Distortion Inside a Piston Bore

Teimuraz Bardzimashvili
James F. Kelly
Elene Romelashvili
April 28, 2004
Abstract: Inside of an engine block are piston bores and corresponding piston rings.
Before and during engine operation, the cylinder bore may distort, possibly causing a loss
of the light-tight seal between the ring and the piston. We examine the conformability of
elastic piston rings to a distorted cylinder bore. e!eral bounds exist that gi!e the maximum bore
distortion for each "ourier harmonic# the $unae!sky, the %&'()' and the (omanik bounds. By
considering the complete bore profile, we analy*e ring conformability in the presence of multiple
orders of distortion with our +I,%-./0 program. We scrutini*e the underlying assumptions for
each bound. We then test our +I,%-./0 simulator with "inite 'lement 1"'2 data and compare
our results to each bound. &ur results indicate that the %&'()' bounds predict conformability
more accurately than the $unae!sky bounds at high orders of distortion.
3333333333333333333333333333333333333333333333333333333333333333
Work done for $aimler/hrysler under the direction of Bruce %eist, in partial fulfillment of the
re4uirements of 5ichigan tate 6ni!ersity 5(7 899, ad!ised by -rofessor William ledd.
:
Table of Contents
Introduction.....;;;..................................................................................................;..<
$efinitions and Bound .ssumptions;;;;;..;;.;................................;;;;9
/omparison of Bounds;;;;;;;;;;;;;;;;;;;;;;;;;;=
"inite 'lement 1"'2 $ata and +ing pecifications;;;;.;;;.;;;;;;;..>?
+I,%-./0 $escription ;;;;;;;;;;;;;;...;;;;;;;;...;><
Boundary /onditions;;;;;;;;;;;;;;;;;;;;;;;.>9
/ur!ature of "ree +ing;;;;;;;;;;;;;;;;;;;;;;..>@
/ur!ature of /ylinder Bore;;;;;;;;;;;;;;;;;;;;...>A
-ressure /alculation;;;;;;;;;;;;;;;.;;;;;;;;..>A
+esults;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;>=
-arameter tudy;;;;;;;;;;;;;;;;;;;;;;;;;.>=
.nalysis of "' $ata;;;;;;;;;;;;;;;...;;;;;;;;>8
$iscussion;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;..:?
+ecommendations...................................................................................;;;;...;;::
"uture Work;;;;;;;;;..;;;;;;;;;;;;.;;;... ;;;;::
.cknowledgements;;;;;;;;;;;;;;;;;;;;;.;;;...;;::
+eferences;;;;;;;;;...;;;;;;;;;;;;;;;;...;.;;...:<
.ppendix .# "ree hape -roblem;;;;;;;;;;;;;;;;;;;;;.:@
.ppendix B# %&'()' Bound $e!iation ...;;;;;;;;;;;;;;;;;..:8
.ppendix /# (hree-$imensional $istortion;;;;;;;;;;;;;.;;;.....<?
.ppendix $# +I,%-./0 /ode;;;;;;;;;;;;;;;;;;;;;;<:
<
Introduction
Inside of an engine block are piston bores and corresponding piston rings. (he piston
ring may be !iewed as a /-shaped, structural elastic beam that makes contact with the
walls of the piston bore. (he piston ring is guided into a gro!e around the piston as the
piston-ring assembly is inserted into a cylinder of the engine block. (he /-shaped ring is
forced closed, so that the /-shape becomes roughly a circle surrounding the piston.
Because the ring wants to re!ert to its free shape, it exerts a pressure on the cylinder
walls. Ideally, the piston ring forms a light-tight seal with the surrounding cylinder wall
and piston, meaning that no gaps are present through which combustion gasses can
escape.
In a typical assembly, there are three rings# two compression rings and an oil control
ring. (he compression rings seal a piston in its combustion chamber, so that pressure
from exploding gasoline can be con!erted to mechanical energy. .lso, the rings assist the
dissipation of heat through the cylinder wall and regulate oil consumption. "or a detailed
discussion of piston ring functionality, see B>C and B:C.
$ue to imperfections in design and assembly, gas pressure and thermal !ariations, the
cylinder may distort before and during operation. 7ence, the circular piston ring must
conform to a slightly imperfect cylinder bore. ince the piston ring acts like an elastic
beam B<C, we expect the ring to successfully conform to a slightly distorted bore.
7owe!er, if these distortions become too large, the ring may be unable to conform and
loose its light-tight seal with the cylinder wall and piston. (his seal breach may result
in increased oil consumption and leakage, blowby, and engine wearD also fuel efficiency
may decrease B9, @C. 7ence, we consider the conformability problem in this report# %i!en
distortions in the cylinder bore and a set of piston ring specifications, determine if the
ring forms a light-tight seal.
5any researchers ha!e attacked the conformability problem using both analytical and
computational tools. 'arly analytical work includes pioneering work by -rescot,
(imoshenko, and 'nglisch BA,=,8C. %intsburg BEC analy*ed splitless rings 1rings with no
gap2 by approximating distortions from the nominal radius r
0
with a "ourier series.
Fetting () denote the measured bore shape 1where is the polar angle2, () is
approximated by

