TECHNICAL MEMORANDUMS NLTIONAL A.DVISORY COMMITTEE FOR AERONAUTICS --------- LIBRARY COPY No. 1056 JUL 3 1196 MANNED SPACECRAFT CENTER 0083TON, TEXAS PISTON RING PRESSURE DISTRIBUTION By M. Kuhn A.T,Z. Automobiltechnische Zeitschrift Vol. 45, No, 3, February 10, 1942 Washington December 1943 r NATIONAL ADVISORY COMMITTEE FOR AERONAUTICS 1 TECHNICAL !tiEMORANDUM NO. 1056 PISTON RING PRESSURE DISTRIBUTTION* By 1 vi . Kuhn The discovery and introduction of the internal combustion engine has resulted in a very rapid development Design has in machines utilizing the action of a p iston. been limited by the internal components of the engine, which has been subjected to ever increasing thermal and mechanical stresses. Of these internal engine components, the piston and piston rings are of p articular importance and the momentary position of engine development is not seldom dependent u p on the development of both of the components. The piston ring is a well—known component and has been used in its present shape in the steam engine of the last century, Corresponding to its importance, the piston ring has been a rich field for creative activity and it is noteworthy that in spite of this the ring has maintained its shape through the many years. From the many and complicated desi g ns which have been suggested as a packing between piston and cylinder wall hardly one suggestion has remained which does not resemble the original design of cast iron rectangular ring. Material Development From the metallurgical aspect it is known that the gra p hite in the ring structure should be present in fine filiform distribution, for only in this form of graphite distribution maximum strength properties can be obtained, The occurrence of eutectic grahite in the structure is fundamentally undesirable because it is invariably associated with . the formation cf ferrite pockets, which, from the point of view of wear, are bad. The remaining carbon is bound as pearlite in iron and its appearance is identi— fied as fine lamella sorbite. The quantity of graphite and structure formation, besides being dependent upon the smelt charge and the composition of slag is dependent also on the gas tem p erature, the mould material and the cooling *"A,T.Z. Automobiltechnische Zeitschrift. 11Vol. 45, No. 3, Feb. 10 3 1942, pp. 62-67. NOTE: An English translation taken from "The Engineers' Di est" Vol. III, No. 11, November 1942. 2 NACA Technical Remorandum ' No . 1056 i speed of the cast. The speed of solubility- of the iron in the surface is de p endent upon the alloying constituents, as y ell as .from the speed of heating •i., .anganese increases, while silicon decreases, the speed of solubility. This reaction of the alloying constituents necessitates t'o uttormoc~t care in their uses because silicon expedites the precipitation of =raphite in the structure while it hinders the pearlite formation. A large addition of silicon necessitates, therefore, an addition of manganese to n-revent excessive grap hite formation. Better carbide formation results in improved thermal and strength properties while better graphite formation results in im p roved running _p roperties. The carbide formin g, elements are chromium, molybdenums, vanadium, tungsten, arsenic, antimony, while the F'ra7) 'iite formin- elements are silicon, nickel, titanium, copper, and aluminium. As has already been pointed out, tie alloying of an element of the first group usually necessitates the alloy— in of an element from the second group, if neither carbide formation nor graphite precipitation is to predominate in the structure and cause the ring, to have either good running ,p roporti . s and bad thermal and strength properties or 'the op p osite effects. I n addition, it is necessary that phosphorous be alloyed. to the ring. Altheu j;h a phosphorous addition affects unfavorably the strength properties of the ring, the running p roperties are improved by its addition owing to tale oossibilit ') of the formation of uniform phosphide pockets, thereby improving the adherence properties of the oil film. Manufacturing Processes In general, t,ie modern method. of manufacturing piston rine's, is the individually cast method, whereby the blanks are moulder singularly a.nd Il heaped if .cast, Cylindrical pot casting was p opular for a long' time, but its use,has declined in spite of the fact th.FL.t a very fine uniform structure was obtained. The elastic'prope.rties of the cylindrical pot cast rings were not sufficient to withstand the conditions in the modern engine;. The individually cast ring showed in this respect promise, in that it was possible to stress the ring to a high degree. In Germany, the centrifugal 1 r NACA Technical Memorandum No. 1056 3 method of casting rings is seldom employed, but in the English—speaking countries the method is adopted, Ring Stressing Piston rings can be prestressed by three methods. The first method is by hammering,a method which is seldom used in Germany. By this method, the ring is -orestressed by stretching the inner fibres of the ring. The process is applied by