Cylinder Liner Protrusions for Aluminum Sheath Bite Force
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Solution Overview
Problem
Existing cylinder liners face challenges in achieving strong bite force and joint strength due to irregularly shaped bosses on their outside surface, which complicates manufacturing and reduces thermal conductivity, and the thermal spraying process is difficult to control and costly.
Innovation Solution
A cylinder liner with Ω-shaped, P-shaped, or taper-shaped protrusions on its outside surface, manufactured using a ceramic paste with specific raw material percentages and a microburst process to form Ω-shaped cavities, enhancing the contact area and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If irregular-shaped bosses are used on the outside surface of the cylinder liner, then the manufacturing process is simplified, but the bite force between the cylinder liner and aluminum sheath is reduced
Solution Approach 1:
The invention changes the geometric parameters of the protrusions by specifying precise height ranges (0.3-1.1mm) and diameter ranges (0.3-2.5mm), and defining specific shape categories (Ω-shaped, P-shaped, taper-shaped) with minimum proportions. This standardization transforms the irregular bosses into controlled geometric features that simultaneously improve manufacturability through clear specifications and enhance bite force through optimized contact geometry.
Solution Approach 2:
The invention applies local quality by creating protrusions with specific three-dimensional geometries that concentrate contact area at critical locations. The Ω-shaped, P-shaped, and taper-shaped protrusions provide localized enhanced contact with the aluminum sheath, ensuring strong bite force at the interface while maintaining simpler manufacturing processes compared to traditional irregular boss formation.
2Strength
If thermal spraying process is used to reduce pores between cylinder liner and cylinder body, then joint strength is improved, but the process complexity and cost increase
Solution Approach 1:
The invention replaces the thermal spraying process (a complex thermal/chemical deposition process) with a mechanical centrifugal casting process. By using centrifugal force during casting to densely pack the molten material and eliminate pores between the cylinder liner and cylinder body, the invention achieves strong joint strength through mechanical means rather than thermal spraying, thereby reducing process complexity and cost.
Solution Approach 2:
The invention uses a disposable ceramic protective layer that is applied to the mold and then removed after casting. This simple, low-cost ceramic coating serves the purpose of protecting the mold and facilitating the casting process, replacing the expensive and complex thermal spraying equipment and materials with a much simpler and more economical solution.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly improves the bite force and thermal conductivity between the cylinder liner and the aluminum sheath, preventing the sheath from breaking away and optimizing engine cooling performance.
Implementation Method 1
spraying a layer of the ceramic paste with a thickness of 1.0±0.1 mm onto the inner surface of a steel mould used for manufacturing the cylinder liner, wherein the ceramic paste is immediately subject to a microburst and then forms a ceramic protective layer having a Ω-shaped cavity
Implementation Method 2
pouring molten iron into the steel mould, and producing the cylinder liner by filling the Ω-shaped cavity with the molten iron under a centrifugal force
Data Source
AI summary
A cylinder liner with a plurality of protrusions on its outside surface and the manufacturing method thereof are disclosed. The protrusions are Ω-shaped, P-shaped or taper-shaped, and the Ω-shaped, P-shaped and taper-shaped protrusions are accounted for 50-99.5%, 0.5-30% and 0-20% of the total number of protrusions, respectively. The density of the protrusions on the outside surface of the cylinder liner is 15-65 per square centimeter. The outer surface of the protrusions of the cylinder liner is curved, and has a large contact area and a concave which can be filled by an aluminum sheath to improve the radial bearing capacity, so as to effectively improve the bite force between the cylinder liner and the outside aluminum sheath and prevent the cylinder liner from breaking away from the cylinder body.