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xv | |
Preface |
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xvii | |
Acknowledgements |
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xxi | |
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1 | (30) |
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1 Wear in the Heavy Duty Engine |
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3 | (10) |
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3 | (1) |
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3 | (1) |
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4 | (1) |
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4 | (1) |
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5 | (1) |
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1.5 Wear of Engine Bearings |
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5 | (1) |
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1.6 Wear of Piston Rings and Liners |
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6 | (1) |
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1.7 Wear of Valves and Valve Guides |
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6 | (1) |
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1.8 Reduction in Wear Life of Critical Parts Due to Contaminants in Oil |
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6 | (2) |
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7 | (1) |
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1.9 Oils for New Generation Engines with Longer Drain Intervals |
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8 | (1) |
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1.9.1 Engine Oil Developments and Trends |
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8 | (1) |
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1.9.2 Shift in Engine Oil Technology |
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9 | (1) |
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9 | (1) |
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9 | (1) |
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10 | (1) |
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10 | (1) |
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10 | (1) |
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1.11 Types of Wear of Critical Parts in a Highly Loaded Diesel Engine |
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10 | (3) |
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10 | (1) |
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11 | (1) |
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11 | (1) |
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11 | (1) |
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11 | (2) |
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13 | (18) |
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13 | (1) |
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13 | (1) |
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2.3 Factors on Which Life is Dependent |
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14 | (1) |
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2.4 Friction Force and Power |
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14 | (1) |
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2.4.1 Mechanical Efficiency |
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14 | (1) |
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15 | (1) |
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15 | (5) |
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2.5.1 Characteristic Size of an Engine |
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15 | (1) |
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16 | (1) |
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17 | (1) |
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18 | (1) |
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2.5.5 Friction Force or Power |
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18 | (1) |
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2.5.6 Indicated Power and Efficiency |
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18 | (2) |
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2.6 Archard's Law of Wear |
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20 | (1) |
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20 | (3) |
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20 | (1) |
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2.7.2 Nondimensional Wear Depth Achieved During Lifetime |
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21 | (2) |
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23 | (8) |
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Appendix 2.A Engine Parameters, Mechanical Efficiency and Life |
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25 | (1) |
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Appendix 2.B Hardness and Fatigue Limits of Different Copper--Lead--Tin (Cu--Pb--Sn) Bearings |
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26 | (2) |
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Appendix 2.C Hardness and Fatigue Limits of Different Aluminium--Tin (Al--Sn) Bearings |
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28 | (1) |
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29 | (2) |
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PART II VALVE TRAIN COMPONENTS |
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31 | (38) |
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3 Inlet Valve Seat Wear in High bmep Diesel Engines |
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33 | (14) |
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33 | (1) |
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34 | (1) |
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3.2.1 Design Aspects to Reduce Valve Seat Wear Life |
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34 | (1) |
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3.3 Shear Strain and Wear due to Relative Displacement |
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35 | (1) |
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35 | (2) |
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36 | (1) |
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3.5 Finite Element Analysis |
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37 | (1) |
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3.6 Experiments, Results and Discussions |
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38 | (7) |
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3.6.1 Valve and Seat Insert of Existing Design |
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39 | (1) |
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3.6.2 Improved Valve and Seat Insert |
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39 | (6) |
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45 | (1) |
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3.8 Design Rule for Inlet Valve Seat Wear in High bmep Engines |
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45 | (2) |
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45 | (2) |
