Analysis On Surface Texturing Design for Wear Protection of ...

Analysis On Surface Texturing Design for Wear Protection

of Automotive Engine Part

NOR SHAZWAN AZRUL BIN NORAZNI

B041110082

BMCA

Email: [email protected]

Draft Final Report

Projek Sarjana Muda II

Supervisor: PN SUSHELLA EDAYU BT MAT KAMAL

Faculty of Mechanical Engineering

Universiti Teknikal Malaysia Melaka

June 2015

ANALYSIS ON SURFACE TEXTURING DESIGN FOR WEAR

PROTECTION OF AUTOMOTIVE ENGINE PART

NOR SHAZWAN AZRUL BIN NORAZNI

Thesis submitted in fulfilment of the requirements

for the award of the degree of

Bachelor of Mechanical Engineering with Automotive Engineering

Faculty of Mechanical Engineering

Universiti Teknikal Malaysia Melaka

JUNE 2015

ii

‘I hereby declare that had read this work and for my/our opinion this work is

adequate in terms of scope and quality for receiving the Bachelor of Mechanical

Engineering (Automotive)’

Signature :...............................................

Supervisor : Sushella Edayu bt Mat Kamal

Date :...............................................

iii

I hereby declare that the work in this report is my own except for summaries and

quotations which have been duly acknowledged.”

Signature : ............................................

Author : Nor Shazwan Azrul Bin Norazni

Date : ............................................

iv

This report was done specially for Puan Sushella Edayu Mat Kamal, Norazni Bin

Abdul Hamid, Aini Binti Mat Hassan and Beloved Family.

v

ACKNOWLEDGEMENT

It is greatest pleasure to acknowledgement many people who contributed

their support, time and physic energy ti this thesis. First, I would like to express my

sincerest gratitude to my main supervisor, Pn Sushella Edayu Binti Mat Kamal for

her guidance, patience in giving me advices and support throughout the whole

process of this study. I gratefully acknowledge Universiti Teknikal Malaysia Melaka

(UTeM) for their financial support in this research activity.

Besides that, I would like take this opportunity to thank my colleagues at the

Faculty of Mechanical Engineering, UTeM for their outstanding collaboration for

being a very good sharing during my research. I also want to say thanks towards all

my course mate, my friends because they give me courage and assistance throughout

the whole semester which have help me a lot during completing the analysis.

Finally, my deepest grateful and thanks go to my parents in giving continuous

prays and moral support that brought me here. Last but not least, I would like to

thank those who helped me in this thesis but not mentioned here. I would like to ask

forgiveness because forget to acknowledge them.

vi

ABSTRACT

Surface texturing is used as the quality indicator for the machined surfaces

after undergoes manufacturing process. These characteristic is the important factor

that effect on several properties such as wear resistance, fatigue strength, coefficient

of friction, lubrication, wear rate and corrosion resistance of the machined parts. The

texture on the material surface alters the properties itself during sliding conditions

which to reduce friction and wear of material. However, it still depends on the

pattern or shape of the texture on the surface of material under certain sliding

condition. For the design of surface texturing, the surface texture with thousands of

micro-dimples used to improve the tribological performance in order to reduce the

friction and wear between two sliding material. This research contribute on conduct

the simulation and analysis using ANSYS FLUENT and CFD in order to study effect

of surface texturing using dimpled texture. In this research, the dimples with a circle

and elliptical shape were investigated according to the sets of diameter size with fix

depth and dimple density.

