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Inertia-driven single compression machine for combustion study

Tadeusz J. Rychter Tomasz Lezanski

Archive of Mechanical Engineering | 2002 | vol. 49 | No 4 | 341-353

Keywords combustion piston engines

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Abstract

The paper presents an original design of a single compression machine for combustion study. The principle of operation is based an old concept, utilizing the inertia energy of a flywheel to accelerate the crank mechanism and the attached piston to compress rapidly the combustible mixture in the combustion chamber. A square piston geometry was adopted to allow visualization of the compression and combustion processes in directions perpendicular to the cylinder axis. To avoid the extensive scratching of glass walls by the moving piston, a special multi-action clutch-brake unit was used; this facilitates coupling of the flywheel with the crank mechanism during the single piston stroke and subsequent immediate uncoupling and fast stopping of the piston. The whole operating cycle can be completed within no more than two revolutions of the crankshaft. The design details of the machine, its acceleration characteristics and a sample of the visualized combustion process are presented.

Authors and Affiliations

Tadeusz J. Rychter

Tomasz Lezanski

Inertial dynamorneter test rig for small, high performance engines

Paweł Mazuro Tadeusz Rychter

Archive of Mechanical Engineering | 2000 | vol. 47 | No 3 | 247-259

Keywords piston engines testing

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Abstract

The paper presents a general idea of the acceleration test method and the design, construction and testing of the inertial dynamorneter test rig developed for small, high performance two-stroke engines. The method is universal and can be also used for four-stroke engines but it is especially useful for the two-stroke ones. The testing procedure is described and the advantages of that type of investigation method are pointed out. It has been proved that the reliability of the method is satisfactory. It was also proven that the individual construction of the inertial dynamorneter of good quality can be performed individually and that it can be a very useful investigation tool in engine tuning practice. The point has been stressed that the major advantage of that method is the possibility of the instantaneous measurement of the engine power characteristic during unsteady engine operation (acceleration) where the time for the single run does not exceed ten seconds.

Authors and Affiliations

Paweł Mazuro

Tadeusz Rychter

Chosen Aspects of Quality Defects of ”Alphin” Inserts in Combustions Pistons

J. Piątkowski P. Kamiński

Archives of Foundry Engineering | 2015 | No 4 | DOI: 10.1515/afe-2015-0080

Keywords Al-Si casting alloys quality defects „Alphin” inserts Motor pistons

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Abstract

The chosen, typical causes of quality defects of cast-iron „alphin” rings embedded in aluminum cast are being presented in this paper.

Diffusive joint of those inserts with the pistons casts is being used, due to extreme work conditions of destructive influence of the fuel mix

and variable thermo-mechanical loads, which reign in the combustion motor working chamber.

Authors and Affiliations

J. Piątkowski

P. Kamiński

Numerical simulation of piston ring pack operation

Andrzej Wolff Janusz Piechna

Archive of Mechanical Engineering | 2003 | vol. 50 | No 3 | 303-329

Keywords hydrodynamics gasdynamics oil consumption piston engines

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Abstract

The motion of a ring pack an oil film covering the cylinder liner has been considered. In the paper, equations, a numerical method, algorithm of solution and results of numerical simulations of this phenomena have been presented. The model presented takes into account hydrodynamic, spring and gas forces acting on each ring. The cases of motion with full and partial wetting of ring land have been considered. The influence of engine rotational speed, ring land curvature, oil viscosity on individual rings radial motion and oil film thickness have been analysed. The results of the calculations have been presented in graphical form.

Authors and Affiliations

Andrzej Wolff

Janusz Piechna

e-mail:

ORCID:

Modelling the blowby in internal combustion engine. Part I: A mathematical model

Grzegorz Koszałka

Archive of Mechanical Engineering | 2004 | vol. 51 | No 2 | 245-257

Keywords piston ring blowby ring dynamics mathematical model

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Abstract

The paper describes a mathematical model of gas flow through crevices between the piston, rings and cylinder in internal combustion engines. The model has been developed to study the influence of numerous. design parameters and engine operation condition on piston ring pack behaviour and the exhaust gases blowby from the combustion chamber to the crankcase. The model integrates the gas flow and axial rings displacements in the grooves, and separately treats lands between piston, cylinder and adjacent rings and regions in the grooves behind the rings. The heat transfer between the gas and the surrounding surfaces is calculated and emphasis is placed on considering the influence of wear and thermal deformations of elements on ring pack performance.

