Research on Measurements for Temperature and Stress of Pistons in Internal Combustion Engine

In both numerical simulation and experimental research for the piston of internal combustion engine, the verification foundations are always insufficient. The reason is the measurements for its transient temperature and stress under actual operation conditions are very difficult. A multi-channel measurement-storage technology is used in the engine bench experiment to measure the piston temperature and stress in real time. The temperature and stress changes in the engine operation process are obtained. They provide reliable instructive criteria for numerical analysis and experiment of the piston working state.

Application of Space-time Conservation Element and Solution Element Method in Intake and Exhaust Flows of High Power Density Diesel Engine

A one-dimensional pipe flow model of single-cylinder diesel engine is established to investigate the intake and exhaust flow characteristics of diesel engine in the condition of high power density(HPD).A space-lime conservation element and solution element(CE/SE)method is used to derive the discrete equations of the partial differential equation for the intake and exhaust systems.The performance parameters of diesel engine with speed of 2100 r/min are simulated.The simulated results are in accordance with the experimental data.The effect of increased power density on charging coefficient is analyzed using a validated model.The results show that the charging coefficient is slowly improved with the increase in intake pressure,and is obviously reduced with the increase in engine speed.

Optimizing the Exhaust System of Marine Diesel Engines to Improve Low-speed Performances and Cylinder Working Conditions

Proper design of exhaust systems in marine high-power turbocharged diesel engines can contribute to improve the low-speed performance of these engines and make the working conditions of the cylinders more uniform.Here a high-power marine 16-cylinder V-type turbocharged diesel engine is simulated using the GT-Power software.The results reveal the differences induced by different exhaust system structures,such as an 8-cylinder-inpipe exhaust system with single/double superchargers and a 4-cylinder-in-pipe exhaust system with a single supercharger.After a comparative analysis,the 8-cylinder type with double superchargers is determined to be the optimal solution,and the structure of the exhaust system is further optimized.The simulations show that the optimized maximum exhaust temperature difference among cylinders is reduced by 66%.Finally,the simulation results and the optimized performance of the designed exhaust system are verified through experiments.

Thermo-Mechanical Analysis of the Sealing Performance of a Diesel-Engine Cylinder Gasket

Taking the combustor composite structure of a high-strength diesel engine as the main research object,dedicated tests have been conducted to verify the accuracy of three distinct cylinder gasket pressure simulation models.Using the measured cylinder gasket compression rebound curve,a gasket unit has been designed and manufactured.For this unit,the influence of the bolt pretension,cylinder body and cylinder head material on gasket sealing pressure has been investigated systematically in conditions of thermo-mechanical coupling.The results show that the bolt pretension force is one of the most important factors affecting the cylinder gasket sealing pressure.The change of the body material has little effect on this pressure.The cylinder gasket seal pressure decreases progressively with the reduction of the elastic module of the cylinder head material.

A Strategy to Control the Turbocharger Energy of a Diesel Engine at Different Altitudes

Power deterioration is a major problem for diesel engines operating at high altitudes.This problem stems from the limited availability of turbocharger energy,which is not enough to increase the boost pressure to the required level.In this study,a control strategy is introduced in order to achieve engine power recovery at different altitudes.It is shown that as the altitude increases from 0 to 4500 m,the required boost pressure ratio increases from 2.4 to 4.3.The needed turbocharger energy should be increased accordingly by 240%,and the TCC(turbine characterization coefficient)should be adjusted within wide ranges.A 12%decrease in the TCC can lead to a rise of the intake air pressure,which can compensate the pressure decrease due to a 1000 m altitude increase.The fluctuation range of boost pressure was within 14.5 kPa for variations in altitude from 0 to 4500 m.

Research on the dynamic response of connecting rod bearing bush wear of reciprocating machine under variable working conditions

As a type of reciprocating machine, the reciprocating compressor has a compact structure and many excitation sources.Once the small end bearing of the connecting rod is worn, it is easy to cause the sintering of the bearing and the abnormal vibration of the body.Based on the characteristics of poor lubrication state and complex force of connecting rod small head bearing, a mixed lubrication model considering oil groove feed was established, and the dynamic simulation of the reciprocating compressor model with lubricated bearings was carried out;considering different speeds and gas load conditions, the law of the impact of the eigenvalues changing with working conditions was explored.The fault simulation experiment was carried out by selecting representative working conditions, which verified the correctness of the simulation method.The study found that two contact collisions between the pin and the bearing bush occurred in one cycle, the collision impact was more severe under the wear fault, and the existence of the gap made the dynamic response more sensitive to the change of working conditions.This research provides ideas for the location and feature extraction of fault symptom signal angular segments in the process of complex measured signal processing.

