Perhaps no interface within a high performance engine is more crucial to optimizing performance and reducing engine wear than that between the inner wall of the cylinder or liner and the piston rings.
The rings and liner walls must work together to perform a number of key functions, including minimizing blow by, preventing oil contamination, and promoting lubrication of the cylinder walls. To achieve this, both the piston rings and cylinder liners must be manufactured within the most precise tolerances achievable.
In the performance automotive world, Total Seal Piston Rings is widely known for producing the widest range of piston rings for the most demanding street and competition requirements. Keith Jones, the sales manager and application expert at Total Seal, knows that even the best piston ring can only perform to its potential when matched with the ideal cylinder surface. Whether a traditional iron liner or a ceramic coated aluminum block, achieving the low surface roughness is both difficult and critical to the performance and longevity of the engine.
Three key components to achieving this are:
- The machine tool & block setup
- Honing stones
- Honing fluid
While a honing machine is a major capital investment, the best combination of stones and fluid to most effectively remove material is difficult to determine for non-OEM engine manufacturers. The increasing use of aluminum blocks with hard ceramic cylinder coatings present additional challenges, as traditional combinations of vitrified stone and a sulfurized machining oil can fall far short of performance requirements.
Like many engine builders, Total Seal had always used the general purpose machining fluid provided with their honing machine. However, when this conventional setup failed to meet very demanding surface finish requirements on some Nikasil coated cylinders for Yamaha, Jones turned to Gehring L.P. of Farmington Hills, Michigan, for solutions. As a leader in OE honing equipment, Gehring was able to provide them with diamond stones that were up to the task. Keith also recommended
QUAKERCUT TM 004 PE from Quaker Chemical as the honing oil of choice to produce the demanding finishes in their own operations.
After hearing back from their customers who have tried the Quaker oil on their blocks, this became the recommended honing oil for Total Seal Piston Rings as well. “We have recommended the QUAKERCUT TM 004 PE to anyone who is looking for the oil to produce the best finishes to work with our rings. Our customers say it’s a lot cleaner and more pleasant to work around as well,” said Jones.
So what makes the QUAKERCUT TM 004 PE the choice of Gehring and other Tier 1 automotive suppliers? “It’s a purpose built honing fluid rather than a thin machining and grinding oil,” said Quaker Chemical’s Daryl Adams.
Quaker Chemical has provided the global automotive industry with innovated solutions to challenging lubrication demands at every step in the production process, from coil or billet to finished cars. The QUAKERCUT TM 004 PE was developed to be a purpose made honing oil built around unique tribology of honing & lapping operations. With the very large contact area and lower heat deposition involved between the hone and the sleeve, the proper viscosity and fines removal properties of the oil are far more important than extreme pressure additives, which remain inactive and may decrease the efficiency of the stock removal and the desired self-sharpening effect of the stone.
Ted Papuga, president of Opel Engineering, has improved the efficiency of their honing operations using the QUAKERCUT TM 004 PE. “This oil is much cleaner to work with than the oil that came with the machine and I had used for years,” he said. “There is noticeably less stone loading, especially with some of the finer stones and on harder aluminum-silicon blocks.”
Unlike most all-purpose machining oils, QUAKERCUT TM 004 PE does not contain sulfurized or chlorinated extreme pressure additive, which add unnecessary cost, odor, cleaning difficulty and regulatory concerns. In comparison to a typical all-purpose EP oil, QUAKERCUT TM 004 PE utilizes a highly refined base oil with our proprietary ester technology for consistent boundary lubrication and fines removal.
In addition, the low viscosity and high fines settling rate of the product reduces the consumption of the product over traditional machining oils, reducing total cost of use. When dealing with the ever more prominent coated aluminum blocks, the ability for fluid to efficiently remove the hard ceramic debris from the tool interface is critical to reaching the sub 0.5Ra roughness that are often called for.
This performance and ease of use of QUAKERCUT TM 004 PE has led to its wide acceptance as the honing oil of choice in a quickly growing number of custom engine builders, including Creason Automotive, Estes Automotive, and Shepherd Engine Development, in addition to its usage as a key component of the production process at larger manufacturers including General Motors Powertrain, Gehring L.P., Chassix, Caterpillar, Cummins and many others.
These advantages are what make QUAKERCUT TM 004 PE the oil recommended not just by Gehring L.P., but also by machine tool builder Rottler Manufacturing. Ed Kiebler, sales manager at Rottler, has recommended the QUAKERCUT TM 004 PE to all of his customers who want to move to an oil-based honing fluid. “Our customers have seen a lot of advantages over conventional machining oils in everything from surface finish to the odor and cleanliness of the oil,” he said.
QUAKERCUT TM 004 PE is available to the performance automotive market through Quaker Chemical’s QAdvantage channel. The QAdvantage team was created to effectively serve Quaker’s specialty customer base, who often have unique needs for flexible logistics and direct accessibility technical support. All of Quaker’s solutions to the challenging industry of automotive manufacturing will be featured at the Performance Racing Industry (PRI) Trade Show, December 10–12 in Indianapolis, Indiana. Stop by then, or contact QAdvantage to get more information about QUAKERCUT TM or Quaker’s other solutions.