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Engine Components and Filters: Damage Profiles, Probable Causes and Prevention
ENGINE COMPONENTS AND FILTERS: DAMAGE PROFILES, PROBABLE CAUSES AND PREVENTION Technical Information AFTERMARKET Contents 1 Introduction 5 2 General topics 6 2.1 Engine wear caused by contamination 6 2.2 Fuel flooding 8 2.3 Hydraulic lock 10 2.4 Increased oil consumption 12 3 Top of the piston and piston ring belt 14 3.1 Hole burned through the top of the piston in gasoline and diesel engines 14 3.2 Melting at the top of the piston and the top land of a gasoline engine 16 3.3 Melting at the top of the piston and the top land of a diesel engine 18 3.4 Broken piston ring lands 20 3.5 Valve impacts at the top of the piston and piston hammering at the cylinder head 22 3.6 Cracks in the top of the piston 24 4 Piston skirt 26 4.1 Piston seizure on the thrust and opposite side (piston skirt area only) 26 4.2 Piston seizure on one side of the piston skirt 27 4.3 Diagonal piston seizure next to the pin bore 28 4.4 Asymmetrical wear pattern on the piston skirt 30 4.5 Piston seizure in the lower piston skirt area only 31 4.6 Heavy wear at the piston skirt with a rough, matte surface 32 4.7 Wear marks on one side of the piston skirt 33 5 Support – piston pin bushing 34 5.1 Seizure in the pin bore 34 5.2 Cratered piston wall in the pin boss area 35 6 Piston rings 36 6.1 Piston rings with burn marks and seizure marks on the 36 piston skirt 6.2 Damage to the ring belt due to fractured piston rings 37 6.3 Heavy wear of the piston ring grooves and piston rings 38 6.4 Heavy radial wear of the piston rings 39 7 Cylinder liners 40 7.1 Pitting on the outer -
MACHINES OR ENGINES, in GENERAL OR of POSITIVE-DISPLACEMENT TYPE, Eg STEAM ENGINES
F01B MACHINES OR ENGINES, IN GENERAL OR OF POSITIVE-DISPLACEMENT TYPE, e.g. STEAM ENGINES (of rotary-piston or oscillating-piston type F01C; of non-positive-displacement type F01D; internal-combustion aspects of reciprocating-piston engines F02B57/00, F02B59/00; crankshafts, crossheads, connecting-rods F16C; flywheels F16F; gearings for interconverting rotary motion and reciprocating motion in general F16H; pistons, piston rods, cylinders, for engines in general F16J) Definition statement This subclass/group covers: Machines or engines, in general or of positive-displacement type References relevant to classification in this subclass This subclass/group does not cover: Rotary-piston or oscillating-piston F01C type Non-positive-displacement type F01D Informative references Attention is drawn to the following places, which may be of interest for search: Internal combustion engines F02B Internal combustion aspects of F02B 57/00; F02B 59/00 reciprocating piston engines Crankshafts, crossheads, F16C connecting-rods Flywheels F16F Gearings for interconverting rotary F16H motion and reciprocating motion in general Pistons, piston rods, cylinders for F16J engines in general 1 Cyclically operating valves for F01L machines or engines Lubrication of machines or engines in F01M general Steam engine plants F01K Glossary of terms In this subclass/group, the following terms (or expressions) are used with the meaning indicated: In patent documents the following abbreviations are often used: Engine a device for continuously converting fluid energy into mechanical power, Thus, this term includes, for example, steam piston engines or steam turbines, per se, or internal-combustion piston engines, but it excludes single-stroke devices. Machine a device which could equally be an engine and a pump, and not a device which is restricted to an engine or one which is restricted to a pump. -
Overview of Materials Used for the Basic Elements of Hydraulic Actuators and Sealing Systems and Their Surfaces Modification Methods