Research on mechanical wear life feature fusion prediction method based on temporal pattern attention mechanism

In order to solve the problem of low prediction accuracy when only vibration or oil signal is used to predict the remaining life of gear wear,a gear wear life feature fusion prediction method based on temporal pattern attention mechanism is proposed.Firstly,deep residual shrinkage network(DRSN)is used to extract the features of the original vibration time series signals with low signal-tonoise ratio,and the vibration features associated with gear wear evolution are obtained.Secondly,the extracted vibration features and the oil monitoring data that can intuitively reflect the wear process information are jointly input into the bi-directional long short-term memory neural network based on temporal pattern attention mechanism(TPA-BiLSTM),the complex nonlinear relationship between vibration features,oil features and gear wear process evolution is further explored to improve the prediction accuracy.The gear life cycle dynamic response and wear process signals are obtained based on the gear numerical simulation model,and the feasibility of the proposed method is verified.Finally,the proposed method is applied to the residual life prediction of gear on a test bench,and the comparison between different methods proved the validity of the proposed method.

Time-dependent Vibration Frequency Reliability Analysis of Blade Vibration of Compressor Wheel of Turbocharger for Vehicle Application

Blade vibration failure is one of the main failure modes of compressor wheel of turbocharger for vehicle application. The existing models for evaluating the reliability of blade vibration of compressor wheel are static, and can not reflect the relationship between the reliability of compressor wheel with blade vibration failure mode and the life parameter. For the blade vibration failure mode of compressor wheel of turbocharger, the reliability evaluation method is studied. Taking a compressor wheel of turbocharger for vehicle application as an example, the blade vibration characteristics and how they change with the operating parameters of turbocharger are analyzed. The failure criterion for blade vibration mode of compressor wheel is built with the Campbell diagram, and taking the effect of the dispersity of blade natural vibration frequency and randomness of turbocharger operating speed into account, time-dependent reliability models of compressor wheel with blade vibration failure mode are derived, which embody the parameters of blade natural vibration frequency, turbocharger operating speed, the blade number of compressor wheel, life index and minimum number of resonance, etc. Finally, the rule governing the reliability and failure rate of compressor wheel and the method for determining the reliable life of compressor with blade vibration is presented. A method is proposed to evaluate the reliability of compressor wheel with blade vibration failure mode time-dependently.

Method for Evaluating the Reliability of Compressor Impeller of Turbocharger for Vehicle Application in Plateau Area

As turbocharging diesel engines for vehicle application are applied in plateau area, the environmental adaptability of engines has drawn more attention. For the environmental adaptability problem of turbocharging diesel engines for vehicle application, the present studies almost focus on the optimization of performance match between turbocharger and engine, and the reliability problem of turbocharger is almost ignored. The reliability problem of compressor impeller of turhocharger for vehicle application when diesel engines operate in plateau area is studied. Firstly, the rule that the rotational speed of turbocharger changes with the altitude height is presented, and the potential failure modes of compressor impeller are analyzed. Then, the failure behavior models of compressor impeller are built, and the reliability models of compressor impeller operating in plateau area are developed. Finally, the rule that the reliability of compressor impeller changes with the altitude height is studied, the measurements for improving the reliability of the compressor impellers of turbocharger operating in plateau area are given. The results indicate that when the operating speed of diesel engine is certain, the rotational speed of turbocharger increases with the increase of altitude height, and the failure risk of compressor impeller with the failure modes of hub fatigue and blade resonance increases. The reliability of compressor impeller decreases with the increase of altitude height, and it also decreases as the increase of number of the mission profile cycle of engine. The method proposed can not only be used to evaluating the reliability of compressor impeller when diesel engines operate in plateau area but also be applied to direct the structural optimization of compressor impeller.

Surface evolution of Al-Si-Cu alloy in thermal shock under different heating speeds

In order to understand the initial surface damage of Al piston in unsteady thermal environment like knock combustion,T6 heat treated cast Al-Si-Cu alloy was thermal shocked under different heating speeds between room temperature and 450°C by adjusting the environmental temperature.The surface evolution was mainly characterized in view of roughness,hardness,morphology,texture,phase and element distribution.Results indicated that both the roughness and hardness went up to the maximum and then decreased with rising heating speed.Micro-structure and phase analysis suggested that the interactions of solid phase transition and oxidation with enhancing thermal stress took responsible for the surface evolution.

