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Tribology and dynamics of engine and powertrain: Fundamentals, applications and future trendsEdited by H Rahnejat, Loughborough University, UK
This fascinating and comprehensive book on current developments in the fields of tribology and multi-body dynamics related to vehicle problems will be of interest to both the industrial and academic communities.
Duncan Dowson, Leeds University and Visiting Professor, Loughborough University, UK
The book covers many important practical engineering and technological issues that the industry faces in design and development today and into the future. The authors comprise experienced technologists, specialists and component engineers from industry with many years of experience in the fields of their expertise. They are joined by established academics and promising researchers to make this a rather unique and comprehensive volume.
Professor Richard Parry-Jones, former Vice President of Ford Global Development and Chairman of Premier Automotive Group
- reviews fundamental aspects of physics in motion, specifically the multi-body approach to multi physics
- describes essential issues in tribology from surface phenomena in thin film tribology to impact dynamics
- examines specific engine and powertrain sub-systems including engine bearings, piston systems and value trains
- considers emerging areas of microengines and gears
Tribology, the science of friction, wear and lubrication, is one of the cornerstones of engineering’s quest for efficiency and conservation of resources. Tribology and dynamics of engine and powertrain: fundamentals, applications and future trends provides an authoritative and comprehensive overview of the disciplines of dynamics and tribology using a multi-physics and multi-scale approach to improve automotive engine and powertrain technology.
Part one reviews the fundamental aspects of the physics of motion, particularly the multi-body approach to multi-physics, multi-scale problem solving in tribology. Fundamental issues in tribology are then described in detail,from surface phenomena in thin-film tribology, to impact dynamics, fluid film and elastohydrodynamic lubrication means of measurement and evaluation. These chapters provide an understanding of the theoretical foundation for Part II which includes many aspects of the physics of motion at a multitude of interaction scales from large displacement dynamics to noise and vibration tribology, all of which affect engines and powertrains. Many chapters are contributed by well-established practitioners disseminating their valuable knowledge and expertise on specific engine and powertrain sub-systems. These include overviews of engine and powertrain issues, engine bearings, piston systems, valve trains, transmission and many aspects of drivetrain systems. The final part of the book considers the emerging areas of microengines and gears as well as nano-scale surface engineering.
With its distinguished editor and international team of academic and industry contributors, Tribology and dynamics of engine and powertrain is a standard work for automotive engineers and all those researching NVH and tribological issues in engineering.
ISBN 1 84569 361 2
ISBN-13: 978 1 84569 361 9
September 2010
1056 pages 234 x 156mm hardback
£240.00 / US$410.00 / €290.00
Usually dispatched within 24 hours
About the editor
Homer Rahnejat is Professor of Dynamics at the Wolfson School of Mechanical and Manufacturing Engineering, Loughborough University, UK. Professor Rahnejat has an international reputation for his research in integrated multi-body dynamics and tribology across the physics of scale, particularly in to automotive engineering.
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Contents
PART 1 INTRODUCTION TO MULTI-PHYSICS AND TRIBOLOGY WITHIN THE MULTI-PHISICS ENVIRONMENT
PART 2 ENGINE AND POWERTRAIN TECHNOLOGIES AND APPLICATIONS
PART 3 MICRO-SYSTEMS AND NANO-CONJUNCTIONS
PART 1 INTRODUCTION TO MULTI-PHYSICS AND TRIBOLOGY WITHIN THE MULTI-PHISICS ENVIRONMENT
An introduction to the multi-physics mutli-scale approach
H Rahnejat, Loughborough University, UK
- Introduction
- Newtonian mechanics
- Lagrange’s equation and reduced configuration space
- Multi-body mechanical systems
- Engine as a multi-body system
- Elasto-multi-body dynamics analysis
- References and further reading
- Nomenclature
- Appendix: multi-physics analysis for investigation of manual transmission gear rattle: drive/creep rattle
Section 1.1 Fundamentals of tribology and dynamics
Mechanism and laws of friction and wear
D Arnell, University of Central Lancashire, UK
- Introduction
- The nature of engineering surfaces
- Surface topography and contact
- The contact of rough surfaces
- Friction
- Wear
- Future trends
- Sources of further information and advice
- References
Surface phenomena in thin-film tribology
P Prokopovich and H Rahnejat, Loughborough University and M Teodorescu, Cranfield University, UK