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4 Wear of the Cam Follower and Rocker Toe |
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47 | (22) |
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47 | (1) |
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4.2 Wear of Cam Follower Surfaces |
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48 | (2) |
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4.2.1 Wear Mechanism of the Cam Follower |
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48 | (2) |
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4.3 Typical Modes of Wear |
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50 | (1) |
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4.4 Experiments on Cam Follower Wear |
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51 | (1) |
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4.4.1 Follower Measurement |
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51 | (1) |
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4.5 Dynamics of the Valve Train System of the Pushrod Type |
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52 | (3) |
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4.5.1 Elastohydrodynamic and Transition of Boundary Lubrication |
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52 | (1) |
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4.5.2 Cam and Follower Dynamics |
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53 | (2) |
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55 | (9) |
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55 | (1) |
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4.6.2 Valve Train Dynamics and Stress on the Follower |
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55 | (6) |
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61 | (3) |
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64 | (1) |
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64 | (1) |
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64 | (1) |
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4.8 Wear of the Cast Iron Rocker Toe |
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64 | (2) |
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66 | (3) |
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66 | (3) |
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PART III LINER, PISTON AND PISTON RINGS |
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69 | (128) |
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5 Liner Wear: Wear of Roughness Peaks in Sparse Contact |
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71 | (24) |
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71 | (1) |
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5.2 Surface Texture of Liners and Rings |
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72 | (4) |
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72 | (1) |
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72 | (1) |
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5.2.3 Surface Finish Parameters |
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72 | (2) |
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74 | (1) |
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5.2.5 Representation of Bearing Area Curve of Normally Honed Surface or Surfaces with Peaked Roughness |
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75 | (1) |
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5.3 Wear of Liner Surfaces |
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76 | (5) |
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76 | (1) |
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5.3.2 Radius of the Asperity in the Transverse Direction |
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76 | (1) |
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5.3.3 Radius in the Longitudinal Direction |
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77 | (1) |
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77 | (2) |
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79 | (1) |
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79 | (1) |
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80 | (1) |
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5.3.8 Detachment of Asperities |
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80 | (1) |
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81 | (4) |
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5.4.1 Normally Honed Liner with Peaked Roughness |
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81 | (1) |
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5.4.2 Normal Surface Roughness |
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81 | (1) |
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5.4.3 Fatigue Loading or Asperities |
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81 | (1) |
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82 | (1) |
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5.4.5 Plateau Honed and Other Liners not Normally Honed |
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83 | (2) |
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5.5 Liner Wear Model for Wear of Roughness Peaks in Sparse Contact |
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85 | (4) |
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86 | (2) |
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5.5.2 Comparison with Archard's Model |
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88 | (1) |
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5.6 Discussions on Wear of Liner Roughness Peaks due to Sparse Contact |
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89 | (3) |
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92 | (3) |
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Appendix 5.A Sample Calculation of the Wear of a Rough Plateau Honed Liner |
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93 | (1) |
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93 | (2) |
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6 Generalized Boundary Conditions for Designing Diesel Pistons |
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95 | (16) |
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95 | (1) |
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6.2 Temperature Distribution and Form of the Piston |
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96 | (1) |
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96 | (1) |
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96 | (1) |
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6.3 Experimental Mapping of Temperature Field in the Piston |
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97 | (1) |
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6.4 Heat Transfer in Pistons |
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98 | (1) |
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98 | (1) |
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6.5 Calculation of Piston Shape |
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98 | (10) |
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6.5.1 Popular Methods Used Before Finite Element Analysis |
