Hybrid Atomistic/Continuum Study of Contact and Friction Between Rough Solids

A hybrid simulation method is used to study the effect of atomic structure and self-affine roughness on non-adhesive contact and friction between two-dimensional surfaces. Rough-on-flat and rough-on-rough contact are compared as a function of system size up to several micrometers. In order to contrast elastic and plastic behavior, interactions within the deformable substrate are either harmonic or Lennard-Jones. The ratio of lattice constants in the solids is varied to examine the effect of commensurability. In all cases the true area of contact rises linearly with load, but the slope is much larger than expected from continuum calculations. These calculations considered a continuous distribution of surface heights that is appropriate for large scales, rather than the discrete height distribution of the crystalline surfaces used here. The ratio of contact area to load depends on the ratio of lattice constants in the solids and varies with system size in small systems that deform plastically. While some dislocations are observed, plasticity is dominated by an asperity flattening mechanism where surface atoms are displaced into a lower layer. The kinetic friction rises linearly with load and is independent of system size, as predicted by Amontons’s laws. Variations in friction with commensurability are smaller for rough surfaces than for flat surfaces, because most of the contact area is in small patches. Asperity flattening increases patch sizes and thus the effect of commensurability on friction. Rough-on-rough contact leads to additional friction associated with the local slope of the contacting regions.

Experimental Investigation of Partial Laser Surface Texturing for Piston-Ring Friction Reduction

An experimental study is presented to evaluate the effect of partial laser surface texturing (LST) on friction reduction in piston rings. In a previous study, 30% friction reduction was obtained with full LST where the full width of the piston ring is textured with a very large number of microdimples that act individually as microhydrodynamic bearings. In partial LST, only a portion of the piston-ring width is textured with high dimple density, producing a “collective” effect of the dimples that provides an equivalent converging clearance even with nominally parallel mating surfaces. Experimental results obtained with flat and parallel test specimens with partial LST are presented, confirming a previously published theoretical model and the advantage of partial over full LST. Friction reduction by LST with actual production-crowned piston rings and cylinder liner segments is not straightforward and needs further investigation.     

Applying Micro-Texture to Cast Iron Surfaces to Reduce the Friction Coefficient Under Lubricated Conditions

The tribological properties of cast iron have been investigated to determine the effects of micro-texturing the surfaces. The micro-textured surfaces were prepared by shot blasting or milling using a shaper. The surfaces with groove patterns and mesh patterns had higher friction coefficients than the flat surfaces. The surfaces with dimpled patterns had lower friction coefficients than the flat surfaces. The results indicated that the dimpled pattern had a beneficial effect by decreasing the friction.     

Significance of Dimple Parameters on the Friction of Sliding Surfaces Investigated by Orthogonal Experiments

Surface texturing has proven to be an effective method to improve tribological performance of sliding surfaces. The pattern of microdimples is the most popular surface texture because it is supposed to obtain additional hydrodynamic pressure easily.

In order to evaluate the significance of the dimple parameters, including dimple diameter, depth, and area ratio, to the frictional performance, the dimple patterns with dimple diameter from 50 to 300 μm, dimple depth from 5 to 20 μm, and area ratio from 5 to 20% were manufactured on chromium-coated specimens by through-mask electrochemical micromachining. Experiments were designed using an L ₁₆ (4 ⁵ ) orthogonal array, which contained the above three factors and four levels for each factor. The frictional tests on the above-textured specimens against the specimens of cast iron with oil lubrication were carried out under the contact pressures of 0.2 and 1 MPa and sliding velocities of 0.1 s and 0.5 m/s.

The range analysis showed that the optimum dimple pattern was that with dimple diameter of 100–200 μm, dimple depth of 5–10 μm, and area ratio of 5%, which induced the friction reduction up to 77.6% compared to that of untextured surfaces.

Both the range analysis and analysis of variance suggested that dimple area ratio is the most important parameter influencing friction coefficient under the test condition of this research.     

