Search Results (21)

This experimental study investigates the critical role and impact of additive concentration in enhancing the tribological performance of castor oil as a biolubricant for agricultural tractor engines. Friction and wear are major contributors to reduced engine efficiency, highlighting the need for effective lubrication strategies. While biolubricants like castor oil offer environmental benefits, they often require additives to achieve optimal performance. However, the concentration of these additives is crucial, as an imbalance can negatively impact the lubrication system, leading to a higher coefficient of friction, increased wear, and reduced engine efficiency and lifespan. This study examines the effects of varying concentrations of a mixture of propyl gallate (PG) and ionic liquid (IL) additives on the tribological performance of castor oil. The tribological behaviour of lubricated top compression piston ring and cylinder liner samples was evaluated under simulated engine conditions using a Bruker UMT Tribolab test rig, in accordance with the ASTM G181 standard. The experimental results revealed an influence of additive concentration on the coefficient of friction and wear behaviour. This emphasises the importance of optimising additive formulations to minimise engine wear and friction. Notably, a 0.5% volume concentration of the additive mixture led to a remarkable 34.8% reduction in the average coefficient of friction (COF) and a lower wear rate. Full article

This study proposes an in-wheel assembly with a variable speed-reduction device designed to maximize torque and vehicle speed, enabling high-performance vehicle-level driving characteristics in front-engine, rear-wheel drive (FR), internal combustion engine (ICE) vehicles, where conventional EV motors cannot facilitate e-4WD. The proposed system integrates a motor and speed reducer within the wheel while avoiding interference from braking, steering, and suspension components. Through various innovative approaches, concepts for an integrated wheel-bearing planetary reducer and a variable speed planetary reducer were derived. The developed system achieved twice the maximum torque and a 35% increase in top speed compared to previously developed in-wheel systems, all without altering the front hard points. Multi-body dynamic analysis and component testing revealed wheel lock-up issues during reverse driving, and instability in the one-way clutch at high speeds. To address these issues, the power transmission structure was improved, and the type of one-way clutch was modified. Additionally, deficiencies in lubrication supply to the friction surface of the one-way clutch were identified through flow analysis and visualization tests, leading to design improvements. The findings of this study demonstrate that even in in-wheel systems where the application of large and complex transmission devices is challenging, it is possible to simultaneously enhance both maximum torque and top vehicle speed to achieve high-performance vehicle-level driving dynamics. Consequently, implementing an in-wheel e-4WD system in ICE FR vehicles is expected to improve fuel efficiency, achieve high-performance vehicle capabilities, and enhance market competitiveness. Full article

Torque is the fundamental working parameter of the internal combustion engine (ICE). In a spark ignition (SI) ICE, static torque is a function of rotational speed and throttle angle. However, ICE inertia, the distance between the throttle and cylinders, the time interval between subsequent intake strokes and increased oil viscosity in the warm-up phase limit the use of this characteristic in dynamic states. The novel and simple formula for calculating ICE torque in dynamic working states, presented in the article, includes all the mentioned factors. The new formula is based on ICE static tests where the torque, speed, throttle angle and airflow are measured. On the basis of the intake manifold geometry, the phenomena occurring in this component are described to determine the delay in the ICE response to throttle position changes. Moreover, the influence of ICE inertia is included. Finally, the formula includes the ICE warm-up period, which is characterized by high friction losses that decrease ICE torque. The proposed formula is validated by comparing model performance in dynamic working states with measurements. The results show a high level of accuracy: the delay in ICE response differs by less than 0.01 s, and the calculated torque differs by less than 5%. Full article

