格茨手册.doc

P1 Preface 前言As a leading manufacturer of piston rings it is our goal, through the GOETZE Piston Ring Handbook, to inform specialists and upcoming generations of engineers about the key areas of piston ring technology.作为一个活塞环行业龙头企业，我们希望通过这本GOETZE活塞环手册，使专家和日后的专业工程师获取活塞环技术核心领域的信息。The last edition of the Piston Ring Handbook appeared in 1995 after the acquisition of the then Goetze AG the T&N Group, Manchester, UK. Since 1998 GOETZE has been part of the world-wide Federal-Mogul corporate group.最近的一本活塞环手册在1995年Goetze AG还属于英国曼彻斯特T&N集团时出的。1998年GOETZE成为辉门全球集团旗下的一员。The retained original GOETZE brand is backed by more than 100 years of experience and know-how.这个保留下来的原创品牌GOETZE背后有着一百多年的经验和技术精华。This new edition of the Piston Ring Handbook contains updated basic knowledge and now includes an application-related section.这本新版的活塞环手册包括了最新的关于活塞环的基础知识及应用知识。We hope this handbook makes interesting reading and provides you with some useful new information.我们希望这本手册能让您轻松阅读并同时提供给您一些有用的新信息。Burscheid, April 2003博希德，2003年4月P2 Content 目录General Principles 基本原理Nomenclature常用符号及单位Piston Ring Functions and Operation活塞环功能及应用Theoretical Relationships理论公式Contact Pressure接触压力Tangential Force切向弹力Diametral Force径向弹力Closure Stress工作弯曲应力Piston Ring Parameter活塞环系数Opening Stress 工作弯曲应力Modulus of Elasticity弹性模量Conformability贴合性Radial Pressure Distribution径向压力分配Piston Ring Types活塞环类型Compression Rings气环Scraper Rings刮油环Oil Control Rings 油环 Single-Piece Oil Control Rings整体控油环 Multi-Piece Oil Control Rings组合控油环Ring Joints活塞环切口Joint Notches接头切口Operational Criteria and Malfunctions操作标准及失控状况Engine Operation发动机操作 Oil Consumption耗油 Blowby漏气 Exhaust Emission排气排放物Tribology摩擦 Wear磨损 Scuffing刮伤/划伤 Microwelding超精焊接 Friction摩擦力Malfunctions失控状况 Ring Sticking活塞环结胶 Ring Flutter活塞环颤振 Ring Breaking活塞环断裂Piston Ring Materials活塞环材料Wear-Resistant Peripheral Coatings表面复层Chromium Plated Peripheries镀铬Thermal Spray Coatings热喷涂料PVD CoatingsPVD涂料Nitriding and Nitrocaburizing氮化及气体碳氮共渗Surface Treatments表面处理Tin and Copper Plating镀锡和镀铜Phosphating磷化Black Oxiding黑氧化CPS and CPG镀钢环的化学钝化及镀铸铁环的化学钝化Ring Side Armouring活塞环侧面防护Chromium Plating镀铬Nitriding氮化Piston Ring Manufacture活塞环制造Application Experience应用经验Examples of Typical Ring Packs典型活塞环组实例Design Potential for Performance Optimization最佳性能设计理论计算References附注Appendix附录Wear Measurement in the Cylinder/Piston Ring System气缸/活塞环系统的磨损测量Material Specifications材料详细说明 Piston Rings and Piston Ring Elements活塞环及其元素 -Cast Iron Materials, Automotive and Large Bore Engine Application铸铁材料、汽车和大型气缸发动机应用 -Cast Iron Materials, Large Bore Engine Applications铸铁材料和大型气缸发动机应用 Piston Rings and Piston Ring Element Steels活塞环及其元素-钢 Coatings涂料 Testing Instructions测试说明Overview of the Current International Piston Ring Standards当前国际活塞环标准概述P5 Nomenclature常用符号及单位Contact pressure p in N/mm GOETZE 接触压力Axial ring width h in mm环高Bending moment M in Nmm弯矩Diametral force Fd in N径向弹力Closure stress b in M/mm2工作弯曲应力Modulus of elasticity E in N/mm2弹性模量Spring force in N弹力Conformability U in mm对气缸变形适应性Gas pressure Pz in N/mm2燃气压力Piston ring parameter k 活塞环系数Radius of curvature of the open ring (ring in free state) 1 in mm自由状态下的曲率半径Radius