Simulation of Valve Train Friction Concerning Large Engines
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1 ECS Conference 2010 Simulation of Valve Train Friction Concerning Large Engines Ian Calvert (GE Energy) Barry Anderson (GE Energy) Thomas Gebhardt (GE Energy) Christoph Priestner (ViF) Christoph Six (ViF) Hans H. Priebsch (ViF) Franz M. Reich (ViF) K2 / K plus Competence Center - Initiated by the Federal Ministry of Transport, Innovation & Technology (BMVIT) and the Federal Ministry of Economics & Labour (BMWA). Funded by FFG, Land Steiermark and Steirische Wirtschaftsförderung (SFG) VIF-K2-Presentation VIRTUAL VEHICLE 1
2 Objectives Friction Reduction Concerning an 24-Cylinder Gas Engine Piston System Crankshaft Bearings Conrod Bearings Valve Train Oil Pump Timing Drive VIF-K2-Presentation VIRTUAL VEHICLE 2
3 Overview Modelling Simulation Results VIF-K2-Presentation VIRTUAL VEHICLE 3
4 Overview Modelling Simulation Results VIF-K2-Presentation VIRTUAL VEHICLE 4
5 Modelling System Identification Which Components Rocker Ball Sockets << Cam Follower Guidance Cam-Roll Contact CS-Slider Bearings Rotocap Valve Rod Guidance Thrust Member to Valve << Spring Assembly Support << VIF-K2-Presentation VIRTUAL VEHICLE 5
6 Modelling System Identification Which Methods MBS FEM EHD Analytical Valve Train Dynamics - Acceleration - Velocity - Displacement - Force Parameters for MBS-Model - Structural- Stiffness Condensation of FE-Structures Fluid-Structure Interaction of CS- Slider Bearings - HD-Distribution - Asperity Contact - Friction Power Loss - Parameters for MBS-Model - Flow - Friction Coefficient - Stiffness VIF-K2-Presentation VIRTUAL VEHICLE 6
7 Modelling Valve Train Dynamics MBS-Model of the 24-Cylinder s Valve Train VIF-K2-Presentation VIRTUAL VEHICLE 7
8 Modelling Valve Train Dynamics MBS-Model of the 24-Cylinder s Valve Train Module VIF-K2-Presentation VIRTUAL VEHICLE 8
9 Modelling Valve Train Dynamics Cam/Roll Contact Dynamic Contact Stress Oil Film Thickness 2d HD Contact Definition: Surface to Surface Finite Sliding Lagrange Multip VIF-K2-Presentation VIRTUAL VEHICLE 9
10 Modelling Valve Train Dynamics Cam Follower Guid Longitudinal: Couette Flow Transversal: Coulomb s Law VIF-K2-Presentation VIRTUAL VEHICLE 10
![Displacement [mm] Modelling Valve Train Dynamics Rocker 0.045 0.04 0.035 0.03 0.025 0.02 0.015 0.01 0.](/docs-images/87/96043432/images/11-4.jpg "005 0 Component-Stiffness Force [N] 0 2000 4000 6000 8000 10000 12000 Simplified representation of")
11 Displacement [mm] Modelling Valve Train Dynamics Rocker Component-Stiffness Force [N] Simplified representation of slider bearings in rocker Couette-Flow in maximum filled slider bearing Friction due to normal forces considering Coulomb s law F R v U F CR ω r x 2 x 1 v C VIF-K2-Presentation VIRTUAL VEHICLE 11
12 Modelling Bearing Analysis Elastic MBS Condensed FE-Structure Fluid-Structure Interaction with Elasto-Hydrodyanamics Solving the Reynolds-PDE considering the elastic shaft and shell structure Model for mixed lubrication regime according Greenwood /Tripp Dynamic Viscosity according Vogel η dynamic viscosity [Ns/mm 2 ] T oil temperature [ C] A, B, C Vogel-Contstants VIF-K2-Presentation VIRTUAL VEHICLE 12
13 Modelling Bearing Analysis Elastic MBS considering EHD C3D10 Structure C3D8 Bearing-Shell Boundary Conditions Dynamic Condensation according Graig-Bampton Method VIF-K2-Presentation VIRTUAL VEHICLE 13
14 Modelling Bearing Analysis Elastic MBS considering EHD VIF-K2-Presentation VIRTUAL VEHICLE 14
15 Overview Modelling Simulation Results VIF-K2-Presentation VIRTUAL VEHICLE 15
16 Simulation Valve Train Dynamics Initial Parameter Set MBS Improved Approach - Accelerations - Forces - Parameters - MBS, FEM, Valve Train Dynamics MBS else - OK Δ Forces if (Δ > tol.) then - Accelerations - Forces - Bearing-Analysis Elastic MBS EHD Loss Contribution - Components - Slider Bearings VIF-K2-Presentation VIRTUAL VEHICLE 16
17 Overview Modelling Simulation Results VIF-K2-Presentation VIRTUAL VEHICLE 17
18 Results Loss Contribution of Relevant Components Camshaft Bearings Cam-Roller Contact Cam Follower Valve Rod Rocker VIF-K2-Presentation VIRTUAL VEHICLE 18
19 Peak Total Pressure Total Friction Power Loss Minimum Oil Film Thickness Results Camshaft Slider Bearings Mean Value of Friction Power Loss per Bearing Rating Criterion AngR (deg) AngR (deg) AngR (deg) VIF-K2-Presentation VIRTUAL VEHICLE 19
20 Bearing Width Bearing Width Bearing Width MOFT Results Camshaft Slider Bearings Shell Angle (deg) 360 MOFT Fill Ratio Fill Ratio = f(oil Supply Pressure, ) 0 Shell Angle (deg) Shell Angle (deg) 360 Share of Pressure-Flow Share of Shear-Flow in Lubrication Gap VIF-K2-Presentation VIRTUAL VEHICLE 20
21 Results Camshaft Slider Bearings Parameters Bearing Shell Width Bearing Diameter Oil Groove Width Radial Clearance Oil Supply Pressure Oil Temperature in Lubrication Gap VIF-K2-Presentation VIRTUAL VEHICLE 21
22 Results Evaluation of Loss Contributions analogue to Strip-Down Attempt Starting with loss-free valve train Successive extension with different loss contributions VIF-K2-Presentation VIRTUAL VEHICLE 22
23 Results Listing of Loss Contributions Component Contribution to Overall Valvtrain Losses Cam-Roller Contact 53.9 % Cam Follower Guidance 26.4 % Camshaft Slider Bearings 11.4 % Rocker 5.5 % Valve Rod 1.7 % Gasforces 1.1 % Total 100% VIF-K2-Presentation VIRTUAL VEHICLE 23
24 Results Validation of Simulation Results Known: P Mech_J624 Assumption η Mech_J624 Mechanical Losses of the J624 P Mech_Loss_J624 Known: P mech_j616 und P Mech_Loss_ValveTrain_J616 Assumption η Mech_J616 η Mech_ValveTrain_J616 Assumption: Due to Similar Construction J624 and J616 η Mech_ValveTrain_J616 = η Mech_ValveTrain_J624 Using P Mech_Loss_J624 Absolute Value P Mech_Loss_ValveTrain_J VIF-K2-Presentation VIRTUAL VEHICLE 24
25 Thanks for your Attention! Kometenzzentrum- Das Virtuelle Fahrzeug Area C NVH & Friction Inffeldgasse 25 F A-8010 Graz / Österreich Christoph Priestner Phone: +43 (0) christoph.priestner@v2c2.at VIF-K2-Presentation VIRTUAL VEHICLE 25
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