+ +
N
k
k k
k A r
>
?
22 1 cos1 2 1
, 1>2
where k is the order and
k

is a phase angle. By assuming a bore profile in this form,

%itsburg deri!ed a set of bounds for each "ourier harmonic of distortion. 5ore recently,
5Geller B>?C and $unae!sky B>>C ha!e deri!ed competing bounds on each harmonic.
%&'()' .% adopted the 5Geller bounds in their Incometer cylinder distortion
measurement system B>:C.
9
+eali*ing the limitations of the analytical methods, automoti!e researchers ha!e
begun de!eloping "inite 'lement 1"'2 models of piston ring dyanamics. (hese models
B><, >9, >@C take into account gas pressure, oil lubrication and complicated three-
dimensional distortions that the abo!e analytical models neglect. +ecently, $unae!sky
B>A,>=,>8,>E,:?C has begun work on a three-dimensional model of the piston ring that
does not assume a constant cross-section. (his model takes into account torsion and twist
of the ring. 7owe!er, the theory behind this three-dimensional analysis is still poorly
understood and currently under de!elopment. "or background on this theory, we refer
the reader to the classic work by Fo!e B:>C.
5ost automakers and piston ring manufacturers use either the %&'()' 1or 5Geller2
bounds or the $unae!sky bounds. 7owe!er, these bounds gi!e different upper limits to
each term in the "ourier series expansion. 5oreo!er, these bounds, cannot predict
conformability in the presence of multiple orders of distortion. (his discrepancy
prompted (omanik B::C to empirically compare the bounds to incometer measurements.
In this report, we follow-up on (omanikHs work and analy*e the physical and
mathematical assumptions underlying each set of bounds. We de!elop a simple program
to analy*e a bore profile, comparing the bounds to "' data.
Definitions and Bound Assumptions
/onsider a cur!ed, prismatic member 1or piston ring2 with height h and thickness t. "or
the present analysis, assume a constant, and rectangular cross-section A = ht. 1We
consider a !ariable cross-section later.2 .ssuming the ring is nearly circular, we impose a
polar coordinate system (, r) about the center of the ring. We assume the ring has
homogenous density and is composed of some flexible material with modulus of
elasticity E. (he ring is split, meaning that there is a gap in the free state. When the
ring is compressed, this gap is reduced to a small space to allow sealing. ee "igure >. In
contrast, some authors ha!e studied the dynamics of splitless BEC.
By applying a radial pressure p( ) andIor bending moment M() to the ring, we
deform 1elastically2 the shape of the ring. ince the cross-section is constant, we can
define an axis from each of the endpoints of the ring. By deforming the ring, we deform
any of these axes. 5oreo!er, there is a neutral axis in the ring, which remains stress free.
We will measure the ring relati!e to this neutral axis.
(he piston ring assumes a free, uncompressed state gi!en by () = r() + ()! By
applying a radial pressure p(), we compress the ring to shape r(). .lso, define the
radis of cr"atre of the uncompressed ring as and the cur!ature of the uncompressed
ring as
0
=#$D likewise, for the compressed ring, define radius of cur!ature r and
cur!ature
#
J#$r.
In order to lineari*e the e4uations of elasticity, 5Geller and $unae!sky make two
fundamental assumptions, discussed below.
@
Hookes Law: tress is proportional to strain. 5athematically, E , where E is the
modulus of elasticity.
Thin Road Approximation: (he thickness of the ring t is much smaller than the radius
of cur!ature .
Figure 1. This shema!i sho"s !he pro#e!ion o$ rin% on !he plane perpendiular !o !he &ore a'is ()*+.
ince bore distortions are well within the elastic limit, we are Kustified in applying
7ookeHs law. /ommon ring specifications B>C gi!e .>? t , Kustifying the thin-rod
approximation. (o simplify the analysis, both 5Geller and $unae!sky make a third
fundamental assumption.
Radial Assumption: (he bore 1and hence the ring2 distorts only in the radial direction.
We neglect both tangential and axial distortions.
"or rings with non-uniform cross-sections, this assumption does not hold. 5oreo!er, the
radial assumption may not be wholly accurate for uniform cross-section rings. e!eral
researchers B>9,>EC are currently considering the effect of these complicated <$
distortions on conformability.
By combining these three assumptions, we arri!e at the fundamental elastic relation#
A

EI
M 2 1
? >

. 1:2
'4uation : relates the bending of the ring to the flexural rigidity 1or stiffness2 EI to the
cur!ature of the ring. In other words, the bending of the ring is directly proportional to
the change in cur!ature.
In the following discussion, we wish to specify ring conformability by a single
parameter. We define the conformability coefficient !ia

EI
r %
&
m t
:
, 1<a2
where %
t
is the tangential force 1applied at the gap2 re4uired to close the ring.
.lternati!ely, we can define & !ia

EI
hr p
&
m
<
?
, 1<b2
where r
m
is the middle radius 1approximated by the nominal radius r
0
)! "or most rings, &
takes !alues between .?> and .?9.
In order to deri!e the pressure distribution that the compressed ring exerts upon the
cylinder bore, $unae!sky makes se!eral assumptions regarding the uncompressed ring
().
Free Shape Approximation: (he de!iations
2 1
and
2 1 L
are small compared to
radius of cur!ature r. 5oreo!er, the free shape is approximated by

2 sin @ . > 1 2 1 +
m f
&r
. 192
'4uation 9 and !ariants are widely used. 7owe!er, researchers at the 'ngine +esearch
Fab ha!e de!eloped an exact solution that does not make the "ree hape .pproximation
B:C. (o !erify this work, we sol!ed for the free shape numerically in .ppendix ..
5oreo!er, we will demonstrate how to relax this approximation and obtain a closed-form
expression for cur!ature.
Uniform Pressure Assumption: (he ring, when inserted into a circular bore, exerts a
uniform pressure.
In a pri!ate con!ersation with $unae!sky, he remarked that this assumption is generally
not true. In fact, some piston ring manufacturers 1such as +iken2, design rings that
produce apple or pear shaped pressure distributions. In practice, the pressure
distribution is !ery difficult to measure with any accuracy.
=
Superposition Assumption: (he pressure distribution induced when a ring whose free
shape is r + y and is compressed to a perfect circle r is approximately the same as the
pressure distribution induced when a ring whose free shape is r + is compressed to o!al
shape
2 1 : cos
9
+ +
e
r
. 5oreo!er, each order distortion does not influence any of the
other orders.
Constant CrossSe!tion Assumption: (he cross section area A is not changed by elastic
deformation. (hat is, the thickness and height do not change e!en though the neutral axis
changes position.
Comparison of Bounds
In this section, we 4uantitati!ely compare the %&'()' B>?C, $unae!sky B>>C and
(omanik B::C bounds. ince we are interested in relating the maximum radial cylinder
distortion to the pressure exerted by the ring on the bore, we wish to analy*e bounds for
the coefficients
k
A
in '4uation >. By determining the tightest set of bounds on each
term, the piston ringHs design characteristics can be optimi*ed for fuel efficiency and
engine durability BAC.
We can represent bore distortion mathematically by a bore profile. "igure : shows a
typical bore profile 1adapted from B>>C2. We can decompose this profile into "ourier
harmonics, thus representing the radial distortion as a "ourier series 1see '4uation >2.
Before we discuss the bounds themsel!es, we interpret the !arious "ourier harmonics
physically.
.t present, many researchers consider terms beyond fourth-order to be negligible BECD
howe!er, other experts recommend considering fifth and sixth order terms
B>A,>=,>8,>E,:?C. econd-order distortions in '4uation > reflect the o!ality of the
distorted cylinder bore. In BEC, cheider found that these distortions depend hea!ily on
the !ertical position of the piston ring relati!e to the cylinder. (hird-order distortions
form a clo!erleaf shapeD machining imperfections are responsible for these distortions.
"inally, excessi!e tightening of the tension bands in the cylinder cause fourth-order
distortions. .lthough these distortions can be minimi*ed, they cannot be eliminated
entirely. 7ence, we re4uire an accurate theoretical bound on the distortions.
"igure < 1reprinted from B>>C2 shows second, third and fourth order distortions using
polar coordinates.
6sing the assumptions outlined in the pre!ious section, $unae!sky deri!es a set of
bounds for each "ourier harmonic. $enoting A
k
as the k-th coefficient, $unae!sky shows

>
> >
@: . >
: <
<

<
k E t
r
h
'
A
k
. 1@2
8
In the abo!e e4uation, ' is the diametrical force re4uired to close the ring. (his
diametrical force is related to the force %
t
re4uired to close the ring by the theoretical
formula

. A< . :
t
% '

7owe!er, the piston manufacturer $ana -erfect /ircle uses a ri!al empirical formula
gi!en by
. >@ . :
t
% '


