University of Engineering and Technology Taxila

Department of Mechanical Engineering

Complex Engineering Problem

Identify the models/theories and provide solutions to minimize the friction loses in
piston assembly / cylinder liner of an IC engine.

Course
Internal Combustion Engines
Submitted To
Course Instructor: Dr. Mubashir Gulzar
Submitted By
Owais Ijlal Bilal
20-ME-38
Muhammad Ikram
20-ME-158
Section
B
Abstract
Within the field of internal combustion engines, engine friction research and analysis is an
essential field of study. Research to date suggests that friction between the piston and cylinder
accounts for around 20% of engine losses. Therefore, any effort to reduce these losses would
have an impact on engine efficiency overall and, in turn, vehicle fuel economy. The
instantaneous indicated mean effective pressure (IMEP) method and the floating liner method are
two commonly used experimental techniques for determining engine friction.
This study presents major findings and addresses potential sources of inaccuracy while providing
a detailed review of the IMEP approach. Though it is a more recent technique than the floating
liner method, scientists and engineers have come to rely on the IMEP method for predicting
piston ring assembly friction since it regularly produces accurate results. Remarkably, the
majority of experiments—regardless of the methodology employed—are carried out under
motoring settings, with scant information accessible for operation in flames.
The force balance idea is the foundation of the instantaneous IMEP approach. The friction force
between the piston and cylinder is calculated by taking into account the forces acting on the
piston, such as side thrust, crankcase pressure, combustion gas pressure, and inertial forces
acting on the piston and connecting rod. One benefit of the instantaneous IMEP approach is that
it requires very little engine modification, which makes it a more affordable option than the
floating liner method and suitable for production engines. It is imperative to recognize, though,
that the friction force is negligible when compared to other piston forces, such as inertial forces
and cylinder gas pressure. For this reason, precise force measurements are essential to avoid
significant mistakes.
Contents
1. Introduction
2. Project Background
3. Problem Statement
4. Project Aim
5. CEP Project Objective
6. Applications
7. Literature Review
7.1 Piston Assembly in IC Engine
7.2 Clinder liner
7.3 Function of Cylinder liner
7.4 Formation of Sliding surface
7.5 Reduction of Wear
7.6 Heat Transfer
7.7 Sealing
7.8 withstand Combustion
8. Methodology
1. Introduction
A workable strategy for lowering friction loss at the piston assembly and liner is suggested in
this CEP project. A review of the literature on different techniques suggested using aluminum
instead of gray cast iron for the cylinder liners. This research entails the creation and evaluation
of the suggested method for reducing friction loss. The project's pros are discussed in the final
section.

2. Project Background
Friction losses are the result of energy being lost as a result of friction, which affects the
efficiency of mechanical systems. Friction is the resistance that exists between surfaces that are
in contact and prevents motion.An internal combustion engine's ability to perform is largely
dependent on friction and the losses it causes.(IC) engine, which is responsible for a sizeable
portion of all energy inefficiencies.
The piston assembly, which consists of cylinders, rings, and pistons, is essential to the
combustion process. The air-fuel combination is compressed by the pistons' reciprocating motion
inside the cylinders, which starts combustion when the spark plug ignites it. This procedure
produces the force required to propel the power output of the engine. Additionally, the pistonTo
keep combustion gasses contained, the assembly's efficient sealing. Controlling the friction that
forms between the cylinder walls and piston rings is essential because too much friction can lose
energy and reduce engine performance by up to 10-12%.
3. Problem Statement
The efficiency of an internal combustion engine is significantly impacted by friction loss in the
liner(18-20% of total energy losses) and piston assembly (40–50% of total energy losses).
controlling the friction that exists between the cylinder walls and the piston rings and lowering
the frictional losses in the piston. For an engine to run more efficiently overall, the piston
assembly is essential.

4. Project Aim
The CEP study's objectives are to discover models and theories as well as offer methods to
reduce friction losses in an IC engine's piston assembly.

5. Objectives
The following are the goals:
• To comprehend the fundamental ideas behind IC engine piston assembly.
• To locate the most recent studies on reducing friction losses.
• Verify that the suggested method for reducing friction loss is feasible.
• To use simulations to verify the design safety.