Optimizing the design of the top compression ring holds immense importance in reducing friction across both traditional Internal Combustion (IC) engines and hybrid power systems. This study investigates the impact of alternative fuels, specifically hydrogen and CNG, on the behavior of top piston rings within internal combustion (IC) engines. The goal of this approach is to understand the complex interplay between blow-by, fuel type, material behavior, and their effects on ring friction, energy losses, and resulting ring strength. Two types of IC engines were analyzed, taking into account flow conditions derived from in-cylinder pressures and piston geometry. Following ISO 6622-2:2013 guidelines, thick top compression rings made from varying materials (steel, cast iron, and silicon nitride) were investigated and compared. Through a quasi-static ring model within Computational Fluid Dynamics (CFD), critical tribological parameters such as the minimum film and ring friction were simulated, revealing that lighter hydrogen-powered engines with higher combustion pressures could potentially experience approximately 34.7% greater power losses compared to their heavier CNG counterparts. By delving into the interaction among the fuel delivery system, gas blow-by, and material properties, this study unveils valuable insights into the tribological and structural behavior of the top piston ring conjunction. Notably, the silicon nitride material demonstrates promising strength improvements, while the adoption of Direct Injection (DI) is associated with approximately 10.1% higher energy losses compared to PFI. Such findings carry significant implications for enhancing engine efficiency and promoting sustainable energy utilization. Full article

One route to reducing global CO₂ emissions is to improve the energy efficiency of machines. Even small improvements in efficiency can be valuable, especially in cases where an efficiency improvement can be realized over many millions of newly produced machines. For example, conventional passenger car combustion engines are being downsized (and also downspeeded). Increasingly, they are running on lower-viscosity engine lubricants (such as SAE 0W-20 or lower viscosity grades) and often also have stop–start systems fitted (to prevent engine idling when the vehicle is stopped). Some of these changes result in higher levels of mixed and boundary friction, and so accurate estimation of mixed/boundary friction losses is becoming of increased importance, for both estimating friction losses and wear volumes. Traditional approaches to estimating mixed/boundary friction, which employ real area of contact modelling, and assumptions such as the elastic deformation of asperities, are widely used, but recent experimental data suggest that some of these approaches underestimate mixed/boundary friction losses. In this paper, a discussion of the issues involved in reliably estimating mixed/boundary friction losses in machine elements is undertaken, highlighting where the key uncertainties lie. Mixed/boundary lubrication losses in passenger car and heavy-duty internal combustion engines are then estimated and compared with published data, and a detailed description of how friction is related to fuel consumption in these vehicles, on standard fuel economy driving cycles, is given. Knowing the amount of fuel needed to overcome mixed/boundary friction in these vehicles enables reliable estimates to be made of both the financial costs of mixed/boundary lubrication for today’s vehicles and their associated CO₂ emissions, and annual estimates are reported to be approximately USD 290 billion with CO₂ emissions of 480 million tonnes. Full article

Graphene-based materials have great potential for tribological applications. Graphene’s unique properties such as low shear resistance, high stiffness, and thermal conductivity make it an attractive material for improving the properties of lubricants in a wide range of industrial applications, from vehicles to house refrigerators and industrial machinery such as gearboxes, large compressors, etc. The current review aims to give an engineering perspective, attributing more importance to commercially available graphene and fully formulated lubricants instead of laboratory-scaled produced graphene and base oils without additives. The use of lubricants with graphene-based additives has produced e.g., an increase in mechanical efficiency, consequently reducing energy consumption and CO₂ emissions by up to 20% for domestic refrigerators and up to 6% for ICE vehicles. Potential effects, other than purely friction reduction, contributing to such benefits are also briefly covered and discussed. Full article

Climate change has a detrimental impact on permafrost soil in cold regions, resulting in the thawing of permafrost and causing instability and security issues in infrastructure, as well as settlement problems in pavement engineering. To address these challenges, concrete pipe pile foundations have emerged as a viable solution for reinforcing the subgrade and mitigating settlement in isolated permafrost areas. However, the effectiveness of these foundations depends greatly on the mechanical properties of the interface between the permafrost soil and the pipe, which are strongly influenced by varying thawing conditions. While previous studies have primarily focused on the interface under frozen conditions, this paper specifically investigates the interface under thawing conditions. In this study, direct shear tests were conducted to examine the damage characteristics and shear mechanical properties of the soil-pile interface with a water content of 26% at temperatures of −3 °C, −2 °C, −1 °C, −0.5 °C, and 8 °C. The influence of different degrees of melting on the stress–strain characteristics of the soil-pile interface was also analyzed. The findings reveal that as the temperature increases, the shear strength of the interface decreases. The shear stress-displacement curve of the soil-pile interface in the thawing state exhibits a strain-softening trend and can be divided into three stages: the pre-peak shear stress growth stage, the post-peak shear stress steep drop stage, and the post-peak shear stress reconstruction stage. In contrast, the stress curve in the thawed state demonstrates a strain-hardening trend. The study further highlights that violent phase changes in the ice crystal structure have a significant impact on the peak freezing strength and residual freezing strength at the soil-pile interface, with these strengths decreasing as the temperature rises. Additionally, the cohesion and internal friction angle at the soil-pile interface decrease with increasing temperature. It can be concluded that the mechanical strength of the soil-pile interface, crucial for subgrade reinforcement in permafrost areas within transportation engineering, is greatly influenced by temperature-induced changes in the ice crystal structure. Full article

