The usage of the Turbocharged Intercooled Diesel Engine automobiles for domestic transport is common due to its High Torque output and better Thermal Efficiency. The Piston Rings are one of the most critical components in any reciprocating Internal Combustion engines. A Diesel Engine Piston Ring Pack’s design is considered wherein the engine itself is a New Product Development.
With high Power density & higher operating pressures, The Engine called for higher Endurance of the Piston Ring Parts with lower blow by & lower Oil Consumption performance throughout its life. Based on the Benchmark, the Piston Rings are designed with Chromium Nitride (CrN), Gas Nitride (GN) & GN coating protection over the base materials of the Top, 2nd & Oil Rings respectively for withstanding the aggressive operating conditions. The parts are developed and validated. The Combustion Gas Blow By Performance results are not within the targeted limits when tested with initial set of samples.
To address the performance requirements of the Engine, the Ring pack called for improvements. Piston Ring dynamics simulation software is used for the design validation of the Maiden design (Bench mark) and improved Engine Ring pack respectively. The Ring Pack’s dynamics and performance results of both Ring pack models are simulated and compared.
Based on the simulated results, the Piston Ring pack parameters are optimized to meet the customer engine targets. The Parts are developed and subjected to the real time Dynamometer validation. The Combustion Gas Blow by, Oil Consumption and Piston Ring’s Peripheral wear performance results are within the Target Limits & expectations respectively with the optimized set of Ring Pack.