Experimental and numerical investigations of oil film formation and friction in a piston ring–liner contact

The piston ring–cylinder liner contact is a major source of the total parasitic losses in an internal combustion engine. The lubrication process of this contact highly influences the amount of friction, oil consumption and wear that occurs. In this work, a reciprocating test rig combined with an ultrasonic film thickness measurement system was developed and then used for tribological investigation of the piston ring–cylinder liner contact under idealised cold conditions. A special piston ring and cylinder liner holder were designed and five sensors were glued on to the back side of the liner specimen. Ultrasonic reflections captured by the sensors, used to obtain the film thickness, and friction were continuously recorded as the piston ring section reciprocated over the liner. Several experiments were performed at different speed and load conditions. Furthermore, a numerical model has been developed to predict film thickness and friction in all lubrication regimes. The experimentally measured film thickness and friction were compared with the output from the numerical model and good correlation was found. The parameters affecting the accuracy of the ultrasound measurements and numerical simulations of film thickness and friction are then discussed.