Tribologically Tailored Cylinder Liner with Machined Microstructures

在DFG研究组内，研究了热机械高应力表面的微结构，包括尺寸、制造和减摩微结构的摩擦学特性的基本知识。使用单缸研究发动机进行的实验测试特别表明，通过切割工艺制造微结构的潜力很大。配备这些微结构的气缸套表现出较低的摩擦损失和润滑剂引起的排放，只要根据不同衬套表面区域(定制气缸套)的摩擦学要求进行微结构即可。由于发动机高达60%的完全摩擦损失与活塞总成有关，微结构衬垫将导致燃料消耗的大幅减少，从而减少二氧化碳和未燃烧的碳氢化合物排放。随着这项技术在内燃机领域的出现，可以为保护世界气候做出重要贡献。除了减少摩擦损失外，量身定制的气缸套还可以促进气缸套表面油膜的形成，从而降低磨损，降低油耗。气缸套表面的一个主要特征是在工作循环中，取决于活塞位置的摩擦学应力是不同的。因此，为了以最好的方式满足摩擦学的要求，必须通过改变衬套表面的几何性质和图案来实现微观结构。该项目的目标是开发为减少内燃机摩擦、磨损和油耗而量身定做的气缸套。通过在实际发动机条件下对这些衬板进行研究，可以实现这项技术的工业应用。该项目的联合体由3所大学研究所和1个产业合作伙伴组成。试验性发动机测试将在Verbrennung技术研究所(ITV，汉诺威)进行，摩擦学性能和布局将由Institut für Maschinenelemente and Konstruktionstechnik(IMK，Kassel)确定，定制的切割制造过程将由Fertigangstechnik and Werkzeugmaschinen研究所(IFW，汉诺威)实现。作为最重要的重型发动机制造商之一，MTU Friedrichshafen(劳斯莱斯动力系统股份公司)将成为工业合作伙伴。

Within the DFG Research Group Microstructuring of Thermo-Mechanically Highly Stressed Surfaces fundamental knowledge concerning the dimensioning, manufacturing and the tribological properties of friction-lowering microstructures was investigated. Experimental tests using a single cylinder research engine showed in particular a high potential of microstructures manufactured by means of a cutting process. Cylinder liners that were equipped with those microstructures showed lower frictional losses and emissions resulting from the lubricant as long as the microstructuring was carried out regarding the tribological demands of the different liner surface areas (tailored cylinder liners). Due to the fact that up to 60% of the complete frictional losses of an engine are related to the piston assembly group, microstructured liners will lead to a substantial reduction of the fuel consumption and therefore of CO2 und unburned hydrocarbon emissions. By the advent of this technology in the field of combustion engines, an important contribution to securing the world climate could be made. Beside the reduction of frictional losses, tailored cylinder liners could enhance the oil film formation on the liner surface and lead consequently to lower wear and tear and lower oil consumptions. A main characteristic of cylinder liner surfaces is the diversity of the tribological stress depending on the piston position in the work cycle. Therefore, it is essential that the microstructures are carried out by varying their geometrical properties and patterns along the liner surface in order to meet the tribological demands in the best possible way. The objective of this project is the development of tailored cylinder liners for the reduction of friction, wear and oil consumption of internal combustion engines. By investigating these liners under realistic engine conditions, the transfer of this technology into the industrial application can be achieved. The consortium of this project consists of 3 university institutes and an industrial partner. The experimental engine tests will be carried out at the Institut für Technische Verbrennung (ITV, Hannover), the tribological properties and layout will be determined aby the Institut für Maschinenelemente und Konstruktionstechnik (IMK, Kassel) and the customized cutting manufacturing process will be realized by the Institut für Fertigungstechnik und Werkzeugmaschinen (IFW, Hannover). As one of the most important manufacturer of heavy-duty engines, the MTU Friedrichshafen (Rolls-Royce Power Systems AG) will be the industrial partner.