coating is designed to reduce the wear of the piston rings and the combustion engine cylinder. This technology has been implemented at Piston Rings Manufactory "Prima" S.A. in Łódź. The tests were carried out using a two-stroke diesel engine of the EMD 645 type. This engine is manufactured by General Motors Corporation in the United States. The described research was carried out in the United States in San Antonio, Texas, at the Southwest Research Institute. The EMD 645 engine is widely used in power units of heavy diesel locomotives and inland waterway barges in the United States of America, India, and South Africa.
EN
Objective of this work was to realize a test of durability of railway engine EMD645 with power about 1300 kW. Within the framework of this test were investigated a prototyped piston’s rings with diamond embankment. Piston rings are made of chromium layer with including of diamond powders technology with a porous chromium coating, where in pores is deposited on said diamond powder with a grain size about 1 micron. The work will be carried out of an analysis of collaboration piston-piston rings-cylinder unit in internal combustion engine and an analysis of the use of hard materials (diamond powder) in friction pairs. During work of this unit we can observe wear of piston rings, precisely - of coating which is deposited on ring to prolong service life. After testing of the locomotive engine EMD645 on the basis of the collected results are developed conclusions of the wearing intensity on piston ring and relating them to the requirements for coatings. The work aims to show the possibilities and benefits of the application of new protective coatings on structural elements of the internal combustion engine in order to reduce their wearing, which is consistent with the observed trend of technology development.
EN
Apparatus was developed to measure piston assembly friction with a floating cylinder liner against crank angle, using components of an eco-mileage vehicle engine as much as possible. This apparatus was then used to investigate the effect of different sets of piston rings on piston assembly friction in an eco-mileage vehicle engine. Results indicated that, compared to the piston with all three rings (a top ring, a second ring and an oil ring), the piston with two rings (a top ring and an oil ring) reduced piston assembly friction at all engine temperatures and engine speeds. Another configuration of two rings, with the top ring and the second ring, but without the oil ring, reduced friction at a lower engine temperature and speed, but was almost the same as the three-ring set at a higher engine temperature and speed. Finally, a one-ring set, with only the top ring, further reduced friction, except at a higher temperature and speed, where friction was greater than the two-ring set without the second ring.
EN
In two-stroke engines of the crankcase-compression type, the piston rings slide over not only the cylinder wall but also the cylinder ports. It is important for piston ring designers to understand how piston rings behave over cylinder ports. In order to clarify the axial motion of piston rings in two-stroke engines, we established a measurement method using light-emitting diodes (LEDs). We attached LEDs inside the piston, and leaked the backlight of LEDs through the side clearance between the piston ring side face and the piston ring groove side face. From the position of the leaked backlight in the piston ring groove, we determined the axial ring position in the ring groove. Our experiments set this piston with LEDs in an experimental two-stroke engine with a transparent cylinder, and investigated the effects of intake and exhaust ports on axial ring motion under motoring operations. Results indicated that the rings moved in the axial direction by the ring projection and catching in the intake and exhaust ports.
PL
W pracy przedstawiono próbę wyjaśnienia mechanizmów zużywania skojarzenia żeliwny pierścień tłokowy/kompozytowa tuleja cylindrowa w mikroskali, używając płytkowego modelu perlitu. Do obliczeń lokalnych wartości naprężeń i odkształceń w perlicie stanowiącym osnowę żeliwa, stykającym się z włóknami zbrojącymi tulei cylindrowej zbudowano model geometryczny i wykonano obliczenia Metodą Elementów Skończonych. Do budowy modelu geometrycznego wykorzystano cechy stereologiczne ziaren perlitu i włókien zbrojących w kompozycie. W wyniku przeprowadzonych obliczeń uzyskano lokalne rozkłady wartości naprężeń i odkształceń w płytkach cementytu i ferrytu oraz w pobliżu włókna w osnowie kompozytu. Naprężenia wyliczone z użyciem modelu uproszczonego (izotropowe ziarna perlitu) są inne niż z użyciem modelu rozbudowanego (płytki cementytu i ferrytu w ziarnach perlitu). Wartości te pozwalają wyjaśnić mechanizm zużywania analizowanego skojarzenia.
