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453-463, 1995
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0301-679X(95)00010-0
ographic features of
cylinder liners - an application
of three-dimensional
racterization techniques
W. P. bong*, E. J. Davis, D. L. Butler and K. J. Stout
BDC
(180)
L
Fig 2 LXagrammatic representation of piston motion (adapted from Ishizuki et al.‘)
-
Heav-y. polish: a mirror finish showing no traces of The techniques used in this paper are visualization,
the original honing pattern (Fig 3). area1 auto-correlation and spectral analysis, and func-
tional parametric analysis.
As the bore polish progresses through these classified
conditmls., a very smooth surface is produced which
leads to lubrication starvation. There is insufficient Characterization with surface bearing area and
boundary Iubrication to prevent solid contact and the topographic volumes
surfaces will run together in intimate contact. Local
contact occurs which leads to welding and material As far as the functional characterization technique is
transfer between the surfaces. This results in scuffing concerned, some functional indices which are based
of the s&aces and complete failure. A heavy bore on characterizing real surface bearing area and
polish area is clearly seen in Fig 3. The honing texture material/void volume are presented here. An illus-
has been completely removed in the indicated bore tration of the surface bearing area is shown in Fig
polish area. 4(a), which indicates that the top part of the surface
has been truncated. It is clear that the real surface
An engine which has developed bore polish will find bearing area ratio, &,(7j) is a function of surface
lubrication oils and exhaust gases passing the piston height q. In order to exclude the scale effect of
ring and entering the combustion chamber. Where unstable extremes (the highest peak and the deepest
this occurs emission problems will transpire, i.e. a valley) on calculating the surface bearing area ratio,
reduction in power output and increased oil consump- it is suggestedI that the surface bearing area ratio be
tion. The lubrication difficulties which arise lead to plotted using the normalized surface height h = r$S,,
increased scuffing and eventual failure of the engine where S, is the root-mean-square (RMS) deviation of
by pistor seizure. the surface. An example of the surface bearing area
ratio is shown in Fig 4(b), where the position of the
mean plane is denoted by 0. At the maximum
3-D characterization techniques
normalized height h,,,, the surface bearing area ratio
In recent years, many 3-D techniques have been is 0, whilst at the minimum normalized height h,i,,
developed to characterize 3-D surface topography17. the surface bearing area ratio is 100%. The cell
Triboiogy international Volume 28 Number 7 November 1995 455
Topographic features of cylinder liners: W. P. Dong et a/.
Bearing area z
2 0
.04
2
8
.z
74
E
8
25 hmio
0 20 40 60 80 100
Bearing area ratio (%)
(a) Surface bearing area (b) An example of the surface
of a truncated surface bearing ratio
Fig 4 Surface bearing area and surface bearing area ratio
Fig 6 Measurement positions and parameters of the cylinder liner: (a) RMS deviation S,; (b) functional indices
Sbi, Sci: svi and St,
10000
I
10000 ,
-a1
8000-- 1
om ,&-J-Jo--....~ ~.~.~.~~~ ~.
0 UL I
In order to characterize cylinder liners comprehen- Position A (Figure 7). Since position A is not
sively, rhe cylinder liner shown in Fig 3 is measured contacted by the piston, the surface topography
at 13 different positions with 128 x 128 data points at this position keeps its original character. The
and the sampling interval Ax = Ay = 10 km. Position parameters retain and represent the character-
A is located at the bottom of the cylinder liner, while istics of the newly manufactured cylinder liner.
position M is located at the top of the cylinder liner. Significant honing marks are visible and are
The RMS deviations and functional indices of mapped clearly reflected by the AACF and APSD. The
surfaces alt the position A to M are given in Fig 6. By most significant texture direction S,, is 22” and
comparing Fig 3 and Fig 6 we are able to make the angle between the honing marks is 4.5”.
