Modeling Dry DLC Coated Piston Skirts Elastic Behavior at Low-Speed Initial Engine Start Up

Zahid-Ur-Rehman; Qasim, S. Adnan; Malik, M. Afzaal
July 2013
Proceedings of the World Congress on Engineering & Computer Scie;Jul2013, Vol. 1, p1
Conference Proceeding
The diamond-like coating (DLC) protects the lubricant-starved dry surface of the piston skirts against wear in a low-load and speed initial engine start-up. Despite a relatively large radial clearance a physical contact between the skirts and the cylinder liner causes an elastic deformation of DLC coated surface producing elastic stress and strains of noticeable amplitudes. The elastic stress accumulation may facilitate a subsequent de-lamination of the DLC coating. This study develops the numerical piston dynamics model by incorporating the secondary eccentric displacements of the skirts and their contact with the liner during the 720-degree crank rotation cycle. The contact zone in the boundary-value problem is discretized using the finite difference method and the elastic displacements, stresses and strains are determined by applying the theory of elasticity and solving the Navier's or Lame's equation numerically. The nature and extent of the displacements, stresses and strains produced at the interface of a fairly thin DLC coating with the substrate are analyzed. The results highlight the extent of the depth of the elastic surface displacements, the stresses and strains produced in the coating and the substrate materials. The simulation results show that the dry piston skirts establish a physical contact with the liner in the compression stroke that remains in the expansion and exhaust strokes. The stresses produced at the low-speed are significant, increase beneath the surface and accumulate at the interface between the coating and the substrate. The elastic displacements of a fairly thin DLC coating prevent the stress accumulation on the substrate and protects it from adhesive wear


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