By MAHLE GmbH (eds.)
The ever-increasing calls for put on combustion engines are only as nice in terms of this centerpiece—the piston. reaching much less weight or friction, or perhaps higher put on resistance, calls for in-depth wisdom of the techniques occurring contained in the engine, compatible fabrics, and applicable layout and production methods for pistons, together with the required checking out measures. it truly is now not attainable for pros in automobile engineering to regulate with out particular services of this sort, whether or not they paintings within the box of layout, improvement, trying out, or upkeep. This technical ebook solutions those questions intimately and in a truly transparent and understandable manner. during this moment, revised version, each bankruptcy has been revised and multiplied. The bankruptcy on “Engine testing”, for instance, now contain large leads to the realm of friction energy loss size and lube oil intake measurement.
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Additional info for Pistons and engine testing
Example text
The temperatures in the top ring groove and the cooling gallery are also significant in terms of oil carbonization. 4 Temperature field and heat flow due to temperature loading 45 ■ pin bore (zenith) top ring groove (spray jet cooling, salt-core cooling gallery) top ring groove (cooled ring carrier) 200–250°C; 200–280°C; 180–230°C; ■ cooling gallery (zenith) 250–300°C. ■ ■ Numerical simulation of the temperature field allows detailed analysis of the heat flows in the piston. 1 for various areas of the piston.
6: Piston profile 34 2 Piston design guidelines For noise-sensitive gasoline engines, in particular, there should be no contact between the ring belt and the cylinder. All of these aspects require optimized machining forms of the outer surface for the various piston types. The final piston profile can only be verified through extensive simulation and engine testing. 6 shows a detail from a piston profile drawing. 4 Dimensional and form tolerances The piston diameter is typically determined absolutely at one of at least three measuring planes.
9: Stress amplitudes due to gas force load on a commercial vehicle piston with salt-core cooling gallery motions) arise under gas force loads at the contact surfaces in each expansion stroke. These are caused by the different deformations of the piston’s crown and skirt. This can lead to wear at the contact surfaces. The screw joint is particularly important for composite pistons in order to minimize the amplitudes from the gas force, particularly in the skirt’s countersunk holes. This is done by appropriately designing the bolted parts (tappet, optimized countersunk depth) and by placing the bores outside of the force flow of the gas force as much as possible (central screw joint, twin screw joint).
