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NAZARUDDIN SINAGA
Efficiency and Energy Conservation Laboratory
Mechanical Engineering Department
Diponegoro University
Engine Friction and Lubrication
Engine Friction and Lubrication
Engine friction
– terminology
– Pumping loss
– Rubbing friction loss
Engine Friction: terminology
• Pumping work: Wp
– Work per cycle to move the working fluid through the engine
• Rubbing friction work: Wrf
• Accessory work: Wa
Total Friction work: Wtf = Wp + Wrf + Wa
Normalized by cylinder displacement MEP
– tfmep = pmep + rfmep + amep
Net output of engine
– bmep = imep(g) – tfmep
Mechanical efficiency
– m = bmep / imep(g)
1
Friction components
1. Crankshaft friction
Main bearings, front and rear bearing oil seals
2. Reciprocating friction
Connecting rod bearings, piston assembly
3. Valve train
Camshafts, cam followers, valve actuation mechanisms
4. Auxiliary components
Oil, water and fuel pumps, alternator
5. Pumping loss
Gas exchange system (air filter, intake, throttle, valves,
exhaust pipes, after-treatment device, muffler)
Engine fluid flow* (coolant, oil)
*Have to be careful to avoid double-counting. The engine coolant and oil flow losses are provided
for by the oil and water pump. The nature of the loss is a pumping loss though.
SI engine
friction
(excluding pumping loss)
Source: FEV Brochure
Front end
accessory
drives (FEAD)
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2
Engine Friction
Fig. 13-1
Comparison of major categories of
friction losess: fmep at different
loads and speeds for 1.6 L four-
cylinder overhead-cam automotive
Spark Ignition (SI) and
Compression-Ignition (CI) engines.
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Fuel energy
accounting for
SI engine
SAE Paper 2000-01-2902
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3
Pumping loss
V / Vmin
Fig. 13-15 Puming loop diagram for SI engine under firing
conditions, showing throttling work Vd(pe-pi), and valve flow work
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SI Engine losses
0.0
0.1
0.2
0.3
0.4
Fuel conversion efficiency
Gross indicated
Brake
Pumping
loss
Rubbing
loss
SI Engine; 2000 rpm
Preferred
operating range
0 20 40 60 80 100
% of brake load
4
Sliding friction mechanism
Wear
particle
Energy dissipation processes:
• Detaching chemical binding between surfaces
• Breakage of mechanical interference (wear)
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Bearing Lubrication
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5
Sommerfeld No.=
Decreasing load,
increasing speed
Increasing load,
Decreasing speed
Stribeck Diagram
for journal bearing
= lubricant viscosity
N = shaft rotation speed
= loading force / area
Fig 13.3
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Motoring break-down analysis
(a) (b)
Fig. 13-14
Motored fmep versus engine speed for engine breakdown tests.
(a) Four-cylinder SI engine.
(b) Average results for several four- and six-cylinder DI diesel engines
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6
Breakdown of engine mechanical friction
1 F.A. Martin, “Friction in Internal Combustion
Engines,” I.Mech.E. Paper C67/85, Combustion
Engines – Friction and Wear, pp.1-17,1985.
T. Hisatomi and H. Iida, “Nissan Motor Company’s
New 2.0 L. Four-cylinder Gasoline Engine,” SAE
Trans. Vol. 91, pp. 369-383, 1982; 1st engine.
2nd engine.
M. Hoshi, “Reducing Friction Losses in Automobile
Engines,” Tribology International, Vol. 17, pp 185-
189, Aug. 1984.
J.T. Kovach, E.A. Tsakiris, and L.T. Wong, “Engine
Friction Reduction for Improved Fuel Economy,”
SAE Trans. Vol. 91, pp. 1-13, 1982
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Valve train friction
From
Bosch
Handbook
Valve train friction depends on:
• Total contact areas
• Stress on contact areas
Spring and inertia loads
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7
Low friction valve train
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Valve train friction reduction
Engine speed (x1000 rpm)
“Friction loss reduction by new lighter valve train system,”
JSAE Review 18 (1977), Fukuoka, Hara, Mori, and Ohtsubo
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license. For more information, see https://ocw.mit.edu/help/faq-fair-use.
