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2015 | Buch

Microstructuring of Thermo-Mechanically Highly Stressed Surfaces

Final Report of the DFG Research Group 576

herausgegeben von: Berend Denkena, Adrian Rienäcker, Gunter Knoll, Friedrich-Wilhelm Bach, Hans Jürgen Maier, Eduard Reithmeier, Friedrich Dinkelacker

Verlag: Springer International Publishing

Buchreihe : Lecture Notes in Production Engineering

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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Über dieses Buch

The fuel consumption of a modern combustion engine is one of the most important purchase criteria in contemporary society. Increasing oil prices and exhaust emissions taxes force the automotive industry to continuously improve the vehicle engines. The fuel consumption is closely related to the frictional losses of an engine. New material pairings or constructive modifications of the piston group can reduce such losses. Another innovative concept to lower the frictional forces is the micro-structuring of thermo-mechanically highly stressed surfaces. Within an interdisciplinary research group sponsored by the German Research Foundation, scientists at the Leibniz Universität Hannover and Universität Kassel have been working together to investigate this research topic. This final report presents their findings and offers scope for further discussion.

Inhaltsverzeichnis

Frontmatter

1 Introduction

Abstract

More than 51 million vehicles with an annual total mileage of about 699 billion kilometres are registered in Germany [DES12, UMW12]. Assuming an average consumption of 7.5 l per 100 km, a reduction in fuel consumption of 1% to 3% would lead to savings of 524 to 1,573 million litres of fuel [UMW12].

Berend Denkena, Adrian Rienäcker, Gunter Knoll, Friedrich-Wilhelm Bach, Hans Jürgen Maier, Eduard Reithmeier, Friedrich Dinkelacker

2 Project overview

Abstract

The interdisciplinary consortium in the fields design, manufacturing, characterisation and scientific testing of microstructured surfaces pursues the above-mentioned subprojects.

Berend Denkena, Adrian Rienäcker, Gunter Knoll, Friedrich-Wilhelm Bach, Hans Jürgen Maier, Eduard Reithmeier, Friedrich Dinkelacker

3 Methods and models for the design of microstructures

Abstract

The objective of this sub-project was the development and validation of simulation methods for the tribological characterisation of the effect of hydrodynamic microdimples with respect to improved friction wear and oil consumption in the system piston ring/cylinder liner.

G. Knoll, A. Rienäcker, S. Brandt, H. Fast

4 Microstructuring by means of cutting processes

Abstract

Goal of this subproject was to explore and develop a cutting process for the manufacturing of high-quality, friction-reducing micro-dimples. Prerequisite was the use of a single-edge cutting tool.

B. Denkena, J. Kästner, T. Göttsching

5 Microstructured thermally sprayed surfaces

Abstract

The aim of this project was the development and research of thermally sprayed coatings with friction reducing micro-dimples. The basis for this approach was the systematic variation of the spray parameters.

Fr.-W. Bach, K. Möhwald, M. Erne, C. Hübsch, H. J. Maier

6 Surface characterisation based on optical metrology

Abstract

For the complex task of measuring the insides of a cylinder liner using optical sensors, new methods had to be developed. Since optical sensors for areal measurements, such as white light interferometers and confocal microscopes, require too much space and have a limited measuring range, a confocal chromatic white light sensor was used. The chromatic sensor is a point sensor that allows for precise positioning inside of cylinder liners, as only a small part of the apparatus has to be brought inside the cylinder while the signal is transported to the controller by optical fibre.

E. Reithmeier, M. Kästner, M. Bretschneider, O. Abo-Namous, F. Engelke

7 Tribological mechanisms of microstructures

Abstract

In order to verify the friction-minimising potential of machined micro-dimples, they were cut into thrust bearing rings; consequently, their functional properties were determined on a ring-on-disc tribometer setup for planar contact with large surface coverage. Furthermore the tribology results of the machined micro-dimples were consequently compared with experimental testing results of micro-dimples that were fabricated with other manufacturing methods.

B. Denkena, J. Kästner, T. Göttsching

8 Test of cylinder liner under fired engine conditions

Abstract

After joining the research group in 2009, the Institute of Technical Combustion built up and evaluated an engine test bench for testing microstructured cylinder liners under realistic engine conditions. The entire test bench - including peripherals such as supply facilities, measurement data acquisition devices, and automatic control technique - was specifically built this project.

F. Dinkelacker, H. Ulmer

9 Own publications

Berend Denkena, Adrian Rienäcker, Gunter Knoll, Friedrich-Wilhelm Bach, Hans Jürgen Maier, Eduard Reithmeier, Friedrich Dinkelacker

Backmatter

Titel: Microstructuring of Thermo-Mechanically Highly Stressed Surfaces
herausgegeben von: Berend Denkena
Adrian Rienäcker
Gunter Knoll
Friedrich-Wilhelm Bach
Hans Jürgen Maier
Eduard Reithmeier
Friedrich Dinkelacker
Verlag: Springer International Publishing
Electronic ISBN: 978-3-319-09692-6
Print ISBN: 978-3-319-09691-9
DOI: https://doi.org/10.1007/978-3-319-09692-6

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