Analytically Predicating the Multi-Dimensional Accuracy of the Honed Engine Cylinder Bore

2020 ◽  
Vol 142 (9) ◽  
Author(s):  
Xueping Zhang ◽  
Zaoyang Zhou ◽  
Zhenqiang Yao ◽  
Lifeng Xi
Keyword(s):  
Surface Texture ◽  
Dimensional Accuracy ◽  
Multiscale Model ◽  
Cylinder Surface ◽  
Initial Shape ◽  
Wear Process ◽  
Force Matching ◽  
Engine Cylinder ◽  
Cylinder Bore

Abstract The dimensional accuracy of engine cylinder bore at multiscale has a tremendous influence on engine performances including friction power loss, vibration, leak tightness between piston and cylinder, and wear resistance. Tremendous researches were devoted to predict the dimensional accuracies of the honed cylinder by means of analytical, experimental, and numerical simulation methods. The dimensional quality of the honed cylinder bore was usually determined by establishing the relationship between honing parameters and dimensional accuracies of the honed cylinder bore. However, most researches predicted dimensional accuracy at macroscale or surface texture at microscale, respectively. Few efforts were devoted to predict the dimensional quality of honed cylinder bore at both macroscale and microscale levels simultaneously. To explore a new understanding of the honing mechanism of the cylinder bore, a multiscale model is proposed to predict the dimensional accuracy and surface texture of cylinder bore generated from the honing process at the macroscale and microscale simultaneously. The model aims to integrate both microscale factors including honing stone abrasives distribution, abrasive wear process, previous cylinder surface topography, and macroscale factors including cylinder geometric features and honing head motion trajectory into a multiscale analytical analysis. A force matching method is adopted in the multiscale predictive model to determine the feed depth in the honing of the cylinder bore. Thus, the proposed multiscale analytical model possesses an excellent capacity to simultaneously predict the roundness and cylindricity of the honed cylinder bore, as well as the surface texture/roughness of the honed cylinder bore in terms of Abbott-Firestone curve. The simulated results also revealed that the material removal process is closely related to the initial shape deviations of the cylinder bore, which cannot be corrected, compensated, or eliminated by the subsequent honing process given the deviations are associated with wavelengths higher than 27 mm under the given honing condition.

Predicting Multi-Scale Dimensional Accuracy of Engine Cylinder by Honing

2017 ◽  
Author(s):  
Zaoyang Zhou ◽  
Xueping Zhang ◽  
Zhenqiang Yao ◽  
Lifeng Xi
Keyword(s):  
Surface Texture ◽  
Dimensional Accuracy ◽  
Scale Model ◽  
Cylinder Wall ◽  
Initial Shape ◽  
Abrasive Resistance ◽  
Micro Scale ◽  
Multi Scale ◽  
Macro Scale ◽  
Cylinder Bore

The deviations of cylinder bore dimensional accuracy have tremendous influence on engine performances including friction power loss, vibration, leak tightness between piston ring and cylinder wall, and abrasive resistance. Many researches were devoted to capturing cylinder dimensional accuracies by honing using analytical, experimental and simulation methods. These researches investigated the topography and roughness of the honed surface, the relationship between the process parameters and the dimensional accuracies. However, most researches focused on macro-scale dimensional accuracy and micro-scale surface texture respectively. To overcome the limitation, a multi-scale model for cylinder bore honing is proposed to predict the dimensional accuracy and surface texture of cylinder bore at macro-scale and micro-scale simultaneously. The model integrates the microscale factors of the honing stone abrasives distribution characteristics, abrasive wear process, previous cylinder surface topography, and macro-scale factors of cylinder geometry and honing head motion trajectory. A Force matching method is adopted to determine the feed depth of cylinder honing process. Thus the model can predict the roundness, cylindricity, roughness and Abbott-Firestone curve of the honed cylinder bore at multi-scale levels. Simulation results show that material removal distribution is closely related to cylinder bore initial shape deviations. The deviations with long wavelengths cannot be eliminated by the sequential honing.

