This paper presents the computational analysis of piston ring wear and oil consumption for an internal combustion (IC) engine. Two computational models, piston-ring wear and oil consumption, are employed to simulate the results for this analysis. Both instantaneous and transient results are discussed. The piston-ring wear model, namely WEAR, is built on the fundamentals of mechanical and adhesive wear mechanism; while the oil consumption, namely OILCONSUME, is on the fundamentals of oil vaporization and upper-ring gap oil reverse flow mechanisms. The two models are integrated with two external engine simulators: the Ford Motor Company General Engine SIMulation (GESIM) of the Ford Motor Company, and the Cylinder kit Analysis System for Engines (CASE) of the Michigan State University Engine Research Laboratory. An objective of this analysis is to understand how the engine operation condition impacts the piston-ring wear and the oil consumption per engine cycle basis. Also, it is to understand how the piston-ring wear affects the oil consumption and other engine mechanisms on a long time basis. A virtual Ford 4.6L-V8 engine has been tested on various engine speeds and loads to produce the computational results. The results show that the engine load and the engine speed play significant roles, individually and collectively, on the engine performance. The results also show the dependence of the oil consumption and the blow-by on the piston-ring wear over long-time engine run. The instantaneous and transient simulations have provided useful insights on the relation between the piston-ring wear and the oil consumption mechanisms in an IC engine.
The cylinder-kit assembly of an internal combustion engine experiences severe conditions during engine operation. The top compression ring, in particular, undergoes extreme stress directly from cylinder gas pressure, inertial and thermal loads. The top compression ring is often the most significantly affected piston ring, and one of the common resultant phenomena is high wear on the ring/bore surfaces. In many previous studies, the modeling of tribological phenomena at the top compression ring/bore region involves hydrodynamic and boundary lubrication, friction and wear. This present work accounts for an additional factor that may affect the piston ring/bore lubrication — the lubricant evaporative effect. A three-dimensional oil evaporative analysis is coupled into the calculation of mixed lubrication in a cyclic engine computation. The presence of the evaporation analysis allows the study of the temperature influence on the piston ring/bore lubrication in addition to its effect on oil viscosity. A prospective application of this model is in diesel engine analysis. Considering the broad operating range of modern diesel fuel injection systems, the injection timing can be made throughout the compression/expansion process. It is well demonstrated that certain areas of fuel injection operation can result in potential adverse consequences such as increased bore wear. A well known example is “bore wall fuel wetting.” Given concerns around the potential for wear-inducing interactions between the fuel injection plumes and the bore wall, we have explored a particular interaction: bore wear in response to an imposed local heating of the bore wall. The simulation result provides valuable insights on this interaction, in which higher bore wear is predicted around bore wall area with locally imposed wall heating.
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