- Introduction
- A question of wetness
- Meniscus action: surface tension
- Contact angle of liquids
- Estimation of interfacial tension between a liquid and a solid
- Adhesion of rough surfaces
- Intermolecular interactions and near-surface effects
- van der Waals forces
- Other near-surface effects
- Conclusion
- References
- Nomenclature
Fundamentals of impact dynamics of semi-infinite and layered solids
M Teodorescu, Cranfield University, UK, V Votsios, Atos, Spain, P M Johns-Rahnejat, formerly Imperial College London and H Rahnejat, Loughborough University, UK
- Introduction
- Basic aspects of contact mechanics for elastic solids
- Hertzian theory
- Analytical treatment of contact mechanics of layered solids
- Impact dynamics
- Contact mechanics based on action of deformation potential
- References
- Nomenclature
Fluid film lubrication
R Gohar, Imperial College London and M M A Safa, Kingston University, UK
- Lubricant properties
- Reynolds equation
- The Energy equations
- The Navier-Stokes equations
- Free surface behaviour of lubricant films
- Externally pressurized (EP) gas journal bearings
- Approximate design of oil thrust bearings
- Thermal design of finite length bearings
- Review of some unusual and recent application of fluid film lubrication
- dynamics
- Contact mechanics based on action of deformation potential
- References
- Appendix: Design coefficients for plane thrust bearing pairs
Elastohydrodynamic lubrication
F Sadeghi, Purdue University, USA
- Introduction
- Conformal and non-conformal contacts
- Regimes of lubrication
- Elastohydrodynamic Lubrication (EHL) minimum film thickness equations
- Experimental film thickness and corroboration with analytical results
- Thermal effects in elastohydrodynamic lubrication (EHL) contacts
- Non-Newtonian fluid motion
- Boundary lubrication
- Mixed elastohydrodynamic lubrication (EHL)
- Surface roughness
- Contact and internal stress
- Application of elastohydrodynamic lubrication (EHL) theory to machine components
- References and further reading
- Nomenclature
Measurement of contact pressure under elastohydrodynamic lubrication conditions
R Gohar, Imperial College London and M M A Safa, Kingston University, UK
- Introduction
- Gauge manufacturing process
- Applications using pressure gauges
- Alternative methods of measuring contact pressure
- Conclusions
- Acknowledgements
- References
PART 2 ENGINE AND POWERTRAIN TECHNOLOGIES AND APPLICATIONS
Section 2.1 Overview
Tribological considerations in internal combustion internal combustion engines
D R Adams, Ford Dagenham Development Centre, UK
- Introduction
- Issues of cost, competition, and reliability in internal combustion (IC) engine tribology
- Drivers for tribological design and innovation
- A systems view of the piston/ring/cylinder bore interface
- The development process in the internal combustion (IC) engines
- The piston in IC engines
- Piston rings in internal combustion (IC) engines
- The cylinder bore surface
- Design validation of internal combustion (IC) engines
- Future trends
- References
Predictive methods for tribological performance in internal combustion (IC) engines
I McLuckie, AIES Ltd, UK
- Introduction
- Integrated knowledge based tribology systems
- Application of integrated knowledge base system (IKBS) and elastohydrodynamic (EHD) to a race engine crank pin
- Application of IKBS and right hand drive (RHD) to piston and liner
- Application of IKBA and RHD to turbocharger bearings
- Engine friction: building a better understanding
- Conclusions
- Acknowledgements
- References
Section 2.2 Tribology of piston systems
Fundamentals of lubrication and friction of piston ring contact
V D’Agostino and A Senatore, University of Salerno, Italy
- Introduction
- Piston ring: history and basics
- Piston rings classification
- Lubrication models
- A brief analysis of the main assumptions on the boundary conditions
- Simplified two-dimensional Reynolds equation for oil ring
- The contact between the asperities: mixed-lubrication regime
- The multi-physics approach to ring friction
- Ring flutter and collapse
- Bore distortion in lubrication models
- Laser-textured surfaces
- Warm-up effect
- Future trends
- References and further reading
- Notation
Measurement techniques for piston ring tribology
I Sherrington, University of Central Lancashire, UK
- Introduction
- Measurement of lubricating film thickness
- Measurement of piston-ring friction
- Measurement of piston-ring movement
- Measurement of piston-ring wear
- Measurement of ring zone temperature
- Observation and measurement of lubricant movement and consumption
- Future trends
- Sources of further information
- References
An ultrasonic approach for the measurement of oil films in the piston zone
R S Dwyer-Joyce, University of Sheffield, UK
- Introduction
- Ultrasonic measurement of oil film thickness
- Ultrasonic measurement equipment
- Case study: measurement from a piston skirt
- Case study: piston rings in a test bench
