Etude tribo-fonctionnelle des textures bas frottement des cylindres de moteurs générées par le procédé de rodage

Abstract : Mechanical honing process is still the reference industrial process for high production engine liners. The current manufacturing way use reduced velocity friction and abrasion mechanisms to print a multiscale and anisotropic texture on the liner surface. The texture signature characteristics satisfy multifunctional requirements of the liner (friction, lubrication, wear, oil consumption etc.). It is generated by a stratified honing process for industrial production which consists of three stages with scale effect: rough (macroscopic scale), finish (mesoscopic scale) and super-finish honing (microscopic scale). Different honing methods emerged during last decade in which the technological and economic differentiation is essentially based on textural attributes of honed surfaces. The present study analyses the industrial honing processes, the possible surface anisotropy choices and texture parameters with a view to honed liner surface functionalisation. A methodological approach about multiscale honed surface tribofunctionality has been developed and then validated by numerical simulation in the case of ring-liner tribocontact. It builds on the following triptych:- the coupling between honing process and functionality through its multiscal textural signature,- the exploitation of the controlled anisotropy by numerical simulation which conducts to fonctionality,- the surface-process interaction which becomes indivisible, particularly in texture manufacturing and its tribofunctional qualification though tribometric trials.The methodology has been applied to industrial honing processes (plateau honing (PH), slide honing (SH) and helical slide honing (HSH)). The results show that smooth texture with lower plateau roughness and valley depth contributes to reduce frictional performances of honed surfaces. Nevertheless, Helical slide honed surfaces are less sensitive in friction to the plateaudness i.e., to superficial roughness comparatively to PH textures. This is promising for HSH process optimization, in which the third stage can be reduced or deleted. Then the developed approach has been extended to honing development for innovative texture anisotropy (circular, undulatory, mixed, trajectory assisted) for low-friction performances. The results show that assisted trajectory (without inversion grooves at top dead (TDC) and bottom dead centers (BDC)) and 45-130-45 mixed textures (with 45° cross-hatched grooves at TDC and BDC, 130° cross-hatched grooves at mid-height) enhance significantly frictional performances in comparison to HSH conventional process.
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Mohammed Yousfi. Etude tribo-fonctionnelle des textures bas frottement des cylindres de moteurs générées par le procédé de rodage. Génie mécanique [physics.class-ph]. Ecole nationale supérieure d'arts et métiers - ENSAM, 2014. Français. ⟨NNT : 2014ENAM0053⟩. ⟨tel-01148194⟩

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