vii

ABSTRAK

Penteksturan permukaan digunakan sebagai penunjuk kualiti untuk

permukaan yang dimesin selepas menjalani proses pembuatan. Ciri-ciri ini

merupakan faktor penting yang mempengaruhi beberapa sifat seperti rintangan

kepada haus, pekali geseran, pelinciran, kadar kepada haus dan rintangan terhadap

karat pada bahagian yang dimesin. Tekstur pada permukaan bahan mengubah sifat-

sifat itu sendiri dalam keadaan gelongsor untuk mengurangkan geseran dan kehausan

bahan. Walau bagaimanapun, ia masih bergantung kepada corak atau bentuk tekstur

pada permukaan bahan. Bagi reka bentuk penteksturan permukaan, tekstur

permukaan dengan ribuan mikro lubang-lubang kecil digunakan untuk meningkatkan

prestasi tribological bagi mengurangkan geseran dan haus di antara dua bahan yang

bergesel. Kajian ini berkait dalam menjalankan simulasi dan analisis menggunakan

ANSYS FLUENT dan CFD untuk mengkaji kesan penteksturan permukaan

menggunakan tekstur lekuk. Dalam kajian ini, lubang-lubang kecil dengan bulatan

dan bentuk elips disiasat mengikut set saiz diameter dengan kedalaman dan

ketumpatan yang tetap.

viii

TABLE OF CONTENT

CHAPTER TITLE PAGE

DECLARATION ii

DEDICATION iv

ACKNOWLEDGEMENT v

ABSTRACT vi

ABSTRAK vii

TABLE OF CONTENT viii

LIST OF FIGURE xii

LIST OF TABLE xiv

LIST OF SYMBOL xvi

CHAPTER I INTRODUCTION 1

1.0 Introduction 1

1.1 Research Background 1

1.2 Problem Statement 2

1.3 Objectives 3

CHAPTER II LITERETURE REVIEW 4

2.0 Introduction 4

2.1 Surface Finish 4

2.2 Dimpled Surface Texture 5

2.2.1 Tribological Effect of Dimpled Surface 6

2.3 Texture Design Consideration 8

2.3.1 Geometry 8

ix

2.3.2 Parameter 8

2.3.2.1 Influence of Dimple Density Area, 9

Diameter and Quantity

2.3.3 Shape 10

2.3.3.1 Optimization of the Geometry 11

of Texture Shape

2.3.3.2 Comparison of Different Texture 12

Shape

2.3.4 Pattern 12

2.3.4.1 Influence of Dimple Pattern 13

2.4 Friction Influence 15

2.5 Surface Texture Influences 15

2.5.1 Effect of Tribological Characteristic 15

2.6 Governing Equation 17

2.6.1 Conservation of Energy 17

2.6.2 k-e Turbulent Model 17

2.6.3 Heat Transfer 18

2.6.4 Hydrodynamic Lubrication 20

2.6.5 Skin Friction 22

2.7 Summary 24

CHAPTER III METHODOLOGY 26

3.1 Methodology Planning 26

3.2 Design Specification of the Texture 26

3.3 Project Workflow 27

3.4 Preliminary Studies 28

3.4.1 Dimpled Texture 28

3.4.1.1 Dimple Parameter Based On Ajm 28

3.4.1.2 Dimple Shape Based On Optimized 28

Geometry

3.4.2 Boundary Condition 29

3.5 Design and Analysis Using Computer Software 30

3.5.1 Dimple Distribution for Analysis 30

x

3.6 Analysis Step 31

3.6.1 Analysis Procedure 31

3.6.2 Analysis Parameter 32

3.7 Problem Solving 34

4.1.1 Unit 34

4.1.2 Geometry 34

3.8 Workbench Modeller for Meshing 35

3.9 Fluent As a Solver 37

3.9.1 Define Model 37

3.9.2 Define Material 38

3.9.3 Boundary Condition 39

3.9.3.1 Velocity Inlet 39

3.9.3.2 Pressure Outlet 39

3.9.3.3 Wall 39

3.9.3.4 Fluid 40

3.9.4 Solution 41

3.9.5 Display 43

CHAPTER IV RESULT AND DISCUSSION 44

4.1 Analysis Result 44

4.1.1 Parameter Configuration 44

4.1.2 CFD Analysis 45

(Contour of Temperature)

4.1.3 CFD Analysis 49

(Contour of Pressure)

