P. A. Lakshminarayanan, Nagaraj S. Nayak

Critical Component Wear in Heavy Duty Engines (eBook, PDF)

• Format: PDF

Produktbeschreibung

The critical parts of a heavy duty engine are theoretically designed for infinite life without mechanical fatigue failure. Yet the life of an engine is in reality determined by wear of the critical parts. Even if an engine is designed and built to have normal wear life, abnormal wear takes place either due to special working conditions or increased loading. Understanding abnormal and normal wear enables the engineer to control the external conditions leading to premature wear, or to design the critical parts that have longer wear life and hence lower costs. The literature on wear phenomenon related to engines is scattered in numerous periodicals and books. For the first time, Lakshminarayanan and Nayak bring the tribological aspects of different critical engine components together in one volume, covering key components like the liner, piston, rings, valve, valve train and bearings, with methods to identify and quantify wear. * The first book to combine solutions to critical component wear in one volume * Presents real world case studies with suitable mathematical models for earth movers, power generators, and sea going vessels * Includes material from researchers at Schaeffer Manufacturing (USA), Tekniker (Spain), Fuchs (Germany), BAM (Germany), Kirloskar Oil Engines Ltd (India) and Tarabusi (Spain) * Wear simulations and calculations included in the appendices * Instructor presentations slides with book figures available from the companion site Critical Component Wear in Heavy Duty Engines is aimed at postgraduates in automotive engineering, engine design, tribology, combustion and practitioners involved in engine R&D for applications such as commercial vehicles, cars, stationary engines (for generators, pumps, etc.), boats and ships. This book is also a key reference for senior undergraduates looking to move onto advanced study in the above topics, consultants and product mangers in industry, as well as engineers involved in design of furnaces, gas turbines, and rocket combustion. Companion website for the book: href="http://www.wiley.com/go/lakshmi">www.wiley.com/go/lakshmi

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Produktdetails

• Verlag: John Wiley & Sons
• Seitenzahl: 448
• Erscheinungstermin: 7. September 2011
• Englisch
• ISBN-13: 9780470828830
• Artikelnr.: 37299572

Autorenporträt

P.A. Lakshminarayanan is the Head of R&D at Ashok Leyland in India. He has been the team leader or lead designer of about 10 diesel and CNG engines for different applications. He has guided 2 PhDs at IIT Delhi and 4 M.Techs at IIT Madras, and has published 40 papers in ASME, SAE, IMechE, and AVL journals and conferences. Previous appointments include 20 years from Manger to Senior General Manger of R&D at Kirloskar Oil Engines Ltd, over 15 years as a Visiting Lecturer at IIT Madras, and 5 years as a Research Associate to J.C. Dent at Loughborough University of Technology. He is a Fellow of SAE-International. Lakshminarayanan holds a B.Tech, and M.S. and a PhD from IIT Madras. Nagaaraj S. Nayak is a Professor of Mechanical Engineering based at Sahyadri College of Engg. & Management. Previously, he was a Senior Manager at the R&D department of Kirloskar Oil Engines Ltd for 9 years, and was a Postdoctoral Fellow at University of Wisconsin Madison for 2 years. He has been a team leader for emission upgrades on 3 engines platforms, and performance development of 2 new engine platforms.

