Automotive Engine Metrology

Salah H. R. Ali

• Publisher: Jenny Stanford Publishing
• Year: 2017
• ISBN:
  9781315341194
• Edition: 1
• Topic: Physical Sciences
• Subtopic: Mechanics

In recent decades, metrology—an accurate and precise technology of high quality for automotive engines—has garnered a great deal of scientific interest due to its unique advanced soft engineering techniques in design and diagnostics. Used in a variety of scientific applications, these techniques are now widely regarded as safer, more efficient, and more effective than traditional ones. This book compiles and details the cutting-edge research in science and engineering from the Egyptian Metrology Institute (National Institute for Standards) that is revolutionizing advanced dimensional techniques through the development of coordinate and surface metrology.

Contents

Preface

PART 1: INTRODUCTION

1. Introduction

1.1 Automotive Engine Metrology

1.2 Engineering Metrology

1.3 Quality Challenges in Automotive Engineering

1.4 Metrology Laboratory

1.5 Automotive Engineering

1.5.1 Types of Automotive Engines

1.5.2 Performance of Automotive Engine

1.6 Conclusion

PART 2: ADVANCED METROLOGY TECHNIQUES

2. Advanced Measurement Techniques in Surface Metrology

2.1 Advanced Measuring Techniques

2.1.1 Mechanical Contact Stylus Techniques

2.1.1.1 CMM coordinate technique

2.1.1.2 Roundness instrument

2.1.1.3 Roughness measurement technique

2.1.2 Optical Measurement Techniques

2.1.2.1 White-light interference microscopy

2.1.2.2 Confocal optical microscopy

2.1.2.3 Confocal white light microscopy

2.1.2.4 Scanning electron microscopy

2.1.2.5 Digital holography technique

2.2 Non-Optical Measurement Techniques

2.2.1 AFM Technique

2.2.2 3D-CT Technique

2.3 Overlapping, Limitations, Sampling, and Filtering of Existing Techniques

2.3.1 Overlapping

2.3.2 Limitations

2.3.3 Sampling and Filtering

2.4 Surface Characterization

2.4.1 Applications in the Mechanical Engineering

2.4.2 Other Applications

2.5 Uncertainty

2.6 Conclusion

PART 3: PERFORMANCE OF CMM METROLOGY TECHNIQUE

3. Characterization of Touch Probing System in CMM Machine

3.1 Types of CMM Probes

3.1.1 Hard Probe

3.1.2 Trigger Probe

3.2 Analytical Model

3.2.1 CMM Probe Ball Tip Error

3.2.2 Results of Analytical Model

3.3 Experimental Work

3.3.1 Verification of CMM Stylus System

3.3.2 Experimental Procedure

3.3.3 Parametric Study of Stylus Design

3.3.4 Measurement Density

3.3.4.1 Stylus tip size 4.0 mm

3.3.4.2 Stylus tip size 2.5 mm

3.3.4.3 Stylus tip size 1.5 mm

3.4 Analysis of the Obtained Uncertainty

3.5 Experimental Results and Discussions

3.5.1 Effect of Probe Stylus Tip Size

3.5.2 Effect of Probing Speed

3.6 Conclusion

4. Error Separation of Touch Stylus System and CMM Machine

4.1 Experimental Work

4.1.1 Verification of CMM Machine

4.1.2 Parametric Study of CMM and Stylus Design

4.2 Analysis of Experimental Results

4.3 Validation of Experiments

4.3.1 Total Measurement Errors

4.3.2 Stylus System Errors

4.3.3 CMM Machine Errors

4.3.4 Other Measurement Errors

4.4 Conclusion

5. Measurement Strategies of CMM Accuracy

5.1 Introduction

5.2 Background and Motivation

5.2.1 Types of Errors

5.2.2 Fitting Algorithm

5.3 Experimental Work

5.3.1 General

5.3.2 Dynamic Calibration of Stylus System

5.3.3 Test Procedure

5.4 Result Presentation and Discussion

5.4.1 Probe Scanning Speed 5 mm/s

5.4.2 Probe Scanning Speed 10 mm/s