Figure 2. This %raph sho"s &ore dis!or!ion in polar oordina!es.
Figure 3. ,n !hese polar %raphs, "e display sample seond, !hird and $our!h order dis!or!ions. The ori%inal
$i%ures "ere prin!ed in ())+.
-rior to $unae!skyHs work, 5Geller deri!ed a similar bound on each of the "ourier
terms B8C. 6sing the notation abo!e, we ha!e the bound
E

: : <
<
2 > 1
> >
@A . 9

<
k E t
r
h
'
A
k
. 1A2
"or second-order distortions 1k=(), '4uations @ and A yield the same bound. 7owe!er,
they de!iate for higher order distortions. (hese de!iations prompted (omanik to deri!e a
semi-empirical formula in B::C. 6sing experimental measurements and linear regression,
(omanik determined a semi-empirical formula gi!en by

:
:?1 >2
k
&r
A
k
<

. 1=2
7ere, & is the conformability coefficient defined by '4uations <. We summari*e all
three bounds in terms of & in (able >.
"igure 9 shows the bounds for distortions up to sixth order using ring parameters
supplied by $aimler/hrysler 1see (able :2. ,ote that the %&'()' bounds are more
conser!ati!e for orders three and four. .lso note that both the $unae!sky and %&'()'
bounds o!erestimate ring conformability by a factor of six for second order deformations.
Both the (omanik and $unae!sky bounds share the #$(k
(
)#) dependence. In general, all
three sets of bounds show that conformability is highly sensiti!e to !ery small, high-order
distortions.
(he differences between '4uations @, A and = prompt se!eral 4uestions. "irstly,
which assumptions made by $unae!sky and %&'()' cause the o!erestimation of the
boundsM econdly, can we deri!e a tighter set of bounds by relaxing these assumptionsM
"inally, how should we use these bounds if we measure multiple-orders of distortion in a
gi!en boreM
Table 1. -e ompare !he ./ET0E, 1unaevs2y, and Tomani2 &ounds via !he on$orma&ili!y oe$$iien! K.
"#$T%$ &unae'sk( Tomanik
: :
1 >2
m
&r
k
:
<1 >2
m
&r
k
:
:?1 >2
m
&r
k
>?
Figure . -e ompare !he 1unaevs2y &ounds 3solid4, ./ET0E &ounds 3do!!ed4 and Tomani2 3dashed4
&ounds.
Finite !lement Data and "ing #pecifications
.nother approach to the ring conformability problem is "inite 'lement .nalysis 1"'.2.
"'. can take into account ring cross sectional properties, ring tension, pressure load
abo!e and below the ring, friction and oil flow. +esearchers at the 'ngine +esearch Fab
1'+F2 at 56 are taking this approach B:,>9,>@C in de!elopment of their /ylinder 0it
.nalysis ystem for 'ngines 1/.'2. ome other engine simulation "'. code
de!elopers include .NF, +icardo, and 5I(. .lthough these models account for
complicated ring dynamics, they are computationally expensi!e.
(o e!aluate each of the bounds and our own method, $aimler/hrysler pro!ided their
own "' data and ring specifications. (he "' data specifies a computational grid and a
displacement !ector associated with each grid point. (he grid itself is arranged in sixteen
decks, each deck ha!ing approximately :< points. (o !isuali*e this data, we map the
magnitude of each displacement !ector onto the grid. "igure @ shows the !arious
magnitude displacements, with a maximum distortion of .?= mm. ,oting that the radius
of the bore is @>.>8> mm, this maximum displacement represents less that ?.>@O of the
bore radius. .lso note that the cylinder is inclined at approximately 9@, much like an
actual cylinder in a N-A engine.
>>
(able : displays the ring specifications pro!ided by $aimler/hrysler. In our
calculations, we used the empirical formula
t
% ' >@ . :
.
182
We note that this ring has a rather low conformability coefficient &.
We extracted bore profiles by calculating the radial displacement and ignoring the
tangential and axial displacement. "or details, see the section describing +I,%-./0.
"igure A shows raw bore profiles for decks <, A and E. We used the default linear
interpolation in 5.(F.B to connect the marked data points. ,ote that the general shape
of each profile is similar. 5oreo!er, the amplitude of distortion appears to increase as we
mo!e up the cylinder bore.
Table 2. This !a&le displays rin% spei$ia!ions provided &y 1aimler5hrysler.
1iame!rial 6oad 374 )8.2998
:ei%h! 3mm4 ).48
Thi2ness 3mm4 8.*89
;iddle Radius 3mm4 9).)8)
<oun%=s ;odulus 37>mm
2
4 )92 000
5losin% Fore 374 ?.)?99
;omen! o$ ,ner!ia 3mm
4
4 @.804*
A!i$$ness 3mm
2
4 ) )8? 800
5on$orma&ili!y 0.0)8?
>:
Figure $. This $i%ure sho"s !he dis!or!ed &ore a! eah %rid poin!. 7o!e !ha! !he &o!!om de2 su$$ers $rom
very li!!le dis!or!ion, "hereas !he !op de2 has muh lar%er dis!or!ion.
><

Figure %. ,n !his $i%ure, "e display FE Bore pro$iles $or de2s 8, ? and *.
"I&'PAC( Description
In order to test the "' data and e!aluate the effecti!eness of each bound, we wrote a
5.(F.B program called +I,%-./0. ee .ppendix $ for code. "igure = shows the
general structure of the program.
(he program has two general components# a ring component and a bore component.
(he ring component calculates the free shape of the ring 1see .ppendix .2 and the
cur!ature gi!en specifications. (he bore component imports "' data, extracts a profile,
interpolates the profile, and calculates cur!ature. We address the cur!ature problem in
the following sections.
>9
Figure ). This $i%ure displays !he R,7.BA5K s!ru!ure dia%ram.
Boundary 5ondi!ions
(o determine the free cur!ature, we must first determine the correct boundary conditions
to impose at the ends of the ring. We consider a split ring, with a small gap at the back of
the ring 1where = , )2. .t the ends of the ring, the bending moment
2 1 M
must
!anish since there is not external tor4ue applied to the ring. In the case of constant
pressure 1or no radial de!iations2, we argue that shear force
2 1 *
must also !anish.
+ecall that the only external force on the ring is a radial pressure acting inwards. By
analy*ing the forces on the ring, we can show that
N
d
d*
phr +

,
where N is the tangential force on the ring. $ue to the free-end condition, the tangential
force !anishes at the back of the ring. In the free case, the constant load condition
implies *ero shear force at the endpoints. 7owe!er, in the distorted case, we would
expect a non-*ero shear at the endpoints.
>@
5urva!ure o$ Free Rin%
-re!ious work B>?,>>C used an approximation for the free shape of the ring 1see '4uation
92. 7owe!er, we can increase the accuracy of our calculations by deri!ing the exact
cur!ature of the free, uncompressed ring.
/onsider the free ring shown in "igure 8. .t each polar angle , the cylinder exerts a
radial pressure p( ). We wish to determine the bending moment M( ) induced by this
radial pressure. "ix an angle and a position !ector r

and consider the small bending

moment dM induced by pressure at angle +! By definition of moment,
% d r M d

,
1E2
where % d

is the small force associated with pressure at angle +. ince the problem is
two-dimension, M d

will only ha!e a ,-component. (herefore, define dM to be the ,-
component of . dM
v
We can then calculate
d hp r % d 2 1

