Structural Performance of Additively Manufactured Cylinder Liner—A Numerical Study

Climate change is exacerbated by vehicle emissions. Furthermore, vehicle pollution contributes to respiratory and cardiopulmonary diseases, as well as lung cancer. This requires a drastic reduction in global greenhouse gas emissions for the automobile industry. To address this issue, researchers are required to reduce friction, which is one of the most important aspects of improving the efficiency of internal combustion engines. One of the most important parts of an engine that contributes to friction is the piston ring cylinder liner (PRCL) coupling. Controlling the linear deformation enhances the performance of the engine and, as a result, contributes positively to its performance. The majority of the tests to study the conformability between cylinder liner and piston were carried out on cylinder liners made of cast iron. It is possible to improve the performance of piston ring cylinder liner couplings by implementing new and advanced manufacturing techniques. In this work, a validated finite element model was used to simulate the performance when advanced manufactured materials were adapted. The deformation of the cylinder liner due to thermal and mechanical loads is simulated with five different additive manufactured materials (Inconel 625, Inconel 718, 17-4PH stainless steel, AlSi10Mg, Ti6Al4V). Simulated roundness and straightness errors, as well as maximum deformation, are compared with conventional grey cast iron liner deformation. Some additive manufactured materials, especially Ti6Al4V, show a significant reduction in deformation compared to grey cast iron, both in bore and circumferential deformation. Results show that Ti6Al4V can reduce maximum liner deformation by 36%. In addition, the roundness improved by 36%. The straightness error when Ti6Al4V was used also improved by 44% on one side, with an average of 20% over the four sides. Numerical results indicate that additive manufactured materials have the potential to reduce friction within the piston liner arrangement of internal combustion engines.