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99 | (2) |
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6.5.2 Calculation by Finite Element Method |
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101 | (2) |
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6.5.3 Experimental Validation |
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103 | (5) |
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108 | (3) |
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109 | (2) |
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7 Bore Polishing Wear in Diesel Engine Cylinders |
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111 | (18) |
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111 | (1) |
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7.2 Wear Phenomenon for Liner Surfaces |
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112 | (1) |
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112 | (1) |
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7.3 Bore Polishing Mechanism |
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113 | (2) |
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7.3.1 Carbon Deposit Build Up on the Piston Top Land |
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113 | (1) |
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7.3.2 Quality of Fuel and Oil |
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113 | (1) |
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7.3.3 Piston Growth by Finite Element Method |
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113 | (1) |
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7.3.4 Piston Secondary Movement |
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114 | (1) |
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115 | (1) |
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115 | (1) |
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115 | (1) |
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116 | (1) |
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7.5 Calculation Methodology and Study of Bore Polishing Wear |
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116 | (2) |
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7.5.1 Finite Element Analysis |
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116 | (1) |
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117 | (1) |
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7.6 Case Study on Bore Polishing Wear in Diesel Engine Cylinders |
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118 | (9) |
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7.6.1 Visual Observations |
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118 | (1) |
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119 | (1) |
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7.6.3 Results of Finite Element Analysis |
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119 | (2) |
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121 | (2) |
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123 | (2) |
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7.6.6 Engine Oil Consumption |
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125 | (1) |
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7.6.7 Methods Used to Reduce Liner Wear |
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125 | (2) |
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127 | (2) |
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127 | (2) |
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8 Abrasive Wear of Piston Grooves in Highly Loaded Diesel Engines |
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129 | (12) |
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129 | (1) |
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8.2 Wear Phenomenon in Piston Grooves |
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130 | (2) |
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130 | (1) |
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130 | (2) |
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132 | (2) |
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8.3.1 Real Contact Pressure |
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132 | (1) |
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132 | (1) |
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132 | (2) |
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8.4 Experimental Validation |
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134 | (3) |
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8.4.1 Validation of the Model |
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134 | (1) |
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135 | (2) |
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8.5 Estimation of Wear Using Sarkar's Model |
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137 | (2) |
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138 | (1) |
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139 | (2) |
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140 | (1) |
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9 Abrasive Wear of Liners and Piston Rings |
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141 | (14) |
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141 | (1) |
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9.2 Wear of Liner and Ring Surfaces |
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141 | (2) |
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143 | (1) |
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9.3.1 Piston and Rings Assembly |
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143 | (1) |
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143 | (1) |
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9.3.3 Sources of Abrasives |
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144 | (1) |
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9.4 Study of Abrasive Wear on Off-highway Engines |
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144 | (5) |
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9.4.1 Abrasive Wear of Rings |
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144 | (1) |
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9.4.2 Abrasive Wear of Piston Pin and Liners |
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144 | (2) |
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9.4.3 Accelerated Abrasive Wear Test on an Engine to Simulate Operation in the Field |
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146 | (3) |
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149 | (1) |
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9.6 Scanning Electron Microscopy of Abrasive Wear |
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150 | (1) |
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9.7 Critical Dosage of Sand and Life of Piston--Ring--Liner Assembly |
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150 | (2) |
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9.7.1 Simulation of Engine Life |
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151 | (1) |
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152 | (3) |