Honed surface multi-scale Prediction based on multi-stage honing process of engine cylinder bore

2019 ◽  
pp. 1-32
Author(s):  
Zaoyang Zhou ◽  
Xueping Zhang ◽  
Kunlun Lv ◽  
Jun Wu ◽  
Zhenqiang Yao ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Texture ◽  
Time Discretization ◽  
Single Step ◽  
Analytical Methodology ◽  
Duration Time ◽  
Engine Cylinder ◽  
Two Stages ◽  
Cylinder Bore ◽  
Abrasive Size

Abstract Sequential honing process is usually implemented in engine cylinder bore processing to obtain the cross-hatched surface texture with excellent function to balance lubricant storage capacities and supporting performance. Many researches have devoted to correlating honed surface quality of cylinder bore with honing process parameters by means of experiments or simulations. Quite a few efforts have addressed the effect of sequential multiple steps on the surface texture in the honing of engine cylinder bore. However, these researches cannot provide an explicit and analytical methodology to predict honed surface texture efficiently and accurately. This paper presents an analytical and explicit methodology to incorporate a proposed microscale abrasive model into the analytical simulation process of sequential honing. The proposed abrasive model synthetically considers the shape, size, posture, and position of abrasives randomly distributed in honing stone, which is incorporated into honing head motions in terms of rotation, oscillation and feeding. The kinematics of honing head is calculated by space-time discretization to capture the interaction between honing stones and cylinder bore surface. The above procedure acts as each single step for the sequential honing processes. This study investigates the sequential honing of two stages including semi-finish honing and plateau honing at different feeding speeds by applying the abrasive model with different abrasive sizes. The formation of cross-hatched surface texture was successfully achieved sequentially by semi-finish honing and plateaus honing. Then the Abbott-Firestone Curve of the honed surface can be obtained to analyze the influences of abrasive size and honing time of two stages on the surface roughness. Correctness of surface roughness predicted by the model is verified by comparing with a group of experiment measurements in terms of Abbott-Firestone Curve. Most errors of all the predicted Rk roughness family roughness parameters in the two honing stages are less than 15%. Based on the model, simulations are done to analyze the influences of abrasive size and honing duration time of two stages on the surface roughness. The result shows that the larger abrasive used in finish honing leads to the decrease of the material portions Mr1, Mr2 and the increase of the reduced valley depth Rvk. The longer plateau honing duration time is preferred to produce the larger Mr1, Mr2 and the smaller Rvk.

Simulating the Sequential Honing Process of Engine Cylinder Bore by Modeling Abrasives in Honing Stone

2019 ◽  
Author(s):  
Zaoyang Zhou ◽  
Xueping Zhang ◽  
Kunlun Lv ◽  
Jun Wu ◽  
Zhenqiang Yao ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Texture ◽  
Time Discretization ◽  
Single Step ◽  
Analytical Methodology ◽  
Duration Time ◽  
Engine Cylinder ◽  
Two Stages ◽  
Cylinder Bore ◽  
Abrasive Size

Abstract Sequential honing process is usually implemented in engine cylinder bore processing to obtain the cross-hatched surface texture with excellent function to balance lubricant storage capacities and supporting performance. Many researches have devoted to correlating honed surface quality of cylinder bore with honing process parameters by means of experiments or simulations. Quite a few efforts have addressed the effect of sequential multiple steps on the surface texture in the honing of engine cylinder bore. However, these researches cannot provide an explicit and analytical methodology to predict honed surface texture efficiently and accurately. This paper presents an analytical and explicit methodology to incorporate a proposed microscale abrasive model into the analytical simulation process of sequential honing. The proposed abrasive model synthetically considers the shape, size, posture, and position of abrasives randomly distributed in honing stone, which is incorporated into honing head motions in terms of rotation, oscillation and feeding. The kinematics of honing head is calculated by space-time discretization to capture the interaction between honing stones and cylinder bore surface. The above procedure acts as each single step for the sequential honing processes. This study investigates the sequential honing of two stages including semi-finish honing and plateau honing at different feeding speeds by applying the abrasive model with different abrasive sizes. The formation of cross-hatched surface texture was successfully achieved sequentially by semi-finish honing and plateaus honing. Then the Abbott-Firestone Curve of the honed surface can be obtained to analyze the influences of abrasive size and honing time of two stages on the surface roughness. Correctness of surface roughness predicted by the model is verified by comparing with a group of experiment measurements in terms of Abbott-Firestone Curve. Most errors of all the predicted Rk roughness family roughness parameters in the two honing stages are less than 15%. Based on the model, simulations are done to analyze the influences of abrasive size and honing duration time of two stages on the surface roughness. The result shows that the larger abrasive used in finish honing leads to the decrease of the material portions Mr1, Mr2 and the increase of the reduced valley depth Rvk. The longer plateau honing duration time is preferred to produce the larger Mr1, Mr2 and the smaller Rvk.

scholarly journals Technological prerequisites for the energy efficiency increase of the engine cylinder bore processing

