This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Development of a Modern Diesel Engine with Ultra-Low Bore Distortion to Reduce Friction, Blowby, Oil Consumption and DPF Ash Loading
Technical Paper
2020-28-0344
ISSN: 0148-7191, e-ISSN: 2688-3627
This content contains downloadable datasets
Annotation ability available
Sector:
Language:
English
Abstract
The stringent emission regulations coupled with tighter CO2 targets demand extreme optimization of the diesel engines. In this context, it is important to minimize the cylinder bore distortions in cold and hot conditions. The cold bore distortion is primarily due to the assembly forces applied by the cylinder head bolts whereas the hot distortion is a resultant of local metal temperatures and structural rigidity. The present work describes the extreme optimization techniques used to reduce the bore distortion of a modern high power-density (60 kW / lit) diesel engine, Moreover, the benefits of reducing the bore distortion are quantified in terms of cylinder system friction, blowby rate, oil consumption (OC) and ash loading rate of the diesel particulate filter (DPF).
An optimized torque plate honing is used to reduce the bore distortion in cold conditions. However, an extreme optimization of the cylinder bore structure and water jacket design was needed to control the hot bore distortion. With the reduced bore distortion, the engine could be optimized to have a reduced tangential force. The cumulative tangential force of all the piston rings could be reduced from 37 N to 23.5 N which could result in a significant reduction in the cylinder system friction. Moreover, the engine level measurements with and without the torque plate honing confirm that a significant reduction in blowby rate (approximately 20 %) and oil consumption (approximately 25 %) could be achieved with the torque plate honing. The results were found to be consistent with the vehicle level results of the oil consumption (g/km).
Furthermore, the reduction in oil consumption could benefit the ash loading behaviour of the DPF. With the low bore distortion (LBD) engine, the ash loading rate of the DPF could be reduced significantly which is extremely important to have consistently higher regeneration intervals throughout the life of the vehicle. Thus, the development approach to have low bore distortion has resulted in multiple benefits and hence it is found to be useful in developing diesel engines with compliance to future regulations.
Authors
Topic
Citation
Vellandi, V., NAMANI, P., Bagavathy, S., and Chalumuru, M., "Development of a Modern Diesel Engine with Ultra-Low Bore Distortion to Reduce Friction, Blowby, Oil Consumption and DPF Ash Loading," SAE Technical Paper 2020-28-0344, 2020, https://doi.org/10.4271/2020-28-0344.Data Sets - Support Documents
| Title | Description | Download |
|---|---|---|
| Unnamed Dataset 1 |
Also In
References
- Sappok , A. , and Wong , V.W. Ash Effects on Diesel Particulate Filter Pressure Drop Sensitivity to Soot and Implications for Regeneration Frequency and DPF Control SAE Int. J. Fuels Lubr. 3 1 380 396 2010 https://doi.org/10.4271/2010-01-0811
- Zhang , J. , and Li , Y. Experimental Study of Lubricant-Derived Ash Effects on Diesel Particulate Filter Performance https://doi.org/10.1177/1468087419874577
- Bagi , S. , Singh , N. , and Andrew , R. Investigation into Ash from Field Returned DPF Units: Composition, Distribution, Cleaning Ability and DPF Performance Recovery SAE Technical Paper 2016-01-0928 2016 https://doi.org/10.4271/2016-01-0928
- Bagi , S. , Bowker , R. , and Andrew , R. Understanding Chemical Composition and Phase Transitions of ash from Field Returned DPF Units and Their Correlation with Filter Operating Conditions SAE Int. J. Fuels Lubr. 9 1 239 259 2016 https://doi.org/10.4271/2016-01-0898
- Morcos , M. , Ayyappan , P. , and Harris , T. Characterization of DPF ash for Development of DPF Regeneration Control and ash Cleaning Requirements SAE Technical Paper 2011-01-1248 2011 https://doi.org/10.4271/2011-01-1248
- Tian , T. Dynamic Behaviour of Piston Rings and their Practical Impact. Part 1: Ring Flutter and Ring Collapse and Their Effects on Gas Flow and Oil Transport Proceedings of the Institution of Mechanical Engineers Part J: Journal of Engineering Tribology 216 4 209 228 2002
- Jeng , Y.R. Friction and Lubrication Analysis of a Piston Ring Pack SAE Technical Paper 920492 1992 https://doi.org/10.4271/920492
- Sun , D.C. A Thermal Elastica theory of Piston-Ring and Cylinder-Bore Contact Journal of Applied Mechanics 58 1 141 153 1991
- Andersson , P. et al. 2002
- Loenne , K. , and Ziemba , R. The GOETZE Cylinder Distortion Measurement System and the Possibilities of Reducing Cylinder Distortions SAE Technical Paper 880142 1988 https://doi.org/10.4271/880142
- Hennessy , M. , and Barber , G.C. The Effects of Cylinder Wall Surface Roughness and Bore Distortion on Blow-by in Automotive Engines Tribology Transactions 38 4 966 972 1995 https://doi.org/10.1080/10402009508983494
- Yamada , T. , Kobayashi , H. , Kusama , K. , Sagawa , J. et al. Development of a Technique to Predict Oil Consumption With Consideration for Cylinder Deformation-Prediction of Ring Oil Film Thickness and Amount of Oil Passing Across Running Surface Under Cylinder Deformation SAE Technical Paper 2003-01-0982 2003 https://doi.org/10.4271/2003-01-0982
- Rodrigues , M.R.P.C. , and Porto , S.F. Torque Plate Honing on Block Cylinder Bores SAE Technical Paper 931679 1993 https://doi.org/10.4271/931679
- Zhao , C. , Zhu , Y. , and Huang , S. Pressure Drop and Soot Accumulation Characteristics through Diesel Particulate Filters Considering Various Soot and Ash Distribution Types SAE Technical Paper 2017-01-0959 2017 https://doi.org/10.4271/2017-01-0959
- Manni , M. , Pedicillo , A. , and Bazzano , F. A Study of Lubricating Oil Impact on Diesel Particulate Filters by Means of Accelerated Engine Tests SAE Technical Paper 2016-01-3416 2016 https://doi.org/10.4271/2016-01-3416
- Zhang , J. , Qi , J. , Shuai , S. , Wang , L. et al. Numerical Analysis on the Potential of Reducing DPF Size Using Low Ash Lubricant Oil SAE Technical Paper 2018-01-1760 2018 https://doi.org/10.4271/2018-01-1760