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BASICS OF TRIBOLOGY PURITY THROUGH SCIENCE
BASICS OF TRIBOLOGY AND THEIR EFFECT ON CLEANLINESS OF COMPONENTS
WAYNE HUBBALL T E C H N I C A L
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D I R E C T O R
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BASICS OF TRIBOLOGY PURITY THROUGH SCIENCE
CURRENT SITUATION AND BOUNDARY CONDITIONS
WHAT IS TRIBOLOGY?
“TRIBOLOGY IS THE SCIENCE AND TECHNOLOGY OF INTERACTING SURFACES IN RELATIVE MOTION. IT INCLUDES FRICTION, WEAR AND LUBRICATION AS WELL AS SURFACE INTERACTIONS BETWEEN SOLIDS OR SOLIDS AND FLUIDS/GASES.”
LEGISLATION
TECHNOLOGY
COSTS/QUALITY
ACEA COMMITMENT EU NORMS
INCREASING REQUIREMENTS
COMPETITIVENESS
- FUEL ECONOMY
- DOWNSIZING
- REDUCED OIL CONSUMPTION
- LIGHT WEIGHT CONSTRUCTION
- REDUCED FRICTION AND WEAR
- INCREASED FUNCTIONALITY
- PRODUCTION/ WARRENTY COSTS - ROBUST PROCESSES - ZERO FAILURE
TRIBOLOGY (DIN 50323)
INCREASED REQUIREMENTS DUE TO AGGRAVATED FUNCTIONAL, ECOLOGICAL AND ECONOMICAL BOUNDARY CONDITIONS
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BASICS OF TRIBOLOGY PURITY THROUGH SCIENCE
DEVELOPMENT OF SPECIFIC POWER AND MAXIMUM PRESSURE FOR DIESEL ENGINES OF PASSENGER CARS
POWERTRAIN SYSTEM REQUIREMENTS INCREASED SPECIFIC LOAD
DOUBLING OF THE POWER DENSITY WITHIN THE LAST 15 YEARS
RAPID INCREASE OF THE MAXIMUM PRESSURE
FURTHER INCREASE CONCEIVABLE
SIGNIFICANT INCREASE OF THE SPECIFIC LOAD FOR ALL ENGINE COMPONENTS
INCREASED LIFECYCLE
THIN LUBRICANT FILMS
INCREASED COMPLEXITY OF PARTS
INTEGRATION OF MECHANICAL AND ELECTRONIC COMPONENTS (MECHATRONIC)
CLOSE TOLERANCES
INCREASED SENSITIVITY WITH RESPECT TO PARTICLES
CLEANLINESS OF COMPONENTS BECOMES A QUALITY FEATURE
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BASICS OF TRIBOLOGY PURITY THROUGH SCIENCE
TRIBO CONTACTS IN ENGINES
PARTICLES IN THE TRIBOLOGICAL SYSTEM POSSIBILITIES
ENGINES - Optimisation of the tribolical system
- Reduce particle ammount & Size
- Surface Design - Practicle Transport
- Measure with respect to the technical
- Material Selection - Particle Intake
cleanliness of components
NORMAL FORCE
PISTON RING – CYLINDER LINER
CONTACT 1
VALVES
VELOCITY
CONTACT 2 SMALL PARTICLES BEARINGS (CAM-/CRANKSHAFT)
GEARS & CHAIN DRIVES
LUBRICATION
CONTACT PARTNERS
LARGE PARTICLES SURFACE
EFFECTS
- Material
- Friction
- Lubricant
- Wear
- Surface
- Oil consumption
- Particles
- Emissions - Failure
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BASICS OF TRIBOLOGY PURITY THROUGH SCIENCE
EFFECTS OF PARTICLES ON THE TRIBOLOGICAL SYSTEM
CAUSE/ORIGIN OF PARTICLES (EXAMPLES)
CASTING - CORE SAND RESIDUE - CORE WASH RESIDUE
MACHINING - CHIPS - BURRS (BECOME PARTICLES) - RESIDUE OF COOLING LUBRICANTS
CLEANING - GRIT BLAST RESIDUE - RESIDUE OF CLEANING AGENTS
JOINING - RESIDUE OF ADHESIVES OR
SMALL PARTICLES
LARGE PARTICLES
SEALANTS - WELD SPATTER
SMALL PARTICLES
LARGE PARTICLES
ASSEMBLY
- CAUSE OF INCREASED WEAR
- CAUSE OF INITIAL DAMAGE
- CHIPS, WEAR DEBRIS
- EARLY FAILURE OF THE
- IMMEDIATE FAILURE OF THE
- RE-CONTAMINATION FROM
COMPONENT / REDUCED
COMPONENT
THE ENVIRONMENT
LIFETIME
- TOP PRIORITY
- PACKAGES AND CONTAINERS
SERVICE FLUIDS
IMPORTANT QUESTION:
- PARTICLES FROM BOTTLING
What amount, size and material of particles is acceptable?
