Search Results

Engine oil consumption is one of the primary interests for the automotive industry in controlling emissions and reducing service cost. Due to a lack of understanding of the mechanisms and flow patterns of oil transport along the piston, reducing oil consumption from the ring pack of internal combustion engines has been extremely challenging for engine manufacturers and suppliers. In work prior to this study (see Part I [1]), individual oil transport processes such as oil flows on the piston lands in both axial and circumferential directions, oil flows through the ring grooves and gaps and oil flows between the piston and the liner have been identified and characterized. One of the major difficulties remaining for oil transport analysis was the lack of description of how the oil transport mechanisms previously investigated affect, through the multitude of flow paths, the oil balance in the various sub-regions and the net oil flow toward the combustion chamber.

Engine oil consumption is one of the primary interests for the automotive industry in controlling emissions and reducing service cost. Due to a lack of understanding of the mechanisms of oil transport along the piston, reducing oil consumption from the ring pack of internal combustion engines has been extremely challenging for engine manufacturers and suppliers. Consequently, a thorough experimental characterization of oil transport processes is critical to 1) reduce lead-time and cost of new piston ring pack development, 2) provide the physically based oil transport models needed to develop analytical tools for oil consumption prediction. In this work, a two-dimensional multiple-dye Laser-Induced Fluorescence (LIF) visualization system was successfully implemented in a diesel and a spark-ignition engine.

Engine oil consumption is an important source of hydrocarbon and particulate emissions in automotive engines. Oil evaporating from the piston-ring-liner system is believed to contribute significantly to total oil consumption, especially during severe operating conditions. This paper presents an extensive experimental and theoretical study on the contribution of oil evaporation to total oil consumption at different steady state speed and load conditions. A sulfur tracer method was used to measure the dependence of oil consumption on coolant outlet temperature, oil volatility, and operating speed and load in a production spark ignition engine. Liquid oil distribution on the piston was studied using a one-point Laser-Induced-Fluorescence (LIF) technique. In addition, important in-cylinder variables for oil evaporation, such as liner temperature and cylinder pressure, were measured. A multi-species cylinder liner oil evaporation model was developed to interpret the oil consumption data.

Engine oil consumption is recognized to be a significant source of pollutant emissions. Unburned or partially burned oil in the exhaust gases contributes directly to hydrocarbon and particulate emissions. In addition, chemical compounds present in oil additives poison catalytic converters and reduce their conversion efficiency. Oil consumption can increase significantly during critical non-steady operating conditions. This study analyzes the oil consumption behavior during ramp transients in load by combining oil consumption measurements, in-cylinder measurements, and computer-based modeling. A sulfur based oil consumption method was used to measure real-time oil consumption during ramp transients in load at constant speed in a production spark ignition engine. Additionally in-cylinder liquid oil behavior along the piston was studied using a one-point Laser-Induced-Fluorescence (LIF) technique.

A two-dimensional Laser Induced Fluorescence (LIF) system was developed to visualize the oil distribution and study the oil transport in the piston ring pack of a single-cylinder diesel engine through an optical window on the liner. The system gives high spatial and intensity resolutions so that detailed oil distribution on the piston as well as between the rings and the liner can be studied. This work primarily focused on investigating different oil transport mechanisms on piston crown land and second land under various engine operating conditions. Oil accumulation on the crown land was observed under certain operating conditions and top ring up-scraping was deemed to be the source for this oil accumulation. Two mechanisms for the oil flow on the second land were identified, namely, inertia driven oil flow in the axial direction and oil dragging by gas flow in the circumferential direction. Finally, the effects of ring rotation were investigated.

The oil control ring is the most critical component for oil consumption and friction from the piston system in internal combustion engines. Three-piece oil control rings are widely used in Spark Ignition (SI) engines. However, the dynamics and lubrication of three piece oil control rings have not been thoroughly studied from the theoretical point of view. In this work, a model was developed to predict side sealing, bore sealing, friction, and asperity contact between rails and groove as well as between rails and the liner in a Three Piece Oil Control Ring (TPOCR). The model couples the axial and twist dynamics of the two rails of TPOCR and the lubrication between two rails and the cylinder bore. Detailed rail/groove and rail/liner interactions were considered. The pressure distribution from oil squeezing and asperity contact between the flanks of the rails and the groove were both considered for rail/groove interaction.

A research program designed to measure the contribution from fuel absorption in the thin layer of oil, lubricating the cylinder liner, to the total and speciated HC emissions from a spark ignition engine has been performed. The logic of the experiment design was to test the oil layer mechanism via variations in the oil layer thickness (through the lubricant formulations), solubility of the fuel components in the lubricants, and variations in the crankcase gas phase HC concentration (through crankcase purging). A set of preliminary experiments were carried out to determine the solubility and diffusivity of the fuel components in the individual lubricants. Engine tests showed similar HC emissions among the tested lubricants. No consistent increase was observed with oil viscosity (oil film thickness), contrary to what would be expected if fuel-oil absorption was contributing significantly to engine-out HC. Similarly, no effect of crankcase purging could be observed.

The single-point LIF-measurement technique has been applied to a four-cylinder spark-ignition production engine for investigation of the oil film layer between the piston, piston rings and the cylinder wall. The lubrication process was studied during engine warm-up and it was found that a scaling law could be successfully used. This scaling law enables simple scaling of the oil film thickness of the compression ring, scraper ring and on the liner during warm-up, assuming the oil film thickness and cylinder liner temperature are known for the steady-state operating condition. Thereby the value of traditional measured steady-state lubrication data is enhanced.

The wear patterns of the rings and grooves of a diesel engine were analyzed by using a ring dynamics/gas flow model and a ring-pack oil film thickness model. The analysis focused primarily on the contact pressure distribution on the ring sides and grooves as well as on the contact location on the ring running surfaces. Analysis was performed for both new and worn ring/groove profiles. Calculated results are consistent with the measured wear patterns. The effects of groove tilt and static twist on the development of wear patterns on the ring sides, grooves, and ring running surfaces were studied. Ring flutter was observed from the calculation and its effect on oil transport was discussed. Up-scraping of the top ring was studied by considering ring dynamic twist and piston tilt. This work shows that the models used have potential for providing practical guidance to optimizing the ring pack and ring grooves to control wear and reduce oil consumption.

A complete one-dimensional mixed lubrication model has been developed to predict oil film thickness and friction of the piston ring-pack. An average flow model and a roughness contact model are used to consider the effects of surface roughness on both hydrodynamic and boundary lubrication. Effects of shear-thinning and liner temperature on lubricant viscosity are included. An inlet condition is applied by considering the unsteady wetting location at the leading edge of the ring. A ‘film non-separation’ exit condition is proposed to replace Reynolds exit condition when the oil squeezing becomes dominant. Three lubrication modes are considered in the model, namely, pure hydrodynamic, mixed, and pure boundary lubrication. All of these considerations are crucial for studying the oil transport, asperity contact, and friction especially in the top dead center (TDC) region where the oil control ring cannot reach.

This paper presents a numerical model of the rotational and lateral dynamics of the piston (secondary motion) and piston slap in mixed lubrication. Piston dynamic behavior, frictional and impact forces are predicted as functions of crank angle. The model considers piston skirt surface waviness, roughness, skirt profile, thermal and mechanical deformations. The model considers partially-flooded skirt and calculates the pressure distributions and friction in the piston skirt region for both hydrodynamic and boundary lubrication. Model predictions are compared with measurements of piston position using gap sensors in a single-cylinder engine and the comparison between theory and measurement shows remarkable agreement.