4.1.4 CFD Analysis Result 53

xi

CHAPTER V CONCLUSION AND RECOMMENDATION 57

5.0 Introduction 57

5.1 Conclusion 57

5.2 Recommendation 58

REFERENCES

APPENDIX

xii

LIST OF FIGURE

FIGURE TITLE PAGE

2.1 A Modified Stribeck Curve on Automotive Engine Part 6

2.2 Average Wear Rate for the Polished and Different Dimple 9

Diameters

2.3 Relationship of Dimple Diameters and Densities to Friction 10

Coefficient

2.4 Dimple Produced By AJM and LBM 14

2.5 Textured Surface Morphology 14

2.6 Variation of Friction Coefficient of the Polished and Dimpled 16

Specimen with Different Diameters

2.7 Schematic of Heat Transfer 18

2.8 Two Contacting Surface with Relative Sliding Velocity 20

2.9 Schematic of Positive Pressure from Cavitation 22

3.1 Flow Chart 27

3.2 Sample Model of Dimples Distribution 31

3.3 Mesh Model of Dimple Distribution 35

3.4 Contour Interface of Dimple Distribution 43

xiii

4.1 Temperature Contour of Conventional Surface 45

4.2 Temperature Contour of Circle Shaped (40µm Diameter, 46

30 % Distribution, And 5 µm Depth)

4.3 Temperature Contour of Rectangle Shaped (40µm Diameter, 47


4.4 Temperature Contour of Ellipsoidal Shaped (40µm Diameter, 48


4.5 Pressure Contour of Conventional Surface 49

4.6 Pressure Contour of Circle Shaped (40µm Diameter, 50


4.7 Pressure Contour of Rectangle Shaped (40µm Diameter, 51


4.8 Pressure Contour of Ellipsoidal Shaped (40µm Diameter, 52


4.9 Average Temperature for Conventional and Dimpled Surface 54

With Different Dimple Shape

4.10 Skin Friction Coefficient for Conventional and Dimpled Surface 54


4.11 Hydrodynamic Pressure for Conventional and Dimpled Surface 56


xiv

LIST OF TABLE

TABLE TITLE PAGE

2.1 Regime of Lubrication Characteristic 7

2.2 Geometry of Texture Shape 11

2.3 Optimized Geometry 12

2.4 Features of Surface Texture 13

2.5 Friction Factor 15

2.6 Information Summarized 24

3.1 Dimple Parameter Set Up 28

3.2 Minimum Friction Coefficient 29

3.3 Lubricant Technical Properties 29

3.4 Piston Condition at Steady State 30

3.5 Parameter Summarized 33

3.6 Analysis Unit 34

3.7 Analysis Geometry 34

3.8 Mesh Analysis 35

3.9 Mesh Control 36

3.10 Analysis Setting 37

xv

3.11 Material Setting 38

3.12 Boundary Condition Setting 40

3.13 Solution Method Setting 41

3.14 Steady State Flow Solution 41

3.15 Steady State Flow Solution Information 41

3.16 Steady State Flow Solution Result 42

4.1 Parameter Configuration Check List 44

4.2 Result of CFD Analysis 53

xvi

LIST OF SYMBOL

A = Reference Piston Body Area

b = Cylinder Characteristic Length or Bore

Cp = Specific Heat at Constant Pressure

gi = Body Force Term

h = Heat Transfer Coefficient

k = Gas Thermal Conductivity

L = Length of the Body That the Flow Travels Across

p = Pressure

q = Overall Heat Transfer

Sh = Radiation Sources

T = Temperature

Γh = Exchange Coefficient

U = Characteristic Gas Velocity

V = Velocity of the Flow

v = Kinematic Viscosity of the Fluid

xvii

LIST OF APPENDICES

NO. TITLE PAGE

A PSM 1Gantt Chart 62

B PSM 2 Gantt Chart 63

C Mesh Model of Conventional Surface 64

D Mesh Model of Circle Shape 64

E Mesh Model of Rectangle Shape 65

F Mesh Model of Ellipsoidal Shape 65

1

CHAPTER 1

INTRODUCTION

1.0 INTRODUCTION

In this chapter, there are discusses about the introduction in this project.

