Detailed 3D Ring Pack Analysis by Federal Mogul

18.
Aachener Kolloquium
Fahrzeug und Motorentechnik 2009
Title: Arial - 44pt

Arial - 24 pt italic
Optimization of Subhead: piston ring dynamics by direct 3D analysis of dynamic effects
Agenda
Fundamentals 3D Ring Pack
3D Hydrodynamic 3D Gas flow
Title: Arial - 44pt

3D Ring-Forces Subhead:
Example of optimization of blow-by and ring movement
Data classification: Customer internal
Richard Mittler Richard Mittler Technology Rings & Liners Technology Rings & Liners
Analysis Analysis
04.05.2009 07.10.2009
2 2
3D Ring Pack Dynamics

FUNDAMENTALS OF 3D Ring Pack
3D dynamic twist calculation 3D dynamic movement calculation 3D gas-flow calculation
Title: Arial - 44pt

Subhead: 3D hydrodynamic friction
3D Influence of heat transfer on radial pressure 3D Radial hydro-dynamic pressure distribution between Ring and Liner
Analysis Analysis
04.05.2009 07.10.2009
3 3
Fundamentals of FM-3D Ring Pack calculation

Piston ring
3D Influence of heat transfer on

piston ring radial pressure distribution 3D Radial hydro-dynamic pressure distribution between Ring and Liner
Title: Arial - 44pt 3D hydrodynamic friction

Top ring profile
Hydrodynamic Subhead: Arial - 24 pt italic Oil- pressure
Oil-film
Physical factors: Bore distortion on every axial level through the liner K-Factor of ring Piston ring pressure distribution Ring peripheral surface Engine crank kinematics
1.2
1.2
0.8
0.8
z [mm]
[mm]
0.6
0.6
0.4
0.4

0.2 0 0 0.01 r [mm] 0.02
0.2
0 -90
90
180
270
360
450
540
[ ] 630
Analysis Analysis
04.05.2009 07.10.2009
4 4

3D gas-flow calculation
pFS pSteg 1
Cylinder wall Piston
convergent
Physical factors:
45
pSteg 2
Clearance by twist divergent convergent In the clearance between the ring and the groove, the sound velocity cannot be exceeded. subsonic-flow Heat exchange between the groove flanks and the gas flow. Therefore, the flow is neither isothermal nor adiabatic. Gas friction Gas choke by friction
40
Title: Arial - 44pt

35 Druck [bar] pressure
Subhead: Arial - 24 pt italic

25
30
divergent
20
15
10

0 -90 0 90 180 270 360 450 540 6
gap
Crank Kurbelwinkel [KW] angle
Analysis Analysis
04.05.2009 07.10.2009
5 5
3D Gas Flow Analysis

End of the clearance Vb Gas speed Pb Gas pressure Tb Gas temperature Ab Gas flow area Begin of the clearance V0 Gas speed P0 Gas pressure T0 Gas temperature A0 Gas flow area
V M= c
M V C
Mach Number Gas speed sound velocity
Title: Arial - 44pt

Subhead: Arial - 24has its maximum close to the start M pt italic
of the clearance
Divergent clearance
Convergent clearance
subsonic-flow. In the clearance between the ring and the groove, the sound velocity cannot be exceeded. Heat exchange between the groove flanks and the gas flow. Therefore, the flow is neither isothermal nor adiabatic.
M has its maximum at the end of the clearance
Analysis Analysis
04.05.2009 07.10.2009
6 6
3D Twist and Movement Analysis

The criterion of a rectangular ring for the stability contact on one groove side is:
Fmas Fmas
p a 3 2 p a 3
or
p a Fmas
= pressure gradient = wall thickness = Mass force
Title: Arial - 44pt

Subhead: Arial - 24 pt ofitalicring movement from Axial Position a top
calculation result
The simplification describes the condition where a stabilized flank contact is given
Analysis Analysis
04.05.2009 07.10.2009
7 7

3D dynamic movement calculation 3D dynamic twist calculation
Physical factors: The twist and arching of the piston ring is caused by the moments acting on the rings, which can also occur in rectangular rings movement as a result of moments and forces contact around the circumference on both ring flanks are possible
~ 60 Title: Arial groove contact - 44pt bottom
Gap end top groove contact
j ,v
b, y

Zylinderwand
Analysis Analysis
04.05.2009 07.10.2009
8 8
3D Twist and Movement Analysis

Moments and Forces as a result of gas flow, hydrodynamic and piston ring properties.
The twist and arching of the piston ring is caused by the moments acting on the rings, which can also occur in rectangular rings Subhead:
cylinder piston
Title: Arial - 44pt

Arial - 24 1pt italic F
MG1 Ms Xs MH
gas pressure
F2 F3
j ,v
b, y
FH
MG3
Zylinderwand
Oil film
Piston movement
Analysis Analysis
04.05.2009 07.10.2009
9 9
Example of FM-3D Ring Pack calculation

Measurement Under full load condition, the 2 l 4 cylinder gasoline engine: measurement in the basic version of P (75kW @ 5600 rpm), the engine showed a blow-by result of 42 45 l/min. M (130Nm @ 4600 U/min) Simulation Pmax (86bar @ 4000 rpm) Subhead: Arial - 24 pt italic
Model data
Title: Arial - 44pt
Piston ring data: top ring: rectangular ring 2nd ring: taper faced ring Oil ring: 2 piece oil ring
Analysis Analysis
04.05.2009 07.10.2009
10 10
Illustration of pressure conditions movements (gap and ring back)
and
ring
Blow-By 42 45 l/min.
20 Zylinderdruck [bar] Zw ischenringdruck [bar] 15
Blow-By 33- 35 l/min.

