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Precision Engineering
journal homepage: www.elsevier.com/locate/precision
a r t i c l e i n f o a b s t r a c t
Article history: A cylinder liner possesses fairly intricate surface requirements due to its complicated functions. It needs
Received 28 September 2010 to provide adequate surface roughness to resist wear as well as to store and retain lubricants during high
Received in revised form 16 February 2011 temperatures. The liner surface texture is anisotropic, produced by the honing process, with resultant
Accepted 29 September 2011
deep visible scratches left on it [1]. The prominence of the honing grooves observed suggests that surface
Available online 6 October 2011
texture significantly affects ring-pack performance, although this effect is not clearly understood.
In this paper, a numerical model was developed to investigate the effects of groove characteristics
Keywords:
on the lubrication condition and friction at the interface between the piston ring and cylinder liner. This
Surface texture
Honing
model aims to solve the average Reynolds equation, which depends on the real surface topographies of the
Hydrodynamic friction cylinder liner, and describes the influence of surface irregularities on the lubricant flow under hydrody-
namic lubrication conditions, considering lubricant film rupture and cavitations. Numerical results help
to determine the optimum lateral groove characteristics to reduce friction and then noxious emissions.
© 2011 Elsevier Inc. All rights reserved.
0141-6359/$ – see front matter © 2011 Elsevier Inc. All rights reserved.
doi:10.1016/j.precisioneng.2011.09.008
S. Mezghani et al. / Precision Engineering 36 (2012) 210–217 211
Using Eq. (3), the weak form of the Reynolds equation can be
expressed by the following relation:
∂H
−∇ P ∇ dX1 dX2 + ∇ P n dL − dX1 dX2 (6)
˝ d˝ ˝
∂X1
Fig. 3. (a) Validation geometry: trapezoidal profile, (b) numerical and analytical pressure fields obtained for trapezoidal profile.
The traditional finite element method was applied to Eq. (6). This to dominate that of the ring surface texture; therefore, the ring
equation coupled with the boundary conditions result in a pres- can be approximated by a smooth surface in the flow simulation.
sure field on the ˝ domain. With this pressure field, it is possible This appears reasonable in most cases because the ring surface is
to determine the friction coefficient, which is calculated using the typically much smoother than the liner’s, with no deep character-
following relation [17]: istic grooves [2]. A diagram showing the typical layout of a ring
cross-section used in simulation is seen in Fig. 4.
x1 x2 ,i d˝
fcx,i = ˝
, i = 1 or 2 (7) The ring and the liner are separated by lubricant thickness h,
w taking the ring curvature into account. Thus, the oil film thickness
where xy,i is evaluated using this following analytic expression: can be expressed as:
Table 1
Parameters used for the validation of the model.
Parameter Value
u1 10 m s−1
p0 1.013 × 105 Pa
( 900 kg m−3
6 × 10−6 m2 s
l1 384.0 m
l2 384.0 m
l3 3.0 m
Fig. 4. Piston–liner contact description.
S. Mezghani et al. / Precision Engineering 36 (2012) 210–217 213
Table 2
Parameters used during simulation.
Parameter Value
u1 2–52 m s−1
p0 1.013 × 105 Pa
( 900 kg m−3
0.04 Pa s
l1 384.0 m
l2 384.0 m
h0 1.0 m
Fig. 6. Plateau honed surface (a) and its radon transform (b).
214 S. Mezghani et al. / Precision Engineering 36 (2012) 210–217
Fig. 7. Simulated honed surface with different honing angles: (a) 20◦ , (b) 50◦ , (c) 120◦ and, (d) 160◦ .
where NL and NR are respectively, the number of grooves in the left the energy consumption of the oscillating components, indicates
and right directions, and Sarea is the analyzed honed surface area. the probability of wear of the sliding surfaces, and reflects the
The groove ratio parameter Rg reveals the balance of the grooves lubrication conditions at the respective positions of the piston.
