Holdings: Pistons and engine testing

Pistons and engine testing: with 20 tables

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Bibliographic Details
Format:	Book
Language:	English German
Published:	Wiesbaden Vieweg + Teubner 2012
Edition:	1. ed.
Subjects:	Kolben Verbrennungsmotor Aufsatzsammlung Lehrbuch
Online Access:	Inhaltstext Inhaltsverzeichnis
Item Description:	Literaturangaben
Physical Description:	XIII, 284 S. Ill., graph. Darst. 24 cm
ISBN:	9783834815903 383481590X

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245	1	0	\|a Pistons and engine testing \|b with 20 tables \|c Mahle GmbH (ed.)
250			\|a 1. ed.
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Record in the Search Index

_version_	1805146269310517248
adam_text	IMAGE 1 CONTENTS 1 PISTON FUNCTION, REQUIREMENTS, AND TYPES 1 1.1. FUNCTION OF THE PISTON 1 1.1.1 THE PISTON AS AN ELEMENT OF POWER TRANSMISSION 1 1.1.2 SEALING AND HEAT DISSIPATION 2 1.1.3 VARIETY OF TASKS 3 1.2 REQUIREMENTS ON THE PISTON 3 1.2.1 GAS PRESSURE 5 1.2.2 TEMPERATURES 5 1.2.3 PISTON MASS 7 1.2.4 FRICTION AND WEAR 8 1.2.5 BLOW-BY 9 1.3 PISTON TYPES 10 1.3.1 PISTONS FOR FOUR-STROKE GASOLINE ENGINES 10 1.3.1.1 CONTROLLED-EXPANSION PISTONS 10 1.3.1.2 BOX-TYPE PISTONS 11 1.3.1.3 EVOTEC PISTONS 12 1.3.1.4 FORGED ALUMINUM PISTONS 13 1.3.2 PISTONS FOR TWO-STROKE ENGINES 14 1.3.3 PISTONS FOR DIESEL ENGINES 15 1.3.3.1 RING CARRIER PISTONS 15 1.3.3.2 COOLING CHANNEL PISTONS 16 1.3.3.3 PISTONS WITH COOLED RING CARRIER 16 1.3.3.4 PISTONS WITH BUSHINGS IN THE PIN BORE 16 1.3.3.5 FERROTHERM PISTONS 17 1.3.3.6 MONOTHERM PISTONS 18 1.3.3.7 OPTIMIZED MONOTHERM PISTONS 18 1.3.3.8 MONOXCOMP PISTONS 19 1.3.3.9 MONOWELD PISTONS 20 1.3.3.10 ELECTRON-BEAM-WELDED PISTONS 20 1.3.4 COMPOSITE PISTONS FOR LARGE ENGINES 21 1.3.4.1 AREAS OF APPLICATION AND DESIGN TYPES 21 1.3.4.2 PISTON UPPER PART 22 1.3.4.3 PISTON LOWER PART MADE OF FORGED ALUMINUM ALLOY 22 1.3.4.4 PISTON LOWER PART MADE OF NODULAR CAST IRON 23 1.3.4.5 PISTON LOWER PART MADE OF FORGED STEEL 24 2 PISTON DESIGN GUIDELINES 25 2.1 TERMINOLOGY AND MAJOR DIMENSIONS 25 2.1.1 CROWN SHAPES AND CROWN THICKNESS 26 2.1.2 COMPRESSION HEIGHT 27 2.1.3 TOP LAND 27 2.1.4 RING GROOVES AND RING LANDS 28 2.1.5 TOTAL HEIGHT 29 BIBLIOGRAFISCHE INFORMATIONEN HTTP://D-NB.INFO/1016559178 DIGITALISIERT DURCH IMAGE 2 VIII CONTENTS 2.1.6 PIN BORE 29 2.1.6.1 SURFACE ROUGHNESS 29 2.1.6.2 FITTING CLEARANCE 29 2.1.6.3 TOLERANCES 30 2.1.6.4 OFFSET 30 2.1.7 PISTON SKIRT 30 2.2 PISTON