of curvature of the closed ring (ring at norminal diameter) 2 in mm封闭状态下的公称直径Inertia force in N惯性力Total free gap m in mm自由开口尺寸Nominal diameter d in mm公称直径Ovality u in mm椭圆度Radial wall thickness a in mm径向壁厚度Radius at outside diameter r in mm外径半径Radius of ring center line rm in mm环中线的半径Friction force in N摩擦力Closed gap s in mm闭口间隙Tangential force Ft in N切向弹力Moment of inertia I in mm4惯性矩 Assembly stress: tangential opening buT in N/mm2套装弯曲应力：切向张开Assembly stress: opening by means of a sleeve buH in N/mm2套装弯曲应力：锥套张开P6 Piston Ring Function and Operation 活塞环的功能和操作Piston rings are metallic seals and have the function of sealing the combustion chamber from the crankcase and assuring the flow of heat from the piston to the cylinder. Other functions are to prevent the oil not needed for lubrication from passing from the crankcase to the combustion chamber and provide a uniform oil film on the cylinder bore surface. 活塞环在发动机中有三大作用，将燃烧室和曲轴箱密封，将活塞上的热量传到汽缸壁上，以及控制机油消耗。To achieve this the piston rings must be in contact with the cylinder wall and piston groove side. Radial contact is generally achieved by means of the inherent spring force of the ring. Fig.1 shows the forces acting on the piston ring and Fig.2 the most important terminology used. 为了产生有效的密封，活塞环既要与气缸壁贴合良好，又要与活塞环槽的上或下平面贴合良好。径向贴合能力活塞环本身的弹力作用产生。图1表示了活塞环受到的作用力，图2为最重要的专用名词用法。Gas pressure in the combustion chamber augments both the radial and the axial contact in the piston ring groove, i.e. the action of the gas pressure increases the sealing capability of the piston ring. Axial contact can alternate between the top and bottom side of the groove owing to the interaction of gas, inertia and friction forces. 在燃烧室的气压增大了在活塞环槽中径向和轴向接触面。例如，增加了活塞环的密 封性。气压、惯性以及摩擦力的相互作用使得活塞环的轴向位置在环槽的上下平面之间往复运动。The operational characteristics of piston rings, i.e. faultless sealing against combustion gas and lubrication oil, are contingent on the engine design, the thermal and combustion-related dynamic loading, the cylinder design and finish, the piston, the lubricating oil used, the fuel and, most significantly, the quality and design of the rings themselves. Besides service in the piston cylinder system of internal combustion engines, piston ring are also employed as metallic seals for rotating shafts and are used both as contracting and expanding seals. 活塞环的工作特性，如对燃气和润滑油的良好密封与发动机设计，热负荷及燃烧产生的动态负荷、缸体的设计和缸孔精加工、活塞、使用的机油及燃油等方面相关，当然最主要的还是活塞环的质量和设计。除了用于内燃机中的活塞气缸系统外，活塞环也被用于旋转轴的金属密封件及收缩和膨胀的密封件中。P7The ring is pressed against the cylinder wall under a contact pressure p which is governed by the dimensions and total free gap of the ring and by the modulus of elasticity of the material used. The total free gap is defined as the distance, measured along the neutral axis, between the ends of a piston ring in its uncompressed state(Fig.2) 活塞环对气缸壁的压力p, 即接触压力取决于环的尺寸大小，自由开口尺寸，及所有材料的弹性模量。自由开口尺寸的定义是：自由状态下，环两开口端径向重点之间所测得的距离。A ring can be given a constant or a variable pressure2,3, the latter being a function of the angle( )(Fig.3).活塞环的径向压力P分布可以是均压的，也可以是非均压的，后者是角的函数（见图3）。