following observations. Position C (Figure 8). This position corresponds
(1) The IRMS deviation changes at different positions, to the piston ring position at bottom dead centre
but the trend of the change is insignificant. (BDC). Therefore the surface at this position
Moreover it is difficult to connect this change experienced more wear than its neighbouring
wi.:h any functional meaning. areas, e.g. position E. The surface bearing index
(2) Ccnsistent changes of some functional indices, Sbi increased and the core fluid retention index
e.&. S,i and Sci, along the cylinder length are Sci decreased significantly as compared with those
observable. They do indicate changes of topo- of its neighbouring areas. Moreover surface
graphic features and hence the functional proper- texture is still seen clearly at this position. The
ties. Figures 7-12 show the originally mapped texture aspect ratio St, indicates that the texture
surfaces of the cylinder liner at positions A, C, is still significant.
E, G., I and L and their AACF and APSD. It Position E (Figure 9). Surface topography in this
is clear that at different positions the topographic position experienced a little wear, apparently just
fea tures are different. The corresponding differ- after running-in. Therefore the values of the
ences are reflected by the surface bearing index parameters (Sbi = 1, S,i = 0.7 and S,, < 0.5) in
Sbi; core fluid retention index S,i and texture this stage indicate good functional properties of
aspect ratio S,,. The characteristics of the surface the surface.
topography of the cylinder liner at the six
representative position are addressed as follows. Position G (Figure 10). As is seen in Fig 10, the
Tribology international Volume 28 Number 7 November 1995 459
Topographic features of cylinder liners: W. P. Dong et al.
10000 (
I
surface topography in this position has worn top of the cylinder liner, surface wear is reduced,
significantly. The surface bearing index Sbi and hence surface texture is retained. The diagrams
fluid retention index Sci also show significant in Fig 12 shows a visible texture in one direction.
change. However the small value of the texture This may be due to the piston dynamics described
aspect ratio S,, implies that the texture still exists. earlier or imperfection in the original honing
No significant changes of the AACF and the process. At this stage the parameters discussed
APSD are observed at this position. Thus the above fall within the range of unworn and/or
values of the parameters in this stage can reveal after running-in stage. At TDC of the cylinder
the transition from normal wear to bore polish. liner (position M), the increases of the surface
bearing index S,i and the texture aspect ratio S,,
Position I (Figure 11). The dramatic increase of
and the decrease in core fluid retention index Sci
the texture aspect ratio S,, (from smaller than
suggest severe surface wear close to TDC.
0.3 to larger than 0.5) indicates that the texturing
The fluid retention index Svi is qrite stable along
property changes significantly. It illustrates a
the cylinder length. The minor change of the
surface topography change from texturing to
index at different positions may be accounted for
isotropy. In fact, the honing marks have been
by inherent and statistical parameter variationZ3zZ
completely removed, which indicates that bore
and different positions of the reference planes
polish occurs. The AACF and APSD of the
for characterizing the mapped surfaces. This
surface also exhibit the properties of an isotropic
surface. In addition the surface bearing area ratio means that no matter what the wear situation
(slightly worn or severely worn) of the surface,
is increased significantly (Sbi = 2), while the core
the valley part of the topography is less affected
fluid retention index is reduced (Sci = 0.25).
by cylinder wear. This phenomenon can also be
Functionally the values of the parameters in this
observed from Figs 7(a)-12(a). It is clear that
stage indicate the appearance of bore polish and
although honing marks at position I (Fig 11(a))
an unsatisfactory tribological situation because
are completely worn away, significant pockets
of the change of texture character. In view of
Figs 3 and 6(b) bore polish occurs at the positions exist. Some may be originally machined into the
surface whilst others may be caused by graphite
II-K and M.
flake delaminating from the surface as a result
Position L (Figure 12). In a small range of the of repeated stress reversals. These pockets still
460 Tribology International Volume 28 Number 7 November 1995
Topographic features of cylinder liners: W. P. Dong et al.