PROFILE 32 2.2.1 PISTON CLEARANCE 32 2.2.2 OVALITY 32 2.2.3 SKIRT AND RING BELT TAPERING 33 2.2.4 DIMENSIONAL AND FORM TOLERANCES 34 2.2.5 FITTING CLEARANCE 34 2.2.6 DEFINING GROUP 36 2.2.7 SKIRT SURFACE 36 SIMULATION OF PISTON OPERATIONAL FATIGUE STRENGTH USING FEA 37 3.1 MODELING 37 3.2 BOUNDARY CONDITIONS FROM ENGINE LOADING 39 3.2.1 THERMAL LOADS 39 3.2.2 MECHANICAL LOADS 41 3.2.2.1 GAS FORCE 41 3.2.2.2 INERTIA FORCE 41 3.2.2.3 LATERAL FORCE 42 3.3 BOUNDARY CONDITIONS DUE TO MANUFACTURING AND ASSEMBLY 43 3.3.1 CASTING PROCESS/SOLIDIFICATION 43 3.3.2 INSERTS 43 3.3.3 PRESSED-IN COMPONENTS 43 3.3.4 BOLT CONNECTIONS 44 3.4 TEMPERATURE FIELD AND HEAT FLOW DUE TO TEMPERATURE LOADING 44 3.5 STRESS BEHAVIOR 48 3.5.1 STRESSES DUE TO TEMPERATURE LOADING 48 3.5.2 STRESSES DUE TO MECHANICAL LOADING 50 3.5.3 STRESSES DUE TO MANUFACTURING AND ASSEMBLY 53 3.6 NUMERICAL VERIFICATION OF OPERATIONAL STRENGTH 53 PISTON MATERIALS 59 4.1 REQUIREMENTS FOR PISTON MATERIALS 59 4.2 ALUMINUM MATERIALS 60 4.2.1 HEAT TREATMENT 61 4.2.2 PISTON ALLOYS 63 4.2.3 FIBER REINFORCEMENT 69 4.3 FERROUS MATERIALS 69 4.3.1 CAST IRON MATERIALS 71 4.3.2 STEELS 73 4.4 COPPER MATERIALS FOR PIN BORE BUSHINGS 76 IMAGE 3 CONTENTS IX 4.5 COATINGS 78 4.5.1 COATINGS ON THE PISTON SKIRT 78 4.5.1.1 GRAFAL 255 AND EVOGLIDE 79 4.5.1.2 TIN 79 4.5.1.3 FERROSTAN/FERROTEC 79 4.5.1.4 FERROPRINT 80 4.5.1.5 HARD OXIDE IN THE FIRST PISTON RING GROOVE 80 4.5.1.6 HARD OXIDE ON THE CROWN 80 4.5.1.7 PHOSPHATE 80 4.5.1.8 GRAFAL 210 81 4.5.1.9 CHROMIUM CONTACT SURFACES 81 4.5.1.10 CHROMIUM RING GROOVES 81 4.5.2 APPLICATION TABLE 82 5 PISTON COOLING 83 5.1 THERMAL LOADS 83 5.2 COMBUSTION AND FLAME JETS 83 5.3 TEMPERATURE PROFILE AT BOWL RIM 84 5.4 PISTON TEMPERATURE PROFILE 85 5.5 EFFECTS ON PISTON FUNCTION 86 5.5.1 THERMALLY INDUCED DEFORMATION 86 5.5.2 TEMPERATURE-DEPENDENT MATERIAL BEHAVIOR 86 5.5.3 EFFECTS OF TEMPERATURE ON THE PISTON RINGS 87 5.6 WAYS TO INFLUENCE PISTON TEMPERATURES 88 5.7 TYPES OF PISTON COOLING 88 5.7.1 PISTONS WITHOUT PISTON COOLING 88 5.7.2 PISTONS WITH SPRAY JET COOLING 88 5.7.3 PISTONS WITH COOLING CHANNELS 89 5.7.3.1 SALT CORE COOLING CHANNEL PISTONS 89 5.7.3.2 PISTONS WITH COOLED RING CARRIER 90 5.7.3.3 MACHINED COOLING CHANNELS 92 5.7.4 COMPOSITE PISTONS WITH COOLING CAVITIES 93 5.7.4.1 SHAKER COOLING 94 5.7.4.2 BORE COOLING 94 5.8 COOLING OIL SUPPLY 95 5.8.1 JET FEEDING OF COOLING OIL 95 5.8.1.1 NOZZLE DESIGNS FOR SPRAY JET COOLING 96 5.8.1.2 NOZZLE DESIGN FOR SUPPLYING