.
1>?2
Inserting '4uation >? into '4uation E and e!aluating the cross-product yields the
expression#

d r p hr dM 2 1 2 1 2 sin1 2 1
.
1>>2
"or the free-ring problem, the pressure p
0
exerted on a perfectly round bore is constant.
7ence, we can integrate '4uation >> o!er the angle + subKect to the boundary condition
M()) = ?.
>A
Figure *. -e use !his shema!i used in deriva!ion o$ $ree shape urva!ure.
(his integration yields the closed-form expression
2 cos > 1 2 1
:
?
+
m
hr p M ,
1>:2
where
m
r
is the middle radius of the cylinder. We can then determine the free cur!ature
?
by using '4uation :. ,oting that final cur!ature
m
r I >
>
, we find

m
r
& 2 cos > 1 >
?

. 1><2
'4uation >< allows use to calculate free cur!ature without considering the actual free
shape 1approximate or exact2. "or readers interested in the exact free shape, please
consult .ppendix . or reference B:C.
5urva!ure o$ 5ylinder Bore
(o determine the cur!ature of the cylinder bore, we first interpolate the bore profile with
a "ourier series. ince we only ha!e :< data points per profile, the fast "ourier
transform 1""(2 does not pro!ide enough accuracy. 5oreo!er, the data points are
irregularly spaced with respect to angle. 5any methods exist to e!aluate "ourier
coefficients for irregularly spaced datasets B:<C. We chose to interpolate the data points
!ia a cubic spline. We then e!aluate the "ourier coefficients !ia %auss 4uadrature B:9C,
with a !ariable number of %auss abscissas. "or implementation details, see the function
fcoeffs_trighi in .ppendix $. &nce we calculate the "ourier coefficients, we can
compute the deri!ati!es of the "ourier series analytically. We then apply the exact, polar
coordinate cur!ature formula
>=

: I < : :
: :
>
2 1
:

+

+

. 1>92
Bressure 5alula!ion
&nce the change in cur!ature is known, we can calculate the bending moment !ia
'4uation :. "inally, we calculate pressure numerically using the relation#

,
_

:
:
:
2 1
>
2 1
d
M d
M
hr
p
. 1>@2
. deri!ation of '4uation >@ can be found in B<C. If the pressure of the ring is positi!e for
all angles, then we assume the ring maintains a light-tight seal. If, howe!er, the
pressure is negati!e for any angle, the ring breaks the seal and conformability is lost.
"esults
In order to compare our +I,%-./0 program with established results, we calculated
bounds numerically. "or each "ourier harmonic 1k = : to A2, we calculated the minimum
radial distortion for which pressure became negati!e. "igure E compares these
+I,%-./0 bounds to the $unae!sky and %&'()' bounds for the parameters in (able
:. ,ote that the +I,%-./0 bounds are !irtually identical to the %&'()' bounds.
(his initial result suggests a hidden flaw in the $unae!sky bounds.
Barame!er A!udy
(o aid in the design of future piston rings, we studied how !arying the ring parameters
effected conformability. In this analysis, we perturbed the middle radius and thickness
gi!en in (able : by :?O in both directions using a <> by <> spatial grid. We then
calculated the bounds for these perturbed radii and thicknesses using second-order, radial
distortions. (hus, we made the implicit assumption#
2 , 1 t r f A
m k

,
where
k
A
is the bound on k-th order distortions.
"igure >? displays bounds as a function of both thickness and radius. ,ote that the
bounds are highly sensiti!e to these two !ariables. +ealistically, a !ery small error in
either radius or thickness could lead to a large difference in the allowable distortion.
>8
Figure +. -e ompare R,7.BA5K &ounds !o 1unaevs2y and ./ET0E &ounds.
Analysis o$ FE 1a!a
We next tested the +I,%-./0 program with "' data. "or the demonstration we chose
deck E with :< data points. "igure >> shows the interpolated profile bore 1with data
points shown as circle2 against polar angle. (o interpolate, we used fi!e terms in the
"ourier series expansion. "igure >: displays pressure distribution of the distorted ring as
a function of angle. ince we are primarily interested in the sign of pressure, we also
show the *ero-pressure line. We see that pressure becomes negati!e, which indicates that
the light-tight seal between cylinder wall and the ring is broken.
ince the standard conformability criterion is the %&'()' bounds, we also
calculated the %&'()' bounds from '4uation @ using the ring parameters listed in (able
:. We plotted the computed "ourier coefficients against the %&'()' bounds in "igure
>< for orders two through fi!e. ,ote that none of the "ourier coefficients exceed the
%&'()' bounds. "or orders beyond fi!e, the coefficients were negligible.
>E
Figure 1,. This $i%ure displays seond order &ounds $or per!ur&ed parame!ers rm and t.
Figure 11. This $i%ure displays !he in!erpola!ed &ore pro$ile $or de2 *.
:?
Figure 12. -e display !he pressure dis!ri&u!ion o$ dis!or!ed rin%, usin% !he &ore pro$ile sho"n in Fi%ure )).
Figure 13. -e ompare !he ompu!ed Fourier oe$$iien!s $or FE da!a 3de2 *4 and !he ./ET0E &ound
3usin% !he rin% parame!ers in Ta&le 24.
:>
Discussion
&ur numerical results let us assess the reliability of both the $unae!sky and the %&'()'
bounds. In "igure E, we see that the bounds obtained !ia our simulation match the
%&'()' bounds almost exactly. .lthough all three bounds match at second order, there
is wide !ariation for higher orders. ince +I,%-./0 actually calculates each elastic
!ariable with minimal approximation, this result suggests the %&'()' bounds are more
accurate.
(o explore this idea deeper, we deri!e the %&'()' bounds from first principles in
.ppendix B. .lthough 5Geller deri!ed these bounds in B>?C, we pro!ide a deri!ation
since B>?C is not a!ailable in 'nglish. Both the $unae!sky B>>C and %&'()' bounds use
the same approximations of elasticity theory found in the .ssumptions ection.
7owe!er, $unae!sky adds one additional assumption in his model.
Criti!al Cur'ature Assumption: (he ring cur!ature at which the light-tight seal
breaks is independent of order k.
(hat is, cur!ature induced by an o!al distortion 1k = () or a clo!erleaf distortion 1k =
-) will produce the same breach. 7owe!er, the %&'()' deri!ation pro!es this
assumption false. We see that pressure is dependent upon both cur!ature and the second
deri!ati!e of cur!ature. 7ence, small distortions of high order can produce large pressure
!ariations, while large distortions of low order may produce mild pressure !ariations. In
fact, the %&'()' deri!ation gi!es an explicit formula for pressure in terms of radial
distortions. "or a k
th
order distortion, the pressure is multiplied by a factor of (k
(
)#)
(
, thus
magnifying pressure !ariations.
"rom our analysis, we must conclude that the /ritical /ur!ature .ssumption is
unphysical. (his false assumption leads the $unae!sky bounds to o!erestimate
conformability for orders three and beyond. /omparing the $unae!sky to the semi-
empirical (omanik bounds, we see that the $unae!sky bounds o!erestimate
conformability to by more than :??O. 7owe!er, the %&'()' bounds agree more
closely with the semi-empirical results. +eturning to "igure E, we also see that the
%&'()' bounds agree closely with our numerical study. "rom this e!idence, the
%&'()' bounds appear to predict conformability more accurately than the $unae!sky
bounds for high orders 1k P <2. 7owe!er, both the $unae!sky and %&'()' bounds
significantly o!erestimate conformability for second-order distortions, which we cannot
explain.
.fter performing our parameter study, a natural 4uestion arises# what is the exact
mathematical dependence of the second-order bound on ring thickness and radiusM (o
answer this 4uestion, we assumed power law dependence and attempted to find the
exponent. We used the standard approach# take the logarithm of dependent and
independent !ariables and find the slope. We calculated slope by differentiating 1!ia
central differences2
k
A
with respect to both r
m
and t. We then a!eraged the deri!ati!es
::
o!er the spatial grid. We determined that
<
:

