How To Predict Cylinder Liner Cavitation To Avoid Warranty Issues and Reduce Maintenance Costs

Tackling Liner Cavitation
Reducing Warranty Issues and Repair Costs
Public
Today’s Presenters
Bruno Haramincic, BSc Simon Gomboc, MSc
Analysis Engineer, Structural Senior Analysis Engineer, Virtual

Dynamics Powertrain and Powertrain
Component Development
▪ Master’s Degree from the
Faculty of Mechanical ▪ Mechanical Engineering
Engineering and Naval Degree and MSc in Fluid
Architecture in Zagreb, Dynamics and Heat Transfer
Croatia from the University of
Maribor, Slovenia
▪ Specialist on multibody
simulations (MBS) with focus ▪ Specialist on CFD with focus
on EHD, NVH and Valvetrain on multi-phase flows, heat
analysis transfer and thermal load
Public /3 | AVL Webinar: Tackling Liner Cavitation |

Today’s Agenda
The Challenge
1
Avoid engine damage, warranty issues and repair costs
The Solution
2
Predict liner cavitation and erosion and identify the design with minimum risk
Summary
3

The Challenge
Public
The Challenge
low
MDPR (cycle averaged)
high
Liner cavitation / erosion

causes
irreparable damage
potentially leading to the
complete destruction of
the IC Engine
low
Displacements
high

The Challenge
Factors Promoting Liner Erosion
▪ Clearance between piston and liner
▪ Engine operation in low temperature range (warm up)
▪ Cranktrain and piston design
▪ Leaking cooling system
▪ Inappropriate coolant, no anti-freeze
▪ Piston and liner material

Liner Cavitation & Erosion Insights
▪ Liner erosion occurs with ‘wetted liners’
Cylinder
head
“wetted” Cylinder
cavitation/erosion IS a block
potential problem
Water jacket
Piston
“dry”
cavitation/erosion is Liner
NOT a reported problem

▪ It is caused by vibrations due Cylinder

head
to piston contact alteration in
TDC and BDC Cylinder
block
Water jacket
Piston secondary
Piston motion
“BANG”
Liner


head
block
Water jacket
▪ Vibrations cause ‘cavitation’,
which can result in ‘erosion’ Piston secondary
→ liner damage motion
“BANG”
Liner
Public / 10 | AVL Webinar: Tackling Liner Cavitation |


head
block
Water jacket
▪ Vibrations cause ‘cavitation’,
which can result in ‘erosion’
→ liner damage
▪ Liner is destroyed, water is entering Liner

the combustion chamber, exhaust
gas is entering the cooling system
Zoomed In
Liquid Wall Liquid Wall Liquid Wall Liquid Wall Liquid Wall
“BANG”
Deformation Deformation Deformation
induced volume expansion volume reduction high speed liquid jets … imposing a
vibration → pressure drop → pressure rise enter the space destructive pressure
→ vapor bubbles → bubbles previously occupied by to the wall, tearing
collapse the bubbles … off material

The Solution
Public
The Solution
Liner cavitation / erosion Simulate the impact of

causes liner vibrations on
cavitation and erosion
irreparable damage
Analyze variants to decide
potentially leading to the for designs with
complete destruction of minimum risk
the IC Engine of damage

The Solution
design
changed → reliable input
→ reliable erosion rate
Multi Body time resolved wall → optimized design
Start velocities, node
Dynamics based, FEA Grid
CAD
Initial &
Boundary time resolved wall
conditions Data Handling velocities, node
based, CFD Grid
Computational Results,
Fluid Dynamics Report
propose time and space

improvements resolved erosion
rate (MDPR)

The Solution
EXCITE™ Power Unit Overview
▪ Strength and durability

▪ Transmission and driveline
▪ NVH
▪ Electrification
▪ Turbochargers

The Solution
EXCITE™ Power Unit Overview
Multi-level simulation models

Analysis from concept to design on
component, sub-system and system level
Target systems
Automotive, transportation, electricity
generation and general industrial applications

The Solution
Multi Body Dynamics

The Solution
Multi Body Dynamics
▪ Linear ELASTIC bodies

(block/liner, piston, piston pin, conrod)
▪ Reduced structure matrices
▪ Highly nonlinear connections (joints)
▪ EHD contact
▪ TIME/ANGLE domain

The Solution
Multi Body Dynamics
▪ Single cylinder model
▪ Elastic Piston Liner Contact (EPIL)

