EHD+T Analysis and Calibration with Test Bench Results to ...

EHD+T Analysis and Calibration

with Test Bench Results to

investigate the effect of the

Waviness of a Rod Crankpin.17/10/2018

Dr. Thierry Garnier

Global Senior Manager D&A Bearing Group

17/10/2018©2018 Federal-Mogul LLC | Data Classification: Public 2

Bearing Lubrication Trends to achieve Co2 / Power Loss Reduction

2010 2015 2020

Downsizing

Turbocharging

Specific Load

increase

V6 I4

1-2 Million

Start-Stops

(5-6 M cruise

mode,

hybridation)

500.000

Start-Stops

250.000 Starts

Critical Lubrication Conditions

RHDEHD

EHD++

Oil Viscosity

Reduction

5W30

0W12 (+ Dilution up to 20%)


Bearing Lubrication System “Post-Engineering”

Material

Geometrical feature

Manufacturing feature

Real clearance

Real wall thickness

Position tolerance of MB,

Bore distorsion, Cap Offset

Axial profile and waviness

Oil drilling chamfer

Oil pressure & aeration,

low viscosity with dilution

EHD model

definition(Elasto-

HydroDynamic)

Real Oil

Lubrication System

Post-Engineering

CONROD Test Rig Description

17/10//2018 4© 2017 Federal-Mogul LLC - Data Classification : Public

Test Principle:

Motored 1 cylinder engine using original conrod (deflection)

Conditions:Load: =f(speed) 31kN@7150rpm

sinusoidal by inertia forces

Speed: 1000 … 7150rpm according test program

Clearance: 30+5µm

Bearing Width: 18,8mm

Journal diameter: ~47,76mm

Oil hole position: 50° before TDC

Oil hole diameter: 5mm, chamfered

Oil: Lukoil Genesis MC SAE0W-20

Temperature Inlet: 120°C

Sleeve / roughness: 42CrMo4; 52+3HRC; finished Ra0,07-0,11µm

Validation / Results:

Validation base: running time (wear or seizure)

Results: Material ranking according measured wear

Conrod Test Rig – Details & Mass Forces


Test Sleeve

42CrMo4; 52+3HRC

Mass forces :

~ 30 kN / 21 kN @ 7150 rpm

Conrod

AUDI EA888Test Rig Assembly

Conrod deformation & lubrication pressure


Bearing lubrication performance behavior


Test Program for wear or seizure


Maximum test time of 200h should not

be exceeded

Test target: elevated abrasive wear ?

- with following adhesive wear ?

- until seizure damage ?

3 Rodpin Geometry waviness types


Circular 36 Lobes x 1 µm 72 Lobes x 0,3 µm

Circular pin (no lobe) @ 120°C


Local extremum of Clearance Height

-9

-4.5

0

4.5

9

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Shell Angle (deg)

0

0.0005

0.001

0.0015

0.002

0.0025

0.003Clearance Height (mm)

Local extremum of Asperity Contact Pressure

-9

-4.5

0

4.5

9

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Shell Angle (deg)

0

50

100

150

200

250Pressure (MPa)

Local extremum of Total Pressure

-9

-4.5

0

4.5

9

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Shell Angle (deg)

0

50

100

150

200

250Pressure (MPa)

M.O.T.

0.1

0.3

0.5

0.7

0.9

1.1

Min

imu

m O

il F

ilm T

hic

kn

ess (

MO

FT

) (m

icro

n)

0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

Min Y

0.248682

at X

679.025

36 lobes x 1 µm pin profile @ 120°C


M.O.T.

0.1

0.3

0.5

0.7

0.9

1.1

Min

imu

m O

il F

ilm T

hic

kn

ess (

MO

FT

) (m

icro

n)

0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

Min Y

0.109103

at X

680.025Local extremum of Clearance Height

-9

-4.5

0

4.5

9

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Shell Angle (deg)

0

0.0005

0.001

0.0015

0.002

0.0025



-9

-4.5

0

4.5

9

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Shell Angle (deg)

0

50

100

150

200

250Pressure (MPa)


-9

-4.5

0

4.5

9

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Shell Angle (deg)

0

50

100

150

200

250Pressure (MPa)

72 lobes x 0,3 µm pin profile @ 120°C


M.O.T.

0.1

0.3

0.5

0.7

0.9

1.1

Min

imu

m O

il F

ilm T

hic

kn

ess (

MO

FT

) (m

icro

n)

0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

Min Y

0.0056

at X

319.025Local extremum of Clearance Height

-9

-4.5

0

4.5

9

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Shell Angle (deg)

0

0.0005

0.001

0.0015

0.002

0.0025



-9

-4.5

0

4.5

9

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Shell Angle (deg)

0

50

100

150

200

250Pressure (MPa)


-9

-4.5

0

4.5

9

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Shell Angle (deg)

0

50

100

150

200

250Pressure (MPa)

EHD MOT. vs. Waviness @ 120°C (only EHD)


Circ. 36 x 1 µm 72 x 0,3 µm @120°C

100% 39% 4%

Shaft

36 x 1 µm

Tmax. ~ 300°C !

Hyundai Theta III T-GDI - Irox-Irox

@ 8000rpm

M.O.T.

0.1

0.6

1.1

Min

imu

m O

il F

ilm T

hic

kn

ess (

MO

FT

) (m

icro

n)

0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

Min Y

0.248682

0.109103

0.0192341


Thermal Calculation Sequences

T increases which decreases µ and MOT

Subsequent EHD+T calculations lead in this case

to a divergence of the performance parameters

and to an unrealistic lubrication behavior.

EHD + T


Thermal Calculation Sequences

When associated with a Wear Calculation, the EHD+T

calculations should lead to a stabilization of the

lubrication performance indicators (with the condition

that the Wear Height reaches very low values).