- Overview
- Conclusions
- Acknowledgements
- References and further reading
Surface texturing for in-cylinder friction reduction
I Etsion, Technion, Israel
- Introduction
- Ultrasonic measurement of oil film thickness
- Ultrasonic measurement equipment
- Case study: measurement from a piston skirt
- Case study: piston rings in a test bench
- Overview
- Conclusions
- Acknowledgements
- References and further reading
Optimised textured surfaces with application in piston-ring/cylinder liner contact
R Rahmani, Loughborough University, A Shirvani and H Shirvani, Anglia Ruskin University, UK
- Introduction
- Surface texturing
- Application of surface texturing in tribology
- Surface texturing materials
- The mechanisms behind tribological improvements through surface texturing
- Debates surrounding surface texturing
- Surface texturing technology and internal combustion (IC) engines
- The basics equations of tribology
- Modelling of the textured surfaces
- Solution methods
- Optimisation of textured surfaces
- Application of the optimum results in the piston-ring/cylinder liner contacts
- Conclusions
- References
- Nomenclature
Transient thermo-elastohydrohynamics of rough piston ring conjunction
P C Mishra, H Rahnejat and P King, Loughborough University, UK
- Introduction
- A brief review
- Compression ring cylinder liner conformability
- Tribology of ring-bore conjunction
- Results and discussion
- Future trends
- Acknowledgements
- References
- Nomenclature
Section 2.3 Valve train systems
Tribological issues in cam-tappet contacts
M Kushwahu, Ford Motor Company, UK
- Introduction
- The cam geometric profile
- Lubrication analysis of the cam and tappet conjunction
- The solution procedure
- Simulation conditions
- Results
- Conclusion
- References
A multi-scale approach to analysis of valve train systems
M Teodorescu, Cranfield University, UK
- Background
- Aspects of valve train geometry and construction
- Valve train as an integrated problem
- Valve train kinematics: cam-to-cat follower contact
- Valve train dynamics
- Valve lift and cam profile
- Cam-tappet tribology: lubricant reaction
- Tribology of rough surfaces
- Applications
- References
- Nomenclature
Section 2.4 Engine bearings
Fundamentals of hydrodynamic journal bearings: an analytical approach
S Balakrishnan, Mercedes Benz High Performance Engines, C McMinn, Ford Motor Company, C E Baker and H Rahnejat, Loughborough University, UK
- Introduction
- Bearing geometry
- Simple analytical solutions for journal bearings
- Simple bearing selection
- Determination of bearing loads
- Thin shell or soft overlay bearings
- Thermo-hydrodynamics
- Tribological conditions
- Concluding remarks
- Nomenclature
- References
Practical tribological issues in big-end bearings
S Boedo, Rochester Institute of Technology, USA
- Introduction
- Bearing duty for big-end bearings
- Geometry of big-end bearings
- Cyclic minimum film thickness
- Oil flow in big-end bearings
- Power loss in big-end bearings
- Sample application of design charts: four-stroke automotive engine
- Experimental results pertaining to big end bearings
- Future trends
- References
- Principle nomenclature
Tribology of big-end bearings
P Mishra and H Rahnejat, Loughborough University, UK
- Introduction
- Brief review of the literature
- Bearing geometry
- Lubricant rheology
- Bearing load
- Method of solution
- A case study
- Effect of surface roughness and pattern
- Tribological problems in big end bearing
- References
- Nomenclature
Section 2.5 Drivetrain systems
An introduction to noise and vibration issues in the automotive drivetrain and the role of tribology
M Menday, Loughborough University, UK
- Introduction to drive train noise, vibration, hardness (NVH)
- The application of multi body dynamics (MBD) analysis
- Noise, vibration, hardness (NVH) characteristics
- Summary of tribological contacts
- Airborne and structure borne noise
- Noise and vibration paths from the driveline into the body
- Signal analysis
- Examples of high energy impacts in the drive train
- Shuffle
- Whoop (clutch in-cycle vibration)
- Summary of drivetrain NVH issues
- Future trends
- References
Friction lining characteristics and the clutch take-up judder phenomenon with manual transmission
M Menday and H Rahnejat, Loughborough University, UK
- Introduction
- Background
- Description of clutch take-up ladder
- Judder and shuffle
- Multi-body dynamics analysis of judder
- Results and discussion of numerical findings of multi-body dynamics analysis of judder
- Vehicle and design of experiments for multi-body dynamics analysis of judder
- Overall conclusions of multi-body dynamics analysis of judder
- Considerations for judder elimination/resolution
- Future trends
- References
- Nomenclature
Contact mechanics of tyre–road interactions and its role in vehicle shuffle
G Mavros, Loughborough University, UK
- Introduction
- Shuffle as a drive-train error-state
- Basic model of vehicular driveline
- Results of driveline simulation