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153 | (2) |
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155 | (12) |
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155 | (1) |
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10.2 Operating Parameters |
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155 | (1) |
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155 | (1) |
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10.3 Corrosive Wear Study on Off-road Application Engines |
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156 | (5) |
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10.3.1 Accelerated Corrosive Wear Test |
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156 | (5) |
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10.4 Wear Related to Coolants in an Engine |
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161 | (4) |
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10.4.1 Under-cooling of Liners by Design |
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161 | (1) |
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10.4.2 Coolant Related Wear |
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161 | (4) |
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165 | (2) |
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165 | (2) |
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11 Tribological Tests to Simulate Wear on Piston Rings |
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167 | (30) |
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167 | (1) |
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11.2 Friction and Wear Tests |
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168 | (2) |
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11.2.1 Testing Friction and Wear of the Tribo-System Piston Ring and Cylinder Liner Outside of Engines |
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168 | (2) |
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11.3 Test Procedures Assigned to the High Frequency, Linear Oscillating Test Machine |
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170 | (2) |
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11.4 Load, Friction and Wear Tests |
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172 | (3) |
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172 | (1) |
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172 | (1) |
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11.4.3 Reagents and Materials |
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172 | (3) |
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175 | (9) |
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11.5.1 Selection of Coatings for Piston Rings |
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175 | (3) |
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11.5.2 Scuffing Tribological Test |
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178 | (1) |
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11.5.3 Hot Endurance Test |
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179 | (5) |
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11.6 Selection of Lubricants |
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184 | (1) |
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11.7 High Performance Bio-lubricants and Tribo-reactive Materials for Clean Automotive Applications |
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185 | (5) |
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185 | (1) |
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11.7.2 Polyalkyleneglycols |
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185 | (5) |
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11.8 Tribo-Active Materials |
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190 | (2) |
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11.8.1 Thematic `Piston Rings' |
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190 | (2) |
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11.9 EP Tribological Tests |
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192 | (5) |
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11.9.1 Piston Ring Cylinder Liner Simulation |
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192 | (2) |
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194 | (1) |
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194 | (3) |
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197 | (56) |
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12 Friction and Wear in Engine Bearings |
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199 | (54) |
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199 | (3) |
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12.2 Engine Bearing Materials |
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202 | (3) |
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12.2.1 Babbitt or White Metal |
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202 | (1) |
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12.2.2 Copper--Lead Alloys |
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203 | (1) |
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12.2.3 Aluminium-based Materials |
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204 | (1) |
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12.3 Functions of Engine Bearing Layers |
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205 | (1) |
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12.4 Types of Overlays/Coatings in Engine Bearings |
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206 | (3) |
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12.4.1 Lead-based Overlays |
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208 | (1) |
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12.4.2 Tin-based Overlays |
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208 | (1) |
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12.4.3 Sputter Bearing Overlays |
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208 | (1) |
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12.4.4 Polymer-based Overlays |
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208 | (1) |
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12.5 Coatings for Engine Bearings |
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209 | (1) |
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12.6 Relevance of Lubrication Regimes in the Study of Bearing Wear |
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210 | (7) |
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12.6.1 Boundary Lubrication |
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212 | (3) |
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12.6.2 Mixed Film Lubrication |
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215 | (1) |
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12.6.3 Fluid Film Lubrication |
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216 | (1) |
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12.7 Theoretical Friction and Wear in Bearings |
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217 | (1) |
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217 | (1) |
