Evaluation of surface texturing on chrome-coated cylinder liners via deterministic mixed lubrication simulation

Abstract

Abstract This study investigates the mixed lubrication performance of various surface texture configurations in the piston ring/cylinder liner conjunction of a two-stroke internal combustion engine using a deterministic mixed lubrication model. The numerical model simultaneously solves the Reynolds equation with mass-conserving cavitation to calculate inter-asperity hydrodynamic pressures and an elastic, perfectly plastic, rough contact model to determine contact pressures at each asperity interaction. Gaussian Mixture Model clustering was employed to enhance surface characterization. The deterministic simulation approach considers the full-scale representation of the cylinder liner topography to accurately capture the influence of surface features on the hydrodynamic support and friction under mixed lubrication conditions. The investigated cylinder liners were initially hard-chrome-coated and honed, resulting in a stochastic arrangement of surface pores, and then deterministic patterns of surface pockets were created by micro electrodischarge machining (EDM). Surface measurements were performed using laser interferometry, providing input for the mixed lubrication simulations. The study also explored the virtual removal of ridges formed around the pockets by the EDM technique. Key findings indicate that the stochastic texture outperformed the hybrid texture (stochastic + deterministic) in the boundary and mixed lubrication regimes, showing higher hydrodynamic support at low separations but increased hydrodynamic shear stresses at higher speeds. Conversely, deterministic textures exhibited a significant decrease in average hydrodynamic shear stress at high velocities. These results highlight the critical role of surface texture in tribological behavior and suggest that localized textures on cylinder liners can potentially optimize engine performance. The study recommends further exploration of a broader range of texture geometries, densities, and distribution patterns to enhance engine design strategies.