CRITICAL COMPONENT WEAR IN HEAVY DUTY ENGINES -- Contents -- List of Contributors -- Preface -- Acknowledgements -- PART I: OVERTURE -- 1 Wear in the Heavy Duty Engine -- 1.1 Introduction -- 1.2 Engine Life -- 1.3 Wear in Engines -- 1.3.1 Natural Aging -- 1.4 General Wear Model -- 1.5 Wear of Engine Bearings -- 1.6 Wear of Piston Rings and Liners -- 1.7 Wear of Valves and Valve Guides -- 1.8 Reduction in Wear Life of Critical Parts Due to Contaminants in Oil -- 1.8.1 Oil Analysis -- 1.9 Oils for New Generation Engines with Longer Drain Intervals -- 1.9.1 Engine Oil Developments and Trends -- 1.9.2 Shift in Engine Oil Technology -- 1.10 Filters -- 1.10.1 Air Filter -- 1.10.2 Oil Filter -- 1.10.3 Water Filter -- 1.10.4 Fuel Filter -- 1.11 Types of Wear of Critical Parts in a Highly Loaded Diesel Engine -- 1.11.1 Adhesive Wear -- 1.11.2 Abrasive Wear -- 1.11.3 Fretting Wear -- 1.11.4 Corrosive Wear -- References -- 2 Engine Size and Life -- 2.1 Introduction -- 2.2 Engine Life -- 2.3 Factors on Which Life is Dependent -- 2.4 Friction Force and Power -- 2.4.1 Mechanical Efficiency -- 2.4.2 Friction -- 2.5 Similarity Studies -- 2.5.1 Characteristic Size of an Engine -- 2.5.2 Velocity -- 2.5.3 Oil Film Thickness -- 2.5.4 Velocity Gradient -- 2.5.5 Friction Force or Power -- 2.5.6 Indicated Power and Efficiency -- 2.6 Archard's Law of Wear -- 2.7 Wear Life of Engines -- 2.7.1 Wear Life -- 2.7.2 Nondimensional Wear Depth Achieved During Lifetime -- 2.8 Summary -- Appendix 2.A: Engine Parameters, Mechanical Efficiency and Life -- Appendix 2.B: Hardness and Fatigue Limits of Different Copper-Lead-Tin (Cu-Pb-Sn) Bearings -- Appendix 2.C: Hardness and Fatigue Limits of Different Aluminium-Tin (Al-Sn) Bearings -- References -- PART II VALVE TRAIN COMPONENTS -- 3 Inlet Valve Seat Wear in High bmep Diesel Engines -- 3.1 Introduction -- 3.2 Valve Seat Wear.

3.2.1 Design Aspects to Reduce Valve Seat Wear Life -- 3.3 Shear Strain and Wear due to Relative Displacement -- 3.4 Wear Model -- 3.4.1 Wear Rate -- 3.5 Finite Element Analysis -- 3.6 Experiments, Results and Discussions -- 3.6.1 Valve and Seat Insert of Existing Design -- 3.6.2 Improved Valve and Seat Insert -- 3.7 Summary -- 3.8 Design Rule for Inlet Valve Seat Wear in High bmep Engines -- References -- 4 Wear of the Cam Follower and Rocker Toe -- 4.1 Introduction -- 4.2 Wear of Cam Follower Surfaces -- 4.2.1 Wear Mechanism of the Cam Follower -- 4.3 Typical Modes of -- 4.4 Experiments on Cam Follower Wear -- 4.4.1 Follower Measurement -- 4.5 Dynamics of the Valve Train System of the Pushrod Type -- 4.5.1 Elastohydrodynamic and Transition of Boundary Lubrication -- 4.5.2 Cam and Follower Dynamics -- 4.6 Wear Model -- 4.6.1 Wear Coefficient -- 4.6.2 Valve Train Dynamics and Stress on the Follower -- 4.6.3 Wear Depth -- 4.7 Parametric Study -- 4.7.1 Engine Speed -- 4.7.2 Oil Film Thickness -- 4.8 Wear of the Cast Iron Rocker Toe -- 4.9 Summary -- References -- PART III LINER, PISTON AND PISTON RINGS -- 5 Liner Wear: Wear of Roughness Peaks in Sparse Contact -- 5.1 Introduction -- 5.2 Surface Texture of Liners and Rings -- 5.2.1 Surface Finish -- 5.2.2 Honing of Liners -- 5.2.3 Surface Finish Parameters -- 5.2.4 Bearing Area Curve -- 5.2.5 Representation of Bearing Area Curve of Normally Honed Surface or Surfaces with Peaked Roughness -- 5.3 Wear of Liner Surfaces -- 5.3.1 Asperities -- 5.3.2 Radius of the Asperity in the Transverse Direction -- 5.3.3 Radius in the Longitudinal Direction -- 5.3.4 Sparse Contact -- 5.3.5 Contact Pressures -- 5.3.6 Friction -- 5.3.7 Approach -- 5.3.8 Detachment of Asperities -- 5.4 Wear Model -- 5.4.1 Normally Honed Liner with Peaked Roughness -- 5.4.2 Normal Surface Roughness -- 5.4.3 Fatigue Loading of Asperities.

