Tribologically Tailored Cylinder Liner with Machined Microstructures

在DFG研究小组中，研究了热机械高应力表面的微结构化，研究了有关降低摩擦的微结构的尺寸，制造和摩擦学特性的基础知识。使用单缸研究发动机的实验测试特别显示了通过切割工艺制造的微结构的高潜力。配备有这些微结构的气缸套表现出较低的摩擦损失和排放量，只要进行微结构化的摩擦学要求的不同的衬里表面区域（定制的气缸套）的润滑剂。由于发动机高达60%的全部摩擦损失与活塞组件组有关，因此微结构衬套将导致燃料消耗的大幅减少，从而减少CO2和未燃碳氢化合物排放。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。在降低摩擦损失的同时，定制气缸套还能促进气缸套表面油膜的形成，从而降低磨损和油耗。气缸套表面的一个主要特征是摩擦应力的多样性取决于活塞在工作循环中的位置。因此，重要的是，通过改变其几何特性和图案沿着衬垫表面来实现微结构，以便以最佳可能的方式满足摩擦学要求。该项目的目标是开发定制气缸套，以减少内燃机的摩擦、磨损和油耗。通过在实际发动机条件下研究这些衬套，可以实现将该技术转移到工业应用中。 该项目的联合体由3个大学研究所和一个工业合作伙伴组成。发动机实验测试将在Institut für Technische Verbrennung（ITV，汉诺威）进行，摩擦学特性和布局将由Institut für Maschinenelemente und Konstruktionstechnik（IMK，Kassel）确定，定制切削制造工艺将由Institut für Fertigungstechnik und Werkzeugmaschinen（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.