6. Applications
Uses
The study's applications include the following:
• The automobile sector
• The locomotive sector.
• Machines used in industry.
• The industry of power generating.
7. Literature Review
Numerous research publications that show practical ways to lower frictional losses in an IC
engine's piston assembly have been reviewed. The piston assembly is what allows the engine to
run; friction is required for the engine to function properly, but losses because it lowers its
efficiency, which need to be managed. The suggested course of action ought to be both effective
and long-lasting.

7.1 Piston Assembly In IC Engine

An internal combustion (IC) engine's piston assembly is essential to the engine's operation and
has several functions. Fundamentally, the piston assembly is in charge of transforming the
energy released during the combustion of fuel into mechanical motion. The piston moves back
and forth inside the cylinder, permitting the compression of exhaust gases or an air-fuel mixture
at various cycles of the engine in strokes. This motion controls the engine's power, intake,
compression,and exhaust strokes, lining up with the combustion phases of the engine.[3]
Additionally, the piston assembly plays a critical role in preserving the seal that separates the
crankcase from the combustion chamber. It ensures effective compression and stops gas leaks
during combustion by fitting tightly against the cylinder walls. The rings of the piston,located on
the outside of the piston, help to seal the combustion chamber while enabling essential
lubrication between the walls of the cylinder and the piston. These rings are involved into cool
the engine by transferring heat from the piston to the cylinder walls.[3]
The piston assembly focuses on two important areas: reducing friction and wear. By reducing
friction between the piston and cylinder walls, advances in piston ring designs, coatings, and
materials are intended to increase engine longevity and efficiency. Furthermore, the assembly's
Design and material choice are essential for withstanding high pressure and temperatures into the
combustion chamber while preserving dependability and structural integrity throughout
prolonged times.[3]
Weight reduction is taken into account while optimizing the piston assembly with the goal of
reducing inertia forces and enhancing engine response. Technological developments in materials,
including the use of strong but lightweight alloys, help to achieve this objective. Additionally,
the piston assembly arrangement and design affect engine balance, vibration management, and
overall engine smoothness, as well as affecting elements like harshness, vibration, and noise
(NVH) inside the car.[3]
where engine efficiency and fuel consumption are significantly influenced by tribology and
lubrication. The following are the main factors to take into account when lubricating and
tribologizing the piston-cylinder assembly in order to minimize fuel consumption. Tribological
factors are important in the piston-cylinder assembly of internal combustion engines crucial part
in determining effectiveness and performance. As an example, hydrodynamic lubrication
cornerstone, successfully maintaining a liquid layer between the cylinder wall and the piston
rings reducing wear and friction. This meticulously upheld lubrication schedule, accomplished
by appropriate lubricant selection, skillful oil flow management, and optimal clearance
optimization, directly affects the efficiency of gasoline. The end result of a well-oiled interface is
less friction helping to improve fuel efficiency.[3]
Another important factor is the design of the piston rings. The intricate details of their design—
from the use of several rings to the application of particular coatings—have a big impact on the
lubricating and sealing qualities. An expertly planned ring arrangement not only reduces oil
usage while simultaneously reducing friction, increasing engine performance overall
effectiveness. Ring geometry, surface quality, and material choice are crucial factors in this
setting forth the delicate balance between minimum friction and maximum efficiency. On the
other hand, in some engine operating situations, such as starting and at high loads,
boundariesThere could be lubrication, which would result in metal-to-metal contact. Managing
this marginal Maintaining overall efficiency and preventing excessive wear requires appropriate
lubrication. Creating the right lubricants with the right additives is essential to avoiding such
problems with boundary lubrication.[1]
The lubricating film thickness, load capacity, and overall friction losses are all impacted by the
choice of oil viscosity and additives. Reducing friction by adding additives and adjusting oil
viscosity is a powerful way to reduce fuel consumption. However, this Optimization requires
careful balance, taking into account the effects of fuel mix, high temperature operation, and
starter protection requirements. Critical parts like cylinder liners and piston rings are affected by
surface coatings. transformative function in reducing friction and improving wear resistance.
When appropriately chosen in terms of substance, application, and thickness, coatings can
considerably support tribological characteristics, which therefore helps to increase fuel
efficiency.[3]
It becomes clear that the piston-cylinder assembly's ability to dissipate heat effectively is crucial.
Controlling high temperatures lowers friction and stops lubricant deterioration. The combination
of design features for cooling, material selections, and the thermal stability of the lubricant
support long-term lubricant performance, which lowers friction losses and improves fuel
efficiency. To sum up, tribological aspects within the piston-cylinder are optimized. A
comprehensive strategy including design, materials, lubrication, and assembly is required.
upkeep. Research and development in these fields work together to reduce friction, increased
effectiveness and, in the end, reduced fuel usage in internal combustion engines.

