Structural Performance of Additively Manufactured Cylinder Liner—A Numerical Study

Abstract

Climate change is exacerbated by vehicle emissions. Furthermore, vehicle pollution contributes to respiratory and cardiopulmonary diseases, as well as lung cancer. This requires a drastic reduction in global greenhouse gas emissions for the automobile industry. To address this issue, researchers are required to reduce friction, which is one of the most important aspects of improving the efficiency of internal combustion engines. One of the most important parts of an engine that contributes to friction is the piston ring cylinder liner (PRCL) coupling. Controlling the linear deformation enhances the performance of the engine and, as a result, contributes positively to its performance. The majority of the tests to study the conformability between cylinder liner and piston were carried out on cylinder liners made of cast iron. It is possible to improve the performance of piston ring cylinder liner couplings by implementing new and advanced manufacturing techniques. In this work, a validated finite element model was used to simulate the performance when advanced manufactured materials were adapted. The deformation of the cylinder liner due to thermal and mechanical loads is simulated with five different additive manufactured materials (Inconel 625, Inconel 718, 17-4PH stainless steel, AlSi10Mg, Ti6Al4V). Simulated roundness and straightness errors, as well as maximum deformation, are compared with conventional grey cast iron liner deformation. Some additive manufactured materials, especially Ti6Al4V, show a significant reduction in deformation compared to grey cast iron, both in bore and circumferential deformation. Results show that Ti6Al4V can reduce maximum liner deformation by 36%. In addition, the roundness improved by 36%. The straightness error when Ti6Al4V was used also improved by 44% on one side, with an average of 20% over the four sides. Numerical results indicate that additive manufactured materials have the potential to reduce friction within the piston liner arrangement of internal combustion engines.

Particulate Matter Emission and Air Pollution Reduction by Applying Variable Systems in Tribologically Optimized Diesel Engines for Vehicles in Road Traffic

“…Also, aluminum alloys have good corrosion resistance and transfer heat more efficiently due to their higher specific thermal conductivity compared to steel alloys, which is important for maintaining optimal temperature [33]. However, it should be noted that for the production of parts of the piston and cylinder liner, connecting rod, and bearings, steels are often used due to their greater durability under high temperatures and pressures [34,35]. However, due to the targeted weight reduction, different technologies are applied to strengthen the sliding surface of the cylinder and pistons made of aluminum alloy [36].…”

Macroscopic Characteristic and Properties of Inconel 625 Cladding Layers on a Cylinder Liner Based on Laser Cladding Assisted by a Steady-State Magnetic Field

“…The wear of the cylinder liner is caused by a combination of physical, chemical, and mechanical factors, and can be divided into abrasive wear, corrosion wear, and adhesive corrosion [4,5]. The corrosion forms of cylinder liners mainly include oxygen absorption corrosion, hydrogen evolution corrosion, and oxygen concentration corrosion [6][7][8]. Premature damage and scrapping of cylinder liners will lead to a waste of resources, so repairing cylinder liners is significant.…”

Simulation Research on Cylinder Liner Shape and Position Tolerance under Thermo-Mechanical Load

“…Then, the temperature distribution result was imported as boundary conditions to simulate deformation during the working process, but the reliance on empirical heat transfer correlations may lead to inaccuracies in temperature distribution estimation. Ahmad et al [13] performed FEA to analyze the deformation of cylinder liners made of different materials under the direct coupling of thermal and mechanical loads. Taking Fourier spectra, coaxiality, and main thrust plane bore variation as evaluation indicators, Zhu et al [14] utilized the FEA to analyze cylinder liner deformation in the pre-tightened state of the diesel engine body-cylinder head assembly, while the cylinder liner's operating conditions were neglected.…”