A review of the published literature has demonstrated a large variability and discrepancies in the measured and predicted values of piston-ring lubricating film thickness in internal combustion engines. Only two papers have been found that compare experiments in firing engines directly with outputs from sophisticated ring-pack lubrication models. The agreement between theory and experiment in these comparisons was limited, possibly because of inadequacies in the models and/ or inaccuracies of measurement. This paper seeks to contribute to the literature by comparing accurately calibrated experimental measurements of piston-ring film thickness in a firing engine with predictions from an advanced, commercial software package alongside details of the systematic analysis of the measurement errors in this process. Suggestions on how measurement accuracy could be further improved are also given. Measurements of oil-film thickness with an error (standard deviation) of +/- 15% have been achieved. It is shown that this error can be reduced further, by changes in the design and installation of the sensors. Detailed experimental measurements of film thickness under the top compression ring in a firing petrol engine have been made and compared with the predictions from a commercial, state-of-the art modelling package. The agreement between theory and experiment is excellent throughout the stroke in most cases, but some significant differences are observed at the lower load conditions. These differences are as yet unexplained, but may be due to the sensor topography influencing the hydrodynamic lubrication, lubricant availability, out-of-roundness in the cylinder or squeeze effects. This is a topic that requires further study.