2021 ◽  
Vol 279 ◽  
pp. 01001
Author(s):  
Lydmila Safarova ◽  
Andrey Malikov ◽  
Alexandr Yamnikov ◽  
Olga Yamnikova
Keyword(s):  
Metal Cutting ◽  
Engine Cylinder ◽  
Efficiency Increase ◽  
Cutting Equipment ◽  
Shaft Furnaces ◽  
Reduce Energy Consumption ◽  
Parameters Of Accuracy ◽  
Machining Operations ◽  
Cylinder Bore

An example of the rationalization of the current technology for manufacturing a cylinder of a small-sized diesel engine at PA “TULAMASHZAVOD” from a cast iron is given. It is shown that lowpower obsolete equipment leads to an increase in the number of technological operations and equipment used. However, even if all the generally accepted technological recommendations are followed, only 80% of the parts meet the requirements for the required parameters of accuracy and quality of the cylinder bore surface. Studies have found that the main reasons for insufficient quality are the presence of residual stresses in the casting, which cannot be removed during artificial aging, as well as insufficient accuracy and rigidity of metal cutting equipment at turning and boring operations. The use of more powerful and accurate modern equipment is theoretically and experimentally justified, which, due to increased refinement, allows reducing the number of machining operations. Replacement of artificial thermal aging by natural, combined with the replacement of shaft furnaces for heat treatment of workpieces with chamber furnaces of lower power and higher capacity, reduce energy consumption for the manufacturing by almost 4 times.

scholarly journals Predicting Microscale Cross-Hatched Surface Texture in Engine Cylinder Bore

Procedia CIRP ◽  
2018 ◽  
Vol 71 ◽  
pp. 272-278 ◽  
Author(s):  
Zaoyang Zhou ◽  
Xueping Zhang ◽  
Kunlun Lv ◽  
Guangya Li ◽  
Jun Wu ◽  
...  
Keyword(s):  
Surface Texture ◽  
Engine Cylinder ◽  
Cylinder Bore

Wear Model for Piston Ring and Cylinder Bore System

2005 ◽  
Author(s):  
Yunchao Qiu ◽  
Qian Zou ◽  
Gary C. Barber ◽  
Harold E. McCormick ◽  
Dequan Zou ◽  
...  
Keyword(s):  
Piston Ring ◽  
Thickness Distribution ◽  
Matrix Ring ◽  
Experimental Investigations ◽  
General Tendency ◽  
Wear Model ◽  
Wear Process ◽  
The Matrix ◽  
Surface Profiles ◽  
Cylinder Bore

A new wear model for piston ring and cylinder bore system has been developed to predict wear process with high accuracy and efficiency. It will save time and cost compared with experimental investigations. Surfaces of ring and bore were divided into small domains and assigned to corresponding elements in two-dimensional matrix. Fast Fourier Transform (FFT) and Conjugate Gradient Method (CGM) were applied to obtain pressure distribution on the computing domain. The pressure and film thickness distribution were provided by a previously developed ring/bore lubrication module. By changing the wear coefficients of the ring and bore with accumulated cycles, wear was calculated point by point in the matrix. Ring and bore surface profiles were modified when wear occurred. The results of ring and bore wear after 1 cycle, 10 cycles and 2 hours at 3600 rpm were calculated. They coincided well with the general tendency of wear in a ring and bore system.

Thermodynamic Analysis of a Multi-Fueled Single Cylinder SI Engine

2011 ◽  
Author(s):  
M. Z. Haq ◽  
M. R. Mohiuddin
Keyword(s):  
Thermodynamic Analysis ◽  
Chemical Properties ◽  
Second Law Of Thermodynamics ◽  
Second Law ◽  
Si Engine ◽  
Gaseous Species ◽  
Single Cylinder ◽  
Engine Cylinder ◽  
Si Engines

The paper presents a thermodynamic analysis of a single cylinder four-stroke spark-ignition (SI) engine fuelled by four fuels namely iso-octane, methane, methanol and hydrogen. In SI engines, due to phenomena like ignition delay and finite flame speed manifested by the fuels, the heat addition process is not instantaneous, and hence ‘Weibe function’ is used to address the realistic heat release scenario of the engine. Empirical correlations are used to predict the heat loss from the engine cylinder. Physical states and chemical properties of gaseous species present inside the cylinder are determined using first and second law of thermodynamics, chemical kinetics, JANAF thermodynamic data-base and NASA polynomials. The model is implemented in FORTRAN 95 using standard numerical routines and some simulation results are validated against data available in literature. The second law of thermodynamics is applied to estimate the change of exergy i.e. the work potential or quality of the in-cylinder mixture undergoing various phases to complete the cycle. Results indicate that, around 4 to 24% of exergy initially possessed by the in-cylinder mixture is reduced during combustion and about 26 to 42% is left unused and exhausted to the atmosphere.

