|  | Lakshminarayanan, P. A. / Nayak, Nagaraj S.
Critical Component Wear in Heavy Duty Engines
 1. Edition March 2012
129.- Euro
2012. 456 Pages, Hardcover
ISBN 978-0-470-82882-3 - John Wiley & Sons
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| Detailed description
The critical parts of a heavy duty engine are theoretically designed for infinite life without mechanical fatigue failure. Yet the life of an engine is in reality determined by wear of the critical parts. Even if an engine is designed and built to have normal wear life, abnormal wear takes place either due to special working conditions or increased loading. Understanding abnormal and normal wear enables the engineer to control the external conditions leading to premature wear, or to design the critical parts that have longer wear life and hence lower costs. The literature on wear phenomenon related to engines is scattered in numerous periodicals and books. For the first time, Lakshminarayanan and Nayak bring the tribological aspects of different critical engine components together in one volume, covering key components like the liner, piston, rings, valve, valve train and bearings, with methods to identify and quantify wear.
* The first book to combine solutions to critical component wear in one volume
* Presents real world case studies with suitable mathematical models for earth movers, power generators, and sea going vessels
* Includes material from researchers at Schaeffer Manufacturing (USA), Tekniker (Spain), Fuchs (Germany), BAM (Germany), Kirloskar Oil Engines Ltd (India) and Tarabusi (Spain)
* Wear simulations and calculations included in the appendices
* Instructor presentations slides with book figures available from the companion site
Critical Component Wear in Heavy Duty Engines is aimed at postgraduates in automotive engineering, engine design, tribology, combustion and practitioners involved in engine R&D for applications such as commercial vehicles, cars, stationary engines (for generators, pumps, etc.), boats and ships. This book is also a key reference for senior undergraduates looking to move onto advanced study in the above topics, consultants and product mangers in industry, as well as engineers involved in design of furnaces, gas turbines, and rocket combustion.
Companion website for the book: www.wiley.com/go/lakshmi
From the contents
List of Contributors xv
Preface xvii
Acknowledgements xxi
PART I OVERTURE 1
1 Wear in the Heavy Duty Engine 3
1.1 Introduction 3
1.2 Engine Life 3
1.3 Wear in Engines 4
1.4 General Wear Model 5
1.5 Wear of Engine Bearings 5
1.6 Wear of Piston Rings and Liners 6
1.7 Wear of Valves and Valve Guides 6
1.8 Reduction in Wear Life of Critical Parts Due to Contaminants in Oil 6
1.9 Oils for New Generation Engines with Longer Drain Intervals 8
1.10 Filters 9
1.11 Types of Wear of Critical Parts in a Highly Loaded Diesel Engine 10
References 11
2 Engine Size and Life 13
2.1 Introduction 13
2.2 Engine Life 13
2.3 Factors on Which Life is Dependent 14
2.4 Friction Force and Power 14
2.5 Similarity Studies 15
2.6 Archard's Law of Wear 20
2.7 Wear Life of Engines 20
2.8 Summary 23
Appendix 2.A Engine Parameters, Mechanical Efficiency and Life 25
Appendix 2.B Hardness and Fatigue Limits of Different Copper-Lead-Tin
(Cu-Pb-Sn) Bearings 26
Appendix 2.C Hardness and Fatigue Limits of Different Aluminium-Tin
(Al-Sn) Bearings 28
References 29
PART II VALVE TRAIN COMPONENTS 31
3 Inlet Valve Seat Wear in High bmep Diesel Engines 33
3.1 Introduction 33
3.2 Valve Seat Wear 34
3.3 Shear Strain and Wear due to Relative Displacement 35
3.4 Wear Model 35
3.5 Finite Element Analysis 37
3.6 Experiments, Results and Discussions 38
3.7 Summary 45
3.8 Design Rule for Inlet Valve Seat Wear in High bmep Engines 45
References 45
4 Wear of the Cam Follower and Rocker Toe 47
4.1 Introduction 47
4.2 Wear of Cam Follower Surfaces 48
4.3 Typical Modes of Wear 50
4.4 Experiments on Cam Follower Wear 51
4.5 Dynamics of the Valve Train System of the Pushrod Type 52
4.6 Wear Model 55
4.7 Parametric Study 64
4.8 Wear of the Cast Iron Rocker Toe 64
4.9 Summary 66
References 66
PART III LINER, PISTON AND PISTON RINGS 69
5 Liner Wear: Wear of Roughness Peaks in Sparse Contact 71
5.1 Introduction 71
5.2 Surface Texture of Liners and Rings 72
5.3 Wear of Liner Surfaces 76
5.4 Wear Model 81
5.5 Liner Wear Model for Wear of Roughness Peaks in Sparse Contact 85
5.6 Discussions on Wear of Liner Roughness Peaks due to Sparse Contact 89
5.7 Summary 92
Appendix 5.A Sample Calculation of the Wear of a Rough
Plateau Honed Liner 93
References 93
6 Generalized Boundary Conditions for Designing Diesel Pistons 95
6.1 Introduction 95
6.2 Temperature Distribution and Form of the Piston 96
6.3 Experimental Mapping of Temperature Field in the Piston 97
6.4 Heat Transfer in Pistons 98