Inhaltsangabe

List of Contributors xv Preface xvii Acknowledgements xxi PART I OVERTURE 1
1 Wear in the Heavy Duty Engine 3 1.1 Introduction 3 1.2 Engine Life 3 1.3
Wear in Engines 4 1.4 General Wear Model 5 1.5 Wear of Engine Bearings 5
1.6 Wear of Piston Rings and Liners 6 1.7 Wear of Valves and Valve Guides 6
1.8 Reduction in Wear Life of Critical Parts Due to Contaminants in Oil 6
1.9 Oils for New Generation Engines with Longer Drain Intervals 8 1.10
Filters 9 1.11 Types of Wear of Critical Parts in a Highly Loaded Diesel
Engine 10 References 11 2 Engine Size and Life 13 2.1 Introduction 13 2.2
Engine Life 13 2.3 Factors on Which Life is Dependent 14 2.4 Friction Force
and Power 14 2.5 Similarity Studies 15 2.6 Archard's Law of Wear 20 2.7
Wear Life of Engines 20 2.8 Summary 23 Appendix 2.A Engine Parameters,
Mechanical Efficiency and Life 25 Appendix 2.B Hardness and Fatigue Limits
of Different Copper-Lead-Tin (Cu-Pb-Sn) Bearings 26 Appendix 2.C Hardness
and Fatigue Limits of Different Aluminium-Tin (Al-Sn) Bearings 28
References 29 PART II VALVE TRAIN COMPONENTS 31 3 Inlet Valve Seat Wear in
High bmep Diesel Engines 33 3.1 Introduction 33 3.2 Valve Seat Wear 34 3.3
Shear Strain and Wear due to Relative Displacement 35 3.4 Wear Model 35 3.5
Finite Element Analysis 37 3.6 Experiments, Results and Discussions 38 3.7
Summary 45 3.8 Design Rule for Inlet Valve Seat Wear in High bmep Engines
45 References 45 4 Wear of the Cam Follower and Rocker Toe 47 4.1
Introduction 47 4.2 Wear of Cam Follower Surfaces 48 4.3 Typical Modes of
Wear 50 4.4 Experiments on Cam Follower Wear 51 4.5 Dynamics of the Valve
Train System of the Pushrod Type 52 4.6 Wear Model 55 4.7 Parametric Study
64 4.8 Wear of the Cast Iron Rocker Toe 64 4.9 Summary 66 References 66
PART III LINER, PISTON AND PISTON RINGS 69 5 Liner Wear: Wear of Roughness
Peaks in Sparse Contact 71 5.1 Introduction 71 5.2 Surface Texture of
Liners and Rings 72 5.3 Wear of Liner Surfaces 76 5.4 Wear Model 81 5.5
Liner Wear Model for Wear of Roughness Peaks in Sparse Contact 85 5.6
Discussions on Wear of Liner Roughness Peaks due to Sparse Contact 89 5.7
Summary 92 Appendix 5.A Sample Calculation of the Wear of a Rough Plateau
Honed Liner 93 References 93 6 Generalized Boundary Conditions for
Designing Diesel Pistons 95 6.1 Introduction 95 6.2 Temperature
Distribution and Form of the Piston 96 6.3 Experimental Mapping of
Temperature Field in the Piston 97 6.4 Heat Transfer in Pistons 98 6.5
Calculation of Piston Shape 98 6.6 Summary 108 References 109 7 Bore
Polishing Wear in Diesel Engine Cylinders 111 7.1 Introduction 111 7.2 Wear
Phenomenon for Liner Surfaces 112 7.3 Bore Polishing Mechanism 113 7.4 Wear
Model 115 7.5 Calculation Methodology and Study of Bore Polishing Wear 116
7.6 Case Study on Bore Polishing Wear in Diesel Engine Cylinders 118 7.7
Summary 127 References 127 8 Abrasive Wear of Piston Grooves in Highly
Loaded Diesel Engines 129 8.1 Introduction 129 8.2 Wear Phenomenon in
Piston Grooves 130 8.3 Wear Model 132 8.4 Experimental Validation 134 8.5
Estimation of Wear Using Sarkar's Model 137 8.6 Summary 139 References 140
9 Abrasive Wear of Liners and Piston Rings 141 9.1 Introduction 141 9.2
Wear of Liner and Ring Surfaces 141 9.3 Design Parameters 143 9.4 Study of
Abrasive Wear on Off-highway Engines 144 9.5 Winnowing Effect 149 9.6
Scanning Electron Microscopy of Abrasive Wear 150 9.7 Critical Dosage of
Sand and Life of Piston-Ring-Liner Assembly 150 9.8 Summary 152 References
153 10 Corrosive Wear 155 10.1 Introduction 155 10.2 Operating Parameters
155 10.3 Corrosive Wear Study on Off-road Application Engines 156 10.4 Wear