8
Piston ring pack
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Piston ring-pack dimensions
(~6 mm height)
•Ring height 1.2-1.5 mm
•Ring gap ~ 0.2 mm
Source: MIT Sloan Automotive Laboratory.
9
(by 1-2% of bore)
Piston slap
Change timing (earlier) of
transition so that the cylinder
pressure at transition is lower –
less force to accelerate piston
Transition is a “roll over” so
that slap is less severe
Also the “slap” force is lower
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Bore distortion
4th order 2nd order 2nd order 3rd order
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11
Lubricants
• Viscosity is a strong function of temperature
• Multi-grade oils (introduced in the 1950’s)
– Temperature sensitive polymers to stabilize
viscosity at high temperatures
Cold: polymers coiled and inactive
Hot: polymers uncoiled and tangle-up:
suppress high temperature thinning
• Stress sensitivity: viscosity is a function of
strain rate
Viscosity
10W30 refers to upper viscosity limit equal to single grade SAE 10 at 0 deg F (-18C)
and lower viscosity limit equal to SAE single grade 30 at 100 C.
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12
Additive to lubricant
• VI Improvers
– To improve viscosity at high temperature
• High temperature stability
• Acid neutralization
• Detergents and dispersants
– To keep partial oxidation products and PM in
suspension and to prevent lacquer formation
• Anti-wear additives
– E.g. Zinc dialkyldithiophospate (ZDDP)
– Formation of anti-wear film
Modeling of engine friction
• Overall engine friction model:
– tfmep (bar) = fn (rpm, Vd, , B, S, ….)
– See text, Ch. 13, section 5; SAE Paper 900223, …
For engine speed N:
tfmep = a + bN + cN2
• Detailed model:
– see text Ch. 13, section 6; SAE Paper 890936
tfmep
fmep
components
With detailed modeling of component friction as a function of rpm, load, …
13
FMEP distribution
MAP= MAP=
Engine speed (x1000 rpm) Engine speed (x1000 rpm)
% of total FMEP
Distribution of FMEP for a 2.0L I-4 engine; B/S = 1.0, SOHC-rocker arm, flat
follower, 9.0 compression ratio
C = crankshaft and seals
R = reciprocating components
V = valve train components
A = Auxiliary components SAE 890836
P = Pumping loss
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14
REFERENCES
1. Wai Cheng. Internal Combustion Engines. Massachusetts Institute of Technology: MIT
Open Course Ware.
2. Heywood, J. Internal Combustion Engine Fundamentals, McGraw-Hill, New York,
1988.
3. Pulkrabek, W.C. Engineering Fundamentals of the Internal Combustion Engine,
Prentice Hall, Upper Saddle River, New Jersey, 2003.
4. Colin R. Ferguson and Allan T. Kirkpatrick. Internal Combustion Engines: Applied
Thermal Sciences, 2nd Edition,, John Wiley and Sons, New York, 2000.
5. Gupta, H. N. Fundamentals of Internal Combustion Engines, PHI Learning Private
Limited, New Delhi, 2009.
6. Priangkoso, Tabah and N. Sinaga. Review of Fuel Consumption Mechanistic Models to
be Applied on the Smart Driving Simulator Program, Proceedings, 2nd National Science
and Technology Seminar, Faculty of Engineering, Wahid Hasyim University, Semarang,
June 2011.
7. Mrihardjono, Juli and N. Sinaga. Driving Cycle Tests of Honda City Passenger Cars
Fueled by Premium Gasoline, Journal of Gema Teknologi, Volume 16, No. 3, October
2011, ISSN: 0852 0232.
8. Sinaga, Nazaruddin and Tabah Priangkoso. Review of Empirical Models of Vehicle
Fuel Consumption, Journal of Momentum, Vol. 7, No. 1, April 2011.
9. Sinaga, Nazaruddin. Energy-Saving Tests of Passenger Cars to Support the Smart
Driving Program in Indonesia, Proceedings, 10th National Seminar on Mechanical
Engineering (SNTTM X), Mechanical Engineering Department, Faculty of Engineering,
Brawijaya University, Malang, November 2011.