▪ Reynolds equation
▪ Secondary piston motion
▪ Piston slap

The Solution
Multi Body Dynamics
▪ High resolution of retained nodes

(wetted liner side)
▪ Nodal displacements (input for CFD)
▪ Result step size (<0.1deg CA)

The Solution
Multi Body Dynamics
Piston Dynamics Results:

▪ Piston tilting/radial
displacement
▪ Side forces
▪ Friction force on piston
▪ Peak total pressure
(asperity/hydrodynamic)
▪ Minimum oil film thickness
▪ Friction power loss
▪ …

The Solution
Multi Body Dynamics Amplitude Velocities
low
Displacements
TS high
1,00
cold
0,90 warm
0,80
0,70
Liner Height
0,60
0,50
0,40
0,30
0,20
0,10
0,00
low high

The Solution
Multi Body time resolved wall

CAD
Initial &
based, CFD Grid
time and space

resolved erosion
rate (MDPR)

The Solution
Data Transfer MBS - CFD

The Solution
Multi Body time resolved wall

CAD
Initial &
based, CFD Grid
time and space

resolved erosion
rate (MDPR)

The Solution
Computational Fluid Dynamics AVL FIRE™ M handles
▪ Laminar/turbulent, compressible/
incompressible flows
▪ Single and multi-phase flows
▪ Lagrangian sprays
▪ Combustion and emissions
▪ Detailed reaction chemistry
▪ Electromagnetics and electro-chemistry
▪ Heat transfer and thermal load
▪ Multi-domain geometries

The Solution
Computational Fluid Dynamics
FLOW FIELD STRUCTURE

Collapsing
Eulerian multi-fluid Cavitation
bubbles
Erosion
approach:

The Solution

Collapsing
bubbles
Erosion
approach:
Cavitation model:
N R

The Solution

Collapsing
bubbles
Erosion
approach: Erosion model:
Cavitation model:
W(e’)
W(e1)

The Solution
Geometry Modeling:
▪ Single or multiple cylinder
simulation
▪ One button meshing solution
▪ Automatic local refinements
▪ 3 mil. computational cells
▪ 2 boundary layers
Detailed view

The Solution
Multiphase Simulation:
Inlet boundary
▪ Entire engine model
▪ Transient simulation
▪ Two phase system:
Outlet boundary
Wall ▪ Liquid: Water/Glycol
▪ Gas: W/G Vapor
▪ Cavitation and erosion model
applied
Liner vibration -
displacements

Discussion of Results
Public
Predicting cavitation and erosion rate with AVL FIRE™ M
low low low low

Wall Velocity Abs. Pressure Volume Fraction MDPR
high high high high
Excitation!
Vibration Pressure drop Cavitation Erosion Rate

Vapor Generation and Collapse:
▪ Vapor generated as piston hits the liner
▪ Temporary local presence of vapor
▪ Damage expected with vapor collapsed near
the wall
▪ Impactful traits:
▪ Bubble size
▪ Vapor location
▪ Collapse frequency
low
Volume Fraction
high

Thrust Anti-Thrust Thrust
low
cycle averaged Erosion rate
high

low Erosion Rate Results:

high
▪ Anti-thrust side (ATS)
▪ Increased penetration rate
during cold engine conditions
▪ Similar erosion distribution
between cylinders
▪ Strong cavitation in upper
Warm engine conditions cooling jacket region
Cold engine conditions

low Erosion Rate Results:

high
▪ Thrust side (TS)
▪ Increased penetration rate
during cold engine conditions
▪ Similar erosion distribution
between cylinders
▪ Strong cavitation in upper
Warm engine conditions cooling jacket region
Cold engine conditions

Warm engine Cold engine

low
high

Validation
Test Setup:
“Modeling cavitation in a rapidly changing pressure field”,

▪ Horn submerged in water
▪ Oscillation dynamics:
▪ Frequency 20 kHz
▪ Amplitude 164 mm
▪ Result monitoring:
▪ High speed camera
▪ Hydrophone
Žnidarčič et.al.
Validation
Simulation
Measurement
THE SIMULATION ACCURATELY PREDICTS THE

