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The increasing demand for environmentally friendly and fuel-efficient transportation and power generation requires further optimization and minimization of friction power losses. Calculating friction of internal combustion engines, especially the friction contribution from piston rings and skirt, requires detailed knowledge of the lubrication and relative motion of the components being in contact. This research presents a successful match of simulated and measured piston inter-ring pressures in several ring field locations. Good correlations demand excellent measurement results combined with a meticulous and comprehensive simulation model setup. This includes all data describing piston, piston rings, liner, and oil under real operating conditions within the entire engine performance map. To do so, the authors utilized a Floating-Liner-Engine - based on a heavy-duty diesel truck engine - to measure inter-ring pressures in the entire cascade from crown land down to third ring groove.

The increasing demand for environmentally friendly and fuel-efficient transportation and power generation requires further optimization and minimization of friction power losses. With up to 50% of the overall friction, the piston cylinder unit (PCU) shows most potential within the internal combustion engine (ICE) to increase mechanical efficiency. Calculating friction of internal combustion engines, especially the friction contribution from piston rings and skirt, requires detailed knowledge of the dynamics and lubrication regime of the components being in contact. Part I of this research presents a successful match of simulated and measured piston inter-ring pressures at numerous operation points [1] and constitutes the starting point for the comparison of simulated and measured piston group friction forces as presented in this research.

In an engine system, the piston pin is subjected to high loading and severe lubrication conditions, and pin seizures still occur during new engine development. A better understanding of the lubricating oil behavior and the dynamics of the piston pin could lead to cost- effective solutions to mitigate these problems. However, research in this area is still limited due to the complexity of the lubrication and the pin dynamics. In this work, a numerical model that considers structure deformation and oil cavitation was developed to investigate the lubrication and dynamics of the piston pin. The model combines multi-body dynamics and elasto-hydrodynamic lubrication. A routine was established for generating and processing compliance matrices and further optimized to reduce computation time and improve the convergence of the equations. A simple built-in wear model was used to modify the pin bore and small end profiles based on the asperity contact pressures.