EHD + T

Wear pattern LoopsRadial Wear SHELL

-7.5

-5.5

-3.5

-1.5

0.5

2.5

4.5

6.5

8.5

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Bearing Angle (deg)

0

0.001

0.002

0.003

0.004

0.005

0.006Normal Wear Height (mm)

Radial Wear JOURNAL

-7.5

-5.5

-3.5

-1.5

0.5

2.5

4.5

6.5

8.5

Be

ari

ng

Wid

th (

mm

)

0 90 180 270 360

Bearing Angle (deg)

-6e-10

-5e-10

-4e-10

-3e-10

-2e-10

-1e-10

0Normal Wear Height (mm)

36 x 1 µm waviness

17/10//2018© 2017 Federal-Mogul LLC - Data Classification : Public

EHD EHD + T EHD + T + W

100% 50% 240%

100% 150% 110%

Hyundai Theta III T-GDI - Irox-EHD-36

@ 8000rpm

M.O.T.

0

0.5

1

Min

imu

m O

il F

ilm

Th

ickn

ess (

MO

FT

) (m

icro

n)

0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

Min Y

0.109103

0.0941251

0.240203

Hyundai Theta III T-GDI - Irox-EHD-36

@ 8000rpm

Max. Temperature

100

150

200

250

300

350

Ma

x.

Oil

Film

Te

mp

era

ture

(T

MA

X)

(de

gC

)

0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

AngR (deg)

Mean Y (arith.)

226.851

209.768

Thermal Load

0

20

40

60

80

100

120

140

160

180

200

Y A

xis

(W

/mm

^2

)

0 90 180 270 360 450 540 630 720

X Axis (deg)

Mean Y (arith.)

57.831

60.1221

40.2281

16

100% 110% 80%

average

average

Profile Impact EHD +T + W


Hyundai Theta III T-GDI - Irox-EHD-T-W

@ 8000rpm

M.O.T.

0.1

0.3

0.5

0.7

0.9

1.1

Min

imu

m O

il F

ilm

Th

ickn

ess (

MO

FT

) (m

icro

n)

0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

Min Y

0.4434

0.240203

0.0424563

Circ 36 x 1µm 72 x 0,3µm

100% 50% 10%

100% 126% 88%

100% 104% 106%

Total Power Loss

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

To

tal F

rictio

n P

ow

er

Lo

ss (

W)

0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

Crank Angle (deg)

Mean Y (int.dX)

2876

3605.57

2529.82

Oil Flow

-12

-11

-10

-9

-8

-7

-6

-5

-4

-3

-2

-1

Oil

Flo

w S

um

of

Oil

Ou

tflo

w (

l/m

in)

0 45 90 135 180 225 270 315 360 405 450 495 540 585 630 675 720

Crank Angle (deg)

Mean Y (int.dX)

-4.11039

-4.13702

-4.19529

Waviness failure Mode = 1 wear, 2 severe wear, 3: seizure

Date of Test: 27.07.2017

Name: G-411

ID: 3143

Test number: CON-1-2017-42

Journal 1.7225

Oil type: Lukoil 0W-20

rod shell cap shell

Fatigue:

Seizure:

Wear (crown): 1,3 µm 0,9 µm

max. Wear (Level 1):

max. Wear (Level 2):

Remarks: 36 Lobes

No fatigue

Slightly wear

after 200 hours running time

Level 1

rod shell

Level 2

Level 1

cap shell

Level 2

angle [°]

wear

[µm

]w

ear

[µm

]

angle [°]

Valuation: x

0

5

10

-65 -52 -39 -26 -13 0 13 26 39 52 65

Level 1 Level 2

2,5 µm at 61°

3,0 µm at 64°

0

5

10

-65 -52 -39 -26 -13 0 13 26 39 52 65

Level 1 Level 2

2,6 µm at 2°

2,8 µm at 31°

G-411 vs. 36 Lobes

02/09/2018© 2017 Federal-Mogul LLC - Data Classification : internal VB 27-2018 V2 18

No No

No No

1 2 3

Shaft running-in

(micro-wear)

Ra 0,11 0,09

Rpk 0,24 0,14

(µ-slide change)

Federal-Mogul Waviness Specificationregarding to EHD-Rodpin Analysis vs. application


P2 low amplitude and high lobes number: high impact on HD and gasoline engine at high speed but

“lower” impact on low speed gasoline engine

ISO/CD 27507

ISO/CD 27507 does not meet the new generation engine requirement !

P1 high amplitude and low lobes number: low impact on HD but already high impact on gasoline car

engines.

Nu

mb

er

of

Lo

bs

Lobs Amplitude (µm)

Iso-MOT Curves vs Waviness Topography(Heavy Duty, middle range speed . V~10m/s)

50%40%

30%

20%10%

Loss of MOT (%)

Nu

mb

er

of

Lo

be

s

Lob Amplitude (µm)

Iso-MOT Rod vs. waviness Topography(Gasoline, high speed. V ~30 m/s)

Loss of MOT (%)

50%

40%

30%

Nu

mb

er

of

Lo

be

sLob Amplitude (µm)

Iso-MOT Rod vs. waviness Topography(Gasoline, low speed . V~15m/s)

Loss of MOT (%)

25%

35%

30%

50%

Conclusions


❖ Post-Engineering happens when the Pre-Engineering shows its limits

(interaction of BC: real tolerances & assembly, supply system…).

❖ The Excite thermal balance resolution needs a local wear pattern

description for each material (several evaluation criteria).

❖ An evolutive wear model (vs. location or load history) would help to

improve the EHD +T lubrication performance prediction .


Thank you for

your attention!

Any Questions?

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