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Abstract

The theoretical analysis of the charge exchange process in a spark ignition engine has been presented. This process has significant impact on the effectiveness of engine operation because it is related to the necessity of overcoming the flow resistance, followed by the necessity of doing a work, so-called the charge exchange work. The flow resistance caused by the throttling valve is especially high during the part load operation. The open Atkinson-Miller cycle has been assumed as a model of processes taking place in the engine. Using fully variable inlet valve timing the A-M cycle can be realized according to two systems: system with late inlet valve closing and system with early inlet valve closing. The systems have been analysed individually and comparatively with the open Seiliger-Sabathe cycle which is a theoretical cycle for the classical throttle governing of the engine load. Benefits resulting from application of the systems with independent inlet valve control have been assessed on the basis of the selected parameters: fuel dose, cycle work, charge exchange work and a cycle efficiency. The use of the analysed systems to governing of the SI engine load will enable to eliminate a throttling valve from the system inlet and reduce the charge exchange work, especially within the range of part load operation.
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Abstract

The study presents a durability analysis of dies used in the first operation of producing a valve-type forging from high nickel steel assigned to be applied in motor truck engines. The analyzed process of producing exhaust valves is realized in the forward extrusion technology and next through forging in closed dies. It is difficult to master, mainly due to the increased adhesion of the charge material (high nickel steel) to the tool’s substrate. The mean durability of tools made of tool steel W360, subjected to thermal treatment and nitriding, equals about 1000 forgings. In order to perform a thorough analysis, complex investigations were carried out, which included: a macroscopic analysis combined with laser scanning, numerical modelling by FEM, microstructural tests on a scanning electron microscopy and light microscopy (metallographic), as well as hardness tests. The preliminary results showed the presence of traces of abrasive wear, fatigue cracks as well as traces of adhesive wear and plastic deformation on the surface of the dies. Also, the effect of the forging material being stuck to the tool surface was observed, caused by the excessive friction in the forging’s contact with the tool and the presence of intermetallic phases in the nickel-chromium steel. The obtained results demonstrated numerous tool cracks, excessive friction, especially in the area of sectional reduction, as well as sticking of the forging material, which, with insufficient control of the tribological conditions, may be the cause of premature wear of the dies.
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