DEVICES AND CONTAINERS
- DEFINITION OF RESIDUAL DIRT LIMIT-VALUES
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BASICS OF TRIBOLOGY PURITY THROUGH SCIENCE
CORE SAND RESIDUE
BURRS LOOSENING OF BURRS DURING SERVICE (BURRS BECOME PARTICLES) - TRANSPORT INTO CRITICAL AREAS OF THE ENGINE - SEVERE DAMAGE OR INCREASED WEAR
CORE SAND RESIDUE FROM THE CASTING PROCESS
- ...
HIGH PRESSURE WATER JETTING // BRUSHING
BEFORE
CYLINDER HEAD
AFTER
LOOSENING OF CORE SAND RESIDUE DURING SERVICE Transport into critical areas of the engine - Severe damage or increased wear - Coating of the cores with core wash - Blasting technologies (grit blasting, high pressure water jetting) - … -
EXAMPLE: HIGH PRESSURE WATER JET DEBURRING OF CYLINDER HEADS
-
COLD
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WARM
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BASICS OF TRIBOLOGY PURITY THROUGH SCIENCE
EXAMPLE 1: CAMSHAFT BEARING
EXAMPLE 2: CYLINDER WALL SCORING MARKS ON THE CYLINDER WALL // INCREASED OIL CONSUMPTION, PISTON SCUFFING
ENGINE DAMAGE CAUSED BY GRIT BLAST RESIDUE
Scoring marks on the piston caused by contamination from lubrication oil
CAMSHAFT BEARING GRIT BLAST MEDIA
Scoring marks on the cylinder wall
BEARING DAMAGE CAUSED BY EMBEDDED PARTICLES
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Embedded iron particles from engine oil
CHEMICAL ANALYSIS
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BASICS OF TRIBOLOGY PURITY THROUGH SCIENCE
EFFECT OF PARTICLES ON OTHER SYSTEMS ENGINES - Clamping of valves, bucket tappets, camshaft bearings
INCREASING CLEANLINESS OF COMPONENTS
CONSIDERATION OF THE COMPLETE PROCESS CHAIN
- Reduction of the cross section/plugging of pipes and nozzles in oil, or fuel-bearing systems (e.g. Fuel injection
DESIGN & DEVELOPMENT
PRODUCTION ENGINEERING
PRODUCTION
system) - ...
AVOIDING CONTAMINATION
CHIP IN A SPARK PLUG
- Optimization of process sequences, machining systems and tools.
GEARBOXES
- Burr minimization and cleaning-oriented design.
- Faulty gear shifts in automatic gear boxes caused by
- ...
clamped shift sliders and regulating sliders
REMOVAL OF CONTAMINATION
- Failure of integrated electronics and sensor systems (e.g.
- Selection and optimization of suitable cleaning technologies.
temporary short circuits)
- Definition of test methods to determine the cleanliness of components.
- ...
SHIFT SLIDER PLATE
- ...
AVOIDING RE-CONTAMINATION - Optimization of assembly processes. - Development of suitable concepts for transportation, storage and packaging.
SYSTEM CONSIDERATION
- ...
Cleanliness of components always requires a consideration of the complete system (Product and Process chain)
DESIGN IT CLEAN. BUILD IT CLEAN. KEEP IT CLEAN.
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BASICS OF TRIBOLOGY PURITY THROUGH SCIENCE
RECAP CLEANLINESS OF COMPONENTS BECOMES A QUALITY FEATURE - Particles have an effect on tribological systems - Large particles > cause of initial damage > immediate failure
- Small particles > increased wear > early failure, reduced lifetime, power loss … - Which amount and size of particles is acceptable?
DEFINITION OF LIMIT-VALUES - Cleanliness of components always requires a consideration of the complete system - Product > Consideration of all components - Process chain > Consideration of all process steps from design and
THANK YOU FOR YOUR TIME.
development to production and assembly
- Increased system requirements due to aggravated functional, ecological and economical boundary conditions - Increased sensitivity with respect to particles due to increased specific loads, closer
FEEL FREE TO GET IN TOUCH. WE’D LOVE TO HEAR FROM YOU.
tolerances and thinner lubricant films
WAYNE HUBBALL T E C H N I C A L
D I R E C T O R
T: +44 (0) 1522 789 097 M: +44 (0) 7715 654 658 E: whubball@reynoldscc.com OUR ADDRESS HAZEL BARN, 39 SANDS LANE, CARLTON LE MOORLAND, LINCS, LN5 9HJ
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BASICS OF TRIBOLOGY PURITY THROUGH SCIENCE
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