P8Measurement of the contact pressure is extremely difficult. Therefore, in practice it is calculated from the tangential force. This is the force which, when applied tangentially to the ends of the ring, is sufficient to compress the ring to the specified closed gap. By comparing the bending moment of the tangential force against that of the constant contact pressure, the following relationships are established(Fig.4): 接触压力P的测量是很困难的，通常主要是间接计算它的切向弹力。切向弹力是压缩环外圆面，使两开口端到闭口间隙，需施加在环开口端切线方向的力。通过比较可以得出以下关系：For the case when p is constant, e.g. the ring is compressed inside a flexible tensioning tape, the following expression can be derived for the bending moment M: 接触压力p是常数时，由下式可得弯矩M。The bending moment M can also be expressed in terms of the tangential force F1：。弯矩M也可用有关的切向弹力Ft:来表示。P9The tangential force is usually measured with the aid of a flexible tensioning tape which encloses the ring and compresses it to closed gap. (For commercially sized rings the friction effects can be ignored.) The tangential force Ft therefore acts at the periphery of the ring. By substituting in the ring diameter d for the radius r the pressure that the ring exerts radially outwards against the cylinder wall is stated by: 切向弹力通常用一根柔性钢带箍紧环进行测量（使用商用切向弹力仪测量时，摩擦力的影响可以忽略不计）。在该情况下，切向弹力Ft受环的公称直径影响，因此环沿整个工作表面对气缸壁的压力由下式给定。The contact pressure of compression rings on account of their inherent tension generally lies between 0.12 and 0.25 N/mm2 for rings conforming to DIN/ISO standard. The actual contact pressure is many times greater due to the gas pressure acting behind the ring. 一般气环的接触压力由其内应力产生，其数值一般在0。12-0.25 N/mm2 之间，以使其达到DIN/ISO 标准。但是环对气缸壁的压力实际上比此值高许多倍，这是由于在环背有工质压力的作用。P10Calculations are sometimes also performed based on the diametral force Fd. This is the force acting diametrically at 90 to the gap that is necessary to compress the ring to its nominal diameter. The following relationship between the diametral and tangential force has been established for the different piston ring materials based on empirical values:径向弹力Fd在此基础上也能计算，这是施加在垂直于开口方向，并通过中心压缩环外圆面到公称直径时的力。一般可根据经验，的出下面材料不同的环Fd和Ft相互关系的公式Fd = 2.05 Ft Fd =2.15 FtThe exact mathematical correlation is实际数学上的关系式为The maximum error using the practical form of the equation is 5% and may be disregarded.方程式计算与实际最大误差在5%甚至可以忽略不计。P11The closure stress b is a measure of the stress present in the ring when installed in the cylinder. For a ring of rectangular cross section b is stated in terms of the total free gap m by工作弯曲应力b是活塞环装入气缸时测得所产生的应力。对于矩形环并忽略其横向应力，b根据自由开口尺m给定下式：And in terms of the tangential force by或根据切向弹力Ft给定For a slotted oil control ring b is expressed in terms of the total free gap m by对于普通油环b与自由开口尺寸m有关式子and in terms of the tangential force by或与切向弹力Ft有关式子式中Iu = 不铣泄油槽处的截面惯性矩Is = 铣泄油槽处的截面惯性矩X1= 重心到外径的两倍长度K = 活塞环系数，根据公式10a带入平均惯性矩并参考公式3。p12The piston ring parameter k is defined as活塞环参数k 表示为or expressed in terms of the constant contact pressure p或者用压力p 表示为with a moment of inertia对矩形环or expressed in terms of the total free gap m 与自由开口尺寸m有关式子p13The greatest stressing of the ring occurs during assembly, as the ring must be stretched open sufficiently to enable the inner contour to slip over the outer diameter of the piston.