Related to Coolants in an Engine 161 10.5 Summary 165 References 165 11
Tribological Tests to Simulate Wear on Piston Rings 167 11.1 Introduction
167 11.2 Friction and Wear Tests 168 11.3 Test Procedures Assigned to the
High Frequency, Linear Oscillating Test Machine 170 11.4 Load, Friction and
Wear Tests 172 11.5 Test Results 175 11.6 Selection of Lubricants 184 11.7
High Performance Bio-lubricants and Tribo-reactive Materials for Clean
Automotive Applications 185 11.8 Tribo-Active Materials 190 11.9 EP
Tribological Tests 192 Acknowledgements 194 References 194 PART IV ENGINE
BEARINGS 197 12 Friction and Wear in Engine Bearings 199 12.1 Introduction
199 12.2 Engine Bearing Materials 202 12.3 Functions of Engine Bearing
Layers 205 12.4 Types of Overlays/Coatings in Engine Bearings 206 12.5
Coatings for Engine Bearings 209 12.6 Relevance of Lubrication Regimes in
the Study of Bearing Wear 210 12.7 Theoretical Friction and Wear in
Bearings 217 12.8 Wear 218 12.9 Mechanisms of Wear 219 12.10 Requirements
of Engine Bearing Materials 234 12.11 Characterization Tests for Wear
Behaviour of Engine Bearings 238 12.12 Summary 251 References 252 PART V
LUBRICATING OILS FOR MODERN ENGINES 253 13 Heavy Duty Diesel Engine Oils,
Emission Strategies and their Effect on Engine Oils 255 13.1 Introduction
255 13.2 What Drives the Changes in Diesel Engine Oil Specifications? 256
13.3 Engine Oil Requirements 258 13.4 Components of Engine Oil Performance
265 13.5 How Engine Oil Performance Standards are Developed 268 13.6 API
Service Classifications 276 13.7 ACEA Specifications 276 13.8 OEM
Specifications 279 13.9 Why Some API Service Classifications Become
Obsolete 279 13.10 Engine Oil Composition 280 13.11 Specific Engine Oil
Additive Chemistry 290 13.12 Maintaining and Changing Engine Oils 302 13.13
Diesel Engine Oil Trends 306 13.14 Engine Design Technologies and
Strategies Used to Control Emissions 306 13.15 Impact of Emission
Strategies on Engine Oils 324 13.16 How Have Engine Oils Changed to Cope
with the Demands of Low Emissions? 328 13.17 Most Prevalent API
Specifications Found In Use 329 13.18 Paradigm Shift in Engine Oil
Technology 336 13.19 Future Engine Oil Developments 348 13.20 Summary 352
References 353 PART VI FUEL INJECTION EQUIPMENT 355 14 Wear of Fuel
Injection Equipment 357 14.1 Introduction 357 14.2 Wear due to Diesel Fuel
Quality 357 14.3 Wear due to Abrasive Dust in Fuel 361 14.4 Wear due to
Water in Fuel 365 14.5 Summary 367 References 367 PART VII HEAVY FUEL
ENGINES 369 15 Wear with Heavy Fuel Oil Operation 371 15.1 Introduction 371
15.2 Fuel Treatment: Filtration and Homogenization 373 15.3 Water and
Chlorine 374 15.4 Viscosity, Carbon Residue and Dust 374 15.5 Deposit Build
Up on Top Land and Anti-polishing Ring for Reducing the Wear of Liner,
Rings and Piston 375 15.6 High Sulfur in Fuel 377 15.7 Low Sulfur in Fuel
380 15.8 Catalyst Fines 383 15.9 High Temperature Corrosion 383 15.10 Wear
Specific to Four-stroke HFO Engines 388 15.11 New Engines Compliant to
Maritime Emission Standards 391 15.12 Wear Life of an HFO Engine 393 15.13
Summary 393 References 394 PART VIII FILTERS 397 16 Air and Oil Filtration
and Its Impact on Oil Life and Engine Wear Life 399 16.1 Introduction 399
16.2 Mechanisms of Filtration 400 16.3 Classification of Filtration 400
16.4 Filter Rating 403 16.5 Filter Selection 404 16.6 Introduction to
Different Filters in the Engine 405 16.7 Oil Filters and Impact on Oil and
Engine Life 409 16.8 Engine Wear 413 16.9 Full Flow Oil Filters 415 16.10
Summary 419 Appendix 16.A Filter Tests and Test Standards 419 References
419 Index 421