Cam–tappet contacts are responsible for ~7.5% of the internal combustion engine’s (ICE) total frictional losses. The application of coatings can improve the tribological performance of these contacts. In this paper, the application of a WC-C coating as a novel approach for cam–tappets in comparison with DLC coating is investigated. The tribological performance of the coated contacts are evaluated by a novel model comprising combined implicit analytical and explicit numerical methods. This model considers the coupled tribo-dynamic behaviour whilst obtaining detailed tribological performance. The combined approach provides a computationally efficient platform. The results show that application of DLC or WC-C can improve the film thickness value by up to 41%. They can improve boundary friction, whilst increasing the viscous friction. Full article

Decreasing production and rising prices of cars, especially those with electric drive, lead to longer use of cars with internal combustion engines. It can be assumed that in the future, more and more cars powered by such engines with high mileage and therefore high wear will be used. Engine wear leads to reduced efficiency and increased emissions. This paper analyzes the impact of wear of the piston–rings–cylinder system components on energy losses associated with gas leakage from the combustion chamber and friction of the rings against the cylinder liner in a car spark-ignition engine. A ring pack model was used for the analyses. The input data for the simulation were gained in measurements made on the engine test stand and measurements of the wear of the engine components used in the car. The energy losses associated with blow-by in an unworn engine ranged from 1.5% of the indicated work at high load to almost 5% at low load. In the engine after 300,000 km, these losses increased to 2.5% and 7.5%, respectively. Ring friction losses in an unworn engine ranged from 1.5% at high load to 9% at low load. The effect of wear on these losses was smaller. They increased by only 0.1% at high load and 1% at low load. Full article

In seasonally frozen soil regions, the influence of temperature change on reinforced-soil engineering cannot be ignored. In particular, the mechanical properties of the reinforced-soil interface have an important impact on the overall stability and long-term service performance of reinforced soil engineering. To explore the interface characteristics and reinforcement mechanism between geogrids and coarse-grained soil under negative temperatures, this paper takes the typical coarse-grained soil in Xinjiang as the material and carries out a direct shear test of the reinforcement–soil interface under different normal stresses, water contents and temperatures. The curve characteristics of the shear displacement-shear stress, the change trend of the peak shear stress and the formation mechanism between the geogrid and coarse-grained soil interface under freezing and nonfreezing conditions are thoroughly analyzed. The formation mechanism of the dilatancy characteristics of the reinforced-soil interface is explained by combining the Mohr-Coulomb strength criterion and apparent friction coefficient. It is concluded that the trend of the shear displacement-shear stress curve between the geogrid and coarse-grained soil interface under the nonfreezing state and freezing state is basically the same. In a state of low normal stress, the curve has no obvious peak, which is closer to the ideal elastic-plastic double linear model. In a state of high normal stress, the curves have more obvious peaks, and the curve type is closer to the elastic-strain softening type. In the nonfreezing state, the shear strength of the reinforcement–soil interface has a great correlation with the water content, which is different in the freezing state. The main sources of the difference are the cementation of pore ice in the soil skeleton in the frozen state, the improvement of the strength of the soil particles themselves, and the further interlocking effect of the geogrid on the soil. In comparison with the reinforced coarse-grained soil under the nonfrozen state, the shear strength under the frozen state is significantly improved. In comparison with coarse-grained soil reinforced by geogrids in the nonfreezing state (0 °C), the shear strength of the frozen state (−5 °C) is significantly improved. Under normal stresses of 40 kPa, 60 kPa, and 80 kPa, when the water content is 2%, the corresponding peak shear stress increases by 19.39%, 21.71% and 11.34%, respectively. When the water content is 4.5%, the corresponding peak shear stress decreases by 29.98%, 16.17%, and 13.83%. When the water content is 7%, the corresponding peak shear stress decreases by 50.85%, 18.64%, and 21.96%. The apparent friction coefficient between the geogrid coarse-grained soil interface in the nonfrozen state and frozen state decreases with increasing normal stress. With the decrease in temperature, the dilatancy phenomenon of the reinforced soil composite is more obvious. The research results can provide a reference for the construction of reinforced engineering in seasonal frozen soil areas. Full article