Experimental and numerical analysis of an air cleaner's acoustic performance

To improve acoustic performance of an air cleaner system,both experimental and theoretical studies were carried out.The air cleaner＇s acoustic numerical model was built by finite element methods（FEM）.Acoustic parameters of filter paper imported in the FEM model were calculated according to experiential formulas.Based on the models,the cleaner＇s acoustic character of transmission loss（TL） was computed.To verify the numerical results,TL results of the real air cleaner with or without filter paper were tested by four-microphone transferring function method.The experimental results show that the filter paper influence acoustic performance of the air cleaner significantly,especially in mid and high frequency band,and should be considered in numerical simulation.Comparisons between experimental and numerical results show that the numerical model is accurate enough to be used in multi-scheme acoustic optimization.Based on our study,TL results of two schemes were calculated and analyzed,which is useful to the air cleaner＇s final design decision.

Numerical study on the separation and superposition of the influences from up-and downstream rotors

A three-dimensional Navier-Stokes solver is used to investigate the separation and superposition of the influences from upstream and downstream rotors in an axial-radial combined compressor for unsteady design applications. The data from rotor/stator and stator/rotor configurations show that the unsteady flow response in axial stator passage is caused only by one rotor. The results from the rotor/stator/rotor configuration revealed the superimposed characteristic of influences from upstream and downstream the rotor. The impact of the superimposed characteristic was studied by analyzing the virtual relative flow angle at the stator exit. The results show that the axial velocity in the passage of axial stator can be influenced by wake from upstream axial rotor and potential field of downstream radial rotor. While they are coupled to have an effect on the unsteady flow in axial statot passage, the excitation or suppression phenomena appear and lead to different levels of deterministic fluctuation kinetic energy. Their locations are determined by the frequencies of the involved influences. In addition, the variability of superimposed characteristic （ excitation and suppression） at the stator exit modulates the inlet flow angle for downstream rotor.

Evolution of surface roughness of a cast Al-Si-Cu piston alloy during thermal exposure

In the present work,samples of Al-Si-Cu piston alloy after T6 heat treatment were exposed for 2 h at temperatures ranging from 400 to 550°C.The evolution of surface roughness and microstructure of the alloy during thermal exposure was studied by combination methods of roughness profiles,optical and scanning electron microscopy as well as XRD analysis.It is found that the roughness and mass of the alloy increase with the raise of the thermal exposure temperature,and the increasing rates of them are slow as the exposure temperature is below 500°C,but accelerates abruptly when the temperature is higher than 500°C.The variation of surface roughness of the alloy is closely related to phase transformation and oxidation during the thermal exposure.

Fatigue Reliability of Blade Root of Turbocharger Turbine for Vehicle Application

The blade root fatigue is one of important failure modes of turbocharger turbine for vehicle application,and the reliability and life of turbine with blade root fatigue failure mode are studied.Firstly,the stress characteristics of turbine are analyzed,and based on the operating profile of turbocharger corresponding to the endurance test of engine,the stress spectrum of turbine with blade root fatigue failure mode is studied with the simulation method.Then,with the number of endurance test profile cycle as the life parameter,the reliability model and failure rate model of turbine with blade root fatigue failure mode are derived respectively. Finally,the rules that the reliability and failure rate of turbine with the blade root fatigue failure mode changes as life parameters are studied,and the life probabilistic characteristics of turbine are also studied.

Reliability Analysis of Repairable System with Multiple Closed-Loop Feedbacks Based on GO Method

In order to solve the problem of reliability modeling and the analysis of complex systems with multiple closed-loop feedbacks,a new reliability analysis method for repairable systems with multiple closed-loop feedbacks is proposed based on the goal-oriented(GO)methodology.Firstly,the basic theories and advantages of GO method are introduced.Secondly,a type-24B multiple closed-loop feedback structure operator is proposed through GO method with its operation formula given,which expands the types of GO method operators and the application scope of their reliability analysis.Finally,taking a certain type of diesel engine fuel supply system an example,the quantitative and qualitative analysis is carried out through GO method,Monte Carlo simulation as well as FTA respectively.The availability results verify the availability of the proposed type-24B operator in the reliability analysis of multiple closed-loop feedback systems.The qualitative analysis results indicate the accuracy and usability of the GO method as a qualitative analysis method.

