Analysis of I C Engine efficiency considering Mechanical and Tribological property for various Matrix Composite: Review Paper Mr. Rajnitu Rajanand Rakshaskar Assistant Professor Mechanical Department MPCOE Velneshwar Abstract

In today’s world automobile is a part of every one’s life and also plays an important role. Here in this paper we have emphasises on IC engine material properties. We discussed about new and advanced material in terms of increase in efficiency of IC engine. Also different type of metal matrix are discussed to design the various parts of IC Engine such as connecting rod, piston and piston ring, valve gear mechanism, crank shaft etc. and are the material considered as matrix of the metal matrix composite as they have very good mechanical and tribological property when they are mixed with and other metical or non-metallic reinforcement. Also we have discussed required change to improve the IC engine efficiency in terms of material property with scope of metal matrix composite in IC engine.

Introduction

As we all know that IC engine is a very important subject which is under continuous development and research. Automobile or IC engine entire life have been classified into three class. Which tell us that in first class we get good efficiency and very few maintenance. In second class we get moderate efficiency and maintenance where as in third class we get reduced efficiency and high maintenance. This is because of wear and damage of engine part due to heat, fatigue, creep etc. To overcome this we can design engine component with advanced material or composite material. Composites are made by compounding of two or more different materials. Their basic constituents have own different characteristics and properties, while the compound presents a completely new material. This material has its own unique, completely new and different properties in relation to constituent components. The aim of this material compounding is to improve structural, tribological, thermal, and chemical or other material properties. Constituent components do not mix and dissolve between each other, so two or more phases are present within composite material. In general, composite materials are made of matrix, constituent with the largest quantity share in relation to other components and reinforce materials that are used in order to obtain projected properties. In case of metal matrices composites, aluminium and its alloys are widely used. Aluminium and its alloys provide the use of different reinforcement materials. The main advantages of composite materials with aluminium matrices in relation to materials with reinforcement materials are - higher strength, higher stiffness, reduced (weight), improved properties at high temperatures, controlled coefficient, controlled heating of material, improved and adoptive electrical conductivity, improved resistance to abrasion and wear, improved amortization ability etc. The average use of aluminium in produced in Europe has increased significantly. The study of European Aluminium Association shows that the amount of aluminium used per produced in Europe almost tripled between 1990 and 2012, increasing from 50kg to 140kg.The Association predicts rise of the average consumption of aluminium per car to 160kg by 2020, and even reaches 180kg. This trend depends on whether small and medium cars follow the evolution recorded in the upper segments of the automobile industry. High-class cars have the highest aluminium content. AudiA8, JaguarXJ, and Range Rover have over 500kg of aluminium in its composition (EAA Brochure, 2013; Hirsch, 2014): Apart from aluminium, lighter materials as magnesium, , and glass or carbon fiber reinforced plastics are also used. Like aluminium many of today’s industries such as aerospace, automobiles etc. finding increasing applications of magnesium alloys and composites have attracted significant research intention due to their low . The hardness plays a significant role in selecting the metal matrix composites for using in various industries, automobiles etc. Metal matrix composites (MMCs) are the composite materials, with two ingredient elements, one being metal essentially, the other constituent may be a dissimilar metal or a different material, such as a ceramic or organic compound. For e.g. Al2O3 particle reinforced in a magnesium matrix and reinforced with the Magnesium matrix composites. With the different types of metal matrix composites, light-weight MMCs such as magnesium (Mg) based composites are of more interest due to their potential applications in aerospace, sports equipment, and automobile industries. Magnesium Metal Matrix Composites have better properties such as elastic modulus, hardness, tensile strength at room and elevated temperatures and significant weight savings over unreinforced alloys.

Literature survey

K.K. Chawla [1] the composite materials have potential to cater the limitations associated with conventional materials. Composite materials are designed and manufactured to solve technological problems for various applications including automotive components, sports goods, aerospace parts, consumer goods and marine applications due to their performance, advantages and possibility to produce light weight components

Drossel, G. and Cheng, N.P.; Zeng, S.M.; Liu, Z.Y. [2] Young’s modulus, the tensile strength, the yield strength, and the wear resistance. The intensity of the individual improvement on the properties due to the reinforcement depends heavily on the type, size, amount, and distribution of the reinforcement particles. To achieve the desired properties, a high degree of dispersion, complete embedding of the particles within the metal matrix, and the development of a suitable interface are required. In general, the smaller the particles, the higher the possible property improvement, but the more