5.4.4 Wear Rate -- 5.4.5 Plateau Honed and Other Liners not Normally Honed -- 5.5 Liner Wear Model for Wear of Roughness Peaks in Sparse Contact -- 5.5.1 Parametric Studies -- 5.5.2 Comparison with Archard's Model -- 5.6 Discussions on Wear of Liner Roughness Peaks due to Sparse Contact -- 5.7 Summary -- Appendix 5.A Sample Calculation of the Wear of a Rough Plateau Honed Liner -- References -- 6 Generalized Boundary Conditions for Designing Diesel Pistons -- 6.1 Introduction -- 6.2 Temperature Distribution and Form of the Piston -- 6.2.1 Top Land -- 6.2.2 Skirt -- 6.3 Experimental Mapping of Temperature Field in the Piston -- 6.4 Heat Transfer in Pistons -- 6.4.1 Metal Slab -- 6.5 Calculation of Piston Shape -- 6.5.1 Popular Methods Used Before Finite Element Analysis -- 6.5.2 Calculation by Finite Element Method -- 6.5.3 Experimental Validation -- 6.6 Summary -- References -- 7 Bore Polishing Wear in Diesel Engine Cylinders -- 7.1 Introduction -- 7.2 Wear Phenomenon for Liner Surfaces -- 7.2.1 Bore Polishing -- 7.3 Bore Polishing Mechanism -- 7.3.1 Carbon Deposit Build Up on the Piston Top Land -- 7.3.2 Quality of Fuel and Oil -- 7.3.3 Piston Growth by Finite Element Method -- 7.3.4 Piston Secondary Movement -- 7.3.5 Simulation Program -- 7.4 Wear Model -- 7.4.1 Contact Pressures -- 7.4.2 Wear Rate -- 7.5 Calculation Methodology and Study of Bore Polishing Wear -- 7.5.1 Finite Element Analysis -- 7.5.2 Simulation -- 7.6 Case Study on Bore Polishing Wear in Diesel Engine Cylinders -- 7.6.1 Visual Observations -- 7.6.2 Liner Measurements -- 7.6.3 Results of Finite Element Analysis -- 7.6.4 Piston Motion -- 7.6.5 Wear Profile -- 7.6.6 Engine Oil Consumption -- 7.6.7 Methods Used to Reduce Liner Wear -- 7.7 Summary -- References -- 8 Abrasive Wear of Piston Grooves in Highly Loaded Diesel Engines -- 8.1 Introduction.