Authors and Affiliations

Grzegorz Koszałka

Modelling the blowby in internal combustion engine. Part 2: Primary calculations and verification of the model

Grzegorz Koszałka

Archive of Mechanical Engineering | 2004 | vol. 51 | No 4 | 595-607

Keywords piston ring blowby ring dvnamics mathematical model

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Abstract

The paper presents computer application of the mathematical model of piston- ring-cylinder packing, which was described in detail in the first part of the paper. Methodology of selection of the input data, results of primary calculations and the method of model verification are also shown. The results allow acknowledging the mathematical model as verified.

Authors and Affiliations

Grzegorz Koszałka

A model of the steam compression process in a piston reactor

Damian Joachimiak Tomasz Borowczyk Magda Joachimiak

Archives of Thermodynamics | 2023 | vol. 44 | No 4 | 261-284 | DOI: 10.24425/ather.2023.149725

Keywords steam critical water parameters piston-cylinder system compression rings thermodynamic parameters Piston reactor heat transfer

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Abstract

The paper discusses the possible determination of steam parameters in a new type of piston machine for steam compression to generate supercritical water parameters. It presents a calculation model that allows one to simulate the process of steam compression in a cylinder with volume regulated by the piston position. In each calculation step, the steam parameters were determined on the basis of fast adiabatic changes which were corrected by the effect of leakage and heat transfer occurrence. The seal of the reactor was assumed to be a compression ring. Depending on the pressure drop on the seal, subcritical and supercritical flow was taken into account. The leak was corrected by the coefficient of flow contraction. Heat transfer was determined by equations for the Nusselt number for water and steam from the homogenous area. The programmed model allows one to simulate changes in the thermodynamic parameters of steam during the process of steam compression with any calculation step. The results presented in this paper show that the application of one compression ring allows us to obtain supercritical steam parameters. Various degrees of sealing leak tightness and their impact on the changeability of steam parameters were analyzed. Heat transfer was shown to have an impact not only on changes in steam temperature, but also on pressure. This paper analyzes the impact of the temperature of the walls of the compression chamber on the value and direction of heat transfer.

Authors and Affiliations

Damian Joachimiak

1

Tomasz Borowczyk

2

Magda Joachimiak

1

Poznan University of Technology, Institute of Thermal Engineering, Piotrowo 3a, 60-965, Poznan, Poland
Grupa inżynieryjna Konstrubowski Sp. z o.o., Święty Wojciech 7/13, 61-749 Poznań, Poland

Radiation Impedance for Square Piston Sources on Infinite Circular Cylindrical Baffles

John L. Valacas

Archives of Acoustics | 2020 | vol. 45 | No 4 | 663-679 | DOI: 10.24425/aoa.2020.135254

Keywords cylindrical baffle radiation impedance radiation mass-load piston source

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Abstract

The evaluation of complex radiation impedance for a square piston source on an infinite circularcylindrical baffle is associated to the Greenspon-Sherman formulation for which novel evaluation methods are proposed. Unlike existing methods results are produced in a very wide range of frequencies and source semi-angles with controllable precision. For this reason closed-form expressions are used to describe the truncation errors of all integrals and infinite sums involved. Impedance values of increased accuracy are also provided in tabulated form for engineering use and a new radiation mass-load model is derived for low-frequencies.