Hunt, W. H [3] Resistance to wear of aluminium MMC is higher than resistance to wear of cast iron. The summary weight of engine block is reduced by 20 % by application of MMC. Besides that, aluminium MMC has higher and, by that, operating temperature is lower so exploitation period is longer. Thickness of cylinder barrel is smaller than one made of cast iron, so the increase of working volume of exact engine is provided without its redesign. The engines with cylinder barrel made of MMC composite are used at S2000 – sport cars, also at Acura NSX cars type and at Bower motors

Surappa MK. [4] The aluminum matrix composites (AMCs) represent a class of MMCs possessing properties like low density, high stiffness and strength, superior wear resistance, controlled co-efficient of thermal expansion, higher fatigue resistance and better stability at elevated temperature. Due to this, these composites are used for the design of a wide range of components for advanced applications Miracle, D. B. [5] by making engine connection rod of aluminium MMC mass reduction of 57 % related to steel one is obtained. By reduction of piston/connection rod mass, vibrations during operation are also reduced. By that, reduction of load at crankshaft and at its bearing is also done, energy losses due to are also reduced, the same as engine fuel consumption It is concluded that reduction of crankshaft by 1 kg caused related reduction of balancing counterweight by 7 kg. J.S. Sureshbabu, et al [6] Hybrid metal matrix composites shows improved mechanical properties due to reduction in meniscus penetration defect and reduced formation of inter- metallic component at interfaces because of increased interfacial area

M. I. Karamangil A. et al[7] research literature about valve failures indicates that valve design is a complicated task because the valve is subjected to various loads at any point of time, such as reverse loading at a high temperature, stress concentration at the keeper groove area and under carbon deposits at exhaust valves. The valves generally fail by fatigue

Mahendra KV, Radhakrishna K.[8] The addition of ceramic particles to the Al-alloy increases the hardness of composite and makes machining of developed composite more difficult. Such problems can be solved by the use of multiple reinforcements in the aluminum alloy. The ceramic reinforcements possess superior strength than any other type of reinforcement and because of the fact, these are used as a primary reinforcement for development of hybrid composites. How-ever, the secondary reinforcements reduces the cost as these are readily available and weight as they have lower density of the hybrid composites Y.B. Liu [9] Exhaust valves operate at very high temperatures and subjected to cyclic loading, the failure of the conical surface of valve is mainly caused by the elastic and plastic deformation, and fatigue. Exhaust valve stem generally fail by overheating because the temperature of the exhaust valve is about 720 ºC. The fracture surface of the valve stem is covered with a black oxide scale formation; fracture surface in the fatigue area is smooth and is covered with thick oxide or deposits that cannot be removed satisfactory. In the middle portion of the stem a longitudinal fretting damage is occurred. Some small cracks are initiated and propagated across the section. With high loading, multiple cracks are initiated if the valves are subjected to high temperatures and, under such operating conditions, it would be logical to expect that failure would occur within a few million cycles

Y.T. Zhao et al [10] Processing of Metal Matrix Composites (MMCs) mainly classified into two groups namely ex-situ synthesis and in-situ synthesis. In ex-situ synthesis the particles are added into the metal matrix from outside and in in-situ synthesis the reinforcement is realized by chemical reaction or exothermic reaction e.g. exothermic dispersion, reactive hot pressing, reactive infiltration and direct melt reaction

Kalaiselvan.K et al [11] In this paper, the stir casting technique is the best and widely used for the preparation of metal matrix composites as it is inexpensive. While the rotation of stirrer into the melt, the chemical bonding between the matrix and the reinforcement is better and the achievement of homogeneity is possible. The main parameters which may affect the performance of stir casting process are stirring speed, time, temperature of molten metal and the uniform addition of reinforcement into matrix.

H. J. C. Voorwalda [12] Available research literature about valve failures indicates that valve design is a complicated task because the valve is subjected to various loads at any point of time, such as reverse loading at a high temperature, stress concentration at the keeper groove area and under carbon deposits at exhaust valves. The valves generally fail by fatigue

Mehedi, M. A. [13] cylindrical pushrods translate motion from the cam to the valve train in overhead valve (OHV) engines. It is vital that the pushrod faithfully reproduces the desired motion from the cam to the valves .High pushrod stiffness is required to control bending, a low mass is needed to reduce lofting, and good damping is essential to limiting vibration. A fibre reinforced aluminium MMC is used in pushrods for high-performance OHV racing engines .Aluminium MMC reinforced by fibres is used for production of pushrods of valves at engines. As reinforcing material, fibres of Al2O3 are used, while for the matrix aluminium alloys are used. The first producer of these parts made of MMC is 3M Corporation. The pushrods of engine valve made of alumina MMC have 25 % higher stiffness to flexion and twice higher absorption capacity than the related parts made of common steel.