EN
The paper presents an attempt to explain the mechanism of wear in a contact cast iron piston ring/composite cylinder liner analysed at a microscale by using of lamellar model of a pearlite. For calculation of local stresses and strains levels in a pearlite, which constitutes the matrix of cast iron being in a contact with reinforcing fibres in a cylinder liner, a geometrical model was built and calculations using FEM were carried out. Stereological parameters of pearlite grains and fibres in a composite were used for the construction of the geometrical model. Local distributions of stresses and strains in cementite and ferrite lamellas have been acquired as a result of calculations carried out. Stresses calculated by using the simplified model (isotropic pearlite grains) are different from those calculated by using the enlarged model (cementite and ferrite lamellas in pearlite grains). These values allow one to explain the wear mechanism of the investigated contact.
6
Content available The numerical calculation module for piston rings
EN
The piston with piston rings and bearing surface is a self-contained and highly complex tribological system. One of the most widespread global friction pairs traversed by reciprocating a pair of ring - cylinder liner piston - rings - cylinder internal combustion engine. Group PRS combustion engine is the solution generating considerable friction. Various researchers estimate the share of friction losses, per node piston rings - cylinder liner, at 19 to 60% of the total friction losses in the combustion engine. This paper describes part of a larger program to reduce wear the set working parts (piston, piston ring and bearing surface). The project is implemented through the development of new designs of piston rings with anti-wear coating that contains synthetic diamond in the form of loose embedded in a coating of chromium (PRS). The aim of the authors was to present the methodology used to compute characterized by a particular procedure. In practical use FEM software is used and the FVM. Developed and implemented Piston Rings Calculation Module is compatible with the idea of numerical computational methods is to say: functionally consists in carrying out a calculation of the desire to achieve the exact solution (the nearest is real) by conducting and receiving intermediate solutions (the next).
EN
The elements creating a friction pairs are described to be very difficult in terms of defining all optimal parameters in an unequivocal way. The research on stability of friction pairs is focused on the surface and the top layer of surface in the parts concerned. The main goal is to find new design solutions and materials, thereby achieving one million kilometers of mileage to main repair in the case of internal combustion engines. The biggest structural difficulties are noticeable in friction pairs where it can be observed sliding and returning motion, which is also connected with sealing function. A typical example of such pair is piston ring – cylinder sleeve in piston – rings - cylinder unit in an internal combustion engine. Engineers are currently seeking an additional factor, which would enable gaining the reduction of tangential force by reducing the friction coefficient in elements of friction pair during operations. The surface free energy may be such factor - it results from molecular structure and nature of the bonds between the molecules present in the material. Components of surface free energy determine the tribological properties of the material, which is reflected in the stability of the units. Energy state of the surface, which is connected with chemistry and characteristics in the material, is the first step to consider about the impact on wearing in internal combustion engine. This is the main topic of this article.
EN
A trial to define the effect of changes in cylinder geometry on compression ring pressure distribution has been presented in this paper which refers to the earlier papers of the authors. The analysis encompasses these cylinders where both circumferential and axial deformations occurred, relative to constructional and assembly errors but above all to engine operation. The conclusions withdrawn from these analyses were applied to exemplary calculations that try to evaluate the effect of cylinder deformation on correct collaboration of ring and liner and particularly on possibility of circumferential gaps leading to blow-by. The drafts presented in the paper show exemplary results of ring pressure distribution for a complete ring path between the dead centers and selected engine operational data. Moreover, such areas of cylinder surface were shown where slots between compression ring and cylinder liner might occur with high probability.
PL
W niniejszym opracowaniu, wiążącym się tematycznie z wcześniejszymi publikacjami autorów, dokonano próby określenia wpływu zmian geometrii cylindra na rozkład nacisku uszczelniającego pierścienia tłokowego. Analizami objęto cylindry, w których wystąpiły zarówno obwodowe, jak i osiowe zmiany kształtu, spowodowane np. błędami konstrukcyjnymi i montażowymi, ale przede wszystkim związane z eksploatacją silnika. Wynikające z tych analiz wnioski wykorzystano do przykładowych obliczeń, obejmujących ocenę wpływu deformacji cylindra na poprawność współpracy pierścienia z gładzią cylindra, a w szczególności na możliwość pojawienia się szczelin obwodowych, ułatwiających wystąpienie przedmuchów gazów. Na zamieszczonych w opracowaniu wykresach pokazano przykładowe wyniki obliczeń rozkładu nacisku pierścienia na gładź cylindra, obejmujące całą drogę pierścienia pomiędzy punktami zwrotnymi, dla wybranych parametrów pracy silnika spalinowego o ZS. Wskazano również obszary położone na gładzi cylindra, w których występuje duże prawdopodobieństwo pojawienia się szczelin pomiędzy gładzią cylindra a powierzchnią ślizgową pierścienia uszczelniającego.
