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Cylinder Liner
8/19/2015
Learning Outcomes
Cylinder Liner
8/19/2015
Form
Cylinder Liner
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Cylinder LinerIntroduction
Cylinder block is made from grey cast iron
Liner is manufactured from cast iron alloyed
with chromium, vanadium and molybdenum.
Alloying elements help resist corrosion and
improve wear resistance at high temperatures
Liner will wear with use, and therefore may
have to be replaced
Cylinder jacket lasts the life of engine.
Cylinder Liner
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Cylinder LinerIntroduction
At working temperature, liner is a lot hotter
than the jacket
Liner will expand more and is free to expand
diametrically and lengthwise.
If liners were cast as one piece, then
unacceptable thermal stresses would be set up
Complex casting, difficult to produce a
homogenous casting
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Wet
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3 PIECES
LINER
(DOXFORDP)
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EXHAUST PORTS
EXHAUST BELT
UPPER LUBRICATION
COOPER RING
STEEL SHRUNK RING
UPPER LINER
UPPER LINER
VALVE POCKET
COMBUSTION BELT
COMBUSTION BELT
COOLING WATER IN
LOWER LUBRICATION
LOWER LINER
SCAVENGE PORTS
TRIPARTITE (3 PARTS)
CYLINDER LINER
AND JACKET
(DOXFORD PTYPE
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JACKET
COOLING WATER IN
ABESTOS PACKING
Copper ring
EXHAUST PORTS
SCAVENGE PORTS
CYLINDER LUBRICATION OIL 2 POINTS
SOME COOLING OUT
WAVE JOINT
SUPPLEMENTARY
CYLINDER OIL SUPPLY
LOWER
UNCOOLED
PART BOLTED
TO JACKET
MAN KZ LINER
(2 PIECES)
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GROUND FACE
ANGLED C/W
DRILLINGS
FREE
THERMAL
EXPANSION
JACKET
BORE COOLING
VIEW
SECOND ADDITIONAL
CYLINDER OIL SUPPLY
C/W INLET
RUBBER RINGS
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Mechanical
Thermal
stress pressure
stress - temperature
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Supercharged
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HOOP STRESS
=PxD
CYLINDER HEAD
2t
WHERE, P = GAS PRESSURE
D = LINER DIAMETER
t = LINER THICKNESS
Thus hoop stress will increase if
bore size and firing pressure increase
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CRACK
DUE TO
HOOP
STRESS
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Cylinder cover
o
1650 oC 500 C
Piston
Cylinder
140 oC jacket
Cylinder
liner
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40 oC
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75 oC
Cooling
water
space
17
THERMAL STRESS
OPTIMUM
METAL
THICKNESS
HOOP or MECHANICAL STRESS
METAL THICKNESS
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Tell-tale
passage
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Holes
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In
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Insulating tube
minimize
condensation of
vapour
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Sulphuric
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Inside
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Cooling
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Modern
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Liner Materials
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Alloy Element
Nickel
Chromium
Copper or molybdenum wear
resistance to corrosion
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For
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Two
methods
Sand casting
Centrifugal casting
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Stronger liner
Homogeneous in structure
Poor wearing quality (fast cooling rate)
Normally used for medium and high
speed engine
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Advantages
Hard surface and improve wear-resistance,
corrosion resistance, uniform surface finish
Disadvantages
Expensive since reduction in wear rate
cannot offset cost
Plating can peel-off, must use only with cast
iron piston rings
Running-in action may be delayed ,leading to
rings collapse or scoring of liner
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Liner Fault
- Crack
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Source
from
Ash in fuel,
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Fuel
consists of vanadium,
sodium silica and scale
(iron rust)
It can be reduced by effective
centrifugal separation
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180
40
160
150
140
Pressure (bar)
80
170
130
120
110
1.0
2.0
3.0.
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LINER
WALL
LINER
WALL
RING
RING
RING
Asperities meet
Tearing out,
cooling, hardening
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OIL - WEDGE
OIL
FILM
LINER
WALL
PISTON
SKIRT
PISTON
SKIRT
LINER
WALL
OIL
WEDGE
(1:150
TAPPER)
OIL
FILM
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CLOVERLEAFING
Lube oil
Lube oil
Lube oil
Wear due to
excessive alkalinity
in cylinder oil
Measured by
profilograph an
instrument
Lube oil
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Gauging a
Liner
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Liner Calibration
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Safety Procedures
Tools required
Spare parts
Work plan
Measurements to take
Liner Assembly
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Insulating tube
minimize
condensation of
vapour
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Liner Wear
Pattern
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WEAR RATE
TEMPLETE
Cyl No
Date
Date fitted
Date of last
gauging
Total hours
Hours since
last gauging
Position
A
B
LINER
TOP RING
POSITION
WEAR
B
E
C
D
E
F
EXHAUST
PORT
F
G
H
SCAVENGE
PORT
Max wear
G
RESULTS
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X 1000
= mm/1000 hrs
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Wear
X 1000
= mm/1000 hrs
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0.3
WEAR RATE
INCREASES
DUE TO WORN
RINGS AND
LINERS
0.2
GRAUDAL WEAR
STARTS
0.1
RUNNING-IN
PERIOD
2
10
12
14
16
18
20
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DG
Di = 0.98 DG
Di
0.7 to 0.8d
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Summary
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Summary
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Exercises
Sketch and explain a normal liner wear pattern
Explain the meaning of wear rate of liner
Sketch and describe procedure in the overhauling
and renewal of liner
Explain clover-leafing in cylinder liner wear
Discuss running-in of liner
Discuss the causes and remedy of excessive wear
on liner
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