3 days MOT/FIMOT-E
- Engineers and technical staff involved in design or testing, who need to know damaging and failure processes of engine components.
- People of Quality department or aftersales technical analysis may also be interested.
- This course provides an understanding of the physical phenomena causing engine parts damage, the phenomena being thermal, mechanical, thermo-mechanical or tribologic ones. The theoretical aspect is punctuated with examples of damaged parts - pictures or real parts.
- Upon completion of the course, participants will be able to:
- diagnose the possible origin of a damage problem of an engine component,
- talk with tests and laboratory specialists to direct parts analysis and the validation tests to be performed,
- suggest solutions likely to solve the problem.
- IC Engine Fundamentals.
Ways and means
- Interactive training using a number of real components, pictures and videos.
- Real life analysis of failures of components, search for origin of failures, description of the deteriorating process.
- It is possible to manage this exercise on a component previously proposed by a learner, with a description of use conditions.
Engine parts damage modes 0.75 day
- Mechanical engineer tools, statistical aspects of reliability.
- Thermal damage: coking, mechanical characteristic losses, intercrystalline corrosion, burnout, creeping, melting, lubricant viscosity drop.
- Mechanical damage: plastic distortion, unshrinking, fracture or fatigue failure, vibration impact.
- Thermo-mechanical damage: stresses caused by constrained metal expansion.
- Tribologic ones: lubrication parameters, stribeck curve, pitting, micro-reptation, loosening, fretting/micro-welding, abrasive wear, adhesive wear, erosive wear, cavitation, scuffing, seizing, stick-slip.
Mobile parts damage 0.75 day
- Conrods: failure modes, almost static stresses, dynamic stresses, buckling, screws resistance.
- Crankshaft: quasi-static (gas pressures and inertia) and dynamic (flexion and torsion) stresses, strengthening treatments, roller-burnishing, dimensioning calculations, fatigue tests.
- Bushing damage modes: fatigue, wear, cavitation wear, abrasive wear, scale and pollution wear, micro-welding, seizing.
- Piston: distortions, ring sticking, skirt crush, seizing, stresses in the pin bosses.
Fixed parts damage 0.5 day
- Ignition pressure and manufacturing related mechanical stresses (assemblies, shrink fitting, tightening).
- Thermal stresses and thermo-mechanical constraints.
- Cylinder head: cracking, materials, fire face behavior and solutions for its resistance, other critical points.
- Exhaust manifold: mechanical and thermal stresses, materials, failures found, solutions.
- Cylinder head gasket: stresses, failures, influence of the cylinder head and crankcase cylinders distortions, solutions.
Cooling 0.5 day
- Heat transfers by conduction, convection, radiation, phase change. Thermal balance.
- Thermics and engine cooling: levels of temperatures reached, critical points, cooling fluid circulation in the block and the cylinder head.
- External cooling circuit: permanent branch, thermally regulated branch, pump, exchangers, thermostat, ventilating, cooling fluid, dimensioning.
- Thermal measure means: thermo-couples, thermistors, flux meter, infrared pyrometry.
Lubrication 0.5 day
- Lubricant cleanliness and consequences on wear.
- Engine oil rheological behavior and change of properties in service:
- Oxidation thickening, soot, black sludge and consequences on cold starting.
- Viscosity decrease by polymer shearing or by dilution and consequences on warm engine.
- Thermal and oxidation stability: cracking, thickening, deposits.
- Timing lubrication.