Authors and Affiliations

John L. Valacas

Casting of Combustion Engine Pistons Before and Now on the Example of FM Gorzyce

M. Czerepak J. Piątkowski

Archives of Foundry Engineering | 2023 | vol. 23 | No 2 | 58-65 | DOI: 10.24425/afe.2023.144296

Keywords Casting Silumins Pistons Permanent moulding casting machines Surface treatment

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Abstract

The article discusses the most important changes in the construction of permanent mould casting machines, as well as the method of casting engine pistons and their construction on the example of Federal-Mogul (FM) Gorzyce. The system of automatic cooling of the presently used permanent mould casting machines coupled with robots which pour the liquid alloy ensures uniform crystallization of the pistons and optimal efficiency of the casting process. As a result of the necessity to improve the engine efficiency and thus reduce the fuel consumption and harmful substance emission, the construction of the pistons has changed as well. The piston castings, which are produced by gravity casting for metal moulds, have undergone a diametric transformation. Typical piston designs for gasoline and Diesel engines are shown together with the most important parts of the piston, the crown (combustion chamber) and the guide part (skirt). Depending on the type of engine, the present pistons characterize in differently shaped crown, a slimmed internal construction as well as component participation (cooling channels and ring inserts), and the piston skirts undergo surface treatment procedures.

Authors and Affiliations

M. Czerepak

1

J. Piątkowski

2

e-mail:

ORCID:

Federal-Mogul Gorzyce sp. z o.o., Odlewników 52, 39-432 Gorzyce, Poland
Silesian University of Technology, Krasińskiego 8, 44-100 Gliwice, Poland

Application of X-S Control Cards to Parameter Control in the Machining Process of Piston Castings for Internal Combustion Engines

A. Krępa J. Piątkowski

Archives of Foundry Engineering | 2021 | vo. 21 | No 4 | 116-120 | DOI: 10.24425/afe.2021.139759

Keywords Control cards Casting quality management SPC Pistons for internal combustion engines

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Abstract

This article discusses the possibility of using a two-track X-S control card on a Mesas device to control the production process parameters of piston castings for combustion engines. The research was carried out at the Federal-Mogul Gorzyce company. The basis for estimating the variability of the process results from the mean value (X) is the standard deviation (S). Thanks to specially designed measuring stations that use algorithms to calculate process indicators (Cp and/or Cpk) and their visualization, the cost of manufacturing products and the number of non-compliant products (scraps) are reduced. The process stability was investigated by measuring the key dimensions of the piston casting in a specific population and a given measurement cycle. Taking into account the precision of details, their technical condition, and surface quality, the production machines and cutting tools were optimally selected. It has been found that an important element of the effective use of Statistical Process Control (SPC) are trained/experienced operators who can correctly interpret the resulting control chart forms.

Bibliography

[1] Czarski, A., Satora, K. (1998). Statistical process control. Teaching materials. Cracow: Stat-Q-Mat s.c.
[2] Dahlgaard, J.J., Kristensen, K., Kanji, G.K. (2002). Podstawy zarządzania jakością. Warsaw: PWN.
[3] Grant, E.L., Leavenworth, R.S. (1996). Statistical quality control. McGraw-Hill.
[4] Hamrol, A. (2005). Quality management with examples. Warsaw: PWN.
[5] Kończak, G. (2000). Application of control cards in quality control in the course of production. Katowice: Publishing House of the University of Economics in Katowice.
[6] Kończak, G. (2007). Statistical methods in controlling the quality of production. Katowice: Publishing House of the University of Economics in Katowice.
[7] Maliński, M. (2004). Computer aided verification of statistical hypotheses. Katowice: Publishing House of the Silesian University of Technology in Gliwice.
[8] Chrapoński, J. (2010). Fundamentals of statistical processes control. Katowice: Publishing House of the Silesian University of Technology in Gliwice.
[9] Statistical Process Control SPC Second edition. AIAG, Berlin-London, July 2005, p. 57.
[10] Polska Norma PN-ISO 8258+AC1: Karty kontrolne Shewharta. PKN, 1996.
[11] Quality Assurance for Suppliers. Quality Management in the Automotive Industry. Production process and product approval (PPA). 5th edition, Berlin 2012.

