Experimental Investigation of Laser Surface

Texturing on Piston Rings for Reduction of Friction

Power
Abstract: In this research work, the surface micro structure of piston rings is changed by Laser
Surface Texturing method, in order to change lubrication regime of surface, and wear resistant.
Piston Ring with line cross hatch marking Fully Textured and the friction data will be compared
to base data say Un-textured Piston Rings. Average percentage of Reduction in Friction power is
10.52 % by using Laser surface texturing piston ring.
Lubricant film in an internal combustion engine (I.C. Engine) is an important factor in
determining friction power, fuel economy and performance of the vehicle.
Keywords: Petrol engine, Laser surface texturing, LST, Piston ring, Friction power.


K. Patel
PG Student

Hiren P.Patel
PG Student
Hitesh J. Yadav
Lecturer, Mechanical Engineering,
R.C.T.I. Ahmedabad, India

Prof. V.R.Patel
Professor, Automobile Engineering Department
L.D. College of Engineering, Ahmedabad, India
I SSN 2319-9725

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International Journal of Innovative Research and Studies Page 58

1. Introduction:
Petrol engine has gained the name and frame in serving the society in many ways. Its main
attractions are fuel efficiency of 10km/lit. to 20km/lit. ,ruggedness in construction, simplicity
in operation and ease of maintenance Small petrol vehicle enjoy the market share more than
65% for domestic, commercial, agriculture and family passenger vehicles purpose. So it is
preferable to select piston ring system of same vehicle for the study of piston ring assembly
friction in multi cylinder engine system.
But due to friction, we may not be able to avail its services for long time. Hence efforts are
being made all over the world, to reducing the friction between the parts in petrol engine.
The friction loss in an internal combustion engine is the most important factor in determining
the fuel economy and performance of the vehicle utilizing the power of the engine.
Approximately 50% of the friction losses in an internal combustion engine are due to the
piston/cylinder system, of which 7080% comes from the piston rings.
2. Laser Surface Texturing (LST):
Proper lubrication and surface texture are key issues in reducing friction in a piston/cylinder
system and, hence, have received great deal of attention in the relevant literature. Surface
texturing as a means for enhancing tribological properties of mechanical components is well
known for many years. Perhaps the most familiar and earliest commercial application of
surface texturing in engines is that of cylinder liner honing. Surface texturing in general and
laser surface texturing (LST) in particular has emerged in recent years as a potential new
technology to reduce friction in mechanical components.
In this work, the surface micro structure of piston rings is changed by Laser Surface
Texturing method, in order to change lubrication regime of surface, and wear resistant. Piston
Ring with line cross hatch marking Fully Textured and the friction data will be compared to
base data say Un-textured Piston Rings.

Figure 1: LST on Piston Ring
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3. Test Rig Description:
A special Experimental set-up was developed at laboratory scale to measure piston ring
assembly friction of multi cylinder 800CC petrol engine system indirectly by measurement of
Friction power consumption under different operating parameters i.e. speed, lubricants, laser
surface texturing piston ring, effect of coolant at various locations of piston cylinder system
(TDC, BDC) are also observed. Efforts are put to study the power consumption under, with
laser surface texturing piston ring set, without laser surface texturing piston ring set.
In the fabrication of laser surface piston ring assembly friction measurements test rig, 800CC
multi cylinder internal combustion engine system with crank mechanism, piston cylinder
head, and engine lubrication system, without engine cooling system, without gear box is
used. Crank shaft is coupled with induction motor to drive the engine. (Fig 3.1) For varying
the speed of test rig, the A.C. motor drive/variable frequency drive is used and to measure the
power consumption variable frequency drive is used. To measure the temperature of engine,
the temperature sensors are installed at different seven locations and the temperature is
indicated by digital value.
In the test rig, Variable frequency drive, Digital tachometer, Laser radiation pyrometer and
the digital indicator to measure the temperature are fitted in a box as shown in fig.

Figure 2: Layout of experimental test rig set-up
3.1.Locations Of Eight Temperature Sensors Are As Follows:
T1- Cylinder 1 (TDC)
T2- Cylinder 1(BDC)
T3- Cylinder 2 (TDC)
T4- Cylinder 2(BDC)
T5- Cylinder 3 (TDC)
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T6- Cylinder 3(BDC)
T7- Oil temp.
T8 & T9- Bearing temp. [ Measure by Digital radiation pyrometer]

Figure 3: Multi Cylinder Engine Test Rig
4. Experimental Methodology:
In this experimental work the Motored engine friction test method (strip method) is used.
Test started at 400 rpm followed by step increments of 200 rpm each, up to the maximum
speed of 3000 rpm. Initially the system is to be run for at least 5 to 10 minutes, so that the
system get stabilize & the lubricating oil can reach properly up to the surface of piston ring &
cylinder liner.
After getting the stable condition, Variable Frequency Drive records the actual power
consumed by the system, rpm of the system and the Pt 100 type thermocouple measures the
temperature of different eight locations of an engine.
Now for the next measurement frequency was changed on VFD to change the rpm of the
system. During the changing there is no need to switch off the power.
Record all the measurements in the observation sheet and plot the graphs of Speed v/s. Temp.
like T1,T2 T9. And speed v/s. power consumption.
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5. Results and Discussion:
As per literature review, friction loss at piston cylinder assembly is maximum, means power
consumption with this piston cylinder assembly system will also be maximum in comparison
to the other friction generating system power consumption. Thus it is important to understand
the contribution of frictional power loss by piston ring at different speed under normal and
laser surface texturing piston ring, following results are derived.
ENGINE SPEED [ RPM ]
0 500 1000 1500 2000 2500 3000 3500
P
O
W
E
R

C
O
N
S
U
M
E
D

[


K
W


]
0
1
2
3
4
5
WTHOUT LST
WITH LST

Figure 4: Engine Speed v/s Power consumed [KW]
Engine Speed [ RPM ]
0 500 1000 1500 2000 2500 3000 3500
%

O
f

R
e
d
u
c
t
i
o
n

i
n

p
o
w
e
r

c
o
n
s
u
m
e
d

[

k
w

]
0
5
10
15
20
25
30
35
Without LST
With LST

Figure 5: Engine Speed v/s % of Reduction in Power consumed [KW]
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6. Conclusion:
Following major observations are derived from the plotted graph.
Power consumption increases with increase in speed
Power consumption with normal piston ring is greater compare to LST piston ring at
all observed speed.
Percentage of Reduction in Power consumption is decreases with speed from 400 rpm
to 1400 rpm.
Max. Percentage of Reduction Power consumption at 400 rpm speed [low speed].
Min. Percentage of Reduction Power consumption at 2400 rpm.
Average percentage of Reduction in power consumption is 10.52 % by using Laser
surface texturing piston ring.










___________________________________________________________________________
Acknowledgement:
Partial support by the M/S. Modtech Machine Pvt. Ltd., Ahmedabad and M/S. Sahajanand
Laser Technology Ltd., Gandhinagar is gratefully acknowledged.
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International Journal of Innovative Research and Studies Page 63

References:
Books:
1. A textbook of Automobile Engineering Vol. I By K.M.Gupta
2. A textbook of Automobile Engineering Vol. I By P.S.Gill
3. A Course of Internal Combustion Engine By Domkundwar
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