t A and
<
: m
r A . (hese sensiti!e
dependencies agree with the results shown in "igure >?.
/omparing "igures >: and ><, we note that a small breach has de!elopedD howe!er,
the bore has not !iolated the %&'()' bounds at any order. In particular, it appears that
the fifth-order contribution has contributed enough distortion to break the seal. "rom this
example, we see the necessity of analy*ing the entire bore profile. If we limit our
analysis to an isolated "ourier harmonic, the bore passes the %&'()' boundD yet we
see from "igure >: that the negati!e pressure indicates a breach. .lso, we note the
unusually strong fifth-order contribution re4uires us to mo!e beyond the standard four-
term "ourier series approach B><C.
We are also faced with an unanswered mathematical 4uestion# if we represent the
bore profile !ia a "ourier series, how many terms should we useM -re!ious studies B9,
>:C ha!e terminated the "ourier series after the fourth termD this assumption was Kustified
on physical grounds. 7owe!er, as "igures >: and >< demonstrate, "ourier coefficients at
fifth order and beyond may be present in a bore profile. We note that the current
+I,%-./0 software shown in .ppendix $ is unstable for a large number of "ourier
coefficients. In terms of conformability, the inclusion or exclusion of these high-order
terms may lead to contradictory results. In fact, calculating the pressure for the example
in "igures >: and >< with only four terms leads to a non-negati!e distribution. 7ence,
the problem of determining the correct number of "ourier coefficients is critical to
understanding the present conformability problem.
"ecommendations
Based on our research, numerical experimentation and data analysis, we recommend the
following#
/onsider all orders of deformation simultaneously instead of only considering the
dominant order.
In!estigate the rele!ance of deformation orders beyond four. %i!en particular
engine and cylinder conditions, at what order should we terminate the "ourier
seriesM
.ccording to our analysis, the %&'()' bounds predict conformability more
accurately than the $unae!sky bounds. $ue to an unphysical assumption, the
$unae!sky bounds o!erestimate allowable distortion at high 1k P :2 orders.
/onsider the effects of three-dimensional twist and combustion gas pressure in
breakingImaintaining the light-tight seal.
Future -or.
We hope to impro!e the accuracy of our conformability calculator by using more
sophisticated deri!ati!e approximations. If time and funding permit, we will in!estigate
the gas dynamic and lubrication problems encountered during engine operation.
:<
"urthermore, we plan to obtain "inite 'lement code from the 'ngine +esearch Fab
1'+F2 as well as "'. programs used by $aimler/hrysler and compare the bounds we
discussed to this data.
Ac.no/ledgements
We would like to thank the following experts for pro!iding helpful ad!ice, data, insight
and references#
N. N. $unae!sky, Bendix /orp
-rof. 7arold chock, 'ngine +esearch Fab, 5ichigan tate 6ni!ersity
Boon-0eat /hui, 'ngine +esearch Fab, 5ichigan tate 6ni!ersity
Bruce %eist at $aimler/hrysler was critical to the success of this proKect. 7e
pro!ided expertise in engine components and ad!anced mathematics, as well as
encouragement and methods of attack.
We would like to express special gratitude to -rof. William ledd for his support in
!arious aspects of proKect implementation.
We also thank -rof. /lifford Weil, $epartment of 5athematics, 5ichigan tate
6ni!ersity for his assistance with our presentation at the econd .nnual 56 tudent
5athematics /onference.
:9
"eferences
B>C %oet*e .%, .iston /ing Manal, Burscheid, $-@?E<, >E8E.
B:C /.' .nalysis ystem, (heoretical 5anual, 5id-5ichigan +esearch, &kemos,
5I, :???.
B<C ". -. Beer and '. +. Qohnston, Mechanics of Materials, ,ew Rork# 5c%raw-7ill
Book /ompany, >EE8, p. ::>.
B9C '. W. cheider, 'ffect of cylinder bore out-of-roundness on piston ring rotation and
engine oil consumption, 0ociety of Atomoti"e Engineers, E<?=EA, pp. ><E->A?, >EE<.
B@C . 7. 7ill, -iston ring designs for reduced friction, 0ociety of Atomoti"e
Engineers, 89>:::, pp. >-:?, >E89.
BAC Q. -rescot, Applied Elasticity, ,ew Rork, $o!er -ublications, >E9A
B=C . (imoshenko, *heory of Elastic 0tability, ,ew Rork# 5c%raw-7ill, >E<A.
B8C /. 'nglisch, &olben/inge, Nienna# pringer-Nerlag, >E@8.
BEC %intsburg, B. Ra, plitless-type piston rings, /ssian Engineering 1ornal, Nol. 98,
,o. =, pp. <=-9?, >EA8.
B>?C +. 5Geller, )ur grage des formuellungs!ermoegens !on kolbenringen in !on der
kreisform abweichenden bohrungen gleicher umfanglaenge, M*2, Nol <>, pp. =E-8:,
>E=?.
B>>C N. N. $unae!sky, .nalysis of distortions of cylinder and conformability of piston
rings, *ribology *ransactions, Nol. <<, ,o. >, pp. <<-9?, >EE?.
B>:C 0. Foenne and +. )iemb, (he goet*e cylinder distortion measurement system and
the possibilities of reducing cylinder distortions, 0ociety of Atomoti"e Engineers,
88?>9:, pp. :@-<<, >E88.
B><C . .be and 5. u*uki, .nalysis of cylinder bore distortion during engine
operation, 0ociety of Atomoti"e Engineers, E@?@9>, pp. E->9, >EE@.
B>9C 5. .. 'Kako!, 7. Q. chock, and F. Q. Brombolich, 5odeling of ring twist for an I/
engine, 0ociety of Atomoti"e Engineers, E8:AE<, >EE8.
B>@C 5 ... 'Kako!, 5odeling of axial and circumferential ring pack lubrication,
.5', :??>, pp. >->:.
:@
B>AC N. N. $unae!sky, Q. (. awicki, Q. "rater, and 7. /hen, .nalysis of elastic
distortions of a piston ring in a reciprocating air brake compressor due to the installation
stresses, 0ociety of Atomoti"e Engineers, ?><==?, :???.
B>=C N. N. $unae!sky and . .lexandro!, "undamentals for analysis of three-
dimensional distortions of the piston rings, .roceedings of the (000 %all *echnical
3onference of the A0ME Internal 3ombstion Engine 4i"ision, pp. >@-::
B>8C N. N. $unae!sky, . .lexandro! and ". Barlat, .nalysis of three-dimensional
distortions of the pistons rings with arbitrary cross-section, 0ociety of Atomoti"e
Engineers, ?><9@<, :???.
B>EC N. N. $unae!sky, . .lexandro!, $e!elopment of conformability model of piston
rings with consideration of their three-dimensional torsional distortions and "ourier series
representation of cylinder bore geometry, 0ociety of Atomoti"e Engineers, ?><9@<,
:??:
B:?C N. N. $unae!sky, . .lexandro! and ". Barlat, (he effect of contact pressure on
piston ring twist, 0ociety of Atomoti"e Engineers, ?>:=:?, :??>.
B:>C Fo!e, .. '. 7., A *reatise on the Mathematical *heory of Elasticity, 9
th
'd., ,ew
Rork# $o!er, >E:=.
B::C '. (omanik, -iston ring conformability in a distorted bore, 0ociety of Atomoti"e
Engineers, EA?<@A, pp. >AE->8?, >EEA.
B:<C .. ". Ware, "ast approximate "ourier transforms for irregularly spaced data,
I.5 +e!iew, Nol. 9?, ,o. 9, pp. 8<8-8@A, $ecember >EE8
B:9C -. Q. $a!is and -. +abinowit*, Nmerical Integration, ,ew Rork# .cademic -ress,
>E=@.