COOLING CHANNELS AND COOLING CAVITIES 96 5.8.2 FEEDING OIL VIA CRANKSHAFT AND CONNECTING ROD 97 5.8.2.1 FEEDING OIL VIA PISTON PIN AND PIN BORE 97 5.8.2.2 FEEDING OIL VIA SLIDE SHOE 97 5.8.2.3 FEEDING OIL VIA JET FROM CONNECTING ROD 97 5.9 HEAT FLOW IN PISTONS 98 5.10 DETERMINING THERMAL LOAD 99 5.11 NUMERICAL ANALYSIS USING THE FE METHOD 100 IMAGE 4 X CONTENTS 5.12 LABORATORY SHAKER TESTS 101 5.13 CHARACTERISTIC QUANTITIES 101 5.14 TEST EQUIPMENT 104 5.15 SIMULATION OF OIL MOTION 105 6 COMPONENT TESTING 107 6.1 STATIC COMPONENT TESTING 108 6.2 DYNAMIC COMPONENT FATIGUE TESTING 110 6.3 WEAR TESTING 113 7 ENGINE TESTING 115 7.1 TEST RUN PROGRAMS WITH EXAMPLES OF RESULTS 115 7.1.1 STANDARD TEST RUN PROGRAMS 116 7.1.1.1 FULL-LOAD CURVE 116 7.1.1.2 BLOW-BY CHARACTERISTIC 116 7.1.1.3 SEIZURE TEST 116 7.1.1.4 DEVELOPMENT TEST 118 7.1.2 LONG-TERM TEST RUN PROGRAMS 119 7.1.2.1 STANDARD ENDURANCE TEST 119 7.1.2.2 HOT-COLD ENDURANCE TEST 120 7.1.3 SPECIAL TEST RUN PROGRAMS 121 7.1.3.1 COLD-START TEST 121 7.1.3.2 MICROWELDING TEST 121 7.1.3.3 FRETTING TEST 122 7.1.3.4 BURNING MARK TEST 123 7.2 MEASUREMENT METHODS USED FOR DETERMINING PISTON TEMPERATURE 126 7.2.1 METHODS FOR MEASURING PISTON TEMPERATURE 127 7.2.1.1 THERMOMECHANICAL METHODS FOR MEASURING PISTON TEMPERATURE 127 7.2.1.1.1 USE OF FUSIBLE PLUGS 127 7.2.1.1.2 USE OF TEMPLUGS 128 7.2.1.2 THERMOELECTRICAL METHODS FOR MEASURING PISTON TEMPERATURE 129 7.2.1.2.1 USE OF NTC RESISTORS 129 7.2.1.2.2 USE OF NICR-NI THERMOCOUPLES 130 7.2.1.3 TRANSMITTING MEASURED VALUES FROM THERMOCOUPLES 131 7.2.1.3.1 TRANSMITTING MEASURED VALUES FROM THERMOCOUPLES WITH MEASUREMENT LEADS SUPPORTED BY LINKAGES . 131 7.2.1.3.2 TRANSMITTING MEASURED VALUES FROM THERMOCOUPLES THROUGH TELEMETRY 132 7.2.1.4 ASSESSMENT OF THE METHODS USED AT MAHLE FOR MEASURING PISTON TEMPERATURES 133 7.2.2 PISTON TEMPERATURES IN GASOLINE AND DIESEL ENGINES 133 7.2.2.1 TYPICAL TEMPERATURE MAXIMA ON THE PISTON 135 7.2.2.2 EFFECTS OF VARIOUS OPERATING PARAMETERS ON PISTON TEMPERATURE 135 IMAGE 5 CONTENTS XI 7.2.2.3 EFFECT OF COOLING OIL QUANTITY ON THE PISTON TEMPERATURE 137 7.2.2.4 PISTON TEMPERATURE MEASUREMENT IN TRANSIENT PROGRAMS 139 7.3 MEASUREMENT OF FRICTION LOSSES ON A FIRED ENGINE 141 7.3.1 MEASUREMENT METHODS FOR DETERMINING THE FRICTION MEAN EFFECTIVE PRESSURE 142 7.3.1.1 WILLANS LINE METHOD 142 7.3.1.2 MOTORING AND TEAR DOWN METHOD 143 7.3.1.3 CYLINDER DEACTIVATION 143 7.3.1.4 COAST DOWN TEST 143 7.3.1.5 FLOATING LINER METHOD 143 