Introduction Engine friction refers to the forces acting between (i) two mechanical components due to their relative motion and (ii) fluid layers when they move through the engine parts. A percentage of power generated by the engine cylinders is lost due to i. direct friction (between sliding/rotating parts) ii. pumping losses iii, power loss towards charging and scavenging iv. power loss towards running various auxiliary components These losses cumulatively reduce the engine power output only to realize the brake power at the crankshaft. BP. “Naess = BIB. bmep/imep ME F317 ENaiNes, Motors & Mosittty Instructor: Prof. N. Jalaian 1 BITS-Pilani, Hyderabad CampusFrictional Losses * Direct frictional losses: Power observed due to relative motion of different surfaces like piston rings, main bearings, cam shaft bearings, ete. + Pumping losses: Net power spent by the engine on the working media (gases) during intake and exhaust strokes. In 2-S engines this is negligible as incoming fresh mixture scavenges the exhaust gas. * Power loss to drive components to charge and scavenge: In 4-S engines in order to supply charge at higher pressures a mechanically driven compressor or a turbine driven compressor is used. * In case of a supercharged engine, engine itself supplies power to the drive the compressor; whereas in a furbocharged engine, the turbine is driven by the exhaust gases of the engine. * Power loss to drive auxiliaries: The generated output is used for water pump, lubricating oil pump, fuel pump, cooling fan, ete. + FMEP (Frictional mean effective pressure) = MMEP (MEP to overcome mechanical friction) + PMEP (MEP required for charging and scavenging) + AMEP (MEP to drive auxiliary components) + CMEP (MEP required to drive the compressor or scavenging pump. 19 October, 2023 ME Fi17 Ew. NES, MoroRs & Mopitity Instructor: Prof.N. Jalaian 2 BITS-Pilani, Hyderabad CampusMechanical Friction * It is due to relative motion of different surfaces like piston rings, main bearings, etc. and may be classified as follows: * Fluid film or hydrodynamic friction: When complete film of lubrication exists between the two moving surfaces. Frictional force entirely depends on the viscosity of the lubricant. This type of friction is the main mechanical friction loss in the engine. * Partial film friction: When rubbing surfaces are not sufficiently lubricated, contact exists between the rubbing surface in some regions. * During normal engine operations, no metallic contact occurs, except between compression piston ring and cylindrical wall. During the starting time, the journal bearings operate in partial film fretion and this may be neglected as its contribution is very little to the total engine friction. N 19 October, 2023 MEFI17 ENaixes, Motors & Mositity Instructor: Prof. N. Jalaian 3 BITS-Pilani, Hyderabad CampusMechanical Friction (Cont’d) kx Rolling friction: This is due to the rolling motion between two surfaces. eR Ball & roller bearings and tappet rollers are subjected to this kind FOX 85 friction. yy SX \c} Coefficient of friction for this type of bearings is independent of load and \ OWN cf speed. Rolling friction coefficient is lower than journal friction coefficient during starting and initial running of engine, due to high oil viscosity. Roller Tappet with Roller Profile MEFi17 ENaixes, Motors & Monitity Instructor: Prof. N. Jalailan 4 BITS-Pilani, Hyderabad CampusMechanical Friction (Cont’d) * Rolling friction: This is due to the rolling motion between two surfaces. * Ball & roller bearings and tappet rollers are subjected to this kind of friction. * Coefficient of friction for this type of bearings is independent of load and speed. Rolling friction coefficient is lower than journal friction coefficient during starting and initial running of engine, due to high oil viscosity. * Rolling friction is negligible compared to total friction. Roler Profile Roler Tappet wit * Dry friction: This is due to metal to metal contact. * When an engine is in non-operational state for long time, there is a possibility for direct metal to metal contact in some parts/regions. + Always some lubricant exists between the rubbing surfaces even after long periods of non-use. Hence, dry friction may be neglected, as it is considered to be non-existent. 