Optimizing Parameter Sets for Laser-Textured Piston Rings Using Design of Experiments and Multibody Dynamics Calculations

Publication Name: Coatings

Publication Date: 2025-05-01

Volume: 15

Issue: 5

Page Range: Unknown

Description:

Friction and wear reduction in internal combustion engines are crucial for improving efficiency and durability. This study investigates the effect of microtextured surfaces on friction power loss in an engine’s piston ring-cylinder system. A numerical analysis was conducted on piston rings equipped with dimple-shaped microtextures using AVL Excite Piston & Rings, modelling a hard chromium-coated piston ring and a cast iron cylinder. The goal was to determine the optimal surface texture parameters that minimize friction power loss under typical urban driving conditions with SAE 0W-30 oil. A two-step Design of Experiments (DoE) approach was employed, where the first step involved mapping the effects of texture parameters, i.e., dimple depth (A = 0.5, 1, 1.5 µm), dimple distance (B = 120, 160, 240 µm), and dimple diameter (C = 50, 60, 70 µm), to identify influential factors. The second step aimed at locating a parameter configuration with minimal friction power loss. The results demonstrated that the optimized texture parameters can significantly reduce friction power loss. The lowest friction power loss of 8.96 W was achieved with a dimple depth of 2 µm, distance of 80 µm, and diameter of 60 µm, which contributed to an 8.3% improvement over the reference surface. The model built to describe the investigated texturing approach exhibited a strong correlation with an R2 value of 0.93, and the deviation between predicted and measured values was below 1%. Future work will involve tribometer tests to experimentally validate the optimized parameters and confirm the simulation results.

Open Access: Yes

DOI: 10.3390/coatings15050528

Authors - 4