Authors and Affiliations

A. Krępa

1

J. Piątkowski

2

e-mail:

ORCID:

Federal-Mogul Gorzyce Sp. z o.o., Odlewników 52, 39-432 Gorzyce, Poland
Silesian University of Technology, Krasińskiego 8 Gliwice, Poland

Effect of Iron Phases Crystallization on the Durability of the Bimetallic Connection Between Ring Inserts and the Piston Casting

M. Szucki J. Piątkowski M. Czerepak

Archives of Foundry Engineering | 2023 | vol. 23 | No 2 | 112-118 | DOI: 10.24425/afe.2023.144302

Keywords crystallization Al-Si alloys Iron phases Piston casting Automotive industry

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Abstract

The article presents the most important causes of the unstable connection between cast iron ring inserts and the silumin casting of an engine piston. It is shown that manufacturing defects are mainly related to the alfin processing of inserts in Al-Si alloy (the so-called AS9 alloy). Exceeding the permissible iron content in AS9 alloy causes the crystallization of brittle -Al5FeSi phases. Their unfavorable morphology and large size are the main reasons for the weakening of the diffusion connection between the inserts and the piston, causing an unacceptable proportion of defective products. The study presented in this work was conducted under industrial conditions on a population of 10.000 pistons. Quality control data, production parameters, as well as the micro- and macro-structures of the cast iron inserts, and the interface area between the inserts and the silumin piston, were analyzed. Material and technological solutions have been proposed to reduce the occurrence of casting defects at the insert-piston joint. This includes the introduction of so-called "morphological correctors" of the -Al5FeSi phases, reducing the possibility of gaseous impurities in the AS9 alloy and optimizing the temperature of the alfin alloy.

Authors and Affiliations

M. Szucki

1

e-mail:

ORCID:

J. Piątkowski

2

e-mail:

ORCID:

M. Czerepak

3

Foundry Institute, Technische Universität Bergakademie Freiberg, Bernhard-von-Cotta-Str. 4,09599 Freiberg, Germany
Department of Material Technologies, Silesian University of Technology, Krasińskiego 8, 40-019 Katowice, Poland
Federal-Mogul Gorzyce sp. z o.o., Odlewników 52, 39-432 Gorzyce, Poland

Design Sensitivity Studies on a Hydroacoustic Projector Using an Experimentally Validated Easy-to-Build Model

Vattaparambil Sreedharan Sreejith Nachiketa Tiwari

Archives of Acoustics | 2022 | vol. 47 | No 1 | 113-124 | DOI: 10.24425/aoa.2022.140737

Keywords low frequency sound source underwater transducer fluid power hydro-electro-mechano-acousticanalogy hydraulic valve piston cylinder

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Abstract

Hydroacoustic projectors are useful for generating low frequency sounds in water. Existing works on hydroacoustic projectors require two significant enhancements, especially for designers. First, we need to understand the influence of important projector design parameters on its performance. Such insights can be very useful in developing a compact and efficient projector. Second, there is a need for an integrated model of the projector based on easily available and user-friendly numerical tools which do not require development of complex customised mathematical analogs of projector components. The present work addresses both such needs. Towards these goals, an experimentally validated, easy-to-build projector model was developed and used to conduct design sensitivity studies. We show that reductions in pipe compliance and air content in oil, and an increase in orifice discharge coefficient can yield remarkable improvements in projector’s SPL. We also show that reductions in pipe length and cylinder diameter cause moderate improvements in performance in mass and stiffness controlled regions, respectively. In contrast, the projector performance is insensitive to changes in pistonic mass, cylinder length, and diaphragm stiffness. Finally, we report that while pipe compliance and air content in oil can sharply alter system resonance, the effects of changes in pipe length and pistonic mass on it are moderate in nature.

