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A model has been developed for estimating the oil vaporization rate from the cylinder liner of a reciprocating engine. The model uses input from an external cycle simulator and an external liner oil film thickness model. It allows for the change in oil composition and the change in oil film thickness due to vaporization. It also estimates how the passage of the compression and scraper rings combine with the vaporization to influence the steady-state composition of the oil layer in the upper ring pack. Computer model results are presented for a compression-ignition engine using a range of liner temperatures, several engine speeds, and two different oils. Vaporization is found to be highly dependent on liner temperature and steady-state oil composition. The steady-state oil composition near the top of the cylinder is found to be significantly different than the composition of the oil near the bottom of the cylinder.

A model which converts flame arrival times at a head gasket ionization probe, used in a spark-ignition engine, into flame contours has been developed. The head gasket was manufactured at MIT using printed circuit board techniques. It has eight electrodes symmetrically spaced around the circumference (top of cylinder liner) and it replaces the conventional head gasket. The model is based on engine flame propagation rate data taken from the literature. Data from optical studies of S.I. engine combustion or studies utilizing optical fiber or ionization probe diagnostics were analyzed in terms of the apparent flame speed and the entrainment speed (flame speed relative to the fluid ahead of the flame). This gives a scaling relationship between the flame speed and the mass fraction burned which is generic and independent of the chamber shape.

The challenge posed by the long run times necessary to accurately quantify ash effects on diesel aftertreatment systems has led to numerous efforts to artificially accelerate ash loading, with varying degrees of success. In this study, a heavy-duty diesel engine was outfitted with a specially designed rapid lubricant degradation and aftertreatment ash loading system. Unlike previous attempts, the proposed methodology utilizes a series of thermal reactors and combustors to simulate all three major oil consumption mechanisms, namely combustion in the power cylinder, evaporative and volatile losses, and liquid losses through the valve and turbocharger seals. In order to simulate these processes, each thermal reactor allows for the precise control of the level of lubricant additive degradation, as well as the form and quantity of degradation products introduced into the exhaust upstream of the aftertreatment system.

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.

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.

Difficulties in the starting and operation of diesel engines at low temperatures are an important consideration in their design and operation, and in selection of the fuels for their use. Improvements in operation have been achieved primarily through external components of the engine and associated subsystems. A Rapid Compression Machine (RCM) has been modified to operate over a wide range of temperatures (−20°C to 100°C). It is used to isolate the combustion chamber in an environment in which all significant parameters are carefully defined and monitored. The influence of temperature and cetane number on the ignition and combustion processes are analyzed. Examination of the combustion characteristics show that temperature is by far the most influential factor affecting both ignition delay and heat release profiles. Cetane number (ASTM D-613) is not found to be a strong indicator of ignition delay for the conditions investigated.

This paper describes the use of a modified quasi-dimensional spark-ignition engine simulation code to predict the extent of cycle-to-cycle variations in combustion. The modifications primarily relate to the combustion model and include the following: 1. A flame kernel model was developed and implemented to avoid choosing the initial flame size and temperature arbitrarily. 2. Instead of the usual assumption of the flame being spherical, ellipsoidal flame shapes are permitted in the model when the gas velocity in the vicinity of the spark plug during kernel development is high. Changes in flame shape influence the flame front area and the interaction of the enflamed volume with the combustion chamber walls. 3. The flame center shifts due to convection by the gas flow in the cylinder. This influences the flame front area through the interaction between the enflamed volume and the combustion chamber walls. 4. Turbulence intensity is not uniform in cylinder, and varies cycle-to-cycle.

A conventional coil ignition system and two breakdown ignition systems with different electrode configurations were compared in M.I.T.'s transparent square piston engine. The purpose was to gain a deeper understanding of how the breakdown and glow discharge phases affect flame development and engine performance. The engine was operated with a standard intake valve and with a shrouded intake valve to vary the characteristic burning rate of the engine. Cylinder pressure data were used to characterize the ignition-system performance. A newly developed schlieren system which provides two orthogonal views of the developing flame was used to define the initial flame growth process. The study shows that ignition systems with higher breakdown energy achieve a faster flame growth during the first 0.5 ms after spark onset for all conditions studied.

Since the early inception of the adiabatic diesel engine in 1974, marked progress has taken place as a result of research efforts performed all over the world. The use of ceramics for heat engines in production applications has been limited to date, but is growing. Ceramic use for production heat engine has included: combustion prechambers, turbochargers, exhaust port liners, top piston ring inserts, glow plugs, oxygen sensors; and additional high temperature friction and wear components. The potential advantages of an adiabatic engine vary greatly with specific application (i.e., commercial vs. military, stationary vs. vehicular, etc.), and thus, a better understanding of the strengths and weaknesses (and associated risks) of advanced adiabatic concepts with respect to materials, tribology, cost, and payoff must be obtained.

The high temperature tribology issue for uncooled Low Heat Rejection (LHR) diesel engines where the cylinder liner piston ring interface exceeds temperatures of 225°C to 250°C has existed for decades. It is a problem that has persistently prohibited advances in non-watercooled LHR engine development. Though the problem is not specific to non-watercooled LHR diesel engines, it is the topic of this research study for the past two and one half years. In the late 1970s and throughout the 1980s, a tremendous amount of research had been placed upon the development of the LHR diesel engine. LHR engine finite element design and cycle simulation models had been generated. Many of these projected the cylinder liner piston ring top ring reversal (TRR) temperature to exceed 540°C[1]. In order for the LHR diesel to succeed, a tribological solution for these high TRR temperatures had to be developed.