7.3.1.6 INDICATION METHOD 144 7.3.2 FRICTION MAPPING USING THE INDICATION METHOD 145 7.3.2.1 REQUIREMENTS 145 7.3.2.2 FRICTION POWER TEST BENCH FOR PASSENGER CAR ENGINES 146 7.3.2.3 MEASUREMENT AND ANALYSIS METHODS 149 7.3.3 SELECTED RESULTS 151 7.3.3.1 PISTON INSTALLATION CLEARANCE 151 7.3.3.2 SURFACE ROUGHNESS OF THE PISTON SKIRT 153 7.3.3.3 PISTON PIN OFFSET 154 7.3.3.4 WIDTH OF THE PISTON RING IN GROOVE 1 155 7.3.3.5 TANGENTIAL LOAD OF THE OIL CONTROL RING 156 7.3.3.6 COATING OF THE PISTON PIN 158 7.3.3.7 ENGINE OIL VISCOSITY 158 7.3.4 COMPARISON OF RESULTS AND OUTLOOK 160 7.4 WEAR TESTING OF THE PISTON GROUP 164 7.4.1 PISTON SKIRT 164 7.4.1.1 SKIRT COLLAPSE AND COATING WEAR 164 7.4.1.2 OVALITY 166 7.4.2 PISTON RING AND CYLINDER SURFACE 167 7.4.2.1 PISTON RING RUNNING SURFACE 167 7.4.2.2 CYLINDER SURFACE 169 7.4.2.3 COIL SPRINGS 170 7.4.2.4 ABNORMAL WEAR PATTERNS 170 7.4.3 PISTON RING SIDE FACE AND PISTON RING GROOVE 171 7.4.3.1 SIDE FACES OF THE 1ST PISTON RING 171 7.4.3.2 SIDE FACES OF THE 1ST PISTON RING GROOVE 173 7.4.4 PISTON PIN AND PIN BOSS 173 7.4.4.1 PISTON PIN 173 7.4.4.2 PIN BOSS 175 7.4.5 LOCKING RING AND LOCKING RING GROOVE 177 7.4.6 CARBON BUILD-UP AND CYLINDER POLISHING 178 7.5 PISTON STRESS DUE TO KNOCKING COMBUSTION 180 7.5.1 KNOCK DAMAGE AND DAMAGE EVALUATION 181 7.5.2 KNOCK MEASUREMENT HARDWARE AND THE MAHLE KL METER 184 7.5.3 EXAMPLES OF MEASUREMENT RESULTS 187 7.5.4 DETECTION QUALITY OF KNOCK CONTROL SYSTEMS 190 7.5.5 THE MEGA-KNOCKING PHENOMENON 192 7.6 PISTON NOISE AND PISTON TRANSVERSE MOTION 195 7.6.1 PROCEDURE FOR SYSTEMATICALLY MINIMIZING PISTON NOISE 195 IMAGE 6 XII CONTENTS 7.6.2 PISTON NOISE IN GASOLINE ENGINES 197 7.6.2.1 SUBJECTIVE NOISE ASSESSMENT 197 7.6.2.2 OBJECTIVE NOISE ASSESSMENT AND QUANTIFICATION 199 7.6.2.3 PISTON TRANSVERSE MOTION AND INFLUENCE PARAMETERS IN GASOLINE ENGINES 204 7.6.3 PISTON NOISE IN DIESEL ENGINES 208 7.6.3.1 SUBJECTIVE NOISE ASSESSMENT 208 7.6.3.2 OBJECTIVE NOISE ASSESSMENT AND QUANTIFICATION 213 7.6.3.3 PISTON TRANSVERSE MOTION AND INFLUENCE PARAMETERS IN DIESEL ENGINES 218 7.7 PISTON PIN NOISE 220 7.7.1 CAUSES OF NOISE 220 7.7.2 STRUCTURE-BORNE NOISE TRANSMISSION PATHS AND MEASUREMENT PROGRAM 221 7.7.3 EVALUATION PROCEDURE IN THE TIME DOMAIN 223 7.7.4 RESULTS FROM PARAMETER STUDIES 225 7.7.4.1 INFLUENCE OF PISTON PIN CLEARANCE 225 7.7.4.2 INFLUENCE OF PIN BOSS GEOMETRY 226 7.7.4.2.1 OIL POCKETS AND CIRCUMFERENTIAL LUBRICATION GROOVE 226 7.7.4.2.2 HORIZONTAL OVAL PIN BORE AND