materials Review Overview of Materials Used for the Basic Elements of Hydraulic Actuators and Sealing Systems and Their Surfaces Modification Methods Justyna Skowro ´nska* , Andrzej Kosucki and Łukasz Stawi ´nski Institute of Machine Tools and Production Engineering, Lodz University of Technology, ul. Stefanowskiego 1/15, 90-924 Lodz, Poland; [email protected] (A.K.); [email protected] (Ł.S.) * Correspondence: [email protected] Abstract: The article is an overview of various materials used in power hydraulics for basic hydraulic actuators components such as cylinders, cylinder caps, pistons, piston rods, glands, and sealing systems. The aim of this review is to systematize the state of the art in the field of materials and surface modification methods used in the production of actuators. The paper discusses the requirements for the elements of actuators and analyzes the existing literature in terms of appearing failures and damages. The most frequently applied materials used in power hydraulics are described, and various surface modifications of the discussed elements, which are aimed at improving the operating parameters of actuators, are presented. The most frequently used materials for actuators elements are iron alloys. However, due to rising ecological requirements, there is a tendency to looking for modern replacements to obtain the same or even better mechanical or tribological parameters. Sealing systems are manufactured mainly from thermoplastic or elastomeric polymers, which are characterized by Citation: Skowro´nska,J.; Kosucki, low friction and ensure the best possible interaction of seals with the cooperating element. In the A.; Stawi´nski,Ł. Overview of field of surface modification, among others, the issue of chromium plating of piston rods has been Materials Used for the Basic Elements discussed, which, due, to the toxicity of hexavalent chromium, should be replaced by other methods of Hydraulic Actuators and Sealing of improving surface properties. -
Assessing Steam Locomotive Dynamics and Running Safety by Computer Simulation
TRANSPORT PROBLEMS 2015 PROBLEMY TRANSPORTU Volume 10 Special Edition steam locomotive; balancing; reciprocating; hammer blow; rolling stock and track interaction Dāvis BUŠS Institute of Transportation, Riga Technical University Indriķa iela 8a, Rīga, LV-1004, Latvia Corresponding author. E-mail: [email protected] ASSESSING STEAM LOCOMOTIVE DYNAMICS AND RUNNING SAFETY BY COMPUTER SIMULATION Summary. Steam locomotives are preserved on heritage railways and also occasionally used on mainline heritage trips, but since they are only partially balanced reciprocating piston engines, damage is made to the railway track by dynamic impact, also known as hammer blow. While causing a faster deterioration to the track on heritage railways, the steam locomotive may also cause deterioration to busy mainline tracks or tracks used by high speed trains. This raises the question whether heritage operations on mainline can be done safely and without influencing the operation of the railways. If the details of the dynamic interaction of the steam locomotive's components are examined with computerised calculations they show differences with the previous theories as the smaller components cannot be disregarded in some vibration modes. A particular narrow gauge steam locomotive Gr-319 was analyzed and it was found, that the locomotive exhibits large dynamic forces on the track, much larger than those given by design data, and the safety of the ride is impaired. Large unbalanced vibrations were found, affecting not only the fatigue resistance of the locomotive, but also influencing the crew and passengers in the train consist. Developed model and simulations were used to check several possible parameter variations of the locomotive, but the problems were found to be in the original design such that no serious improvements can be done in the space available for the running gear and therefore the running speed of the locomotive should be limited to reduce its impact upon the track. -
Optimum Connecting Rod Design for Diesel Engines
SCIENTIFIC PROCEEDINGS XXIV INTERNATIONAL SCIENTIFIC-TECHNICAL CONFERENCE "trans & MOTAUTO ’16" ISSN 1310-3946 OPTIMUM CONNECTING ROD DESIGN FOR DIESEL ENGINES M.Sc. Kaya T. 1, Asist. Prof. Temiz V. PhD.2, Asist. Prof. Parlar Z. PhD.2 Siemens Turkey1 Faculty of Mechanical Engineering – Istanbul Technical University, Turkey 2 [email protected] Abstract: One of the most critical components of an engine in particular, the connecting rod, has been analyzed. Being one of the most integral parts in an engine’s design, the connecting rod must be able to withstand tremendous loads and transmit a great deal of power. This study includes general properties about the connecting rod, research about forces upon crank angle with corresponding to its working dependencies in a structural mentality, study on the stress analysis upon to this forces gained from calculations and optimization with the data that gained from the analysis. In