rolling or by notch—impact. The second method of prestressing piston rings is the heat formed method, which is being used extensively to-In this method a ring which is entirely free of day. stresses is split and the gap thereby resulting is forced apart by a wedge. In this condition the ring is then annealed whereby the stresses are nullified. An external stress is then applied to the ring, and, in the closed condition, is machined to finished size. I ^ The third method of prestressing piston rings is the out—of—round method. In this method ring blanks are used which are not circular but formed according to an involute. The rin- is then cut by cutting away an appreciable piece of the ring to form the gap. The ring is then pressed together and finish turned to a circle. After machining, the ring will maintain its natural casting stresses. A heat treatment follows which prevents any subsequent loss in stress due to the temperatures occurring under engine operation conditions. Heat formed rings result in a uniform ring pressure distribution throughout the ring circumference, that is, a round radial pressure pattern. Out—of—round rings can be liven any ring pressure pattern and it is possible to make the rings with high radial point pressures especially at the gap. It will be shown later that this is also possible with heat formed rings. The Stress Distribution or Ring Pressure Pattern The question now arises as to what type of ring pressure pattern is desirable. Originally, one had endeavored to obtain a uniform ring pressure pattern; this type of p ressure pattern is very favorable, as, with it, the ring 4 NACA Technical Memorandum No. 1056 is pressed at all -p oints with uniform pressure against the cylinder. It was found from experience, however, that where the ring was subjected. to maximum load, that is, at the gan, ring collapse took place. It is desirable not to have a uniform pressure pattern when the rint; is new, but after running the ring for some time under operating conditions a uniform ring pressure pattern should be attained.. This means that when the ring is new the ga p should. have higher radial or point pressure than the rest of the circumference. In addition to this, with the continuous increase in engine speed, towards the higher speed range, certain , p rocesses occur, which cause sudden increases in piston ring blow—by and oil consume— tion. This process is termed piston ring flutter, a p henomenon, which probably occurs when the ring is excited by im-oulses in the range of its natural frequency, Reliable data is, however, not yet available to analyse this condition It can be shown experimentally, and the object of this article is to show, that when the ring pressure at the ring gap is high, the unfavorable condition of piston rind flutter and its undesirable effects can be moved outside the range of actual engine operational speeds. The mean specific ring pressure of the ring is considered as a. most useful criterion. The mean spac,if.ic boring pressure is calculated from the tangential force acting at the gap which is necessary to close the ring to the normal gap cl •oarance. The measurement of the tangential force is made by means of a "toledo rl balance. Tho following relr.tion is-obtained: 2 Pt pm = kilograms per . squared centimeters h D in which pm mean specific ring pressure, kilograms per squared centimeter Pt tangential force, kilograms. h rind; width, centimeter D ring diameter, centimeter NACA Technical Memorandum No y 1056 5 The results of stress obtained by means of the toledo method will agree with the actual mean surface pressure only when the ring pressure is evenly distributed over the whole ring circumference, which means that the radial pressure distribution p attern must be round. The toledo stress and the stress obtained from the calculated mean specific p ressure are not in agreement when the radial ring pressure is not evenly distributed around the ring circumference. The ring with uneven pressure patterns usually has high pressure points at the ring gap and at other parts of the-ring circumference. The remaining sections of the ring may have low or even very low surface pressures. The whole ring cannot be considered stronger than that of its weakest section, and this section cannot be determined from the radial pressure distribution. It follows therefore, that for out--of--round rings, which have been stressed, the radial pressure distribution is important. Measurement of Pressure Distribution To obtain actual measurements of radial pressures is not a simple matter and a method free of error does not exist. kany references are to be found in the literature relating to radial pressure distribution and the results obtained are often represented in a comprehensive manner. It is, however, noteworthy that the manufacturers usually recede for one reason or another, directly measurements are asked for. Most of the measuring methods give such unreliable data that they do not lend themselves to criticism. It may be worth mentioning that the radial pressure distribution can be