基于分形理论的滑动摩擦表面接触力学模型

依据分形理论,考虑微凸体变形特征及摩擦作用的影响建立滑动摩擦表面接触力学模型。采用一个三次多项式来表达弹塑性变形微凸体的接触压力与接触面积的关系,从而满足在变形状态转变临界点处的微凸体接触面积与接触压力转化皆是连续和光滑的条件。推导出滑动摩擦表面临界弹性变形微接触面积、临界塑性变形微接触面积、量纲一真实接触面积的数学表达式。理论计算结果表明,表面形貌一定时,真实接触面积随着载荷的增大而增大;载荷一定时,真实接触面积随着特征尺度系数的增大而减小,随着分形维数的增大先增大后减小;当表面较粗糙时,摩擦因数对真实接触面积的影响很小;随着表面光滑程度的增大,摩擦因数对真实接触面积的影响增大,真实接触面积随着摩擦因数的增大而增大,特别是当摩擦因数较大时,真实接触面积增大的幅度也较大。接触力学模型的建立,为研究滑动摩擦表面间的摩擦磨损性能提供了依据。     

直齿面齿轮啮合效率计算研究

基于直齿面齿轮啮合仿真和弹性流体动力润滑理论,提出了直齿面齿轮啮合效率的计算方法,揭示了输入扭矩、转速等对啮合效率的影响。运用轮齿接触分析和轮齿承载接触分析技术,对直齿面齿轮承载啮合过程进行数值仿真;运用非牛顿热弹流理论,建立滑动摩擦因数的计算模型,从而建立直齿面齿轮啮合效率的计算模型。计算结果表明,滑动摩擦因数是影响齿轮啮合效率的重要因素,齿面不同位置的滑动摩擦因数也不相同,滑动摩擦因数受到输入转速、输入扭矩的影响。     

沟槽织构化表面影响摩擦振动噪声机理

在列车制动盘蠕墨铸铁材料表面上制备出平行间隔分布的沟槽表面织构,将其和光滑表面进行摩擦噪声对比试验,并利用有限元软件ABAQUS/Explicit(显式动态求解器)对试验进行数值模拟分析,研究沟槽织构化表面影响摩擦振动噪声的机理。结果表明,本试验条件下的光滑表面会产生较高强度的噪声而沟槽表面几乎不产生噪声,利用有限元软件ABAQUS/Explicit可以很好地模拟试验现象并揭示沟槽表面织构影响界面摩擦振动噪声的机理,即沟槽织构表面在对磨球滑过并碰击沟槽时引起的摩擦力波动能有效的打断摩擦界面的连续接触,作为不连续激励扰乱系统的自激振动,抑制界面摩擦力和振动加速度高频成分的形成并最终降低摩擦噪声。     

Effect of surface coating and tin plating on friction characteristics of P-110 tubing for different thread compounds

Design factor problems related to galling failure have become an increasing concern for deepwater offshore wells. This paper presents the results of an experimental study conducted to determine friction characteristics of P-110 tubing coated with manganese phosphate and plated with tin. Six repeated tests were run to investigate the effect of lubrication type on friction characteristics of P-110 tubing by using thread compounds of API modified Threadkote-706, Shell Type-3 and Graphite/PTFE at a rotational speed of 5 rpm. In each test the bearing load was increased monotonically to a maximum value of 625 kN. The results of this study clearly indicate the importance of tin-plating in reducing the coefficient of friction.     

Characteristics of turbulent flow in the annuli with smooth and rough surfaces

The structure of turbulence of fully developed flow through three concentric annuli with rough walls shown in Fig. 1 was investigated experimentally for Reynolds number range of Re =15000−66000. Time mean velocity distribution, friction factor, turbulence intensity and turbulent kinetic energy in annuli of three radius ratios of α=0.26, 0.39 and 0.56 for four cases of roughness type were measured. The results show that the structure of turbulence in these asymmetric flows is significantly different depending on the roughness wall position. An experimental study for the case of a smooth annulus was also carried out for a benchmarking purpose. The velocity distributions and friction factors are also presented and discussed.     

