Influence of the Pre-Compensation Profile on the Dynamics and Friction Performance of the Piston Skirt–Cylinder Liner System in a Diesel Engine

A coordinated profile co-optimization strategy for the piston–liner pair was introduced to simultaneously reduce friction losses and dynamic excitation. Based on the main parameters of the engine. Lubrication theory and the finite element method, and explicitly accounting for elastic deformation of flexible bodies, a multibody dynamics simulation model of the piston–connecting rod–crankshaft–cylinder liner system was developed in AVL Excite. This model was used to evaluate the dynamic and tribological performance of five cylinder-liner pre-compensation geometries at rated operating conditions. A bottleneck-shaped liner exhibited the best tribological performance, reducing the average total piston–skirt friction loss by 20.8% and the peak asperity–contact pressure by 19.7%, while leaving piston kinematics essentially unchanged (an increase of 0.001 mm in the maximum radial displacement and 0.009° in the maximum tilt angle). Building on this liner, key piston–skirt profile parameters were optimized via response–surface methodology; with the optimized skirt, the maximum radial displacement decreased from 0.123 mm to 0.113 mm, the maximum tilt angle decreased from 0.463° to 0.462°, the third-order Fourier component of lateral acceleration decreased from 14.53 m/s2 to 13.26 m/s2, and the cycle-averaged total skirt friction loss decreased from 0.307 kW to 0.250 kW.