10. Sinaga, Nazaruddin, T. Priangkoso, D. Widayana, and K. Abdurrohman.
Experimental Study on the Effect of Driving Parameters on Fuel Consumption of 1500-
2000 CC Passenger Cars, Proceedings, 10th National Seminar on Mechanical
Engineering (SNTTM X), Mechanical Engineering Department, Faculty of Engineering,
Brawijaya University, Malang, November 2011.
11. Sinaga, Nazaruddin. Smart Driving: Fuel Saving, Emission Quality Enhancement and
Accident Reduction, Paper presented in the Seminar of Astra-Undip, Mechanical
Engineering Department, Diponegoro University, November 2012.
12. Sinaga, Nazaruddin, and Mulyono. Experimental Study on the Impact of Pertamax and
Pertamax-Plus Fuels on the Exhaust Emissions of Motorcycles, Proceedings, National
Seminar of Research and Community Service Institution, Politeknik Negeri Semarang,
2013, ISBN: 978-979-3514-66-6, Pages 168-172.
13. Sinaga, Nazaruddin and S. J. Purnomo. Relationship of Throttle Position, Engine
Rotation and Gear Position on Fuel Consumption of Passenger Cars, Eksergi, Energy
Engineering Journal, State Polytechnic Semarang, Vol. 9 No. 1, January 2013.
14. Sinaga, Nazaruddin. Smart Driving Training to Reduce Greenhouse Gas Emissions and
Transportation Costs of Land Transportation, Proceeding, 12th National Seminar on
Mechanical Engineering (SNTTM XII), Faculty of Engineering, University of Lampung,
October 2013.
15. Sinaga, Nazaruddin, S. J. Purnomo, and A. Dewangga. Development of Efficient Fuel
Consumption Equation Models for EFI Gasoline Fuel Passenger Cars, Proceeding, 10th
National Seminar on Mechanical Engineering (SNTTM XII), Faculty of Engineering,
University of Lampung, October 2013.
16. Sinaga, Nazaruddin, and Y. N. Rohmat. Comparison of the Performance of LPG and
Gasoline Motorcycles, Proceedings, National Seminar on Green Industry Technology,
Center for Industrial Pollution Prevention Technology (BBTPPI) Semarang, Ministry of
Industry, Semarang May 21, 2014.
17. Syachrullah, L.I, dan N. Sinaga. Optimization and Prediction of Motorcycle Injection
System Performance with Feed-Forward Back-Propagation Method Artificial Neural
Network, Proceedings, 2nd National Seminar on Development of Research and
Technology in Industry, Faculty of Engineering, Gajah Mada University Yogyakarta,
June 2014.
18. Paridawati and N. Sinaga. Reducing Fuel Consumption of an Injection System
Motorcycle Using Artificial Neural Network Optimization Method with Back-
Propagation Algorithm, Proceedings, 2nd National Seminar on Development of
Research and Technology in Industry, Faculty of Engineering, Gajah Mada University
Yogyakarta, June 2014.
19. M. Rifal and N. Sinaga. Impact of Methanol-Gasoline Blend on Fuel Consumption and
Exhaust Emission of an SI Engine, Proceedings, The 3rd International Conference on
Advanced Materials Science and Technology (ICAMST 2015), Semarang State
University, April 2015.
20. Sinaga, Nazaruddin, and Mulyono. Experimental Study on the Motorcycle
Performance with Variation of Gasoline Types, Journal of Eksergi, Vol. 11, No. 1, ISSN:
0216-8685, Pages 1- 6, January 2015.
21. Syachrullah, L.I, and N. Sinaga. Optimization and Prediction of Motorcycle Injection
System Performance with Feed-Forward Back-Propagation Method Artificial Neural
Network, American Journal of Engineering and Applied Science, Vol. 8 Issue 2, pp. 236-
250, ISSN: 1941-7039, February 26, 2016.
22. Rojak, Amirur and N. Sinaga. Analysis of Air and Fuel Consumption on Passenger
Cars Fuel with LGV, Journal of Politeknosains, Vol. XV, No. 1, ISSN: 1829-6181,
March 2016.
23. Khudhoibi and N. Sinaga. Effect of Engine Remap on LGV-Fueled Car Operations,
Journal of Momentum, Islamic University of Wachid Hasyim, Vol. 12, No. 1, ISSN:
0216-7395, April 2016.