PL
W warunkach niskich temperatur zasadniczą rolę odgrywają właściwości rozruchowe silników o zapłonie samoczynnym. Jak dotychczas brak jest modeli termodynamicznych, które ujmowałyby proces rozruchu silnika o zapłonie samoczynnym, zwłaszcza w obniżonych temperaturach otoczenia na parametry termodynamiczne procesu sprężania. Niniejszy referat stanowi fragment badań we wspomnianej tematyce. Jego zasad-niczym celem było zaprezentowanie badań , wykonanych w komorze niskich temperatur, obliczeń maksymalnych ciśnień i temperatur w zależności od temperatury otoczenia, prędkości obrotowej wału korbowego i zużycia układu tłok-pierścienie-cylinder.
EN
At low temperatures, the essential role played by start-up characteristics of compression ignition engines. So far there is no thermodynamic models that would include starting the process of a diesel engine, especially at reduced temperatures on the thermodynamic parameters of the compression process. This paper is a piece of research in that topic. Its principle-like aimed at presenting research carried out in low-temperature chamber, the calculation of the maximum pressure and temperature depending on the ambient temperature, the rotational speed of the crankshaft and wear of the piston rings and cylinder.
EN
Construction of piston-rings-liner assembly of contemporary engines of low and medium power secures a long time reliable operation. In the case of engines of higher output, e.g. marine and railway ones still occur failures caused by improper collaboration of piston rings and cylinder liner. One can mention variations in collaboration surface and difficulties with supply and proper distribution of lubricating oil over the entire surface of cylinder liner among the most important ones. Changes in value of parameters characteristic for compression ring and cylinder liner collaboration that occur during engine run have been analyzed in the following study. Attention has been paid to the ability of ring contact with the liner, especially those features that cause the formation of light slots between ring face and liner surface. Drafts presented in the paper show the results of compression ring pressure distribution and the geometry of light slots carried out for technical data of the earth moving machine engine. Simulation computations take into account both the effect of engine operation cycle phase and selected stages of its run as well.
EN
Problems connected with the circumferential distribution of compression ring pressure against the deformed cylinder wall during engine run were presented in this paper. In particular, division of the resultant force pressing the ring against the wall into component connected with ring own elasticity and the one originated from gas pressure was carried out and the influence of each force at individual phases of engine run was evaluated as well. The relationship allowing calculation of the circumferential ring pressure was also established. The paper contains figures and drafts obtained in a course of exemplary calculations of compression ring pressure concerning a running bulldozer engine. These figures show the areas of cylinder wall where so called light slots can appear. Conclusions resulting from the carried out simulation tests are discussed in Summary. The need for further investigations mentioned in presented study was shown as well.
EN
The article discusses the results of the wear of piston rings for internal combustion engines with self ignition. The research was a prototype multilayer ring sealing of the porous coating and the so-called chromium embankment diamonds [2]. Technology of the rings is the deposition of multilayer coatings in the process of chromium plating. In times of chromium deposited from the bath particles are technical diamond's shape, and granulation. This technology is a response to domestic factory piston rings to the needs of the automotive market and is an innovative development. Conducted engine tests consisted of a 50-hour cycle and to hour break-in team life cycle, which was repeated 150 times. Thus the total duration of sample equal to 200 hours. Cycle life is a team containing a phase-hour cycle engine traffic load at maximum speed and maximum torque and maximum power of the tween partial load and idling. This cycle is repeated in the 200-hour test 150 times. During the measurement of key indicators were measured at the engine, the fuel consumption, coolant temperature and pressure of the lubricating oil. In order to calculate the wear of piston rings, the difference was calculated to measure the thickness and height before and after sample of 200 hours. In a similar way as the use of thickness and height of the rings was calculated by weight loss.
EN
The presented study which refers to the earlier papers of the authors discusses an effect of cylinder wall deformation on the effectiveness of compression ring operation. Presented models permit a mathematical description of a deformed cylinder and definition of ring wall pressure relative to these deformations. The drafts presented in the paper, obtained in a course of calculations of a compression ring installed in a work machine engine, allow to evaluate the effect of cylinder deformations on distribution of ring circumferential pressure and point out areas where the light slots could occur.
