Thermo-Mechanical Fatigue Life Prediction of a Heavy Duty Diesel Engine Liner

2007 ◽  
Author(s):  
Amir Malakizadi ◽  
Hamidreza Chamani ◽  
Seyed Navid Shahangian ◽  
Seyed Ali Jazayeri ◽  
Iraj Sattarifar
Keyword(s):  
Kinematic Model ◽  
Combustion Process ◽  
Cylinder Liner ◽  
Experimental Results ◽  
Lifetime Prediction ◽  
Specific Power ◽  
Heavy Duty ◽  
Liner Material ◽  
Mechanical Fatigue ◽  
Heavy Duty Diesel

Engine designers are increasingly using more advanced simulation techniques to reduce design time and costs and at the same time to improve the accuracy of the work to limit the number of validation tests required. In recent years, the demand for higher specific power has enforced higher operating temperatures in engine parts, so thermo-mechanical fatigue (TMF) analysis is becoming more important. Liners are one of the challenging parts in heavy duty diesel engines which are exposed to high temperature differential between cooling jacket and combustion chamber and also they are in frictional contact with piston rings, therefore liners are subjected to complicated multiaxial thermal and mechanical stresses. In this study, a detailed analysis is conducted on a centrifugal gray cast iron liner using different CAE tools to have a more accurate estimate of thermo-mechanical loads. The coolant flows inside the liner jacket and combustion process within the cylinder are simulated using 3D CFD methods. Besides the linear FE analysis which is known as an oversimplified method, a multilinear kinematic model is used to simulate the material response more accurately. Using experimental results obtained from cylinder liner material, the different TMF approaches have been investigated and the differences between linear and nonlinear FE simulation in lifetime prediction have been revealed. It is shown that modified Manson-Coffin criterion is the promising relation for lifetime prediction of liner material that correlate better with experimental results.

Tribological assessment of NiCr, Al2O3/TiO2, and Cr3C2/NiCr coatings applied on a cylinder liner of a heavy-duty diesel engine

2020 ◽  
pp. 146808742093016
Author(s):  
Onur Biyiklioğlu ◽  
Mustafa Ertunc Tat
Keyword(s):  
Cast Iron ◽  
Diesel Engine ◽  
Wear Rate ◽  
Gray Cast Iron ◽  
Cylinder Liner ◽  
Gray Cast ◽  
Economic Evaluations ◽  
Heavy Duty ◽  
Heavy Duty Diesel Engine ◽  
Heavy Duty Diesel

Internal combustion engines consume about 90% of fuel refined from crude oil which supplies 30% of the annual global flow of energy. Heavy-duty diesel engines are the primary source of power used in highways, marine, railroads, and power stations. The right coating can improve the tribological properties of cylinder liners and increase the mechanical efficiency of an engine. Also, it can help to extend the maintenance periods, and enhance the reliability of the vehicles. In this research, tribological and economic evaluations were performed for coated and uncoated substrates from a cylinder liner of a heavy-duty diesel engine, aiming to lower friction, wear rate, and maintenance cost. A reciprocating friction test was conducted under dry condition using Wolfram carbide (tungsten carbide) ball applied a 10 N normal load on a ball on disk geometry. The cylinder liner was made of gray cast iron, and the substrates obtained were coated with three different coating materials (Cr3C2/NiCr, NiCr, and Al2O3/TiO2) through the thermal spray and high-velocity oxy-fuel coating process. Tribological evaluations showed that the substrates coded with Al2O3/TiO2 and Cr3C2/NiCr had the lowest friction coefficient and wear rate. The most economical coating was Al2O3/TiO2, being able to supply about 61% lower coefficient of friction and 94% less wear rate relative to the uncoated sample, for the price of one-third of the Cr3C2/NiCr coating and one half of a new gray cast iron cylinder liner.

Emissions Characteristics for Heavy-Duty Diesel Trucks Under Different Loads Based on Vehicle-Specific Power

2017 ◽  
Vol 2627 (1) ◽  
pp. 77-85 ◽  
Author(s):  
Shuanghong Zhang ◽  
Lei Yu ◽  
Guohua Song
Keyword(s):  
Carbon Dioxide ◽  
Travel Speed ◽  
Specific Power ◽  
Oxides Of Nitrogen ◽  
Heavy Duty ◽  
Operating Modes ◽  
Vehicle Loads ◽  
Heavy Duty Diesel ◽  
Diesel Trucks ◽  
The Impact

Both operating modes and emissions factors for heavy-duty diesel (HDD) trucks were analyzed under different loads to understand the effect of vehicle loads on emissions. Second-by-second speed data for different loads for HDD trucks were collected first. Then a method for calculating the vehicle-specific power (VSP) values and an emissions model for heavy-duty vehicles by using the VSP value were developed to evaluate the effect of different vehicle loads. The VSP distributions and emissions characteristics for fully loaded and unloaded trucks were analyzed and compared. The results illustrate that the fully loaded vehicles spent more time driving in steady modes and the time percentage of VSP values in the bin of 0 kW/ton for fully loaded trucks was lower than the percentage for unloaded trucks. However, the time percentage at the positive VSP value was significantly higher than the percentage for the unloaded trucks. The emissions factors of fully loaded trucks were significantly higher than those of unloaded trucks. Emissions factors were affected the most at speed intervals of 20 to 40 km/h, with emissions factors for carbon dioxide, carbon monoxide (CO), oxides of nitrogen (NOx), hydrocarbon, and particulate matter (PM) at 20.4%, 23.5%, 29.0%, 11.7%, and 9.4% higher, respectively, than those levels for unloaded vehicles. With an increase of travel speed, the impact of the load on emissions weakened. Vehicle loads had the greatest effect on emissions of NOx, followed by emissions of CO. PM emissions were the least affected by vehicle loads. The impact of vehicle loads on emissions was affected by different acceleration behaviors under different loads.

