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Effect of Piston Profile on Piston Motion and Liner Bore Polishing

  • Engine and Emissions, Fuels and Lubricants
  • Published:
International Journal of Automotive Technology Aims and scope Submit manuscript

Abstract

One of the popular development trends in diesel engine piston assembly is higher reliability and life of components. These can be ensured by actual engine testing and comparing the appearance of piston assembly. However, testing multiple iterations involves significant cost and development which can be avoided by using software for piston-assembly performance parameters simulation. This paper contains a detailed study conducted using commercially available piston secondary dynamics simulation software and actual testing on a 4-cylinder diesel engine. In this study, the effect of piston profile and clearance on piston secondary dynamics parameters and piston-liner appearance are studied. In this study, three piston skirt profiles are designed by varying piston axial profile (barrel shape), radial profile (oval shape), and nominal clearances. The simulation results are studied in which piston profile 2 has shown minimum piston tilting, radial displacement, radial velocity, tilting velocity, radial acceleration, tilting acceleration, pressure, and force at TS and ATS. Testing and component merit rating for liner bores and piston skirts were also conducted in which piston profile 2 has shown significantly less liner bore polishing. A good correlation was observed between piston secondary motion parameters obtained from simulation and piston and liner bore observations after testing.

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Data availability

All data supporting the findings of this study are included in the paper.

Abbreviations

FMEP:

Friction mean effective pressure

MOFT:

Minimum oil film thickness

TS:

Thrust side

ATS:

Anti-thrust side

x p :

Axial piston motion

r :

Crank radius

α :

Crank angle

l :

Connecting rod length

y p :

Radial piston motion

s :

Crank offset

a :

Pin offset

δ :

Radial motion of piston pin

m c, m s :

Piston mass (c—crown part, s—skirt part)

\({\ddot{x}}_{{\text{c}}}\), \({\ddot{x}}_{{\text{s}}}\) :

Acceleration x direction (c—crown part, s—skirt part)

\({F}_{{{\text{c}}}_{i}}\), \({F}_{{{\text{s}}}_{i}}\) :

Contact forces at TS and ATS side at cross-sections i

F gc, F gs :

Force of gravity

F gas :

Gas force considering eccentricity e

F r :

Force of ring/piston contact

F pinc, F pins :

Force at piston pin

F link :

Force of linkage system at connecting rod small end bearing (disabled)

\({\ddot{y}}_{{\text{c}}}\), \({\ddot{y}}_{{\text{s}}}\) :

Acceleration y direction (c—crown part, s—skirt part)

Θ c, Θ s :

Piston moment of inertia around pin

\({M}_{{\text{c}}}\), \({M}_{{\text{s}}}\) :

Moment due to piston/liner contact

\({M}_{{\text{gc}}}\), \({M}_{{\text{gs}}}\) :

Moment due to force of gravity

M r :

Moment due to ring axial and radial force

M pc, M ps :

Moment due to friction at piston pin

m rod :

Connecting rod mass

\({\ddot{x}}_{\mathrm{rod c}}\) :

Acceleration x direction (at center of mass)

Θ rodc :

Connecting rod moment of inertia (at center of mass)

F rod :

Force at connecting rod (at center of mass)

F se :

Force at connecting rod small end

F be :

Force at connecting rod big end

F grod :

Force due to gravity

M se :

Moment due to friction at small end bearing

ӱ rodc :

Acceleration y direction (at center of mass)

\(\ddot{\beta }\) :

Angular acceleration of connecting rod

M Pc, M Ps :

Moment due to friction at piston pin

M be :

Moment due to friction at connecting rod big end

r p :

Distance between pin center and center of gravity

r be :

Distance between connecting rod big end center and center of gravity

CA:

Crank angles

BDC:

Bottom dead center

TDC:

Top dead center

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Acknowledgements

With a sense of gratitude and great pleasure, the author would like to acknowledge the wholehearted cooperation extended by the staff of the Mechanical Engineering Department, College of Engineering, Pune, staff of Corporate Research and Engineering, Kirloskar Oil Engines Ltd, Pune, and the management of Sant Gadge Baba Amravati University for all its support during the entire research work.

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Authors and Affiliations

  1. Mechanical Engineering Department, College of Engineering Pune, Wellesley Road, Pune, 411005, India

    Kunjan Sanadhya & Milankumar R. Nandgaonkar

  2. Sant Gadge Baba Amravati University, Amravati, 444602, Maharashtra, India

    Dileep N. Malkhede

  3. Research and Development Department, Kirloskar Oil Engines Ltd., LK Road, Khadki, Pune, 411003, India

    Yogesh V. Aghav & M. N. Kumar

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  1. Kunjan Sanadhya
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  2. Dileep N. Malkhede
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  3. Milankumar R. Nandgaonkar
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  4. Yogesh V. Aghav
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  5. M. N. Kumar
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Correspondence to Kunjan Sanadhya.

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Sanadhya, K., Malkhede, D.N., Nandgaonkar, M.R. et al. Effect of Piston Profile on Piston Motion and Liner Bore Polishing. Int.J Automot. Technol. 25, 225–233 (2024). https://doi.org/10.1007/s12239-024-00023-9

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  • DOI: https://doi.org/10.1007/s12239-024-00023-9

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