measured by the steel band method, by means of which the ring is stressed to its normal size b y a thin steel band as shown in figure 1. With the aid of calipers, the diameter of the ring is measured at various position of its diameter. The out—of—roundness obtained is ring ovality which can be as much as one percent greater than the normal ring diameter. The positions of low ring pressure cannot be determined by this method of measuring ring pressures. In spite of the fact that rings tested by this method can give .pressure distributions which ap p ear to be entirely 6 NACA Technical l+emorandum No. 1056 satisfactory, they have failed when used in the engine. The failures were more frequent, the higher the loading of the combustion chamber. .After very short operations in the engine, the faces of the rings at certain positions became discolored and there is an increase in blow-by and oil consum p tion. Ring examination for high duty engines should be carried out, therefore, by some other method. The obvious solution of the p roblem lies apparently in the use of a ring gage, the inside surface of which has iDrovision for a series of pressure gage sockets or ni;ooles. It is fully realized that the difficulty of the solution may be the finding and mounting of such pressure gage sockets, which in the radial direction, permit the most accurate force indication s^rith the smallest possible measurements, of the ring pressure. A relativel..T simple solution of the problem is described in the following arrangement and shown in figure 2. The inner surface of a ring gage is arranged with a number of steel rollers. Each roller can be loaded externally through ar. orifice. A pattern of the radial ring pressure distribution is obtained by the resistance of the roller to turning by manual operation. The latter is very troublesome and, in addition, roller turning by hand only gives subjective measurements. A measuring method developed by the Ma.hle Company of Germany is shown in figure 3. This method permits objective measurement to be made by means of pressure gages. The ring to be tested is inserted in a ring gage with a 0.02 millimeter greater diameter than the nominal ring diameter. The g^at;e points of sixteen clock gages are in contact with points around the circumference of the ring These pass through holes drilled radially through the rir}g gage. By suitable screw adjustment the gage points are p ressed against the ring, so that all clock ;ages show identical readings a.nd, therefore, similar stress. The gage points are then. sc:re ed further in against the ring, by merlins of a P m_ .nlweter' : to an amount equal to 0.01 millimeter, The readi_Igb obtained from the clock gages present a pattern of ttie radial pressure distribution. It has been found that this complicated apparatus cannot be used for practical purposes. The time required to take measurements is too lengthy, for when setting the NACA Technical kemorandum No. 1056 7 clock gages with equal pressure an alteration in the setting of one clock necessitates variation and adjustIn addition, it is so comment of the-other clocks. plicated that it is impossible to design an apparatus suitable to test rings of different diameter. A simpler apparatus for measuring pressure ring distribution is that which has been introduced and de=w veloped by Messrs. Alfred Teves in conjunction with the Zeiss Co. This apparatus operates on the biezo—electric princi p le and is shown in figure 4. An inducement to use the piezo—electric effect of a ll ouartz" is that the quartz shows only a small tendency to deform in the direction of the a.pplied load or pressure. The movement of the measuring point is practically zero. But it is a disadvantage that the p iezo—electric effect occurs not at constant pressure but only during pressure changes. . The piston ring is inserted in a ring gage of the apparatus. As the actual measuring procedure has been described by C. Englisch 3 the author does not consider it necessary to describe the apparatus at this stage. As an essential component cf the equipment is a loop or carthode ray tube, it follows that a well equipped laboratory is desirable. Both the last two mentioned highly developed methods of testing piston rings are so elaborate and lengthy in time that they can only be used by specialist firms. The engineer who uses piston rings and. requires fur.ther knowledge concerning their characteristics is, therefore, forced to use .simpler methods of measurements such as the methodwhich is about to be described. The ap p aratus again consists mainly of a ring gage, the nominal diameter of which corres p ond-s to that of the piston ring to be tested`. The ring gage has a shoulder against which the p iston ring is pressed. The gage points of a clock gage, which is graduated in 1, / 100 or 11000 divisions, pass through a hole in the ring gage and rest upon the circumference or bearing surface of the ring. The ap p aratus is shown in figure 5. The front face of the ring has a series of notches which are situated on' the right and left of the holes drilled for the gage points. These notches are used to locate a hook, upon which weights can be suspended in order to load the ring bearing surface. 