24. Rifal, Mohamad and N. Sinaga. Impact of Methanol-Gasoline Fuel Blend on Fuel
Consumption and Exhaust Emission of SI Engine, AIP Conf. Proc. 1725, 020070-1–
020070-6; Published by AIP Publishing, 978-0-7354-1372-6, March 2016.
25. Sinaga, Nazaruddin and D. Alcita. Comparison of Fuel Consumption on EFI Car
Fueled with Gasoline and Methanol-Gasoline M15, Eksergi, Energy Engineering
Journal, State Polytechnic Semarang, Polines, Vol. 12 No. 3, September 2016.
26. Nazaruddin Sinaga. Preliminary Design of a Simple LPG Converter Kit for Small Scale
Gasoline Engines, Journal of Eksergi, Journal of Energy Engineering Polines, Vol. 13,
No. 1, January 2017.
27. Nazaruddin Sinaga and M. Rifal. Effect of Methanol-Gasoline Fuel Composition on
Torque and Power of a 1200 CC EFI Passenger Car, Journal of Rotation Vol. 19, No. 3,
July 2017.
28. Rifal, Mohamad and N. Sinaga. Experimental Study of Methanol – Gasoline Ratio on
Fuel Consumption, Exhaust Emission, Engine Torque and Power, Gorontalo Journal of
Infrastructure and Science Engineering, Vol 1 (1), April 2018, pp. 47-54.
29. Nugroho, A., Sinaga, N., Haryanto, I. Performance of a Compression Ignition Engine
Four Strokes Four Cylinders on Dual Fuel (Diesel-LPG), Proceeding, The 17th
International Conference on Ion Sources, Vol. 2014, 2018, 21 September 2018, AIP
Publishing.
30. Nazaruddin Sinaga, B. Yunianto, Syaiful, and W.H. Mitra Kusuma. Effect of
Addition of 1,2 Propylene Glycol Composition on Power and Torque of an EFI
Passenger Car Fueled with Methanol-Gasoline M15, Proceeding of International
Conference on Advance of Mechanical Engineering Research and Application
(ICOMERA 2018), Malang, October 2018.
31. Ahmad Faoji, Syaiful Laila, Nazaruddin Sinaga. Consumption and Smoke Emission of
Direct Injection Diesel Engine Fueled by Diesel and Jatropha Oil Blend with Cold EGR
System, Proc. The 2019 Conference on Fundamental and Applied Science for Advanced
Technology (Confast 2019), Yogyakarta, January 21, 2019.
32. Johan Firmansyah, Syaiful Laila, Nazaruddin Sinaga. Effect of Water Content in
Methanol on the Performance and Smoke Emissions of Direct Injection Diesel Engines
Fueled by Diesel Fuel and Jatropha Oil Blends with EGR System, Proc. The 2019
Conference on Fundamental and Applied Science for Advanced Technology (Confast
2019), Yogyakarta, January 21, 2019.
33. Sinaga, Nazaruddin, M. Mel, D.A Purba, Syaiful, and Paridawati. Comparative
Study of the Performance and Economic Value of a Small Engine Fueled with B20 and
B20-LPG as an Effort to Reduce the Operating Cost of Diesel Engines in Remote Areas,
Joint Conference of 6th Annual Conference on Industrial and System Engineering (6th
International Conference of Risk Management as an Interdisciplinary Approach (1st
ICRMIA) 2019 on April 23-24, 2019 in Semarang, Central Java, Indonesia.
34. Sinaga, Nazaruddin, B. Yunianto, D.A Purba, Syaiful and A. Nugroho. Design and
Manufacture of a Low-Cost Data Acquisition Based Measurement System for Dual Fuel
Engine Researches, Joint Conference of 6th Annual Conference on Industrial and
System Engineering (6th International Conference of Risk Management as an
Interdisciplinary Approach (1st ICRMIA) 2019 on April 23-24, 2019 in Semarang,
Central Java, Indonesia.
35. Y Prayogi, Syaiful, and N Sinaga. Performance and Exhaust Gas Emission of Gasoline
Engine Fueled by Gasoline, Acetone and Wet Methanol Blends, International Conference
on Technology and Vocational Teacher (ICTVT-2018), IOP Conf. Series: Materials
Science and Engineering 535 (2019) 012013 doi:10.1088/1757-899X/535/1/012013