B:@C 5. -. $o/armo, 4ifferential 5eometry of 3r"es and 0rfaces, 'nglewood /liffs,
,Q# -rentice-7all, Inc., >E=A.
B:AC %intsburg, B. R., *heory of .iston /ing, 5ashinostroenie 15achinery /onstruction
-ublishing 7ouse2, 5oscow, >E=E.
B:=C N. N. $unae!esky and . .lexandro!, . <-$ 'ngineering .pproach to
/onformability .nalysis of -iston +ings, 0ociety of Atomoti"e Engineers 1accepted2.
:A
Appendi0 A: Free #1ape Problem
$uring the deri!ation of the conformability criterion, $unae!sky B>>C makes the "ree
hape .pproximation. 7ere,
( )
describes the free shape de!iation from a perfect
circle. In the following analysis, we relax this assumption in an attempt to 4uantify some
of the error present in the $unae!sky bounds by sol!ing for the free-shape de!iation
using an exact approach.
Instead of using the approximation found in B>>C, we use the exact formula 1'4uation
>92 for the cur!ature of the uncompressed ring B:@C#

( (
0 ( ( 6 $ (
( r ) (( ) ( r )
7( r ) 8

+ + +

+ +
. 1.>2
,ow define the dimensionless 4uantity 9=$r. "actor out an r and apply the definition to
get

[ ]
: I <
: :
L L : L :
?
2 1 2 > 1
2 > 1 2 1 : 2 > 1

+ +
+ + +

. 1.:2
"rom '4uation >:, we can calculate the free shape by using '4uation :. -ressure can be
related to bending moment !ia the con!olution integral

L 2 L sin1 2 L 1 2 1
:
d p hr M
.
1.<2
"or the special case of constant pressure p, we ha!e the closed-form e4uation
2 cos > 1 2 1
:
+ phr M . 1.92
We can then sol!e '4uation : for the dimensionless, free shape () using '4uations >:
and >9. (he resulting e4uation is the following second-order, nonlinear &$'

[ ]
> 2 cos > 1
L 2 > 1
S 2 > 1 L : 2 > 1
: I < : :
: :
+ +
+ +
+ + +

&
, 1.@2
subKect to the initial conditions gi!en below.
)nitial Conditions# $isplacements are the same at both ends of the ring. (hen
&r 2 1 2 ? 1
and
. ? 2 ? 1
:=
.lthough an analytical solution for '4uation .@ exists B:C, it is expressed as a
complicated infinite series in!ol!ing Bessel functions. '!aluation of Bessel functions can
be computationally expensi!eD therefore we chose numerical approach. .lso analytical
solution exists for the uniform pressure distribution, while we might choose to extend our
analysis to the non-uniform pressure distributions.
(able .> shows the parameters used in our calculations.
In our calculations, we used & = ?.?9A: and r J 98.@? mm. We sol!ed '4uation >@
numerically using a fourth-order, adapti!e +unge-0utta sol!er. We imposed the initial
conditions and sol!ed !ia the 5.(F.B sol!er ode45. ee .ppendix . for 5.(F.B
code.
"igure .> shows both the first-order approximation for 1gi!en by '4uation 92 and
our exact solution. ,ote that the two functions de!iate significantly, causing us to
4uestion the !ery foundations of the linear approach. 5ost importantly, there is a >@O
relati!e difference at the end-gap of the piston ring. (his is a significant de!iation, and
warrants further scrutiny.
We repeated the calculations with parameters from B>>C. "igure .: shows the results.
,ote that the relati!e difference at the end-gap exceeds :?O in this case.
Figure A1. -e display !he $irs! order appro'ima!ion and !he e'a! solu!ion o$ !he $reeCshape devia!ion o$ !he
pis!on rin% usin% parame!ers $rom Tomani2 (22+.
:8
:E
Table A1. -e display !he physial parame!ers used in $reeCshape alula!ions.
Parameters &unae'sk( Tomanik
$iametrical Foad 1T2 1,2 >@.=A >>?.9A??
7eight 1mm2 >.@E= :.98?=
(hickness 1mm2 >.A:@ <.A9
+adius of cur!ature 1mm2 >8.99 98.@
RoungHs 5odulus 1,Imm:2 >>A@? ::@???
/losing "orce 1,2 @.EE 9:.?
5oment of Inertia 1mm
9
2 .@=>> E.E=
tiffness 1mm:2 AA@<? ::9????
/onformability .?<?A ?.?99?
Figure A2. -e display !he $irs! order appro'ima!ion and e'a! solu!ion o$ !he $reeCshape devia!ion o$ !he
pis!on rin% usin% parame!ers $rom 1unaevs2y ())+.
<?
Appendi0 B: '2!T3! Bound De4iation
We deri!e the %&'()' bounds based on first principles of elasticity theory. "or
extensi!e theoretical background, see B:AC. +ecall that the cur!ature of the ring in the
free shape is gi!en by 1'4uation ><2#