Nagaraj Nayaka et al [14] In this paper, the rate of wear of cam followers in a valve train system is mainly a function of contact stress between the cam and the follower, sliding velocity and hydrodynamic film thickness between the two mating surfaces. The problem of surface fatigue wear becomes severe as the contact between cam and follower exceeds the plasticity limit of material. It finally leads to an increase in valve lash and loss of engine performance. The wear is minimized by reducing the coefficient of friction and by minimizing the compressive stress.

D.Rajamani, et al [15] Magnesium is available plentifully about 13% by weight of the Earth's crust as like iron, oxygen and silicon. The Atomic number of magnesium is 12. Magnesium is a soft, long-lasting, low weight, high yielding and pliable metal with appearance of grey-white. Magnesium has about two-third the density of aluminium. It can be machined without difficulty, ease of casting, drawing and extruded. Magnesium has high corrosive resistance due to presence of a thin surface layer of magnesium oxide, which prevents further oxidation more effectively. The reinforced magnesium MMCs are prepared by several methods including squeeze casting, stir casting, infiltration and mechanical alloying, . Among these, powder metallurgy (P/M) technique is most likely used to fabricate Mg metal matrix composites. A uniform distribution of reinforcement particulates in the metal matrix can be achieved by using powder metallurgy technique with or without the chemical reactions between the reinforcements and matrix and the composites can fabricate by using powders without melt

Autar K kaw,[16] “Introduction to composite materials” The hardness plays a significant role in selecting the metal matrix composites for using in various industries, automobiles etc. Metal matrix composites (MMCs) are the composite materials, with two ingredient elements, one being metal essentially, the other constituent may be a dissimilar metal or a different material, such as a ceramic or organic compound. For e.g. Al2O3 particle reinforced in a magnesium matrix and Silicon carbide reinforced with the Magnesium matrix composites. With the different types of metal matrix composites, light-weight MMCs such as magnesium (Mg) based composites are of more interest due to their potential applications in aerospace, sports equipment, and automobile industries. Magnesium Metal Matrix Composites have better properties such as elastic modulus, hardness, tensile strength at room and elevated temperatures and significant weight savings over unreinforced alloys. F. Bonatesta, G. et al [17] The restriction on engine emissions and the demand for high power output and fuel economy result in ongoing research for various improvements in engine technology. Variable valve timing (VVT) is potential improvements for both of performance and emission at all engine speeds and load range. At full load condition, increased duration of valve event leads to enhance performance. By arranging intake and exhaust valve opening or closing timing, fuel economy, power output, residual gas mass fraction and pollutant emissions can be improved

Discussion

The failure of different parts of IC engine may occur due to various possible modes like wear, fatigue, thermal fatigue, erosion/corrosion, buckling, thermal stability, overheating of IC engine parts. New technology like I-Vtech, VVT, VTVT etc are used for variation in valve timing in order to optimise the fuel supply and improve the efficiency. Part required for such mechanism should be light in weight and should have very good tribological property. If any part of this system goes under wear or failure efficiency reduced drastically. Most of the engine parts are not easy to replace if they fail or goes under wear. Due to this efficiency and life of IC engine gets reduced. Because of this reason we get reduced efficiency as engine get old. It is essential to replace tradition material of IC engine with advanced material who is having good weight to strength ration, better mechanical, thermal and tribological property. To achieve this property Metal matrix composite is the best option as we can achieve various property by varying reinforcements. Conclusion We can replace traditional IC engine material with advance material such as metal matrix composite with improved material property and improved life span of IC engine components or parts. Aluminium matrix is widely used in IC engine but magnesium can be replaced with it as it is having 2/3 density of aluminium. Ceramic reinforcement can be used to withstand this material at high temperature. The present investigation is showing that the light weight part of IC engine improved mechanical thermal and tribological properties, contributing to increased efficiency and significant reduction in power loss. References:

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