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Cylinder liners<br />
The steadily rising demands on internal combus<br />
tion engines require also in the area of cylinder<br />
working surfaces continuous improvements.<br />
The precise matching of the honed cylinder liners<br />
with the pistons and piston rings, leads to im -<br />
proved results in the engine. For cylinder liners<br />
made from gray cast iron, it is therefore necessary<br />
to create optimum surfaces that contribute<br />
to lower oil consumption and blow-by, produce<br />
less wear particles and allow shorter running-in<br />
times and therefore a longer service life.<br />
<strong>MAHLE</strong> manufactures cylinder liners for international<br />
engine manufacturers for series production<br />
and the aftermarket – always according to the<br />
same strict quality standards. We manufacture<br />
our cylinder liners with very strict tolerances.<br />
There by ensuring, among other things, that the<br />
cylinder liners can be optimally fitted into the<br />
engine block. Additional important quality characteristics<br />
of our cylinder liners are the materials,<br />
the structure and the surface quality. In close<br />
co operation with engine manufacturers, we de -<br />
ter mine the composition of the melt, the treatment<br />
of the melt and the machining process.<br />
Materials<br />
In addition to aluminum, cast iron alloys are used<br />
as materials for cylinder liners. Lamellar graphite<br />
cast iron is alloyed with phosphorus. Additional<br />
alloy materials improve the wear properties and<br />
can strengthen the matrix due to bainite and very<br />
fine perlite formations.<br />
Honing methods<br />
Good honing has a positive effect on piston ring<br />
wear, particle emission, oil consumption and friction.<br />
With further developments and innovations<br />
in the honing of cylinder liners, it is attempted to<br />
keep the running-in phase of the cylinder<br />
(engine) as short as possible and to achieve<br />
improved tribological properties. An important<br />
prerequisite for good and regular honing of the<br />
cylinder liners is high material quality. This<br />
means, cast material free of voids, with homoge -<br />
neous structure and uniform hardness as well<br />
as suitable pre-machining of the bore.<br />
Lamellar graphite.<br />
Honing<br />
Method of machining, in<br />
which the tool carries out<br />
reciprocating and rotating<br />
movements. With this<br />
method, a cylinder form<br />
error below 10 μm and an<br />
even surface roughness<br />
can be achieved.<br />
Tribology<br />
The science of friction,<br />
lubrication and wear of<br />
bodies in relative motion.<br />
The most important honing methods in single processing steps<br />
Description<br />
Honing process<br />
Application<br />
Version<br />
1st Operation<br />
2nd Operation<br />
3rd Operation<br />
4th Operation<br />
Normal honing<br />
1<br />
2<br />
3<br />
Diamond<br />
Diamond<br />
Ceramic<br />
Diamond<br />
Ceramic<br />
Ceramic<br />
Series gasoline car<br />
Series diesel car<br />
Series commercial vehicle<br />
Plateau honing<br />
1<br />
2<br />
3<br />
Diamond<br />
Diamond<br />
Diamond<br />
Diamond<br />
Diamond<br />
Ceramic<br />
Diamond<br />
Diamond<br />
Ceramic<br />
Series gasoline car<br />
Series diesel car<br />
Series commercial vehicle<br />
Brush honing<br />
1<br />
2<br />
Diamond<br />
Diamond<br />
Diamond<br />
Ceramic<br />
Brushing<br />
Brushing<br />
Series car/commercial<br />
Liquid honing<br />
Diamond<br />
Diamond<br />
Liquid honing<br />
Micro-finishing<br />
Series diesel car<br />
Laser honing<br />
1<br />
2<br />
Diamond<br />
Diamond<br />
Laser structure<br />
Diamond/Ceramic<br />
Ceramic<br />
Laser structure<br />
Ceramic<br />
Experimental/motorsports<br />
11
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