6.5 Calculation of Piston Shape 98
6.6 Summary 108
References 109
7 Bore Polishing Wear in Diesel Engine Cylinders 111
7.1 Introduction 111
7.2 Wear Phenomenon for Liner Surfaces 112
7.3 Bore Polishing Mechanism 113
7.4 Wear Model 115
7.5 Calculation Methodology and Study of Bore Polishing Wear 116
7.6 Case Study on Bore Polishing Wear in Diesel Engine Cylinders 118
7.7 Summary 127
References 127
8 Abrasive Wear of Piston Grooves in Highly Loaded Diesel Engines 129
8.1 Introduction 129
8.2 Wear Phenomenon in Piston Grooves 130
8.3 Wear Model 132
8.4 Experimental Validation 134
8.5 Estimation of Wear Using Sarkar's Model 137
8.6 Summary 139
References 140
9 Abrasive Wear of Liners and Piston Rings 141
9.1 Introduction 141
9.2 Wear of Liner and Ring Surfaces 141
9.3 Design Parameters 143
9.4 Study of Abrasive Wear on Off-highway Engines 144
9.5 Winnowing Effect 149
9.6 Scanning Electron Microscopy of Abrasive Wear 150
9.7 Critical Dosage of Sand and Life of Piston-Ring-Liner Assembly 150
9.8 Summary 152
References 153
10 Corrosive Wear 155
10.1 Introduction 155
10.2 Operating Parameters 155
10.3 Corrosive Wear Study on Off-road Application Engines 156
10.4 Wear Related to Coolants in an Engine 161
10.5 Summary 165
References 165
11 Tribological Tests to Simulate Wear on Piston Rings 167
11.1 Introduction 167
11.2 Friction and Wear Tests 168
11.3 Test Procedures Assigned to the High Frequency, Linear Oscillating Test Machine 170
11.4 Load, Friction and Wear Tests 172
11.5 Test Results 175
11.6 Selection of Lubricants 184
11.7 High Performance Bio-lubricants and Tribo-reactive Materials for Clean Automotive Applications 185
11.8 Tribo-Active Materials 190
11.9 EP Tribological Tests 192
Acknowledgements 194
References 194
PART IV ENGINE BEARINGS 197
12 Friction and Wear in Engine Bearings 199
12.1 Introduction 199
12.2 Engine Bearing Materials 202
12.3 Functions of Engine Bearing Layers 205
12.4 Types of Overlays/Coatings in Engine Bearings 206
12.5 Coatings for Engine Bearings 209
12.6 Relevance of Lubrication Regimes in the Study of Bearing Wear 210
12.7 Theoretical Friction and Wear in Bearings 217
12.8 Wear 218
12.9 Mechanisms of Wear 219
12.10 Requirements of Engine Bearing Materials 234
12.11 Characterization Tests for Wear Behaviour of Engine Bearings 238
12.12 Summary 251
References 252
PART V LUBRICATING OILS FOR MODERN ENGINES 253
13 Heavy Duty Diesel Engine Oils, Emission Strategies and their Effect on Engine Oils 255
13.1 Introduction 255
13.2 What Drives the Changes in Diesel Engine Oil Specifications? 256
13.3 Engine Oil Requirements 258
13.4 Components of Engine Oil Performance 265
13.5 How Engine Oil Performance Standards are Developed 268
13.6 API Service Classifications 276
13.7 ACEA Specifications 276
13.8 OEM Specifications 279
13.9 Why Some API Service Classifications Become Obsolete 279
13.10 Engine Oil Composition 280
13.11 Specific Engine Oil Additive Chemistry 290
13.12 Maintaining and Changing Engine Oils 302
13.13 Diesel Engine Oil Trends 306
13.14 Engine Design Technologies and Strategies Used to Control Emissions 306
13.15 Impact of Emission Strategies on Engine Oils 324
13.16 How Have Engine Oils Changed to Cope with the Demands of Low Emissions? 328
13.17 Most Prevalent API Specifications Found In Use 329
13.18 Paradigm Shift in Engine Oil Technology 336
13.19 Future Engine Oil Developments 348
13.20 Summary 352
References 353
PART VI FUEL INJECTION EQUIPMENT 355
14 Wear of Fuel Injection Equipment 357
14.1 Introduction 357
14.2 Wear due to Diesel Fuel Quality 357
14.3 Wear due to Abrasive Dust in Fuel 361
14.4 Wear due to Water in Fuel 365
14.5 Summary 367
References 367
PART VII HEAVY FUEL ENGINES 369
15 Wear with Heavy Fuel Oil Operation 371
15.1 Introduction 371
15.2 Fuel Treatment: Filtration and Homogenization 373
15.3 Water and Chlorine 374
15.4 Viscosity, Carbon Residue and Dust 374
15.5 Deposit Build Up on Top Land and Anti-polishing Ring for Reducing the Wear of Liner, Rings and Piston 375
15.6 High Sulfur in Fuel 377
15.7 Low Sulfur in Fuel 380
15.8 Catalyst Fines 383
15.9 High Temperature Corrosion 383
15.10 Wear Specific to Four-stroke HFO Engines 388
15.11 New Engines Compliant to Maritime Emission Standards 391
15.12 Wear Life of an HFO Engine 393
15.13 Summary 393
References 394
PART VIII FILTERS 397
16 Air and Oil Filtration and Its Impact on Oil Life and Engine Wear Life 399
16.1 Introduction 399
16.2 Mechanisms of Filtration 400
16.3 Classification of Filtration 400
16.4 Filter Rating 403
16.5 Filter Selection 404
16.6 Introduction to Different Filters in the Engine 405
16.7 Oil Filters and Impact on Oil and Engine Life 409
16.8 Engine Wear 413
16.9 Full Flow Oil Filters 415
16.10 Summary 419
Appendix 16.A Filter Tests and Test Standards 419
References 419
Index 421
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