SIDE RELIEFS 227 7.7.4.2.3 SINGLE-SIDED VERTICAL OVAL PIN BORE 228 7.7.4.2.4 SHAPED PIN BORES 229 7.8 CAVITATION ON WET CYLINDER LINERS OF COMMERCIAL VEHICLE DIESEL ENGINES 231 7.8.1 BASIC PRINCIPLES OF CAVITATION 232 7.8.2 THE PHYSICAL PHENOMENON OF CAVITATION 233 7.8.3 TYPES OF CAVITATION 234 7.8.3.1 GASEOUS CAVITATION 234 7.8.3.2 PSEUDO CAVITATION 235 7.8.3.3 VAPOR CAVITATION 235 7.8.3.4 CAVITATION IN REAL FLOWS 235 7.8.4 CAVITATION BUBBLE DYNAMICS AND CAVITATION BUBBLE COLLAPSE 235 7.8.4.1 SPHERICAL CAVITATION BUBBLE IMPLOSION 236 7.8.4.2 ASPHERICAL CAVITATION BUBBLE COLLAPSE 236 7.8.5 CAVITATION DAMAGE IN WET CYLINDER LINERS 238 7.8.6 CAVITATION MEASUREMENT EQUIPMENT 240 7.8.7 CAVITATION INTENSITY FACTOR AND SIGNAL ANALYSIS 242 7.8.8 TEST BENCH SETUP FOR CAVITATION MEASUREMENTS 243 7.8.9 TEST RUN PROGRAMS FOR CAVITATION MEASUREMENTS 244 7.8.10 RELATIONSHIP OF CAVITATION INTENSITY TO THE ARRANGEMENT OF THE CYLINDER AND THE POSITION ON THE CYLINDER 245 7.8.11 INFLUENCING PARAMETERS 246 7.8.11.1 EFFECT OF ENGINE OPERATING PARAMETERS ON CAVITATION 247 7.8.11.1.1 EFFECT OF ENGINE SPEED 247 7.8.11.1.2 EFFECT OF ENGINE LOAD 248 7.8.11.1.3 EFFECT OF COOLING SYSTEM PRESSURE 248 7.8.11.1.4 EFFECT OF COOLANT VOLUME FLOW RATE 249 7.8.11.1.5 EFFECT OF COOLANT TEMPERATURE 249 7.8.11.1.6 EFFECT OF COOLANT COMPOSITION 250 7.8.11.1.7 EFFECT OF COMBUSTION CHAMBER PRESSURE 251 IMAGE 7 CONTENTS XIII 7.8.11.2 EFFECT OF DESIGN PARAMETERS ON CAVITATION 251 7.8.11.2.1 EFFECT OF PISTON AND CYLINDER LINER FITTING CLEARANCE 251 7.8.11.2.2 EFFECT OF PISTON TYPE AND PISTON SHAPE 252 7.8.11.2.3 EFFECT OF OTHER PISTON DESIGN ADAPTATIONS 254 7.8.11.2.4 EFFECT OF DESIGN CHANGES TO THE CYLINDER LINER AND COOLING CHANNEL SHAPE 255 7.9 LUBE OIL CONSUMPTION AND BLOW-BY IN THE COMBUSTION ENGINE 255 7.9.1 LUBE OIL CONSUMPTION MECHANISMS IN THE COMBUSTION ENGINE 255 7.9.1.1 LUBE OIL CONSUMPTION IN THE FRICTIONAL SYSTEM OF THE PISTON, PISTON RINGS, AND CYLINDER SURFACE 258 7.9.1.2 LUBE OIL CONSUMPTION THROUGH VALVE STEM SEALS 259 7.9.1.3 LUBE OIL CONSUMPTION THROUGH CRANKCASE VENTILATION (BLOW-BY) 259 7.9.1.4 LUBE OIL CONSUMPTION AND BLOW-BY IN THE TURBOCHARGER 259 7.9.2 LUBE OIL CONSUMPTION MEASUREMENT METHODS 261 7.9.3 LUBE OIL CONSUMPTION MAPS AND DYNAMIC OIL CONSUMPTION BEHAVIOR 264 7.9.4 EFFECT OF INTAKE MANIFOLD VACUUM ON LUBE OIL CONSUMPTION IN THE GASOLINE ENGINE 268 LITERATURE REFERENCES 271 DICTIONARY/GLOSSARY 274 INDEX 283