conclusion, the connecting rod can be designed and optimized under a given load range comprising tensile load corresponding to 360o crank angle at the maximum engine speed as one extreme load, and compressive load corresponding to the peak gas pressure as the other extreme load. Keywords: CONNECTING ROD, OPTIMIZATION, DIESEL ENGINE 1. Introduction rod. Force caused by pressure inside the cylinder reaches its maximum value around the top dead center. Inertia forces results During the design of a connecting rod, optimized dimensions from the acceleration of moving elements. Numerical values of allowing the motion of rod during operation should be taken into these forces are dependent on the type, rated power and rotational account in the calculation of variable loads induced in the system speed of engine. -
Swampʼs Diesel Performance Tips to Help Remove and Install Power
Injectors-Chips-Clutches-Transmissions-Turbos-Engines-Fuel Systems Swampʼs Diesel Performance Competition Parts For Your Diesel 304-A Sand Hill Rd. La Vergne, TN 37086 Tel 615-793-5573 or (866) 595-8724/ Fax 615-793-5572 Email: [email protected] Tips to help remove and install Power Stroke injectors. Removal: After removing the valve covers and the valve cover gaskets, but before removing any injectors, drain the oil rails by removing the drain plugs inside the valve cover. On 94-97 trucks theyʼre just under where the electrical connectors are on the gasket. These plugs are very tight; give them a sharp blow with a hammer and punch to help break them loose, then use a 1/8" Allen wrench. The oil will drain out into the valve train area and from there into the crankcase. Donʼt drop the plugs down the push rod holes! Also remove one of the plugs on top of each oil rail, (beside where the lines from the High Pressure Oil Pump enter) for a vent to allow air to enter so the oil can drain. The plugs are 5/8”. Inspect the plug O-rings and replace if necessary. If the plugs under the covers leak, it will cause a substantial loss of performance. When removing the injectors, oil and fuel from the passages in the cylinder head drains down through the injector bore into the cylinders. If not removed, this can hydro-lock the engine when cranking. There is a ~40cc dish in the center of each piston. Fluid accumulates in it, as well as in the corner on the outside of the piston between the piston top and the cylinder wall, due to the 45* slope of the cylinder bank. -
Development of Predictive Gasoline Direct Fuel Injector Model for Improved
Development of Predictive Gasoline Direct Fuel Injector Model for Improved In-cylinder Combustion Characterization Thesis Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Mohit Atul Mandokhot Graduate Program in Mechanical Engineering The Ohio State University 2018 Thesis Committee Prof. Shawn Midlam-Mohler, Advisor Prof. Giorgio Rizzoni 1 Copyrighted by Mohit Atul Mandokhot 2018 2 Abstract Gasoline direct fuel injection systems have gained importance due to the increasing level of emissions regulation on SI combustion systems. Direct fuel injection delivery to cylinder provides better atomization and fuel mixing performance, enabling homogenous mixture and better in-cylinder combustion. Increasing focus over the last few decades has been on better characterization of such gasoline direct fuel injection systems. Solenoid powered injectors act as actuators and enable accurate fuel delivery into the cylinder for a combustion event. Characterization of injector’s fuel delivery performance is an important aspect of achieving improved in-cylinder combustion performance. The objective of the current thesis is to develop a numerical physics based fuel injector model that provides a reliable prediction of flow rate and needle lift, in order to be used to improve in-cylinder combustion performance using 3D CFD model methodology. The developed model provides a reliable estimate of flow rate of developed injector, which is experimentally verified against instantaneous flow rate data provided by typical suppliers. In cases where inadequate prediction performance was noted, the errors arise out of lack of high fidelity electromagnetic modeling data, damping characteristics inside model and lack of geometry data to capture performance of highest accuracy. -
[Thesis Title Goes Here]
