Refinement of Engine in-cycle losses of Parasitic and Errant Dynamic Nature (Encyclopaedic)
Lead Research Organisation:
Loughborough University
Department Name: Sch of Mechanical and Manufacturing Eng
Abstract
The automotive industry in the UK remains one of the key strategic sectors in the overall national R&D footprint, employing some 160,000 people (38000 in motor sport) [1]. The UK is home to a number of global OEMs representing the largest inward investment in the country's R&D through the establishment of significant technical centres. Influenced by the stringent emission mandates (Euro 4: Directive 98/70/EC and amendment: 70/220/EEC) and noise pollution targets (EU:DIRECTIVE 70/157/EEC and amendment: 2007/34/EC, USA: FHWA-HEP-06-020) improvements in engine efficiency have assumed a high priority with automotive manufacturers. An effective way is to reduce frictional (parasitic) and mechanical (errant dynamic) losses, accounting for 15 / 25 % of lost energy. Errant dynamic losses refer to inertial imbalance and structural deformation, also contributing to noise and vibration pollution. The largest mechanical losses are due to translational imbalance of pistons and rotational imbalance of the crank system, with increasing engine roughness due to demands for high output power-to-weight ratio. Engine roughness refers to structural vibration of lightly damped engine systems. Worst conditions for frictional losses arise under stop-start conditions or other transient events, where interactions between system dynamics and tribological behaviour of engine sub-systems play significant roles (Andersson [2]). Nearly half of the friction losses in internal combustion engines originate in the piston-ring-cylinder contacts, about 50% (Blau et al [3]), two thirds of which is attributable to the compression ring. Hitherto, interactions between frictional and mechanical losses have not received the fundamental analysis that they deserve. With increasing demand for high performance engines, the piston is subjected to even higher loads and, thus, increased losses. At the same time, engine development is driven by high fuel efficiency and output power-to-weight ratio, as well as reduced NOx and particulate emissions. These requirements frequently lead to conflicting demands put on combustion, system dynamics and tribological performance. It is significant to note that a mere 4% reduction in parasitic losses can lead to 1% improvement in fuel efficiency. Rapidly diminishing fossil fuel deposits in the UK's territorial waters and the difficulty of extraction, together with the adverse environmental impact of significant vehicular emissions, make improved fuel efficiency by reduction of parasitic losses a national imperative and a paramount objective. Whilst large national projects have been undertaken for development of efficient combustion strategies, a large consortium project has not hitherto been undertaken for tribology and dynamics of the piston-connecting rod-crankshaft sub-system which contributes significantly to engine losses. This project will bring together experts in the fields of dynamics, surface engineering, contact mechanics, lubricant rheology and tribology to collectively provide unique and novel solutions for this challenging multi-disciplinary problem of utmost importance to the UK automotive industry. An approach incorporating these inter-related disciplines within a unified analysis framework is referred to as multi-physics. This points to a single integrated project across all the interacting disciplines to deal with physics on a wide range of scales from large displacement dynamics to small thermo-elastic distortion of components and further down to micro-scale tribological contacts (such as EHD films, and asperity interactions) and onto the diminishing conjunctions of surface textured patterns with nano-scale interactions such as the molecular behaviour of lubricants due to their physical chemistry and free surface energy effects.
Organisations
- Loughborough University (Lead Research Organisation)
- BP (British Petroleum) (Collaboration)
- Capricorn Automotive (Collaboration)
- University of Sheffield (Collaboration)
- Aston Martin Lagonda (Collaboration)
- ProDrive (Collaboration)
- Nexcel (Collaboration)
- CRANFIELD UNIVERSITY (Collaboration)
- ES Technology (Collaboration)
- Research Councils UK (RCUK) (Collaboration)
- ES Technology (United Kingdom) (Project Partner)
- Aston Martin Lagonda (United Kingdom) (Project Partner)
- Ford Motor Company (United States) (Project Partner)
- Capricorn Automotive (United Kingdom) (Project Partner)
- BP Lubricants (Project Partner)
- Prodrive (United Kingdom) (Project Partner)
- Ricardo (United Kingdom) (Project Partner)
Publications
Leighton M
(2016)
Boundary interactions of rough non-Gaussian surfaces
in Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology
Leighton M
(2016)
Combined lubricant-surface system perspective: Multi-scale numerical-experimental investigation
in Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology
Morris N
(2016)
A Numerical Model to Study the Role of Surface Textures at Top Dead Center Reversal in the Piston Ring to Cylinder Liner Contact
in Journal of Tribology
Gore M
(2017)
A combined analytical-experimental investigation of friction in cylinder liner inserts under mixed and boundary regimes of lubrication
in Lubrication Science
Rahmani R
(2017)
The effect of cylinder liner operating temperature on frictional loss and engine emissions in piston ring conjunction
in Applied Energy
Morris N
(2017)
Optimisation of the piston compression ring for improved energy efficiency of high performance race engines
in Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering
Morris N
(2017)
A hydrodynamic flow analysis for optimal positioning of surface textures
in Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology
Baker C
(2017)
On the Transient Three-Dimensional Tribodynamics of Internal Combustion Engine Top Compression Ring
in Journal of Engineering for Gas Turbines and Power
Dolatabadi N
(2017)
Passive Control of Piston Secondary Motion Using Nonlinear Energy Absorbers
in Journal of Vibration and Acoustics
