GmbH Cylinder components

Properties, applications, materials
2010
ISBN: 978-3-8348-9697-1
Verlag: Vieweg & Teubner
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 137 Seiten, eBook

Reihe: ATZ/MTZ-Fachbuch

As today's spark-ignition and diesel engines have to fulfil constantly increasing demands with regard to CO2 reduction, emissions, weight and lifetime, detailed knowledge of the components of an internal combustion engine is absolutely essential. Automotive engineers can no longer survive without such expertise, regardless of whether they are involved in design, development, testing or maintenance. This text book provides answers to questions relating to the design, production and machining of cylinder components in a comprehensive technical analysis.

The MAHLE Group is one of the top 30 automotive suppliers globally and is the world market leader for combustion engine components, systems and peripherals.

Zielgruppe

Professional/practitioner

Autoren/Hrsg.

GmbH, MAHLE

Inhaltsverzeichnis

1;Preface;5
2;Acknowledgment;6
3;Contents;7
4;1 Piston rings;11
4.1;1.1 Purpose and function of piston rings;11
4.2;1.2 Principles of operation;13
4.3;1.3 Forces and stresses;14
4.3.1;1.3.1 Forces and temperatures on piston rings;14
4.4;1.4 Types of piston rings;17
4.4.1;1.4.1 Rectangular ring;19
4.4.2;1.4.2 Rectangular ring with taper-faced running face;19
4.4.3;1.4.3 Piston ring with top internal bevel or internal step;20
4.4.4;1.4.4 Piston ring with bottom internal bevel or internal step;20
4.4.5;1.4.5 Keystone ring;21
4.4.6;1.4.6 L-shaped piston ring;21
4.4.7;1.4.7 First piston ring with barrel-shaped surface;21
4.4.8;1.4.8 Napier ring with taper-faced running face;22
4.4.9;1.4.9 Ring gap configuration;22
4.4.10;1.4.10 Slotted oil control ring;23
4.4.11;1.4.11 Spring-loaded oil control ring;23
4.4.11.1;1.4.11.1 Coil spring loaded ring;23
4.4.11.2;1.4.11.2 Spring-supported oil control ring (expander ring);25
4.4.12;1.4.12 U-flex-ring;25
4.5;1.5 Design details;26
4.5.1;1.5.1 Analysis and simulation;26
4.5.1.1;1.5.1.1 Numerical analysis;26
4.5.1.2;1.5.1.2 Stress analysis;26
4.5.1.3;1.5.1.3 Dynamic analysis;27
4.5.1.4;1.5.1.4 Conformability;27
4.5.1.5;1.5.1.5 Specific surface pressure;27
4.5.1.6;1.5.1.6 Ovality;28
4.5.1.7;1.5.1.7 Design guidelines;28
4.6;1.6 Materials, coatings, and surface treatment;28
4.6.1;1.6.1 Materials;28
4.6.1.1;1.6.1.1 Cast iron;28
4.6.1.2;1.6.1.2 Steel;29
4.6.2;1.6.2 Coatings and surface treatments;30
4.6.2.1;1.6.2.1 Gray cast iron as a base material;30
4.6.2.2;1.6.2.2 Martensitic nodular cast iron as a base material;31
4.6.2.3;1.6.2.3 Carbon and stainless steels;32
4.6.2.4;1.6.2.4 Running face and side face coatings;33
4.6.2.5;1.6.2.5 Nitriding of running faces;34
4.6.2.6;1.6.2.6 Surface protection;35
5;2 Piston pins and piston pin circlips;36
5.1;2.1 Function of the piston pin;36
5.2;2.2 Requirements;37
5.2.1;2.2.1 General;37
5.2.2;2.2.2 Strength;37
5.2.3;2.2.3 Deformation;40
5.2.4;2.2.4 Lubrication, oil supply;41
5.2.5;2.2.5 Wear;42
5.2.6;2.2.6 Weight;42
5.3;2.3 Types of piston pins;42
5.4;2.4 Design;44
5.4.1;2.4.1 Dimensioning;44
5.4.2;2.4.2 Analysis;46
5.4.3;2.4.3 Finite element analysis;47
5.4.4;2.4.4 Dimensional and form tolerances, standard;49
5.5;2.5 Piston pin materials;51
5.6;2.6 Component testing;54
5.6.1;2.6.1 Piston pin test bench;54
5.7;2.7 Piston pin circlips;55
6;3 Bearings;57
6.1;3.1 Product range;57
6.1.1;3.1.1 Applications;57
6.1.2;3.1.2 Types and terminology;57
6.2;3.2 Design guidelines;60
6.2.1;3.2.1 Properties;60
6.2.2;3.2.2 Load capacity;60
6.2.3;3.2.3 Wear resistance;62
6.2.4;3.2.4 Seizure resistance;63
6.3;3.3 Bearing geometry;63
6.3.1;3.3.1 Bearing diameter and width;63