5.4.3 Probe Scanning Speed 15 mm/s

5.4.4 Probe Scanning Speed 20 mm/s

5.4.5 Probe Scanning Speed 25 mm/s

5.4.6 Probe Scanning 30 mm/s

5.4.7 Probe Scanning 35 mm/s

5.4.8 Probe Scanning Speed 40 mm/s

5.4.9 Probe Scanning Speed 45 mm/s

5.5 Statistical Analysis

5.5.1 Standard Deviation Average of Roundness Measurement Error

5.5.2 Roundness Error of Scanning Speed Response

5.6 Conclusions

6. Validation Method for CMM Measurement Quality Using Flick Standard

6.1 Introduction

6.2 Experimental Work

6.2.1 Dynamic Verification of Probing System

6.2.2 Flick Standard Artifact

6.2.3 CMM Measurement Procedures

6.3 Measurement Results and Discussion

6.3.1 Least Square Fitting Technique

6.3.2 Minimum Element Fitting Technique

6.3.3 Minimum Circumscribed Fitting Technique

6.3.4 Maximum Inscribed Fitting Technique

6.4 Statistical Analysis

6.4.1 The Error in Diameter Measurement

6.4.2 The Error in Roundness Measurement

6.4.3 Uncertainty Evaluation

6.4.3.1 Repeatability

6.4.3.2 Resolution

6.4.3.3 Indication error

6.4.3.4 Temperature

6.5 Conclusions

PART 4: PERFORMANCE OF TALYROND METROLOGY TECHNIQUE

7. Factors Affecting the Performance of Talyrond Measurement Accuracy

7.1 Introduction

7.2 Background and Motivation

7.2.1 Fitting Filters

7.2.2 Fitting Spectral Wave Responses

7.2.3 Fitting Algorithms

7.2.4 Types of Errors

7.3 Experimental Work

7.4 Results and Discussion

7.4.1 The Effect of Fitting Filters

7.4.2 The Effect of Gaussian Filter and Fitting Techniques

7.4.3 The Effect of 2CR Filter and Fitting Techniques

7.5 Analysis and Estimation of Roundness Accuracy

7.6 Conclusion

PART 5: METROLOGY IN AUTOMOTIVE ENGINES

8. Metrology as an Inspection Tool in New or Overhauled Water-Cooled Diesel Engines

8.1 Introduction

8.2 Engine Inspection Program

8.2.1 Engine General Specifications

8.2.2 Cylinder Liner Inspection

8.2.3 Valve Lapped Area Inspection

8.2.4 CMM Verification

8.2.5 CMM Measurement Strategy

8.3 Experimental

8.3.1 Cylinder Block Measurements

8.3.2 Cylinder Head Measurements

8.3.3 Valve Measurements

8.3.4 Piston and Ring Measurements

8.3.5 Measurement of Engine Performance

8.4 Uncertainty in Measurements

8.5 Results and Discussion of Engine Inspection

8.5.1 Results of Dimensional Deviations

8.5.2 Results of Form Deviations

8.5.3 Results of Location Deviations

8.5.4 Results of Engine Compression Pressure

8.6 Conclusion

9. Metrology as an Identification Tool for Worn-Out Air-Cooled Diesel Engine

9.1 Introduction

9.2 Cylinder Forces and Surface Measurements

9.2.1 Dynamic Friction Force

9.2.2 Surface Geometry Measurements

9.3 Uncertainty Assessment of Measurements

9.4 Results and Discussion

9.4.1 Out-of-Roundness Measurement Results

9.4.2 Concentricity Measurements

9.4.3 Out-of-Straightness Measurement Results

9.5 Conclusions

10. Surface Metrology in Engine Quality

10.1 Engine Quality Using Metrology Techniques

10.1.1 CMM Metrology Technique

10.1.2 AFM Metrology Technique

10.1.3 Scanning Electron Microscopy Technique

10.1.4 Transmission Electron Microscopy Technique

10.2 Tribological Behavior

10.3 Coated Surface Characterization

10.4 New Applied Technology in Engine Coating Surfaces

10.5 Machining Characteristics of Engine Cylinder Surface

10.6 Conclusion

PART 6: CONCLUSIONS AND FEEDBACK FOR FUTURE

11. Conclusions, Rec...

Table of contents

• Cover
• Halftitle
• Title
• Copyright
• Table of Contents