8 XAC-A Technical N:emorandum No. 1056 The procedure of measuring piston ring pressure distribution is as follows: After inserting the piston ring in the ring gage, the ring gage is adjusted to give P. zero reading. A simple turning of the ring gives an indication of ring roundness, in the same way as is obtained with the light method. Everywhere, where the ring diameter does not correspond with the nominal diameter of the ring gage, tha clock indicates the occurring deviation. A satisfactory ring will be within the limits of from 0.002 to 0.005 millimeter of its nominal dimension. It has been found that many rings measured deviate from the nominal diameter by as much as 0.03 millimeter. The weakest section of the ring is in the neighborhood of the ring gap, while the ring ga-j itself retains the dimension of the nominal diameter. Measurement of r:^dial pressure distribution is carried out in the simple manner of hanging weights on the suspen— sion scale pan attached to the hook. The weight is increased until. the clock shows a deflection of 0.01 millimeter. The reduction in clearance at the gap is given by the ,product of . 77 times th-e deflection and is of the order of 0.03 millimeter. This clearance reduction is unimportant, because even with rings of small dimensions the gap clearance is 0.15 millimeter, or greater.. In this way the ring is measured at i , 11 sections and a pattern of the pressure distribution is obtained of surprisin impressiveness. The suspended weight shows, in addition, the bearing or surf^- ce pressure occurring a.t each point with some approximation. By loading the ring .until a reduction in diameter of 0.01 millimeter occurs each point of the ring bearing surface moves a small distance during the measurement in the ring gage. The frictional force, thereb , T set up, varies according to the position of the gap, Should the point at whicth the measurement be made be near the gap, then with a reduction in diameter of 0.01 millimeter the ring gap will not be reduced but the loaded rin g; ends will yield towards the center of the ring. Hence, no friction between the ring and the gage exists. Should the point at which the measurement is made be on the side opposite the gan, then a reduction in ring diameter can only occur with a corresponding reduction in ring gap. The friction which is set u-o between the ring and the gage will be measured. It is for this reason, that the sum of all the pressures ri.easured on the gap half of the ring are always smeller than those occurring on the opposite or other side of the ring. Cn the side opposite to the gap the NACA Technical Memorandum No. 1056 9 measured pressures are higher than the actual ones by an amount equal to the frictional forces which are of unknown magnitude. The occurring error in measurement error is not small, but it can be easily the position of the center point to the bution curve, as the sum of the vectors sures must be zero. or experimental estimated from: pressure distriof all the pres- Considered. as a whole the accuracy of measurement is probably greater than that obtained with the other methods of measuring ring pressure, described in this article, because the latter only gives a pattern of the ring pressure distribution and not an actual value of the measurement, Il With a certain amount of experience, measurements with the apparatus can be made quite quickly. The time required to measure the ring takes five minutes or less. The radial pressure curves are so characteristic for a ring, that from the curves it can not only be ascertained whether the type of stress in the ring was obtained by heat—forming or the out—of—round method, but also indicate the.source from which the rings were obtained, as the tools used in the manufacture give the ring product certain characteristics. Applications Figure 6 shows the radial pressure distribution or pressure pattern of a heat formed ring, which had been used for'some 8000 kilometers in an engine. The stress distribution is very uniform. The reduction of the surface pressure at the gap, that is, the collapse, is not apparent. The sum of all strosses on the side opposite the gap is somewhat greater than those occurring on the gap side of the ring. The cause of this is the error in measurement which has already been fully discussed. This error is a characteristic of the measuring method. A Figures 7 and 8 have been obtained from two rings both of which have been run for some 2000 kilometers. Both rings were heat formed. The first ring had a uniform pressure distribution while the second had a high pressure point at the gap. The stresses are partly typical. The toledo stress of both rings are in agreement. 