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218 | (1) |
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219 | (15) |
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220 | (3) |
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223 | (7) |
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230 | (4) |
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12.10 Requirements of Engine Bearing Materials |
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234 | (4) |
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12.11 Characterization Tests for Wear Behaviour of Engine Bearings |
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238 | (13) |
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239 | (1) |
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239 | (2) |
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12.11.3 Scratch Test for Bond Strength |
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241 | (10) |
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251 | (2) |
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252 | (1) |
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PART V LUBRICATING OILS FOR MODERN ENGINES |
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253 | (102) |
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13 Heavy Duty Diesel Engine Oils, Emission Strategies and their Effect on Engine Oils |
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255 | (100) |
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255 | (1) |
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13.2 What Drives the Changes in Diesel Engine Oil Specifications? |
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256 | (2) |
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13.2.1 Role of the Government |
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256 | (1) |
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257 | (1) |
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13.2.3 The Consumer's Role |
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258 | (1) |
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13.3 Engine Oil Requirements |
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258 | (7) |
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13.3.1 Overview and What an Engine Oil Must Do |
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258 | (7) |
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13.4 Components of Engine Oil Performance |
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265 | (3) |
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265 | (3) |
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13.4.2 Protection against Wear, Deposits and Oil Deterioration |
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268 | (1) |
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13.5 How Engine Oil Performance Standards are Developed |
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268 | (8) |
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13.5.1 Phase 1: Category Request and Evaluation (API, 2011a, pp. 36, 37) |
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269 | (2) |
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13.5.2 Phase 2: Category Development (API, 2011a, pp. 41, 42) |
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271 | (2) |
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13.5.3 Phase 3: Category Implementation (API, 2011a, p. 45) |
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273 | (2) |
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13.5.4 API Licensing Process |
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275 | (1) |
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13.6 API Service Classifications |
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276 | (1) |
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276 | (3) |
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13.7.1 Current E Sequences |
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278 | (1) |
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279 | (1) |
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13.9 Why Some API Service Classifications Become Obsolete |
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279 | (1) |
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13.10 Engine Oil Composition |
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280 | (10) |
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280 | (1) |
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13.10.2 Refining Processes Used to Produce Lubricating Oil Base Stocks |
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281 | (4) |
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13.10.3 Synthetic Base Oils |
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285 | (1) |
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286 | (1) |
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13.10.5 API Base Oil Categories |
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286 | (4) |
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13.11 Specific Engine Oil Additive Chemistry |
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290 | (12) |
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13.11.1 Detergent--Dispersant Additives |
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290 | (4) |
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13.11.2 Anti-Wear Additives |
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294 | (1) |
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13.11.3 Friction Modifiers |
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295 | (1) |
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13.11.4 Rust and Corrosion Inhibitors |
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296 | (1) |
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13.11.5 Oxidation Inhibitors (Antioxidants) |
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296 | (2) |
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13.11.6 Viscosity Index Improvers |
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298 | (2) |
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13.11.7 Pour Point Depressants |
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300 | (1) |
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301 | (1) |
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13.12 Maintaining and Changing Engine Oils |
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302 | (4) |
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13.12.1 Oil Change Intervals |
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303 | (1) |
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13.12.2 Used Engine Oil Analysis |
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303 | (3) |
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13.13 Diesel Engine Oil Trends |
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306 | (1) |
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13.14 Engine Design Technologies and Strategies Used to Control Emissions |
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306 | (18) |