Authors and Affiliations

Vattaparambil Sreedharan Sreejith

1

Nachiketa Tiwari

1

Dhwani Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Uttar Pradesh 208016, India

Comparing of High-Cycle Fatigue Lifetimes in Un-corroded and Corroded Piston Aluminum Alloys in Diesel Engine Applications

M. Azadi H. Aroo M.. Azadi M.S.A. Parast

Archives of Foundry Engineering | 2021 | vo. 21 | No 1 | 89-94 | DOI: 10.24425/afe.2021.136083

Keywords Bending fatigue Corrosion-fatigue Piston aluminum alloys Immersion times Diesel engines

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Abstract

Diesel engine components in the combustion chamber have been exposed to cyclic loadings under environmental effects, including high temperatures and corrosive fluids. Therefore, knowing the corrosion-fatigue behavior of materials is essential for designer engineers. In this article, pure fatigue and corrosion-fatigue behaviors of the piston aluminum alloy have been experimentally investigated. For such an objective, as-cast and pre-corrosive standard samples were tested by the rotary bending fatigue machine, under 4 stress levels. Some specimens were exposed to the corrosive fluid with 0.00235 % of the sulfuric acid for 100 and 200 hours. The results showed higher weight losses for 200 hours immersion times. As another result, it could be concluded that the lifetime decreased in pre-corrosive samples for both 100 and 200 hours of the immersion time, compared to that of as-cast specimens. However, such a lifetime reduction was more significant for 200 hours of the immersion time, especially within the high-cycle fatigue regime (or lower stress levels). Under high stress levels, both pre-corrosive sample types had almost similar behaviors. The field-emission scanning electron microscopy images of specimen fracture surfaces indicated that the brittle region of the fractured surface was larger for specimens after the 200 hours of corrosion-fatigue testing than the other specimen.