当活塞环装上活塞时，必须把其内径扳开得比活塞外径还要大，而产生一个较大的应力。The standard formula for the opening stressbu = b found in the literature makes the assumption that the closure stress are equal. This assumption is only true for a particular value of the total free gap m and a given d/a relationship. Use of the formula for any other value of m can lead to significant errors. 一般的公式所涉及的套装弯曲应力，在资料中都由假设bu = b而得，这个假设仅对于个别的自由开口尺寸m值，对于给定的d/a之比才是正确的。这个公式用在其它的m值的活塞环上会引起较大的误差。When determining the ring dimensions given in the DIN/ISO piston ring standards a new formula for calculating the opening stress was used which is valid for all values of m and also makes allowance for assembly by means of sleeve. However, it is rather complicated to use.按DIN/ISO标准给定的活塞环尺寸确定时，此手册补充一条新的套状弯曲应力公式，它不仅对所有m值正确，而且对锥套安装也适用，但是，在应用中颇为复杂。从数学上严密推导：= 最大应力值1=一定位置环的自由状态曲率半径2=在同一位置环的工作状态曲率半径a more convenient expression for the opening stress was derived, since the solution to the mathematically exact relationship would be too complicated. 因为数学推导关系太过复杂，已有一个更实用的表达方式，。The constants in equations（12） to （15）were determined by means of computed tables and assure a high degree of conformity between the equations in the stated form and the exact solution: 下面公式所涉及的系数可查计算表来确定。公式（12）至（15）与对应的准备解答，保证相当一致。P14The following applies to rings of rectangular cross section:下列公式用于矩形环：1. Opening the piston ring solely under tangential force:活塞环仅用切向力套装时其中k是活塞环系数。2. Opening the piston ring by means of a sleeve:活塞环用锥套套装时k是活塞环系数The following applies to slotted oil control rings:下列公式用于油环：1. Opening the piston ring solely under tangential force: 活塞环仅用切向力套装时。2. Opening the piston ring by means of a sleeve:活塞环用锥套套装时。Iu = 不铣泄油槽处的截面惯性矩Is = 铣泄油槽处的截面惯性矩X2= 重心到外径的两倍长度K = 活塞环系数P15The modulus of elasticity for the ring material is obtained from the relation环材料的弹性模量由此可得Given that the moment of inertia I of an uncoated ring with rectangular cross section is因为无镀层矩形环的惯性矩是：P16Conformability is defined as the ability of a piston ring to conform to a deformed cylinder bore. A long process of calculation is required to derive the mathematically exact solution from theory. In practice, however, a simplified equation may be used derived from the theory of the closed(uncut) ring and the ring with constant radial pressure.贴合性的定义的活塞环贴合变形气缸孔的能力。用数学方法获得精确理论解法需要较长的演算过程。然而在实际中，由圆形环（不开口）理论而得的一个简单公式可以应用。并适用于因有沿整个外圆面的均匀径向压力而闭合The conformability opposite the ring gap(see also fig.5) in a cylinder with an “i”th order radial deformation ui under which the ring is still light tight at a contact pressure p=0 is calculated as: 并适用于因有沿整个外圆面的均匀径向压力而闭合且保证环也能紧密铁和在外圆周某些部位接触压力p=0的活塞环。在气缸内的贴合性有一个径向应变，Ui的变形量: “i”，由下式计算：Ui=气缸因偏离公称半径“I”变形量的径向应变。K=活塞环系数Since with increasing i the conformability decreases by approximately the 4th power, it follows that high order cylinder distortions are particularly critical for the functioning of piston rings.贴合性随“i”增加，大约与其成4次方关系降低，由此可见，高数量级的气缸应变能严重影响活塞环的性能。It should be noted that the simplified theory only indicates the conformability opposite the ring gap and not the local conformability around the ring periphery.要指出的一点是简化的理论只表示对活塞环缺口的贴合性而不是对局部环柱体表面的贴合性。