TIMING AND THE AMPLITUDE OF VAPOR PRESENCE

Validation
“Modeling cavitation in a rapidly changing pressure field”,

… AND PROVIDES IMPRESSIVE INSIGHTS ABOUT
VAPOR GENERATION AND BUBBLE COLLAPSE
20kHz, 164mm
Žnidarčič et.al.
Note: Frame rate changes during animation low
Vapor Volume Fraction
high
Hydrophone
position

Summary
Public
Summary
▪ Predictive model for cavitation and erosion in AVL FIRE™ M

▪ sensitive on temperature, pressure and coolant properties
▪ realistic boundary conditions for piston motion provided by AVL EXCITE™ Power Unit
▪ Easy and safe data transfer between Multibody- and Fluiddynamics-Model
▪ Supporting front loading

▪ crank train design
▪ piston selection
▪ piston / liner clearance definition
… to avoid excessive liner excitation
▪ Reduced failure rates and warranty issues

Q&A
Public
Contact
LOCATION PHONE EMAIL WEBSITE
AVL List GmbH +43 316 787 1222 ASTmarketing@avl.com www.avl.com

Hans-List-Platz 1
8020 Graz
Austria

Thank you
www.avl.com
Confidential

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Tackling Liner Cavitation

Reducing Warranty Issues and Repair Costs

Bruno Haramincic, BSc Simon Gomboc, MSc

Analysis Engineer, Structural Senior Analysis Engineer, Virtual

Public /3 | AVL Webinar: Tackling Liner Cavitation |

Public /4 | AVL Webinar: Tackling Liner Cavitation |

Liner cavitation / erosion

Public /6 | AVL Webinar: Tackling Liner Cavitation |

Public /7 | AVL Webinar: Tackling Liner Cavitation |

▪ Liner erosion occurs with ‘wetted liners’

Public /8 | AVL Webinar: Tackling Liner Cavitation |

▪ Liner erosion occurs with ‘wetted liners’

▪ It is caused by vibrations due Cylinder

Public /9 | AVL Webinar: Tackling Liner Cavitation |

▪ Liner erosion occurs with ‘wetted liners’

▪ It is caused by vibrations due Cylinder

Public / 10 | AVL Webinar: Tackling Liner Cavitation |

▪ Liner erosion occurs with ‘wetted liners’

▪ It is caused by vibrations due Cylinder

▪ Liner is destroyed, water is entering Liner

Public / 12 | AVL Webinar: Tackling Liner Cavitation |

Liner cavitation / erosion Simulate the impact of

Public / 14 | AVL Webinar: Tackling Liner Cavitation |

propose time and space

Public / 15 | AVL Webinar: Tackling Liner Cavitation |

▪ Strength and durability

Public / 17 | AVL Webinar: Tackling Liner Cavitation |

Multi-level simulation models

Public / 18 | AVL Webinar: Tackling Liner Cavitation |

Public / 19 | AVL Webinar: Tackling Liner Cavitation |

▪ Linear ELASTIC bodies

Public / 20 | AVL Webinar: Tackling Liner Cavitation |

▪ Single cylinder model

▪ Elastic Piston Liner Contact (EPIL)

Public / 21 | AVL Webinar: Tackling Liner Cavitation |

▪ High resolution of retained nodes

▪ Nodal displacements (input for CFD)

▪ Result step size (<0.1deg CA)

Public / 22 | AVL Webinar: Tackling Liner Cavitation |

Piston Dynamics Results:

Public / 23 | AVL Webinar: Tackling Liner Cavitation |

Public / 24 | AVL Webinar: Tackling Liner Cavitation |

Multi Body time resolved wall

time and space

Public / 26 | AVL Webinar: Tackling Liner Cavitation |

Public / 27 | AVL Webinar: Tackling Liner Cavitation |

Multi Body time resolved wall

time and space

Public / 28 | AVL Webinar: Tackling Liner Cavitation |

Public / 29 | AVL Webinar: Tackling Liner Cavitation |

FLOW FIELD STRUCTURE

Public / 30 | AVL Webinar: Tackling Liner Cavitation |

FLOW FIELD STRUCTURE

Public / 31 | AVL Webinar: Tackling Liner Cavitation |

FLOW FIELD STRUCTURE

Public / 32 | AVL Webinar: Tackling Liner Cavitation |

Public / 33 | AVL Webinar: Tackling Liner Cavitation |

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low low low low

Vibration Pressure drop Cavitation Erosion Rate

Public / 36 | AVL Webinar: Tackling Liner Cavitation |

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Thrust Anti-Thrust Thrust