7.2 Cylinder Liner

An essential part of internal combustion engines is a cylinder liner, often known as an engine
liner or cylinder sleeve. It functions as a functional and protective component inside the engine's
cylinder block, giving the piston a durable, smooth surface to move on in addition to providing
structural and thermal advantages. It is an essential component of many automotive, industrial,
and marine engines because it preserves engine durability, performance, and efficiency.
All the information concerning cylinder liners will be provided to readers within the scope of this
site.[4]

7.3 Functions of Cylinder Liner:

Engine cylinder liners perform vital tasks such as giving pistons a smooth, wear-resistant
surface, guaranteeing correct sealing, facilitating heat dissipation, and enhancing engine
longevity and performance.

7.4 Formation of Sliding Surface:

Because they offer a smooth sliding surface for the piston's reciprocating action, cylinder liners
are essential components of internal combustion engines. Piston rings can move easily along the
inner walls of the liner since there is less friction resistance there. The inside surface of the liner
develops a thin lubricating coating, which lowers frictional resistance even more.[5]

7.5 Reduction of Wear:

Cylinder liners for internal combustion engines have outstanding anti-galling characteristics that
reduce wear on the liner and the piston rings that come into touch with it. The piston rings would
come into direct touch with the cylinder block in the absence of a cylinder liner. Since the
cylinder block would be far more worn in such a situation, replacing the cylinder liner would be
more economical than replacing the entire block. The liner's presence lessens galling, a type of
wear brought on by adhesion forces between mating parts.[5]

7.6 Heat Transfer:

The transfer of heat produced during combustion is one of the cylinder liners' other essential
roles. These liners help the heat move from the burning charge into the engine block and then, in
the case of wet liners, into the surrounding air or coolant. Effective heat dissipation is ensured by
the coolant's role as a heat sink.

7.7 Sealing:
The maintenance of a tight seal between the piston rings and the liner walls is largely dependent
on cylinder liners. The extraordinary smoothness of the inner cylinder walls is necessary for this
sealing function. It minimizes charge leakage during the compression stroke and stops exhaust
gasses from escaping during the exhaust stroke as a result.

7.8 Withstand Combustion:

High pressure and temperature levels are produced by internal combustion engines during their
harsh operating circumstances. Withstanding pressures of up to 25 bars and temperatures as high
as 2500 degrees Celsius, cylinder liners are made to resist these extreme circumstances. The
engine's cylinder block would be exposed to harm from the high heat and pressure produced
during combustion if the cylinder liners were missing.[5]

8. Methodology
9. Model and Analysis

9.1 3D Model
In this study we use solidworks for making our model and also for performing various
simulations of model in order to study different deformations occur in it.

The above figure shows the 3D Model of our design.

9.1.1 Overview
Piston
One of the most important parts of an internal combustion engine is the piston. It travels up and
down inside a cylinder to transform the mechanical motion produced by the burning of fuel into
energy. Pistons are cylindrical in shape and exactly fit within the cylinder bore; they are usually
constructed of aluminum alloy. During combustion, the piston's upper surface, known as the
crown, endures intense heat and pressure. To seal the combustion chamber, control oil
consumption, improve efficiency, and lower friction, piston rings are fitted around the piston.
Connecting Rod
In an engine, the connecting rod acts as a link between the crankshaft and the piston. It enables
the engine to turn linear motion into rotational power by converting the piston's reciprocating
action into rotational motion at the crankshaft.

Piston Pin
An internal combustion engine's piston pin, sometimes referred to as a wrist pin or gudgeon pin,
is an essential part. It acts as a pivot point to allow the piston to move freely while attaching it to
the connecting rod.
Here are some essential details regarding the piston pin:
1. Situated and Operated: A cylindrical rod known as the piston pin connects to the higher end of
the piston by passing through the connecting rod's small end. It keeps the connecting rod
securely fastened while enabling the piston to travel up and down inside the cylinder.
2. Material and constructionTypically:, high-strength materials such as steel, titanium, or alloys
that can tolerate high temperatures, pressures, and mechanical stresses are used to make piston
pins.
3. Lubrication: In order to minimize wear and friction, piston pins must be properly lubricated.
Some engines include full-floating piston pins, which are able to pivot inside the piston and
connecting rod. To keep these pins from overheating and causing excessive friction, lubrication
must be applied continuously.