In order to make the reader understand about this project, a research background of

the surface texturing design is explains more detail. In this chapter also, there are

include of the objectives of the project, scopes and the problem statement while doing

this project.

1.1 RESEARCH BACKGROUND

In many applications, materials are subjected to vibrating, impact or

oscillating forces. The behavior of materials under such load conditions differs from

the behavior under a static load. Because the material is subjected to contacted

surface in actual use, designers are faced with predicting wear resistance, which is

defined as the frictional energy losses under specified loading conditions.

Wear is defined as an interaction between surfaces which material will

removal and deform on a surface as a result of mechanical action of the opposite

surface (Qiu et al, 2013). The definition of wear may include loss of dimension from

plastic deformation if it is originated at the interface between two sliding surfaces.

Wear can also be defined as a process where interaction between two surfaces or

bounding faces of solids within the working environment results in dimensional loss

2

of one solid, with or without any actual decoupling and loss of material. In practice a

real component from a machine or structure will generally have various surface

finishes and different mechanical properties.

One of the main methods to enhance the performance of mechanical seals

studied and discussed in the literature of tribology is surface texturing. Many

theoretical and experimental studies showed the benefit of surface texturing on the

mechanical and automotive part performance. The types of dimple texture have been

particularly studied by (Erdemir, 2005). Density and depth ratio are the main

parameters studied and optimized to enhance lubrication. However, in recent years,

studies have shown that geometric shape and distribution of dimples have an obvious

influence on the performance of textured surfaces (Qiu et al, 2013).

The automobile industry is experiencing in competition due to rapid

technological improvements and advances. Thus, it is necessary to have a better

understanding of the effect of friction and wear in automotive part in order to meet

competitive durability goals in the automobile industry. For this reason, surface

modification be a good and effective way to improve the tribological characteristics

of mechanical components. Hence, surface texturing is important on improving the on

reducing friction and wear was depended considerably on the shape, size, density, and

pattern of dimples.

1.2 PROBLEM STATEMENT

Wear is a complex phenomenon that is affected by a number of factors,

such as the surface finish of the component, environmental effects, heat treatments,

presence of stress concentration factors, etc. Therefore, it is important to carefully

analyses components that subjected to fluctuating loads so the desired reliability can

be built into these components and over-designed or under-designed components can

be avoided. It is well known that wear resistance generally initiate from the surface

and the performance of the component or part dependent on the surface finish

produced by machining or other manufacturing processes.

3

Surface texturing is used as the critical quality indicator for the machined

surfaces and has influence on several properties such as wear resistance, fatigue

strength, coefficient of friction, lubrication, wear rate and corrosion resistance of the

machined parts (Etsion, 2009). Nowadays, developing more fuel efficient and

compact automobile engine with reduced environmental impact is one of the biggest

challenges that tribologists are facing in this era. The friction loss in an internal

combustion engine is a major factor in determining the engine efficiency,

performance and fuel economy of the vehicle (Etsion, 2009). Hence, surface texturing

is used to increase hydrodynamic pressure and reduce friction and wear between two

surfaces by creating patterned microstructure on the mechanical contact surface. The

shape, geometry and distribution pattern play a key role to the tribological behavior

of that surfaces in contact. Thus, investigating of surface texturing important for

enhancing tribological properties of mechanical components in order to improve wear

protection and enhance fatigue or toughness indirectly to increase the lifetime of

components.

1.3 OBJECTIVE

This research aims to design parameter of surface texturing for dimples

and to investigate the influence of surface texturing on the lubricant flow. It is

intended that the research finding will contribute to conduct the simulation and

analysis using ANSYS FLUENT and CFD.

These above aims raise the following core research objective:

1. To investigate the effects of the shape of surface texturing for dimples by

using simulation.

2. To evaluate the distributions of the geometry of surface texturing for

dimples.

