Development, Calibration and Validation of a Tribological Simulation Model for the Piston Ring Pack of a Large Gas Engine

Increasing demands regarding the efficiency and emissions of internal combustion engines will require higher peak firing pressures and increased indicated mean effective pressures in the future. Adaptation of these parameters will result in higher thermal and mechanical loads that act on core engine components. To meet the future requirements, it is essential to make changes to the design of the tribological system, which is composed of the piston, piston rings, liner and lube oil, while maintaining the robustness and reliability of the engine and its components. Modification of the tribological system requires in-depth knowledge of wear and friction. This paper presents the setup of a model of the tribological system (piston, piston rings, liner and lube oil) of a large gas engine in the commercial software AVL EXCITE™ Piston as well as its calibration and validation with data obtained from a test bed. Initial analysis of necessary input data has revealed a high number (>300) of different parameters, some of which are known and others that have to be determined. Strategies are identified for how missing input data can be specified or generated with appropriate tools. The model is calibrated with respect to blow-by and lube oil consumption data measured on the test bed at two different load points. Subsequent validation shows satisfactory agreement between simulation and measurements. A final summary proposes how the extensive and time-consuming process of setting up, calibrating and validating the presented model could be complemented by the integration of data-driven models and sensitivity analysis approaches.