- Tyre modelling for shuffle analysis
- Steady-state tyre modelling
- A brush-type model for shuffle analysis
- Relationship between tyre modelling and the Magic Formula
- Transient tyre response: a first approach
- Further tyre modelling possibilities
- Case study: the influence of transient tyre behaviour on shuffle
- References
- Notation
Tribology of differentials and traction control devices
S K Mohan, Magna Powertrain, USA
- Introduction
- Vehicle drivetrain architecture
- The basics of vehicle propulsion and dynamics
- The need for differentials and slip control devices
- Types of slip control devices
- Advantages of electronically controllable ‘active’ slip control devices
- Tribological considerations in the design and development of slip control devices
- Modelling and simulation of traction control devices
- Future trends
- Sources of further information and advice
- Acknowledgements
- References
- Notation
Non-linear dynamics of gear meshing and vibro-impact phenomenon
S Natsavias and D Giagopoulos, Aristotle University, Greece
- Introduction
- Mechanical model and equations of motion of example gear pair
- Typical numerical results from mechanical model and equations of motion of example gear pair
- Future trends
- Conclusions
- References
- Nomenclature
Rattle and clatter noise in powertrains – automotive transmissions
S N Dogan, Daimler AG, USA
- Introduction
- Significant noises in automotive transmissions
- Investigation strategy for rattling and clattering noises in automotive transmissions
- Automotive transmission lubricants
- Peripheral instruments for measuring drag torque
- Automotive transmissions investigated
- Automotive transmission lubricants studied
- Automotive transmission measurement results
- Parameter studies for rattle and clatter noises in automotive transmissions
- Correlation of measurement and calculation results in automotive transmissions
- Noise reduction methods in automotive transmissions
- Engineering design catalogue for low rattle and clatter automotive transmissions
- Conclusions
- References
- Nomenclature
Various forms of transmission rattle in automotive powertrains
P Kelly, Ford Werke GmbH, Cologne, Germany and M Menday, Loughborough Univesity, UK
- Introduction: history of powertrain torsional vibration
- Noises in the powertrain
- Definition of rattle phenomenon in automotive powertrains
- System dynamics of automotive powertrains
- Types of rattle and their causes within automotive powertrains
- Traditional rattle palliations in automotive powertrains
- Experimentation and evaluation method of rattle sensitivity in automotive powertrains
- Simulation of rattle phenomenon in automotive powertrains
- Future trends
- References
Dual mass flywheel as a means of attenuating rattle
P Kelly, Ford Werke GmbH, B Pennec, R Seebacher, B Tlatlik and M Mueller, LuK GmbH & Co. oHG, Germany
- Basic dual mass flywheel (DMF)
- Dual mass flywheel (DMF) interactions at different operating points
- Dual mass flywheel (DMF) interactions with engine environment
- Future trends
- Consequences on damper development
- References
Multi-physics approach for analysis of transmission rattle
S Theodossiades, O Tangasawi and H Rahnejat, Loughborough University, UK
- Introduction
- Theoretical formulation for analysis of transmission rattle
- Experimental set-up for analysis of transmission rattle
- Parametric studies for analysis of transmission rattle: discussion
- Conclusions
- Acknowledgements
- References
- Nomenclature
High-energy impact-induced phenomena in driveline clonk
M Gnanakumarr, Loughborough University, UK
- Introduction
- Impact-induced noise and vibration
- Fundamentals of impact-induced noise
- Lashes in vehicular drivetrain
- An experimental rig for driveline clonk
- Results and discussion of driveline clonk experiment
- Some methods of palliation of driveline clonk
- Acknowledgements
- References
Tribo-elasto-multi-body dynamics of a single cylinder engine under fired condition
M S M Perera, S Theodossiades and H Rahnejat, Loughborough University, UK
- Introduction
- Engine model with flexible components
- Tribological conjunctions in the models
- Conjunctional friction in the engine model
- Temperature effects in lubricated conditions
- Parametric study – crankshaft offset
- Concluding remarks
- References
- Nomenclature
PART 3 MICRO-SYSTEMS AND NANO-CONJUNCTIONS
Microengines and gears
M Teodorescu, Cranfield University, H Rahnejat and S Theodossiades, Loughborough University, UK
- Introduction
- Impact dynamics in micro electrochemical systems (MEMS) gears
- Concluding remarks
- References
- Nomenclature
Small-scale surface engineering problems
F W DelRio, National Institute of Standards and Technology, C Carraro and R Moubadian, University of California at Berkeley, USA
- Introduction
- Interfacial forces between two flat plates
- Experimental methods
- Physical modification of surfaces
- Chemical modification of surfaces
- Future trends
- References