4

CHAPTER 2

LITERATURE REVIEW

2.0 INTRODUCTION

In this chapter there are consists of all previous studies related to this

project and explains more detail and deeper history of the surface texturing design

and performance aspect of surface texture. However, to investigate the effect of the

shape and the distribution of geometry of dimples, the background of the study

should be exposed. The early section of this part will be explaining some of the

literature review about surface texture of dimples. The other part involves on

elaborating in design consideration of texture and the surface influences on lubricant

flow.

2.1 SURFACE FINISH

Surface finish, or texture, can be viewed from two very different

perspectives which is result from the manufacturing process. Texture can be changed

by altering the process while by changing the surface finish specification; the

functionality can be enhanced and be improved. Today, various forms and geometric

features of surface texturing for tribological applications are carried out widely. There

are have a various texturing techniques in these studies including machining,

photoetching, etching techniques, ion beam texturing, and laser texturing.

5

In engineering fields, surface texturing as a means for enhancing

tribological properties of mechanical components is well known since many years. It

is the most familiar and earliest commercial application of surface texturing in

engineering. In most cases, surface finish control starts in the drafting room. The

designer has the responsibility of specifying a surface that will give the maximum

performance and surface life at the lowest cost.

There are two principal reasons for surface control which is to reduce and

control friction and wear in order to extend the lifetime oh mechanical systems, to

improve their efficiency and reliability, to conserve scarce material resources and

energy, and to improve safety. The degree of friction is expressed as a coefficient of

friction µ, which is expressed as the ratio of force required to initiate or sustain

relative motion to the normal force that presses the two bodies together. Two modes

of friction may occur either in sliding or rolling friction. In friction reduction, surface

texture created a film of lubricant between two moving parts and the surface

irregularities must be small enough so they will not penetrate the oil film under the

most severe operating conditions.

2.2 DIMPLED SURFACE TEXTURE

Dimples texture is a surface texturing form by micro or nano scale

cavities or pockets in an arrayed pattern on one of the sliding surfaces. Several

fabrication techniques can be used to manufacture this type of texture, such as vibro-

rolling, reactive ion etching, abrasive jet machining, LIGA, vibro mechanical

texturing and laser surface texturing (Etsion, 2009). In recent years, surface texturing

has been surfaces lift that contact increase successfully in many applications to

improve the tribological properties of sliding surfaces, such as golf ball, engine

cylinder, modern magnetic storage device, sliding bearing and mechanical seal, and

slider and disc of hard disc driver (Wakuda et al, 2000).

In surface engineering, surface texturing of dimples be the most advanced

methods for tribological application. Different patterns have also been used either

being linear grooves, crossed grooves, or circular dimple-like depressions (Qiu et al,

6

2013). These patterns are useful for effective lubrication between contact by

providing micro-hydrodynamic bearing, lubricant reservoirs and traps for wear debris

in both lubricated and non-lubricated application, which protect the surface from

scratching. In cases of mixed lubrication, micro-scale dimple can create an

asymmetric pressure distribution that can change hydrodynamic and boundary

lubrication, thus reducing both friction and wear. At this stage, pressure increase in

the thin lubricant film to separating the sliding surfaces, so that the additional

pressure will increases the separation between the sliding surfaces and

correspondingly reduces the friction and wear.

2.2.1 Tribological Effect of Dimpled Surface

According to (Amanov, 2013), they found that a dimpled pattern reduced

the coefficients of friction, whereas a grooved pattern increased. They observed that

laser surface texturing could reduce the friction on components operating in a

boundary-lubricated regime. This study included different sized dimples, but its more

focused on the tribological behavior rather than the effects of the dimple dimensions.

Figure 2.1 shows that texturing the surface reduced the coefficient of friction, and the

transition from the hydrodynamic regime to the mixed or boundary lubrication regime

increase in the wear lifetime.

Figure 2.1: A Modified Stribeck Curve On Automotive

Engine Part (Amanov et al, 2013)

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