Engine Performance and Emissions for a Heavy-Duty Diesel Engine Converted to Stoichiometric Natural Gas Operation

2020 ◽  
Author(s):  
Jinlong Liu ◽  
Christopher Ulishney ◽  
Cosmin E. Dumitrescu
Keyword(s):  
Natural Gas ◽  
Catalytic Converter ◽  
Combustion Process ◽  
Engine Performance ◽  
Intake Manifold ◽  
Heavy Duty ◽  
Indicated Mean Effective Pressure ◽  
Performance And Emissions ◽  
Heavy Duty Diesel ◽  
Ci Engines

Abstract Converting existing compression ignition (CI) engines to spark ignition (SI) operation can increase the use of natural gas (NG) in heavy-duty engine applications and reduce the reliance on petroleum fuels. Gas fumigation upstream of the intake manifold and the addition of a spark plug in place of the diesel injector to initiate and control the combustion process is a convenient approach for converting existing diesel engines to dedicated NG operation. Stoichiometric operation and a three-way catalytic converter can help the engine to comply with increasingly strict emission regulations. However, as the CI-to-SI conversion usually maintains the conventional geometry of a CI engine (i.e., maintains the flat cylinder head and the bowl-in piston), the goal of this study was to observe some of the effects that the diesel conversion to stoichiometric NG SI operation will have on the engine’s performance and emissions. Dynamometer tests were performed at a constant engine speed at 1300 rpm but various spark timings. The experimental results for a net indicated mean effective pressure ∼ 6.7 bar showed that ignition timing did not affect the end of combustion due to the slow-burn inside the squish. Moreover, the less-optimal conditions inside the squish led to increased carbon monoxide (CO) and unburned hydrocarbon (UHC) emissions. While the combustion event was stable with no signs of knocking at the medium load conditions investigated here, the results suggest that the engine control needs to optimize the mass fraction trapped inside the squish region for a higher efficiency and lower emissions.

Design and Flow Analysis of a Novel Optically Accessible Heavy Duty Diesel Research Engine

2011 ◽  
Author(s):  
Stephen Busch ◽  
Maurice Kleindienst ◽  
Christoph Dahnz ◽  
Uwe Wagner ◽  
Ulrich Spicher
Keyword(s):  
Quartz Glass ◽  
Soot Formation ◽  
Laser Sheet ◽  
Cylinder Liner ◽  
Operating Conditions ◽  
Optical Measurements ◽  
Heavy Duty ◽  
Glass Cylinder ◽  
Trade Offs ◽  
Heavy Duty Diesel

A new single-cylinder optically accessible heavy duty diesel engine has been conceived and constructed at the Institut fu¨r Kolbenmaschinen. Rather than being made from a quartz glass cylinder, the cylinder liner of this engine is modified with three round, flat optical access ports to facilitate laser-optical measurements within the combustion chamber. The flat optical surfaces prove less problematic than a quartz glass cylinder in terms of internal reflections, cleaning procedures, cost, and robustness. A specially adapted piston facilitates the passage of the laser sheet into the piston bowl and provides a view into the bowl at top dead center. Computational fluid dynamics (CFD) simulations were performed in order to estimate the effects of the optically necessary piston and cylinder liner modifications on in-cylinder flow and to compare the flow characteristics with those simulated for a non-modified engine. Emphasis is placed on turbulence behavior before top dead center. The trade-offs and limitations inherent in the modified piston design are discussed in this context. Further optical investigations with this engine will provide insight into the mixture formation and combustion processes. In particular, the soot formation and oxidation processes will be studied under realistic engine operating conditions.

Interactions of Piston Ring Pack With Coated Cylinder Liners of Heavy Duty Diesel Engines

2014 ◽  
Author(s):  
Fabio Araujo ◽  
Luiz de Sá Filho ◽  
Jason Bieneman ◽  
Eduardo Nocera ◽  
Edney Deschauer Rejowski
Keyword(s):  
Piston Ring ◽  
Engine Performance ◽  
Cylinder Liner ◽  
Heavy Duty ◽  
Performance Measurements ◽  
Heavy Duty Diesel ◽  
Cylinder Bore ◽  
Cylinder Liners ◽  
The Impact ◽  
Coated Cylinder

The heavy duty diesel (HDD) engine market continues to strive for improvements in engine efficiency and durability which places ever increasing development demands on the power cylinder unit. One of the methods being developed to help meet these demands is coated cylinder bore technology. By applying a coating to the inner diameter surface of a cylinder liner the wear on the liner can be significantly reduced. The reduction in liner wear is not however the only advantage that this technology can offer. Liner coatings can also offer corrosion protection, reductions in wear on the running surface of the rings, improved scuff resistance, and enable improvements in the efficiency of the engine. New piston ring technologies will be valuable in maximizing these advantages and their contribution will be detailed. The system must be properly designed to take full advantage of all of these opportunities. In this paper both the advantages and difficulties coated liners present will be explored by evaluating the impact on the liner, rings and the fuel consumption. This paper will additionally provide details regarding the different liner coating technologies being developed today. To support these recommendations the system’s performance characteristics will be demonstrated through rig testing and engine performance measurements.

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