4i 10 NACA Technical Memorandum No. 1056 It can be seen that high pressure points can be obtained with heat formed rings. It is interesting to note that, while with a ring having a uniform ring pressure distribution, the piston blow—by increased above 3800 rpm (fig. 9), the blow—by remained practically constant with a heat formed ring which had uneven pressure distribution. The opinion that the phenomenon of ring flutter can be overcome-by the use of rings with high pressure points, is confirmed by the above measurements.. Attention should be paid by the manufacturers that high pressure points at the gap are not exaggerated, otherwise rings are produced having ring pressure characteristics as shown in figure 10. The high pressure at the gap is exaggerated and directly-next to it 'a position of very low pressure is shown, so that the ring aan hardly bear against the cylinder. The result is a break through of the hot combustion gases at the dangerous section and excessive heating of the rings, just at its weakest point. In an engine of low output the progressive running—in can remove at first the position of high pressure and eliminate the position of low pressure. In the high duty engine, the ring is often disturbed at the point of its minimum stress due tc overloading of thermal stresses, before the running— in process can be of assistance. This type of unsatisfactory stress distribution is especially found in out—of—round rings. Figure 11 shows a series of radial pressure distribution curves of piston rings, which have been picked out from a batch of rings. A number of these cut—of—round rings used in a high duty engine had to, be replaced after short running periods, because at different parts of the circumference the rings showed burnt sections. The measurements of the rings showed ring pressure distribution curves as shown in figure 12. The position of the burnt sections occurring at the circumference of the ring are indicated and prove that the measurements of pressure distribution are correct. Further measurements obtained, with the steel band method, are shown in figure 12 by the pressure curve indicated by the broken line. This shows that the ring ovality is about 6 percent, but does not show the characteristic of minimum ring pressure which was apparent as indicated by the burnt or discolored ring sections. That out—of—round rings with satisfactory ring pressure distribution can be manufactured is shown by the curves in figure 13. This type of ring, NACA Technical Memorandum No. 1056 11 formed by turning, is especially of interest in that it was manufactured from plain cast—iron. Its ackowledgeable quality is not due to highly developed materials, but apparently due to careful balancing of the ring pressure distribution, which was very uniformly maintained with all rings. The ring stress at the gap is not very great, but the points of minimum pressure which occur next to the gap are hardly noticeable. I Page intentionally left blank NACA Technical Memorandum No. 1056 Figs. 112j31415 Fig. 1 Fig. 2 Fig. 3 Fig. 5 sr,» 9 W. Fig. 4 Page intentionally left blank Figs. 619 NACA Technical Memorandum ivo. 1056 ff o' ►o° t era' Oo• a- W 44 Fig. 6 46 ^'rie a. orme evenly Stressed ring8 — He tfo d venly s^rQbse^. r^nga Q# 03 3av 320 34Ox W 3" O Spsed r.p.m. Fig. 9. Gas blow by with heat formed rings having uniform pressure distribution and high pressure point or uneven pressure distribution. Page intentionally left blank NACA Technical Memorandum No. 1056 a• 0' Figs. 758 +o' x M' Od° r• tao• e• N7' Fig. 7. Heat formed rings from an Opel engine after 2,000 km., with evenly distributed pressure. Mean specific pressure obtained from the tangential force to close the ring, pm — 1.28 kg'cm". 4 11 D' 10' otg 90 • to rOr' AV y0• .. I 7p I/O • f 70• Fig. 8. Heat formed rings from an Opel engine after 2,000 km., with high pressure point. Mean specific pressure determined from the tangential force to close the ring, pm -- 1.35 kg cm2. Page intentionally left blank NACA Technical Memorandum No. 1056 Figs. 10111 r 0• iv, a 0• w• -99. 011 tM e 10• Fig. 10. Heat formed high pressure point ring with exaggerated high pressure point near the gap and sections of minimum pressure next to it. New rings. ^W to of N' got >• V. tv 44 — 'V' MG' 110' Turned ring with exaggerated pressure point at gap, Fig. 11. followed by points of minimum pressure at other sections of the ring circumference. Mean specific pressure determined from the tangential force to close the ring, pm = 1.42 kg/cm2-. NACA T.M. No. 1056 Figs. 12 5 13 4e o' ,o• eo• ^ r^ 25 0 r +a' C ^e SI` b oo Zoo \ .Zj^ 1500 100 •^ t'0,^ -V. 50 000-r 9v. U go ?f0• x, 4U n "°'^ X10 ,^.^`uo• +M 1W 1 Iv` .^w •' Fig. 12. Turned high pressure point ring with burnt sections. The radial pressure distribution is exaggerated at the gap and is useless. The stress determined by the steel band method is given by the broken line diagram. Time of running not known. 4e 0' 90• a se CAI• -4 .rip• M . fV - Turned high pressure point ring with Fig. 13. determined pressure distribution. No exaggerated high pressure point at gap and absence of low pressure points in the surface pressure. Mean specific pressure determined from the tangential force to close the ring, pm = 1.35 kg/cm z . New rings.
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