?
2 cos > 1 >
r
&
f

, 1B>2
where & is the conformability coefficient defined by '4uation <b and r
0
is the radius of
the undistorted bore.
'4uation >9 gi!es the cur!ature of the distorted bore in polar coordinates. .ssuming that

LI

is negligibly small, we can simplify the formula to the form#

:
>
2 1

.
1B:2
(he bore profile

can be represented in polar coordinates as

2 1
?
+ r
,
1B<2
where
2 1
is small de!iation from the circular shape. Inserting '4uation B< into B:,
decomposing into geometric series and using the fact that Ir
?
is small 1?.?@2 we obtain
the formula for the cur!ature of the distorted bore 1or compressed ring inserted into the
distorted bore2#

:
? ?
L L >
2 1
r r


+

. 1B92

ince any physical bore profile can be expanded in "ourier series, assume the de!iation
() is the k)term of the "ourier series#

22 1 cos1 2 1
k k
k A +
,
1B@2
where A
k
is radial distortion amplitude, k is the order of distortion and
k
is the phase.
We need to find the bending moment generated by compressing the ring from the free
shape into the cylinder bore. 6sing the fundamental relation gi!en by '4uation : and
substituting corresponding expressions for the cur!atures gi!en by '4uations B: and B9,
we obtain 1after inserting expression for
2 1
into '4uation B92#
<>

[ ] 22 1 cos1 2 > 1 2 cos > 1 2 1
:
?
:
?
k k
k k A &r
r
EI
M + + +
. 1BA2
"inally, we determine the pressure that the ring exerts on the bore using '4uation >@.
ubstituting expression for the moment from '4uation BA into '4uation >@ and
simplifying, we attain the formula#

[ ] 22 1 cos1 2 > 1 2 1
:
? 9
:
?
k k
k k A &r
hr
EI
p +
.
1B=2
We want to determine maximum A
k
such that pressure is non-negati!e. (he maximum
!alue of cosine function is unity, so set the cosine term to unity and set pressure e4ual to
*ero. ol!ing for amplitude yields#

: :
?
2 > 1

k
&r
A
k
. 1B82
'4uation B8 corresponds with the %&'()' Bounds deri!ed by 5Geller in >E=?.
<:
Appendi0 C: T1ree5Dimensional Distortion
o far we considered only two-dimensional distortions that occur in piston rings. But we
can go further and build a conformability model in case of three-dimensional torsional
distortions 1or so-called t:ist2 of piston rings. .s a basis for this model we take the
$unae!skyHs papers B>A,>=,>8,>E,:?,:=C. (o build this model let us make some
preliminary assumptions#
Assumption ): When ring is in the free state, the shape of centerline of ring differs from
a perfect circle only insignificantly. +atio of the radial thickness of the ring to its radius
of the cur!ature is small. In free state, absent twist, all cross-sections of ring are identical.
Fet
0
be the twist and k
0
be the cur!ature of the ring in the initial, uncompressed
state. (hen

? ? ?
I > , ? r
, 1/>2
where r
0
is the radius of the centerline in the initial state.
Assumption )): In the deformed state, the centerline of a ring is symmetrical about x-
axis 1see "igure />2. (he maximum !ertical displacement of any point of the centerline is
small compared with a typical radius of the ring. . hori*ontal displacement of the
centerline of the ring caused by twist is also small 1compared with the !ertical
displacement2 and can be neglected.
"rom this assumption, we can represent the centerline of the ring by '4uation />. "or
con!enience we introduce the following dimensionless 4uantities# /()$/
0
, where /
0
is
the typical radis of the centerline and "()$; where ; is the maximum possible !ertical
displacement of any point of the cross-section. We retain notations /() and "() for
these dimensionless 4uantities.
In his paper, $unae!sky deri!es the formula for the infinitesimal element ds of the
deformed centerline. (aking the initial general formula
( (
0
/ "
ds / / # d
/ /

_ _
+ +

, ,
,
assuming
0
( ; $ / ) # <<
and neglecting
(
<( ) term, the simplified formula will look
like#
(
0 0
/
ds / / # d / a( )d
/

_
+

,
,
where
(
/
a( ) / # !
/

_
+

,
1/:2
<<
.lso, $unae!sky deri!ed formula for the cur!ature k of the deformed ring#
( (
# (
0
g ( ) g ( )
k
/
+
. 1/<2
7ere
#
/ ( ) / ( )
g ( )
a( ) a ( )

and
(
/ ( ) / ( )
g ( )
a( ) a ( )

.
"urther, $unae!sky declares the system of e4uations describing gi!en model#
( # ) ( # )
# 0
( ( ) ( ( )
( 0
6 0
M A( k k )
M =( k k )
M 3( )

'

