Abstract:

Despite new developments like E-mobility or hybrid concepts, the combustion engine will remain of great importance in individual mobility. The article highlights the recent trends, i.e. moving away from monolithic materials in the crankcase towards coated liners with adapted surface structures generated by honing processes. Results of tribological tests are presented for determined surface modifications and different materials to decrease frictional losses. Methods of process monitoring are outlined together with discussion of results from running-in experiments and boundary layer characterisation. Thus, conclusions for the specific finishing of cylinder running surfaces are drawn to improve the honing process. The maximum allowable honing pressure and related distortions can be determined by a simulation of the honing process. The optimization of the finishing process of cylinder running surfaces by honing can only be realized due to the consideration of all effects occurring whilst production and running-in. Therefore, an interdisciplinary work between research and industry is essential.