DETAILED STUDY OF THE TRANSIENT ROD PNEUMATIC SYSTEM ON THE ANNULAR CORE RESEARCH REACTOR A Thesis Presented to The Academic Faculty by Brandon M. Fehr In Partial Fulfillment of the Requirements for the Degree Master of Science in Nuclear Engineering in the School of Nuclear and Radiological Engineering and Medical Physics Program, George W. Woodruff School of Mechanical Engineering Georgia Institute of Technology May 2016 COPYRIGHT © 2016 BY BRANDON M. FEHR iv DETAILED STUDY OF THE TRANSIENT ROD PNEUMATIC SYSTEM ON THE ANNULAR CORE RESEARCH REACTOR Approved by: Dr. Farzad Rahnema, Advisor Mr. Michael Black School of Nuclear and Radiological R&D S&E Mechanical Engineering Engineering Sandia National Laboratories Georgia Institute of Technology Dr. Tristan Utschig School of Nuclear and Radiological Engineering Georgia Institute of Technology Dr. Bojan Petrovic School of Nuclear and Radiological Engineering Georgia Institute of Technology Date Approved: April 11, 2016 v ACKNOWLEDGEMENTS I would like to give the utmost appreciation to my colleagues at Sandia National Laboratories for their support, with special thanks to Michael Black, James Arnold, and Paul Helmick for their technical guidance. I would also like to thank Dulce Barrera and Elliott Pelfrey for their encouragement and support, and Bennett Lee for his help with proofreading and formatting. Special thanks to Dr. Farzad Rahnema for his guidance and contract support, as well as, Dr. Bojan Petrovic and Dr. Tris Utschig for serving on my committee. Lastly, I would like to thank my parents for their support and encouragement during the whole journey. This research was funded by Weapons Science & Technology (WS&T), Readiness in Technical Base and Facilities (RTBF). -
Lean's Engine Reporter and the Development of The
Trans. Newcomen Soc., 77 (2007), 167–189 View metadata, citation and similar papers at core.ac.uk brought to you by CORE provided by Research Papers in Economics Lean’s Engine Reporter and the Development of the Cornish Engine: A Reappraisal by Alessandro NUVOLARI and Bart VERSPAGEN THE ORIGINS OF LEAN’S ENGINE REPORTER A Boulton and Watt engine was first installed in Cornwall in 1776 and, from that year, Cornwall progressively became one of the British counties making the most intensive use of steam power.1 In Cornwall, steam engines were mostly employed for draining water from copper and tin mines (smaller engines, called ‘whim engines’ were also employed to draw ore to the surface). In comparison with other counties, Cornwall was characterized by a relative high price for coal which was imported from Wales by sea.2 It is not surprising then that, due to their superior fuel efficiency, Watt engines were immediately regarded as a particularly attractive proposition by Cornish mining entrepreneurs (commonly termed ‘adventurers’ in the local parlance).3 Under a typical agreement between Boulton and Watt and the Cornish mining entre- preneurs, the two partners would provide the drawings and supervise the works of erection of the engine; they would also supply some particularly important components of the engine (such as some of the valves). These expenditures would have been charged to the mine adventurers at cost (i.e. not including any profit for Boulton and Watt). In addition, the mine adventurer had to buy the other components of the engine not directly supplied by the Published by & (c) The Newcomen Society two partners and to build the engine house. -
I Lecture Note
Machine Dynamics – I Lecture Note By Er. Debasish Tripathy ( Assist. Prof. Mechanical Engineering Department, VSSUT, Burla, Orissa,India) Syllabus: Module – I 1. Mechanisms: Basic Kinematic concepts & definitions, mechanisms, link, kinematic pair, degrees of freedom, kinematic chain, degrees of freedom for plane mechanism, Gruebler’s equation, inversion of mechanism, four bar chain & their inversions, single slider crank chain, double slider crank chain & their inversion.