1/92
where M
#
and M
(
are couples transforming the ring in plane perpendicular to bore axis,
M
6
is torsional couple 1one that causes twist2, k
(#)
and k
(()
are the components if k
cur!ature !ector in the principle torsion-flexure axes on each cross-section in the
deformed state. (hat is if we take arbitrary cross-section of the ring 1"igure />2 then for
k
(#)
and k
(()
we will ha!e the following e4uations#
( # ) ( ( )
k k cos , k k sin , 1/@2
where is the twist angle for the particular cross-section. k
0
(#)
and k
0
(()
are the components
if k cur!ature !ector in the initial state and is the twist in the deformed state.
Figure C1. This $i%ure sho"s an ar&i!rary rossCse!ion o$ a pis!on rin%. The an%le deno!es !he !"is! an%le.
(he constants A, = and 3 in '4uation /9 can be found for any cross-section of the ring.
.t this point, $unae!sky attempts to sol!e the system /9 numerically.
<9
Appendi0 D: "I&'PAC( Code
function [profile, angles]=importbore(layer,rm)
%loads grid and displacement data from "grid.dat" and
%"3L_stopper_displaced.dat"
% layer = deck to import
% rm = known radius of bore/ring
% profile = bore profile (radius as a function of angle)
% angles = angles for which profile is known
%load data files here (reverse ordering)
A=importdata('grid.dat');
A = flipud(A);
B=importdata('3L_stopper_displaced.dat ');
B = flipud(B);
len = length(A);
%get grid locations and each component of displacement
x0 = A(1:len,2); y0 = A(1:len,3); z0 = A(1:len,4);
dx0 = B(1:len,2); dy0 = B(1:len,3); dz0= B(1:len,4);
%Bottom and Top deck centers, given by Bruce
XCent = [-94.102, -94.102]; YCent = [66.2796, 166.268]; ZCent =
[66.0163, 166.072];
%the cylinder is titled in a V-engine, rotate s.t. parrallel with z-axis
[THETA,RHO] = cart2pol(y0,z0);
[TH,PHI,R] = cart2sph(dx0,dy0,dz0);
tiltangle=atan((ZCent(2)-ZCent(1))/(YCent(2)-YCent(1)));
%tiltangle=pi/4;
THETA = THETA+tiltangle;
PHI = PHI + tiltangle;
x=x0;
[y,z] = pol2cart(THETA,RHO);
[dx,dy,dz]=sph2cart(TH,PHI,R);
[THETA,RHO] = cart2pol(YCent,ZCent);
THETA = THETA+tiltangle;
[YCent,ZCent] = pol2cart(THETA,RHO);
%extract the deck: deck 1 has 22 points, the other have 23
SP = 24*(layer-1); num = 23;
if layer == 1
SP = SP+1; num = 22;
end
boreX = x(SP:SP+num); boreY = y(SP:SP+num); boreZ = z(SP:SP+num);
dispX = dx(SP:SP + num); dispY = dy(SP:SP + num); dispZ= dz(SP:SP +
num);
centX = XCent(1); centY = YCent(1); centZ = mean(boreZ);
%calculate radial component, through away the rest
for i=1:length(boreX)
rv = [boreX(i)-centX, boreY(i)-centY];
[angles1(i),grid(i)] = cart2pol(rv(1),rv(2));
deltar(i)=cos(angles1(i))*dispX(i) + sin(angles1(i))*dispY(i);
<@
end
%generate the profile (make sure angles are increasing)
prof = ([angles1;rm + deltar])';
prof = sortrows(prof);
angles = (prof(:,1))';
profile = (prof(:,2))';
function [a0,ak,bk]=fcoeffs_trighi(y,x,Ncoeffs)
%assume interval (-pi,pi)
%calculate Fourier coefficients from definition (NO FFT)
%use for irregularly spaced data
%use Gaussian quadrature
load gauss1to30;
NGauss=30;
yp=spline(x,y);
ak=zeros(1,Ncoeffs);
bk=zeros(1,Ncoeffs);
psi=pi.*abscissas(1:NGauss,NGauss);
w=pi.*weights(NGauss,1:NGauss);
term1=ppval(yp,psi);
a0=sum(w'.*term1)./pi;
for k=1:Ncoeffs
term2=cos(k.*psi);
term3=sin(k.*psi);
ak(k)=sum(w'.*term1.*term2)./pi;
bk(k)=sum(w'.*term1.*term3)./pi;
end
function y=fscurvature(A0,an,bn,theta)
%calculates exact curvature in polar coordinates of Fourier series
% an = cos terms
% bn = sin terms
% A0= DC component
% theta = interval of evaluation
[A0p,anp,bnp]=fsderv(A0,an,bn);
[A0pp,anpp,bnpp]=fsderv(A0p,anp,bnp);
x=fseval(A0,an,bn,theta);
xp=fseval(A0p,anp,bnp,theta);
xpp=fseval(A0pp,anpp,bnpp,theta);
num=x.^2 + 2.*xp.^2 - x.*xpp;
denom=(x.^2 + xp.^2).^(3/2);
y=num./denom;
function [A0p,anp,bnp]=fsderv(A0,an,bn);
%calculates derivative of Fourier series
A0p=0;
Ncoeffs=length(an);
k=1:Ncoeffs;
anp=k.*bn;
bnp=-k.*an;
<A
function y=fseval(A0,an,bn,theta);
%evaluates a trignometric Fourier series
% an = cos terms
% bn = sin terms
% A0= DC component
% theta = interval of evaluation
Ncoeffs=length(an);
y=(A0/2).*ones(size(theta));
for k=1:Ncoeffs
y=y + bn(k).*sin(k.*theta) + an(k).*cos(k.*theta);
end
function pp = freeshapespline(rm,conform)
% returns the free shape as a natural cubic spline
% rm=middle radius
% conform=conformability
% calls ringsystem.m, which defines the ODE system
rm=48.5;
conform=.04;
y0=[conform ;0];
phi=[0 pi];
%we need to play with these
options=odeset('RelTol',1e-8);
[theta u]=ode45(@ringsystem,phi,y0,options,conform);
Nhalf=length(theta);
N=2*Nhalf -1;
theta2=zeros(N,1);
theta2(1:Nhalf)=-flipud(theta);
theta2(Nhalf + 1:N)=theta(2:Nhalf);
u2(1:Nhalf)=flipud(u(:,1));
u2(Nhalf + 1:N)=u(2:Nhalf,1);
u2=rm + rm.*u2;
pp=spline(theta2,u2);
function dydt = ringsystem(phi,y,conform)
%Calculates Cam shape of ring from exact theory
%used by freeshape.m and freeshapespline.m
source=1-conform.*(1+cos(phi));
dydt = [ y(2);
((1 + y(1))^2 + 2*y(2)^2 -source*((1+y(1))^2 +
y(2)^2)^1.5)/(1+y(1));
]
%ringparameters.m
%holds data for ring fitted on distorted bore
h=1.48 % h, ring height (mm)
t=3.985 % t (or a), piston ring thickness (mm)
rm=51.181 % r, piston ring OUTER radius (mm)
Q=13.2558 % Q, diametrical load (= Ft / 2.15)
<=
E=1.52e+05 % E, modulus of elasticity (Mpa)
Ft=Q/2.15; %use empirical formula
I=h.*t^3/12;
stiffness=E*I; %stiffness
conform=Ft.*rm^2./stiffness; %conformability
Area=h.*t;
%RINGPACK2 calculator
%calculates pressure distribution for a distorted bore
clear all;
ringparameters; %loads parameters of ring
deck_number=7;
Ncoeffs=6;
[profile, angles]=importbore(deck_number,rm);
%profile=rm.*ones(size(angles));
Ntheta=256;
theta=linspace(-pi,pi,Ntheta);
delta_theta=2*pi/Ntheta;
[a0,ak,bk]=fcoeffs_trighi(profile,angles,Ncoeffs);
Ak=sqrt(ak.^2 + bk.^2); %radial distortions
zeta=fseval(a0,ak,bk,theta);
kappa0=(1-conform.*(1 + cos(theta)))./rm; %curvature of
free shape
kappa1=fscurvature(a0,ak,bk,theta); %curvature of
distorted cylinder
%now determine how the ring distortes
Moment=stiffness.*(kappa1-kappa0); %bending
moment
Momentp=zeros(size(Moment));
shear=Momentp./zeta; %shear force
in the ring
Momentpp=zeros(size(Moment));
%finally, calculate the pressure distribution
Momentp=nd5p(Moment,delta_theta,Ntheta);
shear=Momentp./zeta;
Momentpp=nd5p(Momentp,delta_theta,Ntheta);
pressure=1./(h.*rm^2).*(Moment + Momentpp);
%fix this
rconvert=180./pi;
figure(1)
plot(rconvert.*theta,pressure,rconvert.*theta,zeros(size(theta)))
set(gca,'fontsize',17);
xlabel('polar angle \phi (degrees)');
ylabel('pressure (\muPa)');
title('pressure distribution of distorted ring');
axis([-180 180 -1 1])
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