Statistics by the UK Health and Safety Executive (HSE) suggest that slips, trips and falls account for up to one in three major workplace accidents. Many of these accidents are the result of contaminant (fluid or solid) within the shoe-floor contact.Though the lubrication mechanisms for liquid contaminants within the contact are well understood, the same cannot be said for particulate contaminants. This paper considers the key parameters controlling friction in a shoe-floor contact contaminated with various particles of different diameters and shape factors and floors with different roughness values (R z ). Experiments were conducted using a Stanley Pendulum Tester, which is the floor friction tester recommended in the current British standards. Results suggest the adhesive friction is significantly affected by particulate contaminants whilst the hysteretic component is not. Three lubrication mechanisms identified as sliding, shearing and rolling have been observed depending on floor roughness, particle size and shape factor and have been plotted in a simple map to predict behaviour.
The contact between the piston ring and cylinder liner is the most important sealing interface in an automotive engine. Understanding the contact interactions and lubricant film formation at this interface is crucial for the development of fuel-efficient and low emission engines. This article outlines the development of an ultrasonic approach to enable noninvasive measurement of the lubricant film thickness formed between piston and cylinder wall of a fired engine. The sensor system consisted of a series of small, low cost piezoelectric elements which were bonded to the external surface of a four-stroke, single-cylinder engine. Each element could be individually energised with a short duration voltage pulse and reflections from the cylinder inner bore recorded. By using high frequency pulsing and data capture it proved possible to image individual ring and skirt contacts at full engine speeds. These captured reflections were processed to give lubricant film thickness directly and without the need for independent calibration. The results show good repeatability between cycle sets at specific running conditions. The lubricant films at each of the ring contacts can be measured at sufficient resolution such that individual rails of the oil control ring can be monitored. In addition, the film generated at the skirt was measured, the results from which, suggest the occurrence of 'piston slap' and highlight the potential for this ultrasonic method to enable indirect measurements of piston secondary dynamics.
Advanced piston technology for motorsport applications is driven through development of lightweight pistons with preferentially compliant short partial skirts. The preferential compliance is achieved through structural stiffening, such that a greater entrainment wedge is achieved at the skirt's bottom edge through thermo-elastic deformation, whilst better conforming contact geometry at the top of the skirt. In practice, the combination of some of these conditions is intended to improve the load-carrying capacity and reduce friction. The approach is fundamental to the underlying ethos of race and high-performance engine technology. Contact loads of the order of 5 kN and contact kinematics in the range 0-35 m/s result in harsh transient tribological conditions. Therefore, piston design requires detailed transient analysis, which integrates piston dynamics, thermo-elastic distortion and transient elastohydrodynamics. The paper provides such a detailed analysis as well as verification of the same using noninvasive ultrasonic-assisted lubricant film thickness measurement from a fired engine under normal operating conditions, an approach not hitherto reported in literature. Good agreement is noted between measured film thickness and predictions.
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