In the case of self-conforming piston rings the conformability decreases progressively from the region opposite the ring gap towards the gap.对活塞环自我贴合来说，其贴合性在环缺口所对的缺口区域中不断降低。P17Conformability is improved by the gas pressure pz acting behind the piston ring: 作用于环背面的气压能使贴合性改善，如果气体压力用pz表示：Spring backed rings have a very uniform conformability around the whole periphery.回弹的活塞环在整个环柱体表面有很均匀的顺应性。Accordingly, for a spring loaded ring:对于带弹簧的活塞环是 ： P18Radial pressure distribution is an important aspect that determines the sealing function between the piston ring periphery and cylinder wall.径向压力分配是决定活塞环表面与气缸壁之间密封功能的重要方面。Continuing development led from constant unit pressures (fig.6) to unit pressures with a variable radial pressure distribution (Fig. 7, Fig. 8) designed to influence piston behavior in the engine. Variable radial pressure distributions in the past could only be created when there was an additional requirement for positive or negative ovality. 由不变的单位压力（见图六）到影响活塞在发动机内表现的不同轴向单位压力分配（见图7，图8），设计在不断发展。不同的径向压力分配在过去只可能当有个附加正或负椭圆度的情况下实现。The measure of ovality is assumed as the difference between outer diameters measured in the direction ring gap/ring back and at an offset of 90.对椭圆度的测量被假定为环缺口/活塞背部方向上的外径和90的偏位差别。P20The main functions of compression rings are to seal the combustion chamber from the crankcase and transfer heat from the piston to the cylinder. However, they also play an important part in controlling engine oil consumption.压缩环的主要作用就是将活塞的热从曲轴箱中的密封燃烧室传到气缸，同时起到控制机油耗的作用。There are the following types:压缩环有以下几种类别：Rectangular Ring:矩形环A piston ring with a rectangular cross section. This ring with its geometrically simple shape performs the necessary sealing functions under normal operation conditions. With a peripheral coating and appropriate barrel face the rectangular ring is today used mainly in the top groove in passenger car gasoline and diesel engines. Besides service in internal combustion engines, rectangular rings are commonly used as rotary shaft seals, e.g. transmission seals. 一个矩形截面的活塞环。矩形截面气环具有简单几何形状，在一般工作情况下能形成有效密封。这种外围附有涂料圆柱体面的矩形环现在主要用在客车车用汽油和柴油机的顶槽。除了在内燃机上的作用，矩形环还被广泛用于旋转轴的密封，比如变速器密封。Taper Faced Ring:锥面活塞环：Owing to the tapered running face the ring contacts the cylinder bore with its bottom outer edge. This shortens running-in and improves oil scraping. The gas forces acting initially at the running face provide a degree of pressure relief (especially when used in the top groove). Taper faced rings are chiefly installed in the second groove in passenger car gasoline and passenger car gasoline engines they are also used in the top groove. 这种气环有一个带锥度的工作表面，能缩短磨合器期。在环表面流过的气流为其提供了卸压（尤其是用在顶槽时）。锥面环主要是安置在客车车用汽油和客车车用汽油发动机的第二槽，顶槽上也可装。 Internally Bevelled or Stepped Ring:内倒角扭曲环或内切扭曲环：By providing an edge relief on the top side of rectangular and taper faced rings a twist effect is achieved which, in all operating phases without gas pressure loading, brings the ring into bore contact only with its bottom outer edge while the inner edge contacts the bottom groove side (positive twist). This helps to improve oil consumption control. Under operating conditions the gas pressure forces the ring f