1,
0 30 60 90 120 150 180
Angular spectrum (degree)
n.aintain the fluid retention capability, but since benefit to use these parameters to predict the functional
the striations of the honing marks are worn away, status of surface topography and therefore to realize
the real lubrication capability is bound to be functional control in the manufacturing process.
reduced. Therefore in manufacturing process we
e:cpect the surface to have significant striation
features, hence good fluid retention capability
and a large fluid retention index in the valley Conclusions
zone. But whenever the lubrication property is
As discussed, the working mechanism of the engine
discussed the fluid retention in the valley zone
results in uneven wear of the cylinder liner along the
hits to be considered in conjunction with other
longitudinal axis. Therefore the characteristics of
factors, e.g. the fluid retention in the core zone
surface topography at different positions are quite
arid the texture aspect ratio of the surface.
different. In general, cylinder liner wear mainly
H:awever this can only be implemented by 3-D
corresponds to the wear of surface topography in the
c&aracterization techniques rather than 2-D.
peak and core zones. The valley zone is less affected.
(4) It is important to note although the positions of
Bore polish appears at the upper middle part of the
the reference planes will not be at the same
cyllinder liner. The lubrication property in this position
surface height for all the surfaces, this does
deteriorates significantly because of the absence of
net have a significant influence on the correct
honing marks. At positions corresponding to TDC
representation of surface features by the func-
tional indices. The functional indices are robust and BDC, surface wear is more severe than at the
lower middle area. These different topographic statuses
for tribological applications.
can be successfully characterized by 3-D characteriz-
All the changes in the parameters shown in Fig 6 ation techniques. The AACF and APSD exhibit
are highly coincident with the changes in surface changes of surface topography features. The para-
topography of the cylinder liner shown in Fig 3. Since meters presented in the paper give a quantitative
the parameters have definite functional meanings and representation of the changes. They present a compre-
their approximate distribution ranges for different hensive characterization of the cylinder Biner, which
kinds cf surface topography are knownr7, it is of cannot be shown by 2-D characterization techniques.
Tribology International Volume 28 Number 7 November 1995 461
Topographic features of cylinder liners: W. P. Dong et al.
The observations addressed above are not only appli- 3. Wilson J. and Callow J. Cylinder liner bore polishing in
automotive diesels - a progress report on a European study.
cable to the cylinder liner discussed in this paper, but SAE 1976, 760772
they are also applicable to all types of engine bores
4. San&hi M. and Vignale M. A study on the functional properties
which have the same working mechanism. Therefore of a honed surface. Ann. CIRP 1982, 31, 1, 431-434
the characterization techniques and the parameters
5. Willis E. Surface finish in relation to cylinder liners. Wear 1986,
discussed in this paper serve as a universal approach 109, 351-366
for the characterization of cylinder bores. Since indices 6. Eyre T. S., Dent N. and Dale P. Wear characteristics of piston
rather than absolute values (e.g. pm, ~m3/~m2) are rings and cylinder liners. ASLE 1983, 39, 216-221
used here, it would be appropriate to adopt these 7. Santochi M. and Tantussi G. Surface parametrical microgeometry
parameters to realize functional analysis and functional and functional models: a new approach. Precis. Eng. 1984, 6,
control of surface topography during manufacturing 201-206
processes. 8. Stout K. J. and Davis E. J. Surface topography of cylinder
bores - The relationship between manufacture, characterisation
and function. Wear 1984, 95, 111-125
Acknowledgements 9. Ishizuki Y., Sato and F. and Takase K. Effect of cylinder liner
wear on oil consumption in heavy duty diesel engines. Proc.
The authors would like to give their thanks to Dr L. Sot. Automotive Eng. 1982, 90, 2794-2803
Blunt and Mr E. Mainsah for their constructive 10. Ai-Khalidi C. F. and Eyre T. S. Bore polishing - identification
discussions in preparing the paper. and simulation. Tribal. Intern. 1987, 20, 18-24
11. Schneider U., Steckroth A., Rau N. and Hubner G. An approach
to the evaluation of surface profiles by separating them into
functionally different parts. Surf. Topogr. 1988, 1, 71-83
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