Investigation of reciprocating conformal contact of piston skirt-to-surface modified cylinder liner in high performance

The article presents detailed analysis of the conforming contact between a piston and cylinder liner in a high-speed racing engine under extreme operating conditions owing to high loads and operating speeds in excess of 19 000 r/min, resulting in a high sliding velocity of 42 m/s. The analysis indicates contact forces generated in the order of 2.5 kN. The contribution due to fluid film lubrication is found to reside in iso-viscous rigid or elastic regimes of lubrication, which is insufficient to form a coherent lubricant film during some parts of the cycle, such as at top-dead-centre (TDC). The article shows that at combustion, 95 per cent of the contact can remain in boundary or mixed regimes of lubrication. Piston skirt surface modification features are used in conjunction with an electrolytically applied composite coating, Ni[SiC]p to produce advanced cylinder liners to remedy the situation. Detailed numerical analysis shows that significant improvement is achieved in the regime of lubrication condition.