Tribologically Tailored Cylinder Liner with Machined Microstructures

在DFG研究小组热机械高应力表面微结构的基本知识有关的尺寸，制造和减少摩擦的微结构的摩擦学性能进行了调查。使用单缸研究发动机的实验测试特别表明，通过切削工艺制造的微结构具有很高的潜力。只要根据不同衬套表面积的摩擦学要求（量身定制的气缸衬套）进行微结构处理，配备这些微结构的气缸衬套显示出更低的摩擦损失和由润滑油引起的排放。由于发动机高达60%的摩擦损失与活塞总成组有关，因此微结构衬套将大大减少燃料消耗，从而减少二氧化碳和未燃烧的碳氢化合物排放。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，定制的气缸套还可以增强气缸套表面的油膜形成，从而降低磨损和油耗。缸套表面的一个主要特征是摩擦应力的多样性，这取决于活塞在工作循环中的位置。因此，为了以最好的方式满足摩擦学要求，必须通过改变衬垫表面的几何特性和图案来实现微观结构。该项目的目标是开发量身定制的气缸套，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对这些衬管进行研究，可以实现将该技术转化为工业应用。该项目的联合体由3所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德国<s:1>机械制造技术研究所（ITV，汉诺威）进行，摩擦学性能和布局将由德国<s:2>机械制造与工程技术研究所（IMK，卡塞尔）确定，定制切削制造工艺将由德国<s:2>机械制造与工程技术研究所（IFW，汉诺威）实现。作为最重要的重型发动机制造商之一，MTU Friedrichshafen （Rolls-Royce Power Systems AG）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.