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.

A spark-ignition engine friction model developed by Patton et al. in the late 1980s was evaluated against current engine friction data, and improved. The model, which was based on a combination of fundamental scaling laws and empirical results, includes predictions of rubbing losses from the crankshaft, reciprocating, and valvetrain components, auxiliary losses from engine accessories, and pumping losses from the intake and exhaust systems. These predictions were based on engine friction data collected between 1980 and 1988. Some of the terms are derived from lubrication theory. Other terms were derived empirically from measurements of individual friction components from engine teardown experiments. Recent engine developments (e.g., improved oils, surface finish on piston liners, valve train mechanisms) suggested that the model needed updating.

This paper provides an overview of spark-ignition engine unburned hydrocarbon emissions mechanisms, and then uses this framework to relate measured engine-out hydrocarbon emission levels to the processes within the engine from which they result. Typically, spark-ignition engine-out HC levels are 1.5 to 2 percent of the gasoline fuel flow into the engine; about half this amount is unburned fuel and half is partially reacted fuel components. The different mechanisms by which hydrocarbons in the gasoline escape burning during the normal engine combustion process are described and approximately quantified. The in-cylinder oxidation of these HC during the expansion and exhaust processes, the fraction which exit the cylinder, and the fraction oxidized in the exhaust port and manifold are also estimated.

The two newest internal combustion engine technologies which have demonstrated the most promise in the last 25 years are the direct-injection stratified-charge (DISC) rotary engine [1] and the adiabatic diesel engine [2]. The (DISC) engine is particularly attractive for aviation applications [3] because of its light weight, multi-fuel capability and potential for low fuel consumption. However, one disadvantage with the DISC engine is the weight and size of the liquid cooling system. NASA Lewis Research Center has supported a technology enablement program to advance the DISC rotary engine for general aviation applications and recognizes the importance of improvement in fuel consumption and reductions in the coolant system weight [4].

An analysis method for characterizing fuel behavior during spark-ignition engine starting has been developed and applied to several sets of start-up data. The data sets were acquired from modern production vehicles during room temperature engine start-up. Two different engines, two control schemes, and two engine temperatures (cold and hot) were investigated. A cycle-by-cycle mass balance for the fuel was used to compare the amount of fuel injected with the amount burned or exhausted as unburned hydrocarbons. The difference was measured as “fuel unaccounted for”. The calculation for the amount of fuel burned used an energy release analysis of the cylinder pressure data. The results include an overview of starting behavior and a fuel accounting for each data set Overall, starting occurred quickly with combustion quality, manifold pressure, and engine speed beginning to stabilize by the seventh cycle, on average.

The direct injection spark-ignition engine is the only internal combustion engine with the potential to equal the efficiency of the diesel and to tolerate a wide range of fuel types and fuel qualities without deterioration of performance. However, this engine has low combustion efficiency and excessive hydrocarbon emissions when operating at light load. In this paper, potential sources of hydrocarbon emissions during light load operation are postulated and analyzed. The placement of fuel away from the primary combustion process in conjunction with a lack of secondary burnup are isolated as important hydrocarbon emissions mechanisms. Analyses show that increasing cylinder gas temperatures can improve secondary burnup of fuel which would reduce hydrocarbon emissions. Practical means to achieve this include higher compression ratio and use of ceramic parts in the combustion chamber.

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.

This paper investigates theoretically the effects of heat transfer characteristics, such as crank-angle phasing and wall temperature swings, on the thermodynamic efficiency of an IC engine. The objective is to illustrate the fundamental physical basis of applying thin thermal barrier coatings to improve the performance of military and commercial IC engines. A simple model illustrates how the thermal impedance and thickness of coatings can be manipulated to control heat transfer and limit the high temperatures in engine components. A friction model is also included to estimate the overall improvement in engine efficiency by the proper selection of coating thickness and material.

A laser fluorescent diagnostic method was employed to measure lubricant film thickness on the cylinder wall/piston interface of two engines. The system output signal was calibrated using lubricant samples of known thickness, and by comparison of a known piston ring profile to measured lubricant film contours. Agreement of the results of the two calibration methods was within 5%. A relative calibration was performed with three oils having different additive packages, and with an oil contaminated through use in a commercially operated engine. The calibration coefficients for the oils, relating output voltage to film thickness, varied within a factor up to two, depending on lubricant type and age. The laser fluorescent apparatus was installed for use with a single cylinder test version of the Cummins VT-903 diesel engine. An optical passage was created through the block and cylinder wall using a quartz window.

The trend toward lighter vehicles for improved performance has recently introduced the use of aluminum and plastic materials for vehicle bodies and drive trains. In particular, the aluminum alloy block for engine application is certain to reappear. The soft aluminum cylinder liner will require additional treatment before acceptance. Three possible approaches appear to solve the aluminum cylinder liner dilemma. These approaches are: 1. Use of high silicon aluminum such as the 390 aluminum. 2. Insert or cast steel liners into the aluminum engine block. 3. Ceramic coat the low cost standard aluminum engine block. Each has known advantages and disadvantages. It is the purpose of this paper to present the merits of Option 3, the ceramic coated aluminum cylinder bore from the standpoint of low weight, cost, and tribological effectiveness. The advantages of approaches (1) and (2) are obvious. High temperature after treatment of the ceramic engine components is not required.