PL
W niniejszej pracy, wiążącej się tematycznie z wcześniejszymi publikacjami autorów, określono wpływ zmian kształtu otworu cylindra na skuteczność pracy pierścienia uszczelniającego. Zaprezentowano modele, umożliwiające matematyczny opis odkształconego otworu cylindra, a także wyznaczenie odpowiadającego tym odkształceniom nacisku pierścienia na gładź cylindra. Na zamieszczonych w opracowaniu wykresach, uzyskanych podczas obliczeń pierścienia uszczelniającego pracującego w silniku spalinowym maszyny roboczej, pokazano przebiegi pozwalające ocenić wpływu wartości zniekształcenia otworu cylindra na rozkład nacisków obwodowych, a także wskazano miejsca, w których możliwe jest pojawienie się tzw. szczelin świetlnych.
PL
W artykule opisano możliwości wykonania powłoki z azotku tytanu na powierzchni roboczej pierścienia tłokowego silnika spalinowego. Powłoki te znajdują liczne zastosowania w przemyśle. W literaturze polskiej są one nazywane powłokami twardymi, natomiast w zagranicznej są znane jako powłoki ceramiczne. Powłokę z azotku tytanu zwiększającą odporność na zużycie ścierne można uzyskać na powierzchni roboczej pierścienia tłokowego, stosując różne technologie inżynierii powierzchni, np.: natryskiwanie plazmowe, technologie elektronowe, laserowe, implantacyjne, jarzeniowe, osadzania metodami CVD (Chemical Vapour Deposition) i PVD (Physical Vapour Deposition). Otrzymywane warstwy czy też powłoki, pomimo zastosowania tych samych składników, wykazują znacznie różniące się właściwości fizykomechaniczne. Celowe jest zatem rozpatrzenie możliwości osadzania powłoki azotku tytanu za pomocą wymienionych technologii, uwzględniając przy tym jej pożądane właściwości tribologiczne.
EN
This paper describes the feasibility of the titanium nitride coating on the surface of the piston ring engine. These coatings are known for their range of applications in industry. In Polish literature they are called hard coatings, and in foreign literature meets to determine ceramic coatings. Titanium nitride coating increasing the wear resistance can be obtained from the piston ring face by applying the various technologies of surface engineering. Among these technologies can be distinguished: plasma spraying, electron, laser, implant, fluorescent, deposition methods, CVD (Chemical Vapour Deposition) and PVD methods (Physical Vapour Deposition). Obtained by the use of these technologies or the coating layer, despite using the same ingredients, significantly different physical and mechanical properties. Therefore it is advisable to consider the possibility of deposition of titanium nitride coatings using different, the above technologies, taking into account the desired tribological properties.
EN
Elastic properties of correctly designed piston compression ring should provide full contact of ring face and the cylinder surface. Actually, because of various phenomena and processes experienced during engine assembly and operation an initially cylindrical liner is being subjected to wear and deformations which eventually affects that contact and cause formation of slots distributed along the cylinder circumference. Following paper describes the most often met deformations of cylinder and presents an evaluation of their influence on the process of compression ring collaboration with the surface of misshaped cylinder. Mathematical relations that allow to calculate the change of ring cylinder pressure and location of areas where blow-by can occur have been presented as well. The presented analyses were supplemented with charts illustrating changeability of certain quantities characteristic for ring and liner construction, using a marine engine ring as an example. The relations established during investigation will be used for a construction of mathematical model of phenomena accompanying the operation of piston-cylinder assembly elements, in the subject of blow-by in particular.
EN
A ring pack of modern IC engine consists of at least one compression ring that should guarantee secure a necessary tightness of combustion chamber. A circumferential wall pressure of correctly designed compression ring should be sufficient to achieve a full contact between wall and ring, which means light tightness preventing gas blowby. Lack of tightness is being considered as a principal cause of deterioration of engine performance data including torque instability, and a rapid grow in ring and cylinder wear within the area of blow-by. During engine design process mathematical models are applied which implement analytical and numerical methods of calculation. Analytical methods that were used earlier presented a limited range of application and lower accuracy in comparison to the numerical methods but they allowed achieving approximate results quicker. Taking this into consideration the presented study describes the most important relations between ring geometry and its wall pressure, which were obtained using the analytical methods. Presented formulas facilitate the evaluation of cylinder wear effect on the ring circumferential pressure distribution, especially the change in liner diameter. An attempt of light slits evaluation has been performed as well. The study was supplemented with graphs and calculative example.