20 Combustion Pressure [bar] 2nd Land Pressure [bar] 15
15 20
Blow-By 36 - 38 l/min.
Combustion Pressure [bar] 2nd Land Pressure [bar]
10
Title: Arial - 44pt

10
10
0 -180 -135 -90 100% 75% 50% 25% 0% -180 100% 75% 50% 25% 0% -180 -90 -90
-45
1 46 91 136 181 rel. ax. Pos. Topring (gap) [%]
226 271 316 361 406 451 rel. ax. Pos. Topring (back) [%]
496

100% 75% 50% 25%
100% 75% 50% 25% 0% -180 100% 75% 50% 25% 0% -180
0 -180 -135 -90
-45
496
0 -180 -135 -90
-45
496
90 rel. ax.0 Pos. 2nd Ring (gap) [%]180
270 360 450 rel. ax. Pos. 2nd Ring (back) [%]
540
0% -180 100% 75% 50% 25%
-90
540
-90
540
90
180
270
360
450
540
0% -180
-90
90
180
270
360
450
540
-90
90
180
270
360
450
540
1. basis
2. optimization 1
Reduction of close gap 2nd ring
3. optimization 2
Reduction of close gap 2nd ring optimization of piston 2nd land volume
04.05.2009 07.10.2009 11 11
Analysis Analysis
Animation Axial Ring Motion

Visualization of the movement @ 4600 rpm (2 and 3)
Optimization 1 Reduction of close gap 2nd ring Blow-by 33.4 l/min Inter-ring pressure 19.7 bar
Title: Arial - 44pt

Optimization 2 Reduction of close gap 2nd ring optimization of piston 2nd land volume Blow-by 36.9 l/min Data classification: Customer internal Inter-ring pressure 16.0 bar
Analysis Analysis
04.05.2009 07.10.2009
12 12
Summary
- 3D Ring Pack analysis shows the possibility of - prediction of blow-by values without adjusting gas flow factors or engine results results of real twist and piston ring movements to detect wear effects
direct optimization of piston ring and piston design to engine requirements
Title: Arial - 44pt

Ring movement may have an effect of the emission values. Effects of blow back can reduce the Blow-by. However the blow-back may carry oil with it and adversely affect oil consumption. Also, as the ring twists and arches, it will affect the orientation of the running surface of the ring with respect to the liner. This may affect how well the ring scrapes oil.
rel. ax. Pos. Topring (gap) [%] 100% 75% 50% 25% 0% -180 rel. ax. Pos. Topring (back) [%]

-80 20 120 220 320 420 520
Analysis Analysis
04.05.2009 07.10.2009
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Detailed 3D Ring Pack Analysis by Federal Mogul

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18.

Title: Arial - 44pt

Optimization of Subhead: piston ring dynamics by direct 3D analysis of dynamic effects

Title: Arial - 44pt

Example of optimization of blow-by and ring movement

Data classification: Customer internal

3D Ring Pack Dynamics

Title: Arial - 44pt

Subhead: 3D hydrodynamic friction

Data classification: Customer internal

Fundamentals of FM-3D Ring Pack calculation

3D Influence of heat transfer on

Title: Arial - 44pt 3D hydrodynamic friction

Hydrodynamic Subhead: Arial - 24 pt italic Oil- pressure

Data classification: Customer internal

Fundamentals of FM-3D Ring Pack calculation

Cylinder wall Piston

Title: Arial - 44pt

Subhead: Arial - 24 pt italic

Data classification: Customer internal

Crank Kurbelwinkel [KW] angle

3D Gas Flow Analysis

Mach Number Gas speed sound velocity

Title: Arial - 44pt

M has its maximum at the end of the clearance

Data classification: Customer internal

3D Twist and Movement Analysis

= pressure gradient = wall thickness = Mass force

Title: Arial - 44pt

Data classification: Customer internal

Fundamentals of FM-3D Ring Pack calculation

~ 60 Title: Arial groove contact - 44pt bottom

Subhead: Arial - 24 pt italic

Gap end top groove contact

Data classification: Customer internal

3D Twist and Movement Analysis

Title: Arial - 44pt

Example of FM-3D Ring Pack calculation

Title: Arial - 44pt

Illustration of pressure conditions movements (gap and ring back)

Blow-By 33- 35 l/min.

Title: Arial - 44pt

1 46 91 136 181 rel. ax. Pos. Topring (gap) [%]

Subhead: Arial - 24 pt italic

0 -180 -135 -90

1 46 91 136 181 rel. ax. Pos. Topring (gap) [%]

0 -180 -135 -90

1 46 91 136 181 rel. ax. Pos. Topring (gap) [%]

90 rel. ax.0 Pos. 2nd Ring (gap) [%]180

0% -180 100% 75% 50% 25%

90 rel. ax.0 Pos. 2nd Ring (gap) [%]180

90 rel. ax.0 Pos. 2nd Ring (gap) [%]180

Animation Axial Ring Motion

Title: Arial - 44pt

direct optimization of piston ring and piston design to engine requirements

Title: Arial - 44pt

Data classification: Customer internal

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