Enhanced Hybrid Model to Predict the Surface Roughness of Honed cylinder Bore

2021 ◽  
pp. 1-25
Author(s):  
Burhan Afzal ◽  
Xueping Zhang ◽  
Anil Srivastava
Keyword(s):  
Surface Roughness ◽  
Hybrid Model ◽  
Surface Texture ◽  
Prediction Accuracy ◽  
Analytical Models ◽  
Superior Performance ◽  
Functional Surface ◽  
Model Framework ◽  
Multiple Variables ◽  
Cylinder Bore

Abstract Cylinder bore honing is a finishing process that generates a crosshatch pattern with alternate valleys and plateaus responsible for enhancing lubrication and preventing gas and oil leakage in the engine cylinder bore. The required functional surface in the cylinder bore is generated by a sequential honing process and is characterized by Rk roughness parameters (Rk, Rvk, Rpk, Mr1, Mr2). Predicting the desired surface roughness relies primarily on two techniques: (i) analytical models (AM) and (ii) machine learning (ML) models. Both of these techniques offer certain advantages and limitations. AM's are interpretable as they indicate distinct mapping relation between input variables and honed surface texture. However, AM's are usually based on simplified assumptions to ensure the traceability of multiple variables. Consequently, their prediction accuracy is adversely impacted when these assumptions are not satisfied. However, ML models accurately predict the surface texture but their prediction mechanism is challenging to interpret. Furthermore, the ML models' performance relies heavily on the representativeness of data employed in developing them. Thus, either prediction accuracy or model interpretability suffers when AM and ML models are implemented independently. This study proposes a hybrid model framework to incorporate the benefits of AM and ML simultaneously. In the hybrid model, an Artificial neural network (ANN) compensates the AM by correcting its error. This retains the physical understanding built into the model while simultaneously enhancing the prediction accuracy. The proposed approach resulted in a hybrid model that significantly improved the prediction accuracy of the AM and additionally provided superior performance compared to independent ANN.

Large-Diameter Line Pipe Expanding Process

2012 ◽  
Vol 192 ◽  
pp. 180-184 ◽  
Author(s):  
Ai Xia He ◽  
Rong Chang Li
Keyword(s):  
Process Parameters ◽  
Large Diameter ◽  
Dimensional Accuracy ◽  
Optimization Method ◽  
Main Process ◽  
Shape Accuracy ◽  
Line Pipe ◽  
Factors Affecting ◽  
Array Optimization

Mechanical expanding process for large diameter line pipe, a detailed analysis of factors affecting the quality of the final products of the mechanical expansion and proposed optimization using orthogonal array optimization method, as an indicator of dimensional accuracy and shape accuracy of the products, combination of a variety of specifications of mechanical expanding products, the main process parameters to be optimized. Analysis and discussion of results, revealing the degree of influence of various factors on the quality of the final product, and gives the optimum combination of the results. Experiments show that the combination of optimized process parameters, and more help to improve the accuracy of the size and shape of products.

scholarly journals Investigation of the Heat Transfer Process in Internal Combustion Engine Cylinders

2020 ◽  
pp. 266-274
Author(s):  
Volodumur Suvolapov ◽  
◽  
Andriy Novitskiy ◽  
Vasul Khmelevski ◽  
Oleksandr Bustruy ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Internal Combustion Engines ◽  
Combustion Engine ◽  
Contact Layer ◽  
Internal Combustion ◽  
Temperature Fields ◽  
Cylinder Surface ◽  
Stationary Mode ◽  
Cylinder Wall ◽  
Engine Cylinder

The article analyzes scientific publications and literary studies of heat transfer processes in cylinders of internal combustion engines. The research of temperature fields in engines during their operation at different modes with the use of a software package and calculation module is presented. The results of modeling and thermo-metering in homogeneous and laminated engine cylinder liners are analyzed. Graphic dependencies and temperature distribution by cylinder wall thickness at maximum and minimum temperature on cylinder surface are given. On the basis of researches it is established that at laminating and pressing of inserts temperature fields in the engine cylinder change, temperature on an internal surface of the cylinder increases at laminating on 6,5 °С, and at pressing - on 4,5 °С. This is explained by the fact that the contact layer during plastification is in the zone of non-stationary mode, and when pressing the contact layer is in the zone of stationary mode and thus increases the thickness of the cylinder by 2 millimeters. It is established that the difference of minimum and maximum temperatures on the inner surface of the cylinder practically remains the same as that of a homogeneous cylinder. Thus, modeling becomes the most effective scientific tool in the development and implementation of long-term evaluation of options for improving ICE.

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