4. Design VariationsSolid (one-piece) pins and semi-floating pins, which reduce friction by using
bushings or bearing surfaces, are two examples of the several designs available for piston pins.

5. Impact on Performance The performance, longevity, and efficiency of an engine are greatly
impacted by the design and caliber of the piston pin. The longevity and ideal operation of the
piston pin within the engine are contingent upon proper maintenance and lubrication.
In general, the piston pin is a tiny but essential part of an engine that makes the piston move
smoothly.

9.2 Analysis in Solidworks

By using solidworks we perform various simulations like deformation, strain and
force applied in different section of pistion and also do stress analysis.
9.2.1 Deformation Analysis

9.2.2 Mesh Formation

9.2.3 Stress Analysis

9.2.4 Strain Analysis

10. Frictional Loses:
Depending on their intended use, modern internal combustion engines may run under a range of
load and speed circumstances. Due to the range of driving conditions faced, weights and speeds
vary significantly in both passenger automobiles and cargo trucks. Racing engines are usually
run at high loads and speeds. Because a high load produces more power and a low speed is
necessary to connect with the power gird and electric generator, stationary power generation
engines run under high load, low speed conditions.
The amount of friction created between the piston rings and the liner is influenced by both
engine speed and load.

10.1 Effect of Engine Speed

The impact of engine speed as defined by the equation on the friction produced between the
piston rings and the liner. Usually, a significantly lower contribution is obtained from the
pressure gradient integrated throughout the wetted width. The inclusion of the viscosity term in
this connection is due to its dependence on the piston speed. The kind of oil being considered
determines how much of this dependence there is. Shear rate, which is closely correlated with
piston speed, regulates the viscosity of multigrade oils, which are classified as shear thinning
fluids. The cumulative effect of these changes on friction power loss is the consequence of a
compromise between the viscosity, which will decrease as piston speed increases.

10.2 Effect of Engine Load

Engine load has less of an impact on friction. The amount of air and fuel that are introduced into
the cylinder to be compressed and burned during combustion must be increased in order to
maintain constant engine speed when the engine's load increases. Higher peak pressures are thus
achieved in the cylinder.
The pressure that the cylinder reaches during the engine cycle has a big impact on the friction
that the piston rings produce. The cylinder pressure regulates the land pressures, which have an
impact on the dynamics of the rings and, consequently, the lubrication conditions the rings
experience during the engine cycle.
However, generally speaking, as the load increases, the percentage of the engine's stated power
production that comes from friction decreases.

Conclusion:
The oil control ring increases the contribution from top ring boundary friction around TDC of
compression throughout the engine cycle, resulting in a boundary friction power loss that
increases as U at low speed and low load.
Boundary friction power loss increases with U at low speed and heavy load; additionally, the oil
control ring contributes more power loss throughout the engine cycle, and the top ring around the
TDC of compression/expansion increases the amount of boundary friction power loss.
Oil control ring entire engine, hydrodynamic friction power loss increasing as at high speed and
low load.
The power loss due to hydrodynamic friction increases at high speed and low load. Additionally,
the oil control ring contributes more throughout the engine cycle, and the top ring around the
TDC of compression/expansion increases the portion of friction from the top ring boundary.

References
[1] A. Gangopadhyay, “A Review of Automotive Engine Friction Reduction Opportunities Through
Technologies Related to Tribology,” Trans. Indian Inst. Met., vol. 70, no. 2, pp. 527–535, 2017, doi:
10.1007/s12666-016-1001-x

[2] “Introduction to Aircraft Internal Combustion Engines | AeroToolbox.”

https://aerotoolbox.com/engine-intro/ (accessed Nov. 29, 2023).

[3] G. Gopal, L. Suresh Kumar, K. Vijaya Bahskar Reddy, M. Uma Maheshwara Rao, and G. Srinivasulu,
“Analysis of Piston, Connecting rod and Crank shaft assembly,” Mater. Today Proc., vol. 4, no. 8, pp.
7810–7819, 2017, doi: 10.1016/j.matpr.2017.07.116

[4] 2009; ISSN 1818-4952; World Applied Science Journal 7(8): 998-1003. 2009 IDOSI Publications.

[5] proceedings of workshop in current trends in I.C. Engine Development, Hyderabad.