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13.14.1 High Pressure Common Rail (HPCR) Fuel System |
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309 | (1) |
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13.14.2 Combustion Optimization |
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310 | (2) |
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13.14.3 Advanced Turbocharging |
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312 | (1) |
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13.14.4 Exhaust Gas Recirculation (EGR) |
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313 | (1) |
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13.14.5 Advanced Combustion Emissions Reduction Technology |
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314 | (1) |
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13.14.6 Crankcase Ventilation |
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315 | (1) |
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13.14.7 Exhaust After-Treatment |
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315 | (9) |
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13.14.8 On-Board Diagnostics (OBD) |
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324 | (1) |
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13.15 Impact of Emission Strategies on Engine Oils |
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324 | (4) |
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13.15.1 Impact of Cooled EGR on Engine Oil |
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325 | (2) |
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13.15.2 Effects of Post-Injection on Engine Oils |
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327 | (1) |
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13.16 How Have Engine Oils Changed to Cope with the Demands of Low Emissions? |
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328 | (1) |
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13.17 Most Prevalent API Specifications Found In Use |
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329 | (7) |
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329 | (1) |
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330 | (1) |
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331 | (2) |
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333 | (3) |
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13.18 Paradigm Shift in Engine Oil Technology |
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336 | (12) |
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13.18.1 Backward Compatibility and Engine Tests |
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337 | (1) |
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13.18.2 New Engine Sequence Tests |
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338 | (5) |
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13.18.3 Previous Engine Oil Sequence Tests |
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343 | (4) |
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13.18.4 Differences Between CJ-4 and Previous Categories and Benefits of Using CJ-4 Engine Oils |
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347 | (1) |
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13.19 Future Engine Oil Developments |
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348 | (4) |
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352 | (3) |
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353 | (2) |
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PART VI FUEL INJECTION EQUIPMENT |
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355 | (14) |
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14 Wear of Fuel Injection Equipment |
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|
357 | (12) |
|
|
357 | (1) |
|
14.2 Wear due to Diesel Fuel Quality |
|
|
357 | (4) |
|
14.2.1 Lubricity of Mineral Diesel Fuel |
|
|
357 | (4) |
|
14.2.2 Oxygen Content of Biodiesel |
|
|
361 | (1) |
|
14.3 Wear due to Abrasive Dust in Fuel |
|
|
361 | (4) |
|
14.3.1 Wear of Injector Nozzle due to Heat and Dust |
|
|
361 | (3) |
|
|
364 | (1) |
|
14.4 Wear due to Water in Fuel |
|
|
365 | (2) |
|
14.4.1 Corrosive Wear due to Water Ingress |
|
|
365 | (1) |
|
14.4.2 Use of Emulsified Water for Reducing Nitric Oxides in Large Engines |
|
|
365 | (1) |
|
14.4.3 Microbiological Contamination of Fuel Systems |
|
|
366 | (1) |
|
|
367 | (1) |
|
|
367 | (2) |
|
|
367 | (2) |
|
PART VII HEAVY FUEL ENGINES |
|
|
369 | (28) |
|
15 Wear with Heavy Fuel Oil Operation |
|
|
371 | (26) |
|
|
371 | (2) |
|
15.2 Fuel Treatment: Filtration and Homogenization |
|
|
373 | (1) |
|
|
374 | (1) |
|
15.3.1 Fuel Injection Equipment |
|
|
374 | (1) |
|
15.4 Viscosity, Carbon Residue and Dust |
|
|
374 | (1) |
|
15.4.1 Fuel Injection Equipment |
|
|
374 | (1) |
|
15.5 Deposit Build Up on Top Land and Anti-polishing Ring for Reducing the Wear of Liner, Rings and Piston |
|
|
375 | (2) |
|
|
377 | (3) |
|
15.6.1 Formation of Sulfuric Acid |
|
|
377 | (1) |
|
15.6.2 Mechanism of Corrosive Attack by Sulfuric Acid |
|
|
377 | (1) |
|
15.6.3 Control of Corrosion by Basicity and Oil Consumption |
|
|
378 | (1) |
|
15.6.4 Control of Sulfur Corrosion by Maintaining Cooling Water Temperature High |
|
|
379 | (1) |
|
|
380 | (3) |
|
|
380 | (1) |
|
15.7.2 Lack of Formation of Oil Pockets on the Liner Bore |
|
|
381 | (1) |
|
15.7.3 Sudden Severe Wear of Liner and Rings |
|
|
382 | (1) |
|
|
383 | (1) |
|
15.9 High Temperature Corrosion |
|
|
383 | (5) |
|
|
385 | (1) |
|
|
385 | (3) |
|
15.10 Wear Specific to Four-stroke HFO Engines |
|
|
388 | (3) |
|
|
388 | (3) |
|
|
391 | (1) |
|
15.10.3 Corrosive Wear of Valve Tips |
|
|
391 | (1) |
|
15.11 New Engines Compliant to Maritime Emission Standards |
|
|
391 | (2) |
|
15.11.1 Steps to Satisfy Emission Standards |
|
|
391 | (2) |
|
15.12 Wear Life of an HFO Engine |
|
|
393 | (1) |
|
|
393 | (4) |
|
|
394 | (3) |
|
|
397 | (24) |
|
16 Air and Oil Filtration and Its Impact on Oil Life and Engine Wear Life |
|
|
399 | (22) |
|
|
399 | (1) |
|
16.2 Mechanisms of Filtration |
|
|
400 | (1) |
|
16.3 Classification of Filtration |
|
|
400 | (3) |
|
16.3.1 Classification by Filter Media |
|
|
401 | (1) |
|
16.3.2 Classification by Direction of Flow |
|
|
402 | (1) |
|
16.3.3 Classification by Filter Size |
|
|
402 | (1) |
|
|
403 | (1) |
|
|
403 | (1) |
|
|
403 | (1) |
|
16.4.3 Mean Filter Rating |
|
|
403 | (1) |
|
|
403 | (1) |
|
|
404 | (1) |
|
|
404 | (1) |
|
16.6 Introduction to Different Filters in the Engine |
|
|
405 | (4) |
|
|
405 | (4) |
|
16.6.2 Cleaning Air Filters and Impact on Wear Life |
|
|
409 | (1) |
|
16.7 Oil Filters and Impact on Oil and Engine Life |
|
|
409 | (4) |
|
16.7.1 Oil Performance and Life |
|
|
410 | (1) |
|
|
411 | (2) |
|
16.7.3 Application of the Concept of Oil Stress |
|
|
413 | (1) |
|
16.7.4 Advances in Oil Filter Technology |
|
|
413 | (1) |
|
|
413 | (2) |
|
16.8.1 Method to Predict Wear of Critical Engine Components |
|
|
415 | (1) |
|
16.9 Full Flow Oil Filters |
|
|
415 | (4) |
|
|
417 | (1) |
|
16.9.2 Centrifugal Filters |
|
|
418 | (1) |
|
|
419 | (2) |
|
Appendix 16.A Filter Tests and Test Standards |
|
|
419 | (1) |
|
|
419 | (2) |
Index |
|
421 | |