用计算法确定滑动摩擦系数初探

通过以一定法向压力相互接触的两物体之间的接触柱、在滑动摩擦过程中的物理变化和几何关系,揭示滑动摩擦原理,推导和建立滑动摩擦系数的计算公式、用计算法确定滑动摩擦系数且与实验法数值对照。     

Tribological Properties of Fluorinated Carbon Nanofibres

This work is concerned with the study of the tribological properties of fluorinated carbon nanofibres with various fluorination rates. The tribological tests, carried out in the presence of pentane and in air after liquid’s evaporation demonstrate good friction properties for all the compounds (the friction coefficients ranging between 0.04 and 0.06 in the presence of pentane and between 0.07 and 0.09 in air). Raman analyses reveal that the friction process induces a partial deterioration of the carbon fibres and SEM studies show that the tribofilm is composed of individual fibres embedded in a more disordered carbonaceous matrix. The fibrous nature of the tribofilm and the experimental relationship between friction coefficient and fluorination rate strongly support that friction properties of fluorinated carbon nanofibres are governed by surface fibres interaction. The modification of the nanofibres surface tension by action of pentane or optimum fluorination rate leads to a lowering of interfibres interactions resulting in an improvement of the friction properties.     

Analysis of Strain Rates and Microstructural Evaluation during Metal Forming: Role of Surface Texture and Friction

The surface texture of a die plays an important role in friction during metal forming. In the present study, unidirectional and random surface finishes were produced on hardened steel plate surfaces. To understand the influence of surface texture on friction, experiments were conducted using Al-Mg alloy pins that slid against steel plates of different surface textures. In the sliding experiments, a high coefficient of friction was observed when the pins slid perpendicular to the unidirectional grinding marks and low friction occurred when the pins slid on the random surfaces. Finite element simulations were performed using the measured friction values to understand the stress and strain evolutions in the deforming material using dies with various friction. The numerical results showed that the states of stress and strain rates are strongly influenced by the friction at the interface and hence would influence the final material microstructure. To substantiate the numerical results, laboratory compression tests were conducted. Different surface textures were obtained in order to experience different friction values at different locations. A large variation in the microstructure at these locations was observed during experiments, verifying that surface texture and die friction significantly influence fundamental material formation behavior.     

Atomic-scale study of friction and energy dissipation

This paper presents an analysis of the interaction energy and various forces between two surfaces, and the microscopic study of friction. Atomic-scale simulations of dry sliding friction and boundary lubrication are based on the classical molecular dynamics (CMD) calculations using realistic empirical potentials. The dry sliding of a single metal asperity on an incommensurate substrate surface exhibits a quasi-periodic variation of the lateral force with two different stick-slip stage involving two structural transformation followed by a wear. The contact area of the asperity increases discontinuously with increasing normal force. Xe atoms placed between two atomically flat Ni surfaces screen the Ni-Ni interaction, decrease the corrugation of the potential energy as well as the friction force at submonolayer coverage. We present a phononic model of energy dissipation from an asperity to the substrates.     

Diffusion effects in hypersonic flows with a ternary mixture

An evaluation of multi-component diffusion effects in hypersonic flows is presented. A comparison is made of the results obtained from the common simplifying assumption of Fick’s law with the results obtained from the precise constitutive relations stemming from the kinetic theory of gases. To fix the ideas, the flow of a ternary mixture past a flat plate is considered, for which pressure diffusion is negligible. Whereas the precise analysis is more complicated, the results for the mass-fraction distribution can be significantly different from the corresponding simpler analysis stemming from Fick’s Law.     

Tribological Behavior of Ti<Subscript>3</Subscript>SiC<Subscript>2</Subscript> Sliding Against Ni-based Alloys at Elevated Temperatures

Understanding the mechanism of “rubbing” noise and low-amplitude friction exited vibration generation in steady sliding can be helped by models describing the contact interactions. In the current article, we consider a simple microscopic contact model for surfaces in sliding, which is based on the adhesion theory of friction. In the proposed model, we consider that the formation and shearing of a junction contributes to a small change in the real contact area. The model incorporates random size and random spacing between junctions. We investigate the dependence of the instantaneous real contact area on the average size and number of junctions. We find that from the viewpoint of vibration reduction, it is advantageous if the real contact area needed to support the given load is obtained as a sum of many small-sized micro-contacts, instead of few large-sized micro-contacts. The above result is in agreement with experimentally observed reduction of vibrations of a hard-disk slider after texturing.     