Bibliography

[1] Li, Z., Li, Ch., Liu, Y., Yu, L., Guo, Q. & Li, H. (2016). Effect of heat treatment on microstructure and mechanical property of Ale10%Mg2Si alloy. Journal of Alloys and Compounds. 663, 16-19. DOI: http://dx.doi.org/10.1016/ j.jallcom.2015.12.128.
[2] Wang, M., Pang, J.C., Li, S.X. & Zhang, Z.F. (2017). Low-cycle fatigue properties and life prediction of Al-Si piston alloy at elevated temperature. Materials Science and Engineering A. 704, 480-492. DOI: http://dx.doi.org/ 10.1016/j.msea.2017.08.014.
[3] Azadi, M. (2017). Cyclic thermo-mechanical stress, strain and continuum damage behaviors in light alloys during fatigue lifetime considering heat treatment effect. International Journal of Fatigue. 99, 303-314. DOI: http://dx.doi.org/10.1016/j.ijfatigue.2016.12.001.
[4] Guerin, M., Alexis, J., Andrieu, E., Blanc, C. & Odemer, G. (2015). Corrosion-fatigue lifetime of Aluminum-Copper-Lithium alloy 2050 in chloride solution. Materials and Design 87, 681-69. DOI: http://dx.doi.org/10.1016/j.matdes. 2015.08.003.
[5] Chen, Y., Zhou, J., Liu, Ch. & Wang, F. (2017). Effect of pre-deformation on the pre-corrosion multiaxial fatigue behaviors of 2024-T4 aluminum alloy. International Journal of Fatigue. 108, 35-46. DOI: https://doi.org/10.1016/ j.ijfatigue.2017.11.008.
[6] Chen, Y., Liu, Ch., Zhou, J. & Wang, X. (2017). Multiaxial fatigue behaviors of 2024-T4 aluminum alloy under different corrosion conditions. International Journal of Fatigue. 98, 269-278. DOI: http://dx.doi.org/10.1016/j.ijfatigue. 2017.02.004.
[7] Chen, Y., Liu, Ch., Zhou, J. & Wang, F. (2019). Effect of alternate corrosion factors on multiaxial low-cycle fatigue life of 2024-T4 aluminum alloy. Journal of Alloys and Compounds. 772, 1-14. DOI: https://doi.org/10.1016/ j.jallcom.2018.08.282.
[8] Rodriguez, R.I., Jordon, J.B., Allison, P.G., Rushing, T. & Garcia, L. (2019). Corrosion effects on fatigue behavior of dissimilar friction stir welding of high-strength aluminum alloys. Material Science and Engineering. 742, 255-268. DOI: https://doi.org/10.1016/j.msea.2018.11.020.
[9] Mishra, R.K. (2020). Study the effect of pre-corrosion on mechanical properties and fatigue life of aluminum alloy 8011. Materials Today: Proceedings. 25(4), 602-609. DOI: https://doi.org/10.1016/j.matpr.2019.07.375.
[10] Azadi, M., Bahmanabadi, H., Gruen, F. & Winter, G. (2020). Evaluation of tensile and low-cycle fatigue properties at elevated temperatures in piston aluminum-silicon alloys with and without nano-clay-particles and heat treatment. Materials Science and Engineering A. 788, 139497. DOI: https://doi.org/10.1016/j.msea.2020.139497.
[11] Metallic materials-rotating bar bending fatigue testing. (2010). Standard No. ISO-1143, ISO International Standard.
[12] Aroo, H., Parast, M.S.A., Azadi, M. & Azadi, M. (2020). Investigation of effects of nano-particles, heat treatment process and acid amount on corrosion rate in piston aluminum alloy using regression analysis. 11th International Conference on Internal Combustion Engines and Oil, Tehran, Iran (in Persian).
[13] Azadi, M., Zolfaghari, M., Rezanezhad, S. & Azadi, M. (2018). Effects of SiO2 nano-particles on tribological and mechanical properties of aluminum matrix composites by different dispersion methods. Applied Physics A. 124(5), 377. DOI: https://doi.org/10.1007/s12540-019-00498-7
[14] Azadi, M. & Aroo, H. (2020). Temperature effect on creep and fracture behaviors of nano-SiO2-composite and alsi12cu3ni2mgfe aluminum alloy. International Journal of Engineering. 33(8), 1579-1589. DOI: 10.5829/ije. 2020.33.08b.16.
[15] Azadi, M. & Aroo, H. (2019). Creep properties and failure mechanisms of aluminum alloy and aluminum matrix silicon oxide nano-composite under working conditions in engine pistons. Material Research Express. 6, 115020. DOI: https://doi.org/10.1088/2053-1591/ab455f.
[16] Zainon, F., Rafezi Ahmad, K. & Daud, R. (2015). Effect of heat treatment on microstructure, hardness and wear of aluminum alloy 332. Applied Mechanics and Materials. 786, 18-22. DOI: 10.4028/www.scientific.net/AMM.786.18.
[17] Han, L., Sui, Y., Wang, Q., Wang, K. & Jiang, Y. (2017). Effects of Nd on microstructure and mechanical properties of cast Al-Si-Cu-Ni-Mg piston alloys. Journal of Alloys and Compounds. 695, 1566-1572. DOI: https://doi.org/10.1016/ S1003-6326(20)65333-X.
[18] Humbertjean, A. & Beck, T. (2013). Effect of the casting process on microstructure and lifetime of the Al-piston-alloy AlSi12Cu4Ni3 under thermo-mechanical fatigue with superimposed high-cycle fatigue loading. International Journal of Fatigue. 53, 67-74. DOI: 10.1016/j.ijfatigue. 2011.09.017.
[19] Mollaei, M. Azadi, M. Tavakoli, H. (2018). A parametric study on mechanical properties of aluminum-silicon/SiO2 nano-composites by a solid-liquid phase processing. Applied Physics A, 124, 504. https://doi.org/10.1007/s00339-018-1929-2
[20] Arab, M., Azadi, M. & Mirzaee, O. (2020). Effects of manufacturing parameters on the corrosion behavior of Al–B4C nanocomposites, Materials Chemistry and Physics, 253, 123259. DOI: https://doi.org/10.1016/j.matchemphys.2020.123259.

Authors and Affiliations

M. Azadi

1

e-mail:

ORCID:

H. Aroo

1

M.. Azadi

1

M.S.A. Parast

1

Semnan University, Iran

1

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