Transient elastohydrodynamic lubrication of rough new or worn piston compression ring conjunction with an out-of-round cylinder bore

Abstract

Real cylinder bores are out-of-round and axially asymmetrical. The top compression ring, nominally an incomplete circle, is subjected to ring tension and cyclic combustion force in order to conform to the bore surface. The bounding surfaces are rough and their conjunction is subject to a transient tribological state. Therefore, the ring–bore conjunction is only partially conforming for most of the engine cycle. The conjunction may be viewed as a problem of scale, depending on the analysis carried out at a certain bore order (out-of-roundness). Therefore, the contact may be viewed as a multi-lobed rough conjunction, where the regime of lubrication may vary from hydrodynamics to mix with dominant asperity friction at piston reversals. Measured bores and ring profiles are used to predict conjunctional power loss and percentage fuel energy consumed. Furthermore, lubricant’s flow through the ring is predicted throughout the engine cycle. These measures are key industrial design drivers for fuel efficiency and reduction of emissions. The results show that the effect of bore out-of-roundness can be even more significant than the surface topography.