023 MEFII7 ENGINES, Morons & Mositity Instructor: Prof.N. Jalaian 4 BITS-Pilani, Hyderabad Campus 19 OctetMechanical Friction (Cont’d) * Journal bearing friction: Shaft is journal and cylindrical doorre! surface is bearing. * Journal bearings are called partial when the bearing surface is less than full circumference. * Engine journal bearing operates under load, which varies in magnitude and direction with time. Equilibrium point, running * Coefficient of friction for engine journal bearings is usually different from the ordinary journal bearings. + Friction due to piston motion: + Viscous friction due to piston. + Non-viscous friction due to piston ring. This can be further divided into: MEFI17 ENaixes, Motors & Mositity Instructor: Prof. N. Jalailan 5 BITS-Pilani, Hyderabad CampusPiston Rings 19 Octo Piston rings are categorized into compression rings and oil rings. Compression rings are on the top portion of the piston to seal against gas pressure. Pressure exerted by the compression ring on the cylinder wall is partly due to elasticity of the ring and partly due to the gas pressure which leaks between ring and piston. Gas pressure behind the top compression ring is nearly equal to cylinder pressure. Behind the second compression ring, it is less than that of the first/top compression ring (i.e., cylinder pressure) and much less in the third ring. Oil rings are designed to scrape some of the oil from the cylinder wall and allow it to return to oil sump through radial passage in the ring. These grooves for the rings are vented by holes drilled into the piston interior and therefore no gas pressure can act behind it. Pressure of the ring surface on the cylinder wall is entirely due to elasticity. Piston rings press against the cylinder walls at all times due to their spring action, hence the friction due to piston motion always exists. 3 MEFi17 ENatxes, Motors & Mosittty Instructor: Prof. N. Jalaian 6 BITS-Pilani, Hyderabad CampusFactors Affecting Mechanical Friction| Jim ngine design: + Swroke-Bore ratio: Lower the L-D ratio, slightly decrease the FMEP (due to less fiictional area) + Engine size: Large engines have more frictional surfaces, + Piston rings: Reducing the no. of piston rings and the contact area of ring with cylinder wall decrease the friction. + Compression ratio: FMEP inereases with compression ratio. + Journal bearing: Reducing joumal dia/diamettical clearance ratio reduces FMEP. Engine speed: Friction increases rapidly with increase in speed. Therefore, nan decreases. 3. Engine load: Increasing the load, increases the max pressure in the cylinder which results in slight increase in friction values. At the same time, temperature increases leading to decrease in viscosity of oil, hence slight reduction in friction. 4. Cooling water temperature: Rise in cooling water temperature reduces the friction (due to increase in oil temperature and so decrease of viscosity). 5. Oil viscosity: Frictional loss and viscosity are directly proportional to each other. Viscosity can be reduced by increasing oil temperature, but it may result to metal to metal contact under extreme conditions. 19 October, 2023 MEFi17 ENaixes, Motors & Mosittty Instructor: Prof.N. Jalaian 7 BITS-Pilani, Hyderabad CampusLubrication — Functions * Lubrication is essential to reduce friction thus to control the wear and tear between the engine components. * It reduces the friction and wear between the moving parts and thereby reduce energy loss and to increase the engine life. * Provides sealing action, i.c., lubricating oil helps piston rings to effectively seal against high pressure gases. * Cools the surfaces by carrying away the heat. * Cleans the surfaces by carrying away the carbon and the metal particles, if any, caused by the wear. MEFi17 ENatxes, Motors & Mositity Instructor: Prof. N. Jalaian 8 BITS-Pllani, Hyderabad Campus* Because of variation in gas force on the piston and inertia force on moving parts, the bearings are subjected to fluctuating loads, hence providing effective lubrication at all Inernal combustion engine operating conditions become very difficult. Comin wate Contmiion taht sain os | ca ‘ Fred = ) Cyne a | Mala teeing Comesing rid enings Sai beara, 1¥ Instructor: Prof.N. Jalaian 9 BITS-Pilani, Hyderabad Campus. 19 October, 2023