and defines the ratio of left NL and right grooves NR (Eq. (12)): Fig. 8 shows the influence of the honing angle on the friction
coefficient with maintaining statistically identical surface height
Sup(NR , NL )
Rg = (12) distributions for all the surfaces generated. By examining Fig. 8,
NR + NL
the two minima of friction respectively can be observed for a hon-
Rg equal to 0.5 shows perfect balanced grooves on the surface ing cross-hatch angle range of [40–55◦ ] and [115–130◦ ]. These two
texture. When Rg → 1, the texture tends toward a unidirectional honing angle ranges are commonly used in two kinds of honing
surface. respectively, plateau honing and helical slide honing. The minimum
observed in the second range is in accordance with the experimen-
3.2. Effect of honing cross-hatch angle tal test results given in [22]. The 140◦ honed liners are shown to
have the same performance in wear and friction properties for the
The honing cross-hatch angles are determined in the actual hon- top dead center area compared to the 40◦ honing angle.
ing process revealed by the honing stone as it spirals down the Some experimental studies reveal that oil consumption is
cylinder liner, which itself is determined by the feed, and speed reduced by increasing the honing angle [4,22]. Further, decreasing
rates of the honing tool, with respect to the following formula: the honing cross-hatch angle slightly was experimentally shown to
Va
tan = (13)
2 Vr
Fig. 9. Friction coefficient vs groove width for contact speed of 20 m s−1 . Fig. 10. Friction coefficient vs groove density.
and the contact pressure used during finish honing has no impact
raise the chances of scuffing failure [2]. Therefore, in conclusion it
on the friction performance.
is noted that the helical-slide honing [115–130◦ ] could be the opti-
In the following study, the groove width is fixed at 32 m.
mized honing process, providing the best global compromise for
global engine performance. To study the effect of the other groove
3.4. Effect of groove density
features, the honing angle is fixed at 50◦ .
The groove density parameter Dg (Eq. (11)) was determined
3.3. Effect of groove width for various plateau-honed surfaces derived from the honing pro-
duction series. The conformity of these surfaces is systematically
The honed surfaces are obtained by a succession of three honing given by the expert’s visual inspection. Groove density is known
stages: the first stage, often categorized as rough honing, estab- to vary in the range of 20–40 grooves/mm2 . To isolate the effect of
lishes the cylindricity of the bore. The second stage or “finish plateau roughness variability when comparing the honed surfaces
honing” creates the basic surface texture of the hole (valley groove). with different groove densities, different groove textures were sim-
This enables the third honing operation – plateau stage – to remove ulated with groove density variants from 16 to 42 grooves/mm2 .
the plateau surface peaks, increasing the micro-relief quality with- The influence of groove density on friction performance is shown in
out surface damage [23,24]. Fig. 10. This figure clearly shows that optimal friction performance
In this simulation, surface texture with valley width variant is obtained in the range from 20 to 30 grooves/mm2 . As the deep
from 8 to 64 m was considered. In fact, the width of valley honing grooves provide a pathway for flow, particularly at small
grooves on honed surface textures produced in automotive indus- film thicknesses, decreasing the density of grooves will effectively
try present width variant from 15 to 35 m. Moreover, Sabri et al. block the pressure-driven flow and reduce the shear-driven flow
[20] proved by using a multiscale characterization based on con- carried by the ring. Pressure-driven flow blockage alters the effec-
tinuous wavelet transform decomposition that the plateau honing tive lubricant viscosity whereas the shear-driven flow changes the
affects only wavelengths lower than 20 m. So valley groove have effective ring profile [2]. Thus, decreasing the groove density mainly
a widths higher than this limit. Fig. 9 shows the prediction result increases the hydrodynamic pressure generated between the ring
of friction of the ring cylinder contact for various valley groove and the liner. On the contrary, increasing the groove density was
widths. For groove width higher than 20 m, the friction is optimal found to lead to higher oil consumption [20].
and remains constant. This result involves that the width of valley
grooves has no effect on the friction coefficient. This allows to make 3.5. Effect of groove balance
link between the process variable and the honed surface function-
ality (friction performance). In fact, the process can be optimized The balance of the two sets of grooves and the honing angle are
according to the surface performance. In this context, the grit size the most important properties of the honing texture [19]. During
Fig. 11. (a) Balanced grooves (conform surface) and (b) unbalanced grooves (not conform surface).
216 S. Mezghani et al. / Precision Engineering 36 (2012) 210–217
deviations from an “ideal” groove texture” like chatter marks, holes, Acknowledgement
flakes and material smearing, etc. [4,24]. In Fig. 14, a groove inter-
rupt is marked in grey level image of real honed surface. Some The authors thank S. Legros for his dedication and computer
automotive manufactures presume that groove interrupts are most support during this work.
important for oil consumption and noxious emissions.
The influence of groove continuities on engine behavior is References
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