The wide use of different alternative fuels (AL) has led to challenges to the internal combustion (IC) engine tribology. To avoid any unpredicted damages to lubrication joints by using AL fuels, this study aims to accurately evaluate the influences of alternative fuels on the tribological behavior of IC engines. Recent achievements of the acoustic emission (AE) mechanism in sliding friction provide an opportunity to explain the tribological AE responses on engines. The asperity–asperity–collision (AAC) and fluid–asperity–shearing (FAS) mechanisms were applied to explain the AE responses from the piston ring and cylinder liner system. A new adaptive threshold–wavelet packets transform (WPT) method was developed to extract tribological AE features. Experimental tests were conducted by fueling three fuels: pure diesel (PD), biodiesel (BD), and Fischer–Tropsch (F–T) diesel. The FAS–AE indicators of biodiesel and F–T diesel show a tiny difference compared to the baseline diesel using two types of lubricants. Biodiesel produces more AAC impacts with higher AAC–AE responses than F–T diesel, which occurs at high speeds due to high temperatures and more particles after combustion than diesel. This new algorithm demonstrated the high performance of using AE signals in monitoring the tribological impacts of alternative fuels on engines. Full article

Electric vehicle sales are growing globally in response to the move towards a greener environment and a reduction in greenhouse gas emissions. As in any machine, grease lubricants will play a significant role in the component life of these new power plants and drivetrains. In this paper, the role of grease lubrication in electric vehicles (EVs) and hybrid vehicles (HVs) will be discussed in terms of performance requirements. Comparisons of grease lubrication in EVs and HVs for performance requirements to current internal combustion engines (ICEs) will be reviewed to contrast the major differences under different operating conditions. The operating conditions for grease lubrication in these EVs and HVs are demanding. Greases formulated and manufactured to meet specific performance specifications in EVs and HVs, which will operate within these specific electrification components, will be reviewed. Specifically, the thermal and electrified effects from the higher operating temperatures and electromagnetic fields on lubricant degradation, rheology, elastomer compatibility, and corrosion protection of the grease need to be evaluated to accurately meet the performance requirements for EVs and HV. The major differences between EVs and conventional ICEVs can be grouped into the following technical areas: energy efficiency, noise, vibration, and harshness (NVH), the presence of electrical current and electromagnetic fields from electric modules, sensors and circuits, and bearing lubrication. Additional considerations include thermal heat transfer, seals, corrosion protection, and materials’ compatibility. The authors will review the future development trends of EVs/HVs on driveline lubrication and thermal management requirements. The future development of electric vehicles will globally influence the selection and development of gear oils, coolants, and greases as they will be in contact with electric modules, sensors, and circuits and will be affected by electrical current and electromagnetic fields. The increasing presence of electrical parts in EVs/HVs will demand the corrosion protection of bearings and other remaining mechanical components. Thus, it is imperative that specialized greases should be explored for specific applications in EVs/HVs to ensure maximum protection from friction, wear, and corrosion to guarantee the longevity of the operating automobile. Low-viscosity lubricants and greases will be used in EVs to achieve improvements in energy efficiency. However, low-viscosity fluids reduce the film thickness in the driveline application. This reduced film thickness increases the operating temperature and reduces the calculated fatigue life of the bearings. Bearing components for EVs/HVs will be even more crucial as original equipment manufacturers (OEMs) specify these low-viscosity fluids. The application of premium bearing components using low-viscosity grease will leverage materials, bearing geometries, and surface topography to combat the impact of low-viscosity lubricants. In addition, EVs and HVs will create their own NVH challenges. Wind and road noise are more prominent, with no masking noise from the ICE. Increasing comfort, quality, and reliability issues will be more complicated with the introduction of new electrified powertrain and E-driveline subsystems. This paper elaborates on the current development trends and industrial test standard for the specified grease used for electrical/hybrid driveline lubrication. Full article