8.2 Wear Phenomenon in Piston Grooves -- 8.2.1 Abrasive Wear -- 8.2.2 Wear Mechanism -- 8.3 Wear Model -- 8.3.1 Real Contact Pressure -- 8.3.2 Approach -- 8.3.3 Wear Rate -- 8.4 Experimental Validation -- 8.4.1 Validation of the Model -- 8.4.2 Wear Measurement -- 8.5 Estimation of Wear Using Sarkar's Model -- 8.5.1 Parametric Study -- 8.6 Summary -- References -- 9 Abrasive Wear of Liners and Piston Rings -- 9.1 Introduction -- 9.2 Wear of Liner and Ring Surfaces -- 9.3 Design Parameters -- 9.3.1 Piston and Rings Assembly -- 9.3.2 Abrasive Wear -- 9.3.3 Sources of Abrasives -- 9.4 Study of Abrasive Wear on Off-highway Engines -- 9.4.1 Abrasive Wear of Rings -- 9.4.2 Abrasive Wear of Piston Pin and Liners -- 9.4.3 Accelerated Abrasive Wear Test on an Engine to Simulate Operation in the Field -- 9.5 Winnowing Effect -- 9.6 Scanning Electron Microscopy of Abrasive Wear -- 9.7 Critical Dosage of Sand and Life of Piston-Ring-Liner Assembly -- 9.7.1 Simulation of Engine Life -- 9.8 Summary -- References -- 10 Corrosive Wear -- 10.1 Introduction -- 10.2 Operating Parameters -- 10.2.1 Corrosive Wear -- 10.3 Corrosive Wear Study on Off-road Application Engines -- 10.3.1 Accelerated Corrosive Wear Test -- 10.4 Wear Related to Coolants in an Engine -- 10.4.1 Under-cooling of Liners by Design -- 10.4.2 Coolant Related Wear -- 10.5 Summary -- References -- 11 Tribological Tests to Simulate Wear on Piston Rings -- 11.1 Introduction -- 11.2 Friction and Wear Tests -- 11.2.1 Testing Friction and Wear of the Tribo-System Piston Ring and Cylinder Liner Outside of Engines -- 11.3 Test Procedures Assigned to the High Frequency, Linear Oscillating Test Machine -- 11.4 Load, Friction and Wear Tests -- 11.4.1 EP Test -- 11.4.2 Scuffing Test -- 11.4.3 Reagents and Materials -- 11.5 Test Results -- 11.5.1 Selection of Coatings for Piston Rings.

11.5.2 Scuffing Tribological Test -- 11.5.3 Hot Endurance Test -- 11.6 Selection of Lubricants -- 11.7 High Performance Bio-lubricants and Tribo-reactive Materials for Clean Automotive Applications -- 11.7.1 Synthetic Esters -- 11.7.2 Polyalkyleneglycols -- 11.8 Tribo-Active Materials -- 11.8.1 Thematic 'Piston Rings' -- 11.9 EP Tribological Tests -- 11.9.1 Piston Ring Cylinder Liner Simulation -- Acknowledgements -- References -- PART IV ENGINE BEARINGS -- 12 Friction and Wear in Engine Bearings -- 12.1 Introduction -- 12.2 Engine Bearing Materials -- 12.2.1 Babbitt or White Metal -- 12.2.2 Copper-Lead Alloys -- 12.2.3 Aluminium-based Materials -- 12.3 Functions of Engine Bearing Layers -- 12.4 Types of Overlays/Coatings in Engine Bearings -- 12.4.1 Lead-based Overlays -- 12.4.2 Tin-based Overlays -- 12.4.3 Sputter Bearing Overlays -- 12.4.4 Polymer-based Overlays -- 12.5 Coatings for Engine Bearings -- 12.6 Relevance of Lubrication Regimes in the Study of Bearing Wear -- 12.6.1 Boundary Lubrication -- 12.6.2 Mixed Film Lubrication -- 12.6.3 Fluid Film Lubrication -- 12.7 Theoretical Friction and Wear in Bearings -- 12.7.1 Friction -- 12.8 Wear -- 12.9 Mechanisms of Wear -- 12.9.1 Adhesive Wear -- 12.9.2 Abrasive Wear -- 12.9.3 Erosive Wear -- 12.10 Requirements of Engine Bearing Materials -- 12.11 Characterization Tests for Wear Behaviour of Engine Bearings -- 12.11.1 Fatigue Strength -- 12.11.2 Pin-on-disk Test -- 12.11.3 Scratch Test for Bond Strength -- 12.12 Summary -- References -- PART V LUBRICATING OILS FOR MODERN ENGINES -- 13 Heavy Duty Diesel Engine Oils, Emission Strategies and their Effect on Engine Oils -- 13.1 Introduction -- 13.2 What Drives the Changes in Diesel Engine Oil Specifications? -- 13.2.1 Role of the Government -- 13.2.2 OEMs' Role -- 13.2.3 The Consumer's Role -- 13.3 Engine Oil Requirements.

13.3.1 Overview and What an Engine Oil Must Do.