Measuring Fuel Stratification in Cylinder of a Spark Ignition Engine by a Two-Tracer PLIF System

A two-tracer PLIF system was developed to measure fuel stratification in cylinder of a spark ignition engine which is achieved by producing a strong tumbling flow and introducing two fuels through two separate intake ports.Two tracers,3-pentanone and N,N-dimethylaniline(DMA),were doped in two fuels,hexane and iso-octane,respectively.A spectroscopic test result showed that when subject to irradiation by a XeCl Excimer laser(308 nm),3-pentanone and DMA emit fluorescence within different wavelength regions.Their fluorescence can be separated by two band-pass optical filters and recorded into a single intensified CCD camera through a specially designed image doubling system.The advantage of the measurement method is that both fuel distributions in cylinder can be visualized by one shot.Measurement results showed that two fuels were well stratified in the cylinder.

PIV Measurements of Coolant Flow Field in a Diesel Engine Cylinder Head

This paper presents experimental measurements of coolant flow field in the water jacket of a diesel engine cylinder head. The test was conducted at three different flow rates using a 2-D PIV system. Appropriate tracing particles were selected and delivery device was designed and manufactured before the test. The flow parameters, such as velocity, vorticity and turbulence, were used to analyze the flow field. The effects of vortex which was located between the intake valve and the exhaust valve were discussed. The experimental results showed an asymmetric distribution of velocity in the water jacket. This led to an asymmetric thermal distribution, which would shorten the service life of the cylinder head. The structure optimization to the water jacket of cylinder head was proposed in this paper. The experimental system, especially the 2-D PIV system, is a great help to study the coolant flow structure and analyze cooling mechanism in the diesel engine cylinder head.

Reliability Analysis of Retracting Actuator with Multi-State Based on Goal Oriented Methodology

In order to conduct effective reliability analysis of retracting actuator with multi-state(success state,safety failure state and action failure state), we redefine type-3 operator in goal oriented(GO) method to describe three states of main charge of retracting actuator and improve type-15 operator in GO method to describe the logic relations of multi-state output. The quantitative and qualitative reliability analyses of retracting actuator are made based on GO method in this paper. The system state probability of retracting actuator is obtained through quantitative analysis, and its weakness is found through qualitative analysis. The analysis results show that GO method is effective to improve the reliability of retracting actuator, and this method is also feasible for reliability analysis of other complicated initiating explosive systems.

Chatter identification of thin-walled parts for intelligent manufacturing based on multi-signal processing

Machine chatter is still an unresolved and challenging issue in the milling process,and developing an online chatter identification and process monitoring system towards smart manufacturing is an urgent requirement.In this paper,two indicators of chatter detection are investigated.One is the real-time variance of milling force signals in the time domain,and the other one is the wavelet energy ratio of acceleration signals based on wavelet packet decomposition in the frequency domain.Then,a novel classification concept for vibration condition,called slight chatter,is proposed and integrated successfully into the designed multi-classification support vector machine(SVM)model.Finally,a mapping model between image and chatter indicators is established via a distance threshold on the image.The multi-SVM model is trained by the results of three signals as an input.Experiment data and detection accuracy of the SVM model are verified in actual machining.The identification accuracy of 96.66%has proved that the proposed solution is feasible and effective.The presented method can be used to select optimized milling parameters to improve machining process stability and strengthen manufacturing system monitoring.

Tribological performance and scuffing behaviors of several automobile piston rings mating with chrome-plated cylinder liner

The friction and wear properties,as well as the scuffing resistance,of different piston-ring coatings mating with a chrome-plated cylinder liner were investigated.Interrupted wear tests under the lubricant starvation condition were conducted to examine the wear behavior of Cr-diamond coating(GDC)and diamond-like coating(DLC).The results indicated that the DLC coating had outstanding tribological properties(small coefficient of friction and wear loss)at 150°C,while the GDC coating exhibited better performance at an elevated temperature(240°C).The DLC coating had a better scuffing resistance;no material adhesion occurred for 70 min under the unlubricated condition.The interrupted wear behaviors revealed that the scuffing process of the GDC coating involved the consumption of lubricant oil with relatively stable wear,a reduction in the friction force,and the occurrence of scuffing,in sequence.In contrast,although the friction force also increased after a short period of weak friction,no scuffing was observed.This is attributed to the formation of a mixed oxide and graphitic C tribolayer.