Several approaches have been developed to measure instantaneous friction between the piston assembly and cylinder in internal combustion (IC) engines, such as floating-liner, reciprocating liner, instantaneous mean effective pressure (IMEP), fixed sleeve, and (P-ω) method and tribological bench tests. However, the “floating-liner method” and the “(IMEP) method” are the most common methods used to measure instantaneous friction between the piston assembly and IC engines. This paper critically evaluates different approaches to the design of the “floating-liner”. The paper begins by discussing piston assembly frictional losses and their significance and then discuss the development of instantaneous piston-friction measurements. After that, it reviews the main design challenges in the floating-liner approach. “Methods of cylinder sealing” and “force balancing methods” are also reviewed. Design challenges associated with firing operation were presented. Floating-liner designs were classified into different categories with a detailed presentation of the features of each. The paper ends by presenting a range of broad recommendations for further work which would benefit future designs. Full article

Reducing friction is an important aspect to increase the efficiency of internal combustion engines (ICE). The majority of frictional losses in engines are related to both the piston skirt and piston ring–cylinder liner (PRCL) arrangement. We studied the enhancement of the conformation of the PRCL arrangement based on the assumption that a suitable conical liner in its cold state may deform into a liner with nearly straight parallel walls in the fired state due to the impact of mechanical and thermal stresses. Combining the initially conical shape with a noncircular cross section will bring the liner even closer to the perfect cylindrical shape in the fired state. Hence, a significant friction reduction can be expected. For the investigation, the numerical method was first developed to simulate the liner deformation with advanced finite element methods. This was validated with given experimental data of the deformation for a gasoline engine in its fired state. In the next step, initially conically and/or elliptically shaped liners were investigated for their deformation between the cold and fired state. It was found that, for liners being both conical and elliptical in their cold state, a significant increase of straightness, parallelism, and roundness was reached in the fired state. The combined elliptical-conical liner led to a reduced straightness error by more than 50% compared to the cylindrical liner. The parallelism error was reduced by 60% to 70% and the roundness error was reduced between 70% and 80% at different liner positions. These numerical results show interesting potential for the friction reduction in the piston-liner arrangement within internal combustion engines. Full article

As a vital component in the valve train of internal combustion engines (ICEs), the cam/tappet pair undergoes high mechanical and thermal loads and usually works in a mixed and boundary lubrication regime. This leads to considerable friction loss and severe surface wear. Currently, the applications of diamond-like carbon (DLC) coatings for automotive components are becoming a promising strategy to reduce the friction and lower the wear. However, the practical performance of the coating is related to many factors, including friction coefficient, thermal properties, load conditions, and surface topography. In order to investigate these factors and successively improve the fuel efficiency and durability of the cam/tappet pair, a comprehensive multi-physics analytical model considering the mechanical, thermal and tribological properties of DLC coatings is established in this paper. Simulations are carried out for the coated as well as the uncoated cam/tappet conjunctions with different roughness at various ambient temperatures. The results show that both the fluid and asperity contact friction for the coated cam/tappet conjunction are significantly reduced due to their favourable characteristics. As a result, the friction loss of the coated cam/tappet pair is noticeably lower by almost 40% than that of the uncoated, despite a slightly higher asperity contact. In addition, the wear resistance of DLC coatings is also impressive, although the wear condition becomes progressively more severe with the increasing ambient temperature. Moreover, the roughness has complex effects on the friction and wear under different conditions. Full article