Internal Combustion Engine Bearings Lubrication in Hydrodynamic Bearings

This Series provides the necessary elements to the development and validation of numerical prediction models for hydrodynamic bearings. This book with the specific case of internal combustion engine (ICE) journal bearing lubrication. Many examples, relating to various types of ICE, are presented.

Aurelian FATU, Associate Professor, Prime Institute, University of Poitiers, France.

Dominique SOUCHET, Associate Professor, Prime Institute, University of Poitiers, France.

PREFACE ix

NOMENCLATURE xi

CHAPTER 1. KINEMATICS AND DYNAMICS OF CRANK SHAFT–CONNECTING ROD–PISTON LINKAGE 1

1.1. Kinematic model of crank shaft–connecting rod–piston linkage 2

1.1.1. Model description 2

1.1.2. Expressions of angular velocities 5

1.1.3. Expressions of velocity for points A, G2 and B 5

1.1.4. Expressions of connecting rod angular acceleration and points G2 and B accelerations 7

1.2. Efforts in the links between the crank shaft, the connecting rod and the piston 8

1.2.1. Hypothesis and data 8

1.2.2. Dynamics equations for the piston 9

1.2.3. Dynamics equations for the axis 9

1.2.4. Dynamics equations for the connecting rod 10

1.2.5. Dynamics equations for the crank shaft 11

1.2.6. Efforts for frictionless links 12

1.3. Load diagram correction in the case of large deformations 13

1.3.1. Kinematics of crank shaft–connecting rod–piston system with mobility 14

1.3.2. Dynamics of crank shaft–connecting rod–piston system with mobility 20

1.4. Examples of link efforts between the elements of crank shaft–connecting rod–piston system 23

1.4.1. Data 23

1.4.2. Load diagrams for the connecting rod big end bearing 24

1.4.3. Load diagrams for a connecting rod small end bearing 26

1.4.4. Load diagrams for a crank shaft main bearing 27

1.4.5. Engine torque 28

1.5. Bibliography 29

CHAPTER 2. THE CRANK SHAFT–CONNECTING ROD LINK 31

2.1. Geometrical and mechanical characteristics of the connecting rod big end bearing 31

2.2. Lubricant supply 33

2.3. Correction of the load diagram in the case of large deformations 34

2.4. Multibody models 38

2.4.1. Interfaces and interactions: main assumptions 39

2.4.2. Equations of unilateral contact with friction and equilibrium equations 41

2.4.3. Compliance matrices 42

2.4.4. Finite element modeling of the contact in the joint plane 46

2.4.5. Modelization of the contact between the housing and the shells 65

2.5. Case of V engines 72

2.6. Examples of connecting rod big end bearing computations 79

2.6.1. Presentation of connecting rods and corresponding load diagrams 80

2.6.2. Geometry and lubricant data 84

2.6.3. Analysis of some isothermal results 85

2.6.4. Influence of mesh downsizing 96

2.6.5. Search of potential damage zones due to cavitation 98

2.6.6. Examples taking into consideration thermoelastohydrodynamic effects 100

2.7. Bibliography 118

CHAPTER 3. THE CONNECTING ROD–PISTON LINK 123

3.1. Geometrical particularities and mechanics of connecting rod–piston link 123

3.2. Lubricant supply 125

3.3. Example of computation for a connecting rod small end bearing with the axis embedded into the piston 127

3.4. Complete model of the connecting rod–piston link 133

3.4.1. Equations 134

3.4.2. Integration of dynamics equation 137

3.4.3. Piston structural model 139

3.4.4. Example: the piston–axis–connecting rod small end link for a Formula 1 engine 142

3.5. Bibliography 158

CHAPTER 4. THE ENGINE BLOCK–CRANK SHAFT LINK 161

4.1. Geometrical and mechanical particularities of the engine block – crank shaft link 161

4.2. Lubricant supply 162

4.3. Calculus of an isolated crank shaft bearing 163

4.4. Complete model of the engine block – crank shaft link 170

4.4.1. Model presentation 171

4.4.2. Expression of the elastic deformations 173

4.4.3. Expression of the film thickness 175

4.4.4. Equation system 175

4.4.5. Resolution method 178

4.4.6. Examples 180

4.5. Bibliography 196

CHAPTER 5. INFLUENCE OF INPUT PARAMETERS AND OPTIMIZATION 197

5.1. Design of experiments method 197

5.2. Identification of the input parameters: example 201

5.3. Multiobjective optimization 202

5.4. Optimization of a connecting rod big end bearing: example 204

5.4.1. Viscosity factors 208

5.4.2. Radial clearance factor 209

5.4.3. Radial shape defect 209

5.4.4. Axial shape defect 210

5.4.5. Shell bore relief factors 210

5.4.6. Supply pressure and temperature 210

5.4.7. Power loss 211

5.4.8. Contact pressure velocity factor 211

5.4.9. Severity criterion based on the minimum film thickness 212

5.4.10. Leakage 213

5.4.11. Global functioning temperature 214

5.4.12. Bearing optimization method 214

5.5. Bibliography 221

INDEX  223

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