Description | Lubricant-surface combination should be considered as a system, not in isolation. Suitably textured surfaces can mitigate friction in contacts which are only partially lubricated. Positioning of texturing on surfaces in motion reversal is found to be crucial in many applications. Form of textures and distribution also play important roles. |
Exploitation Route | There are good opportunities to use combinations of surface coating and texturing for many sliding/reciprocating conjunctions to reduce friction,thus improving energy efficiency. Lubricant-surface combination must also be considered as a system. New additional finding has been obtained from a number of sources, reported in this updated version. |
Sectors | Aerospace, Defence and Marine,Energy,Manufacturing, including Industrial Biotechology,Transport |
URL | http://www.encyclopaedic.org/Pages/default.aspx |
Description | Capricorn Automotive is implementing preliminary surface texturing to some advanced cylinder liners for motorsport application (2014). The blow-by model developed has been used by Aston Martin as a technical aid in the development of their new series of engines. They have acknowledged this in their marketing output (2016). |
First Year Of Impact | 2014 |
Sector | Manufacturing, including Industrial Biotechology,Transport |
Impact Types | Economic |
Description | BP |
Amount | £125,000 (GBP) |
Organisation | BP (British Petroleum) |
Department | Castrol |
Sector | Private |
Country | United Kingdom |
Start | 03/2017 |
End | 02/2018 |
Description | Development of simulation methodologies for the design evaluation of white metal overlay journal bearings |
Amount | £22,000 (GBP) |
Organisation | Coleherne Engineering |
Sector | Private |
Country | United Kingdom |
Start | 03/2013 |
End | 10/2013 |
Description | Development of simulation methodologies for the design evaluation of white metal overlay journal bearings |
Amount | £22,000 (GBP) |
Organisation | Coleherne Engineering |
Sector | Private |
Country | United Kingdom |
Start | 01/2013 |
End | 07/2013 |
Description | Development of surface modified and coated advanced cylinder liners |
Amount | £20,000 (GBP) |
Organisation | Capricorn Automotive |
Sector | Private |
Country | United Kingdom |
Start | 03/2013 |
End | 10/2013 |
Description | Development of surface modified and coated advanced cylinder liners |
Amount | £20,000 (GBP) |
Organisation | Capricorn Automotive |
Sector | Private |
Country | United Kingdom |
Start | 01/2013 |
End | 09/2013 |
Description | EPSRC Centre for Embedded Intelligence |
Amount | £140,000 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 08/2015 |
End | 08/2019 |
Description | EPSRC Centre for Embedded Intelligence |
Amount | £140,000 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 08/2014 |
End | 09/2017 |
Description | EPSRC Centre for Embedded Intelligence |
Amount | £140,000 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 01/2016 |
End | 12/2020 |
Description | EPSRC DTP |
Amount | £75,000 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 09/2016 |
End | 01/2020 |
Description | International Cavitation Institute |
Amount | £380,000 (GBP) |
Organisation | Lloyd's Register |
Department | Lloyd's Registry Education Trust |
Sector | Charity/Non Profit |
Country | United Kingdom |
Start | 08/2012 |
End | 09/2016 |
Description | International Cavitation Institute |
Amount | £380,000 (GBP) |
Organisation | Lloyd's Register |
Department | Lloyd's Registry Education Trust |
Sector | Charity/Non Profit |
Country | United Kingdom |
Start | 06/2012 |
End | 06/2016 |
Description | Lubricant-surface system perspective |
Organisation | Nexcel |
Country | United Kingdom |
Sector | Private |
PI Contribution | Tribometry, LFM, XPS |
Collaborator Contribution | Chemistry |
Impact | None |
Start Year | 2017 |
Description | Progress Report (Aston Martin) |
Organisation | Aston Martin Lagonda |
Country | United Kingdom |
Sector | Private |
PI Contribution | Chair Steering Committee and contribute to website |
Start Year | 2009 |
Description | Research Report (BP Castrol) |
Organisation | BP (British Petroleum) |
Department | Castrol |
Country | United Kingdom |
Sector | Private |
PI Contribution | Research support/collaboration in lubricant rheology and supply + expertise |
Start Year | 2009 |
Description | Research Report (Capricorn Automotive) |
Organisation | Capricorn Automotive |
Country | United Kingdom |
Sector | Private |
PI Contribution | participation in research, development, project management |
Start Year | 2009 |
Description | Research Report (ES Technology) |
Organisation | ES Technology |
Country | United Kingdom |
Sector | Private |
PI Contribution | Coating/laser texturing, research, project management |
Start Year | 2009 |
Description | Research Report (ProDrive) |
Organisation | ProDrive |
Country | United Kingdom |
Sector | Private |
PI Contribution | participation in engine testing and project management |
Start Year | 2009 |
Description | Research Report (Ricardo Consulting Engineers) |
Organisation | Research Councils UK (RCUK) |
Department | Ricardo Consulting Engineer |
Country | United Kingdom |
Sector | Public |
PI Contribution | Participation in analytical research, Project management |
Start Year | 2009 |
Description | Research report (Cranfield University) |
Organisation | Cranfield University |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Research collaboration, Project Management |
Start Year | 2009 |
Description | Research report (University of Sheffield) |
Organisation | University of Sheffield |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Research, project management |
Start Year | 2009 |
Description | www.Encyclopaedic.org |
Form Of Engagement Activity | A magazine, newsletter or online publication |
Part Of Official Scheme? | Yes |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | Project website, created in-house, updated and maintained and regularly visited by a global audience. presents the latest findings/outcomes and impacts of the Encyclopaedic Project. Many queries from practitioners and researchers in the field. |
Year(s) Of Engagement Activity | 2009 |
URL | http://www.encyclopaedic.org/Pages/default.aspx |