6.3.2;3.3.2 Oil grooves and holes;64
6.3.3;3.3.3 Bearing clearance;64
6.3.4;3.3.4 Bearing and bushing fit;65
6.3.4.1;3.3.4.1 Eccentricity;65
6.4;3.4 Numerical simulation;66
6.4.1;3.4.1 Hydrodynamic lubrication (LOCUS);66
6.4.2;3.4.2 Elasto-hydrodynamic lubrication (EHL);67
6.4.3;3.4.3 Axial bearing simulation (ABAS);68
6.4.4;3.4.4 Overlaps (PRESSFIT);68
6.5;3.5 Bearing materials;69
6.5.1;3.5.1 Composition and properties of bearing materials;70
6.6;3.6 Market requirements and technology trends;75
7;4 Connecting rod;77
7.1;4.1 Introduction;77
7.2;4.2 Stresses;80
7.3;4.3 Requirements;81
7.3.1;4.3.1 Mass of the connecting rod;81
7.4;4.4 Crank end;82
7.4.1;4.4.1 Cracking (fracture splitting);82
7.4.2;4.4.2 Angle split of the crank end;83
7.5;4.5 Connecting rod shank;84
7.6;4.6 Small end;84
7.6.1;4.6.1 Pin bearing in the small end;84
7.6.2;4.6.2 Geometry of the connecting rod small end;85
7.6.3;4.6.3 Bushing-less pin bearing in the small end;86
7.7;4.7 FE analysis of the connecting rod;87
7.7.1;4.7.1 Modeling;87
7.7.2;4.7.2 Stresses from assembly;88
7.7.2.1;4.7.2.1 Bolt force;88
7.7.2.2;4.7.2.2 Bushings, bearings, and shrink fit;89
7.7.3;4.7.3 Stresses from engine operation;89
7.7.3.1;4.7.3.1 Gas pressure;90
7.7.3.2;4.7.3.2 Inertia force;92
7.8;4.8 Component testing of the connecting rod;94
7.9;4.9 Steel grades for forged connecting rods;98
7.10;4.10 Connecting rod bolted joint;99
7.10.1;4.10.1 Requirements for connecting rod bolted joint;99
7.10.2;4.10.2 Design and analysis of connecting rod bolted joint;99
7.10.3;4.10.3 Shape of the connecting rod bolts;100
8;5 Crankcase and cylinder liners;102
8.1;5.1 Introduction;102
8.1.1;5.1.1 Forces and stresses;102
8.1.2;5.1.2 Development goals;103
8.2;5.2 Types of crankcases;103
8.2.1;5.2.1 Methods for reducing noise emissions;104
8.2.2;5.2.2 Main bearing seats;105
8.2.3;5.2.3 Cooling;106
8.3;5.3 Crankcase materials;107
8.3.1;5.3.1 Cast iron;107
8.3.2;5.3.2 Aluminum alloys and material properties;107
8.3.2.1;5.3.2.1 Effects of the casting process on the material properties of aluminum alloys;111
8.3.2.2;5.3.2.2 Effects of heat treatment on the properties of cast aluminum alloys;112
8.3.3;5.3.3 Magnesium;113
8.3.4;5.3.4 Material trends;113
8.3.5;5.3.5 Effects of the casting process on the design of the crankcase;113
8.3.5.1;5.3.5.1 Sand casting;113
8.3.5.2;5.3.5.2 COSCASTTM method;114
8.3.5.3;5.3.5.3 Molding sand–“green sand”;114
8.3.5.4;5.3.5.4 CPS method;114
8.3.5.5;5.3.5.5 Full-mold casting method (lost foam method);115
8.3.5.6;5.3.5.6 Permanent mold casting;115
8.3.5.7;5.3.5.7 Gravity die casting;115
8.3.5.8;5.3.5.8 Low-pressure die casting;115
8.3.5.9;5.3.5.9 Pressure die casting;116
8.3.5.10;5.3.5.10 Squeeze casting;116
8.3.5.11;5.3.5.11 Semi-solid method;116
8.4;5.4 Cylinder liners and cylinder surfaces;116
8.4.1;5.4.1 Requirements for the cylinder surface;116
8.4.2;5.4.2 Cylinder surfaces in aluminum crankcases;117
8.4.3;5.4.3 Types of cylinder liners;118
8.4.4;5.4.4 Materials for cylinder liners;123
8.4.5;5.4.5 Treatment of cylinder surfaces of liners;125
8.5;5.5 Light-alloy cylinders;126
8.5.1;5.5.1 Types of light-alloy cylinders for small engines;126
8.5.2;5.5.2 Air-cooled cylinders;127
8.5.3;5.5.3 Channel shapes and charge exchange in two-stroke engines;128
8.5.4;5.5.4 Cylinders for four-stroke engines;131
8.5.5;5.5.5 Bore coatings for light-alloy cylinders;131
9;Glossary;134
10;Index;136

Piston rings.- Piston pins and piston pin circlips.- Bearings.- Connecting rod.- Crankcase and cylinder liners.

Über Autor(innen)

The MAHLE Group is one of the top 30 automotive suppliers globally and is the world market leader for combustion engine components, systems and peripherals.