EN
The article discusses the results of the wear of piston rings for internal combustion engines with spark ignition. The research was a prototype multilayer ring sealing of the porous coating and the so-called chromium embankment diamonds. Technology of the rings is the deposition of multilayer coatings in the process of chromium plating. In times of chromium deposited from the bath, particles are technical diamond's shape, and granulation. This technology is a response to domestic factory piston rings to the needs of the automotive market and is an innovative development. Conducted engine tests consisted of a 50-hour cycle and to hour break-in team life cycle, which was repeated 150 times. Thus, the total duration of sample equal to 200 hours. Cycle life is a team containing a phase-hour cycle engine traffic load at maximum speed and maximum torque and maximum power of the tween partial load and idling. This cycle is repeated in the 200-hour test 150 times. During the measurement of key indicators were measured at the engine, the fuel consumption, coolant temperature and pressure of the lubricating oil. In order to calculate the wear of piston rings, the difference was calculated to measure the thickness and height before and after sample of 200 hours. In a similar way as the use of thickness and height of the rings was calculated by weight loss.
EN
Presented paper deals with cylinder deformations which could be most often encountered and tries to explain the causes of such situations. The essential part of the paper presents relations which allow to describe cylinder shape of any geometry and the attached example explains better the principles of their application. The obtained relations will be applied to the constructed mathematical model, in particular in a module describing the link between cylinder deformations and blowby during engine run. It should be added that the presented study is a part of a series concerning the collaboration of compression ring with the cylinder wall observed on a running engine.
PL
W niniejszym opracowaniu opisano najczęściej spotykane deformacje cylindra i dokonano próby wyjaśnienia przyczyn ich powstawania. W zasadniczej jego części zaprezentowano związki pozwalające opisać kształt cylindra o dowolnej, złożonej geometrii, a załączony przykład obliczeniowy pozwala lepiej wyjaśnić zasady ich stosowania. U zyskane zależności zostaną wykorzystane w budowanym modelu matematycznym, w module dotyczącym wpływu odkształceń cylindra na przedmuchy gazów spalinowych w czasie pracy silnika. N ależy dodać, że niniejsze opracowanie jest częścią większego cyklu dotyczącego współpracy uszczelniającego pierścienia tłokowego z gładzią cylindra w czasie pracy silnika spalinowego.
19
Content available remote Niezawodność wybranych par ciernych pierścień tłokowy–tuleja cylindrowa
PL
Problematyka niezawodności współczesnych obiektów technicznych nabiera szczególnego znaczenia ze względu na wzrost ich złożoności. Narzędziami zwiększającymi efektywność analiz niezawodności są aplikacje komputerowe umożliwiające m.in. prowadzenie symulacji czasu poprawnej pracy systemów, prognozowanie niezawodności oraz jej optymalizację. W niniejszym artykule zdecydowano się wykorzystać aplikację Weibull++ do modelowania niezawodności skojarzenia pierścień tłokowy–tuleja cylindrowa na podstawie danych empirycznych przedstawionych w pracy [5].
EN
The problems of reliability of modern technical facilities is of particular importance due to the increase in their complexity. The tools that increase the efficiency of reliability analysis are computer applications, including simulation of reliability, prediction and optimization. In this paper, it was decided to use the Weibull++ application to associate reliability modeling piston ring – cylinder sleeve based on life data presented in.
EN
The following study presents typical cylinder deformations that come up during engine assembly and operation and provides results of analysis of how these changes affect the operation of the compression ring. Special attention has been paid to the effect of cylinder diameter increase on the distribution of the circumferential wall pressure and the cause of light gaps formation has been explained. The analyses presented in the following paper have been carried out using a computer program that has been formulated based on a compression ring mathematical model. Exemplary results of simulation have been obtained for a medium speed generator engine of a cylinder diameter of 0.48 m.
PL
W opracowaniu opisano typowe deformacje cylindra pojawiające się podczas montażu i eksploatacji silnika oraz przedstawiono wyniki analizy wpływu tych zmian na pracę pierścienia uszczelniającego. W szczególności omówiono wpływ wzrostu średnicy cylindra na rozkład obwodowego nacisku pierścienia oraz wyjaśniono przyczyny powstawania tzw. szczelin świetlnych. Prezentowane w opracowaniu analizy przeprowadzono przy wykorzystaniu programu obliczeniowego powstałego na podstawie modelu matematycznego uszczelniającego pierścienia tłokowego. Zaprezentowane w artykule przykładowe wyniki symulacji uzyskano dla agregatowego silnika średnioobrotowego o średnicy cylindra równej 0,48 mm.
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