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Dynamic Deformation Testing and Analysis of Wet Cylinder Liners Using the Eddy Current Method

Haining He, Lizhong Shen, Song Zu, Yuchen Xu, Jianping Song and Yuhua Bi ()
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Haining He: Yunnan Key Laboratory of Internal Combustion Engines, Kunming University of Science and Technology, Kunming 650500, China
Lizhong Shen: Yunnan Key Laboratory of Internal Combustion Engines, Kunming University of Science and Technology, Kunming 650500, China
Song Zu: Yunnan Key Laboratory of Internal Combustion Engines, Kunming University of Science and Technology, Kunming 650500, China
Yuchen Xu: Yunnan Key Laboratory of Internal Combustion Engines, Kunming University of Science and Technology, Kunming 650500, China
Jianping Song: Yunnan Key Laboratory of Internal Combustion Engines, Kunming University of Science and Technology, Kunming 650500, China
Yuhua Bi: Yunnan Key Laboratory of Internal Combustion Engines, Kunming University of Science and Technology, Kunming 650500, China

Energies, 2025, vol. 18, issue 16, 1-18

Abstract: Improving the thermal efficiency of internal combustion engines plays a crucial role in reducing fuel consumption and engine emissions. Studies have shown that the friction loss caused by the piston ring–cylinder liner pair accounts for approximately 30–40% of the engine’s total mechanical friction. The key to improving mechanical and thermal efficiency lies in reducing frictional losses through advanced solutions. However, as engine intensification increases, the growing thermal and mechanical loads lead to out-of-round deformation of the cylinder liner. This deformation reduces the sealing conformity of the piston rings, leading to increased blow-by and elevated particulate matter (PM) emissions. To address this, a dynamic–static deformation testing system for cylinder liners, combined with a multi-physics simulation for data validation, has been developed to achieve energy conservation and emission reduction in engines. Based on established strain gauge and eddy current displacement sensors, this study developed a dynamic deformation testing system, modified for a specific type of diesel engine, and analyzed the cylinder liner deformation under fired conditions. Test results show that under engine speeds ranging from 700 rpm to 1100 rpm, the overall radial out-of-roundness of the cylinder liner increased, with a maximum deformation of 49.2 μm. The second-order component of out-of-roundness also increases with speed, showing a maximum rise of 28.9 μm, while the third-order and fourth-order components exhibit relatively minor changes. These findings suggest that the overall radial deformation under fired conditions is mainly dominated by second-order out-of-roundness, with third-order and fourth-order components contributing marginally.

Keywords: cylinder liner deformation; out-of-roundness; thermal efficiency; diesel engine; eddy current displacement sensor (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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