(8) Module – II 2. Kinematics analysis: Determination of velocity using graphical and analytical techniques, instantaneous center method, relative velocity method, Kennedy theorem, velocity in four bar mechanism, slider crank mechanism, acceleration diagram for a slider crank mechanism, Klein’s construction method, rubbing velocity at pin joint, coriolli’s component of acceleration & it’s applications. (12) Module – III 3. Inertia force in reciprocating parts: Velocity & acceleration of connecting rod by analytical method, piston effort, force acting along connecting rod, crank effort, turning moment on crank shaft, dynamically equivalent system, compound pendulum, correction couple, friction, pivot & collar friction, friction circle, friction axis. (6) 4. Friction clutches: Transmission of power by single plate, multiple & cone clutches, belt drive, initial tension, Effect of centrifugal tension on power transmission, maximum power transmission(4). Module – IV 5. Brakes & Dynamometers: Classification of brakes, analysis of simple block, band & internal expanding shoe brakes, braking of a vehicle, absorbing & transmission dynamometers, prony brakes, rope brakes, band brake dynamometer, belt transmission dynamometer & torsion dynamometer.(7) 6. Gear trains: Simple trains, compound trains, reverted train & epicyclic train. (3) Text Book: Theory of machines, by S.S Ratan, THM Mechanism and Machines Mechanism: If a number of bodies are assembled in such a way that the motion of one causes constrained and predictable motion to the others, it is known as a mechanism. -
WSA Engineering Branch Training 3
59 RECIPROCATING STEAM ENGINES Reciprocating type main engines have been used to propel This is accomplished by the guide and slipper shown in the ships, since Robert Fulton first installed one in the Clermont in drawing. 1810. The Clermont's engine was a small single cylinder affair which turned paddle wheels on the side of the ship. The boiler was only able to supply steam to the engine at a few pounds pressure. Since that time the reciprocating engine has been gradually developed into a much larger and more powerful engine of several cylinders, some having been built as large as 12,000 horsepower. Turbine type main engines being much smaller and more powerful were rapidly replacing reciprocating engines, when the present emergency made it necessary to return to the installation of reciprocating engines in a large portion of the new ships due to the great demand for turbines. It is one of the most durable and reliable type engines, providing it has proper care and lubrication. Its principle of operation consists essentially of a cylinder in which a close fitting piston is pushed back and forth or up and down according to the position of the cylinder. If steam is admitted to the top of the cylinder, it will expand and push the piston ahead of it to the bottom. Then if steam is admitted to the bottom of the cylinder it will push the piston back up. This continual back and forth movement of the piston is called reciprocating motion, hence the name, reciprocating engine. To turn the propeller the motion must be changed to a rotary one. -
Design and Stress Analysis of Crankshaft for Single Cylinder 4 Stroke Diesel Engine
Published by : International Journal of Engineering Research & Technology (IJERT) http://www.ijert.org ISSN: 2278-0181 Vol. 7 Issue 11, November-2018 Design and Stress Analysis of Crankshaft for Single Cylinder 4 Stroke Diesel Engine K. Durga Prasad1 K. V. J. P. Narayana2 N. Kiranmayee3 Dept of Mechanical Engineering, Dept of Mechanical Engineering, Dept of Mechanical Engineering, V.K.R, V.N.B & A.G.K College of V.K.R, V.N.B & A.G.K College of V.K.R, V.N.B & A.G.K College of Engineering, AP, India. Engineering, AP, India Engineering, AP, India Abstract-In this paper a static simulation is conducted on a Forging demands for several dies to achieve the crankshaft from a single cylinder 4- stroke diesel engine. A final component and casting requires non-permanent, three dimension model of diesel engine crankshaft is created usually sand, molds. These two processes also need various using CATIA V5 software. Finite element analysis (FEA) is finishing operations, such as grinding and balancing. As for performed to obtain the variation of stress magnitude at the machining process, it is only viable for unitary or low critical locations of crankshaft in. The static analysis is done using FEA Software HYPERMESH which resulted in the load production, as the material waste and machining time is spectrum applied to crank pin bearing. This load is applied to enormous, despite not requiring much in the way of the FEA model in HYPERMESH, and boundary conditions balancing. The prototype tool developed in this paper, are applied according to the engine mounting conditions allows to overcome the shortcomings associated with the conventional processes, as the pre-form used is a round bar, I.