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discipline	Maschinenbau / Maschinenwesen
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isbn	9783834815903 383481590X
language	English German
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physical	XIII, 284 S. Ill., graph. Darst. 24 cm
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publisher	Vieweg + Teubner
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spelling	Pistons and engine testing with 20 tables Mahle GmbH (ed.) 1. ed. Wiesbaden Vieweg + Teubner 2012 XIII, 284 S. Ill., graph. Darst. 24 cm txt rdacontent n rdamedia nc rdacarrier Literaturangaben Kolben (DE-588)4164629-0 gnd rswk-swf Verbrennungsmotor (DE-588)4062661-1 gnd rswk-swf 1\p (DE-588)4143413-4 Aufsatzsammlung gnd-content 2\p (DE-588)4123623-3 Lehrbuch gnd-content Kolben (DE-588)4164629-0 s Verbrennungsmotor (DE-588)4062661-1 s DE-604 Mahle GmbH Sonstige (DE-588)2032790-0 oth Parallele Sprachausgabe deutsch Kolben und motorische Erprobung X:MVB text/html http://deposit.dnb.de/cgi-bin/dokserv?id=3902678&prov=M&dok_var=1&dok_ext=htm Inhaltstext DNB Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=024808075&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis 1\p cgwrk 20201028 DE-101 https://d-nb.info/provenance/plan#cgwrk 2\p cgwrk 20201028 DE-101 https://d-nb.info/provenance/plan#cgwrk
spellingShingle	Pistons and engine testing with 20 tables Kolben (DE-588)4164629-0 gnd Verbrennungsmotor (DE-588)4062661-1 gnd
subject_GND	(DE-588)4164629-0 (DE-588)4062661-1 (DE-588)4143413-4 (DE-588)4123623-3
title	Pistons and engine testing with 20 tables
title_auth	Pistons and engine testing with 20 tables
title_exact_search	Pistons and engine testing with 20 tables
title_full	Pistons and engine testing with 20 tables Mahle GmbH (ed.)
title_fullStr	Pistons and engine testing with 20 tables Mahle GmbH (ed.)
title_full_unstemmed	Pistons and engine testing with 20 tables Mahle GmbH (ed.)
title_short	Pistons and engine testing
title_sort	pistons and engine testing with 20 tables
title_sub	with 20 tables
topic	Kolben (DE-588)4164629-0 gnd Verbrennungsmotor (DE-588)4062661-1 gnd
topic_facet	Kolben Verbrennungsmotor Aufsatzsammlung Lehrbuch
url	http://deposit.dnb.de/cgi-bin/dokserv?id=3902678&prov=M&dok_var=1&dok_ext=htm http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=024808075&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA
work_keys_str_mv	AT mahlegmbh pistonsandenginetestingwith20tables

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