Rotordynamic analysis for stepped-labyrinth gas seals using Moody’s friction-factor model

The governing equations are derived for the analysis of a stepped labyrinth gas seal generally used in high performance compressors, gas turbines, and steam turbines. The bulk-flow is assumed for a single cavity control volume set up in a stepped labyrinth cavity and the flow is assumed to be completely turbulent in the circumferential direction. The Moody’s wall-friction-factor model is used for the calculation of wall shear stresses in the single cavity control volume. For the reaction force developed by the stepped labyrinth gas seal, linearized zeroth-order and first-order perturbation equations are developed for small motion about a centered position. Integration of the resultant first-order pressure distribution along and around the seal defines the rotordynamic coefficients of the stepped labyrinth gas seal. The resulting leakage and rotordynamic characteristics of the stepped labyrinth gas seal are presented and compared with Scharrer’s theoretical analysis using Blasius’ wall-friction-factor model. The present analysis shows a good qualitative agreement of leakage characteristics with Scharrer’s analysis, but underpredicts by about 20 %. For the rotordynamic coefficients, the present analysis generally yields smaller predictied values compared with Scharrer’s analysis.     

Tribological Performance Optimization of Electroless Ni–P Coatings Using the Taguchi Method and Grey Relational Analysis

The present article considers an experimental study of tribological performance of electroless Ni–P coatings and optimization of tribological test parameters based on the Taguchi method coupled with grey relational analysis. A grey relational grade obtained from the grey relational analysis is used as performance index to study the behaviour of electroless Ni–P coating with respect to friction and wear characteristics. Experiments are carried out by utilizing the combination of tribological test parameters based on L₂₇ Taguchi orthogonal design with three test parameters, viz., load, speed and time. It is observed that all the three test parameters have significant contribution in controlling the friction and wear behaviour of electroless Ni–P coating. In addition, the interaction of load and time has significant influence on tribological performance. The surface morphology, composition and wear mechanism of the coatings are studied with the help of scanning electron microscopy, X-ray diffraction analysis and energy dispersed X-ray analysis.     

Evaluation of interfacial friction condition by boss and rib test based on backward extrusion

Proper consideration of tribological problems at the contact interface between the tool and workpiece is crucial in metal forming, since interfacial friction condition plays an important role in metal forming by influencing the metal flow, forming load, die wear, etc. In order to quantitatively estimate such friction condition, a new friction testing method “Boss and Rib Test” based on the backward extrusion process is proposed in this work. In boss and rib test, a key design is to use a tube-shaped punch so that the boss and rib at the deforming workpiece along the inner and outer surfaces of the punch are formed during backward extrusion. It was experimentally and numerically revealed that the heights of the boss and rib vary according to the friction condition applied. It was also found that the height of the boss is higher than that of the rib when the friction condition at the contact interface is severe. From this finding, the shear friction factor can be evaluated according to lubricant characteristics assigned. In addition, simulation results revealed that calibration curve demonstrating deformation pattern of the workpiece is affected by strain-hardening exponent of the workpiece.     

Self-assembled monolayer on diamond-like carbon surface: formation and friction measurements

We have investigated self-assembled monolayers (SAMs) of heptadecafluoro-1,1,2,2-tetradecyltrietoxysilane (FTE) on diamond-like carbon (DLC) surfaces formed by a simple immersing process. SAM formation on DLC surfaces was verified by contact angle measurements, ellipsometry and X-ray photoelectron spectroscopy (XPS). Water and hexadecane contact angles increased gradually with immersing time and saturated at about 110 and 70 degrees, respectively. Ellipsometric measurements showed that the film thickness was 1.4 to 1.6 nm, which corresponded reasonably to the thickness of FTE monolayer. XPS data showed the presence of FTE molecules on the DLC surface. These results ensured the SAM formation of FTE molecules on the DLC surface.We further measured and compared the friction of unlubricated, SAM coated and 2 nm thick perfluoropolyether (PFPE) coated DLC surfaces using lateral force microscopy (LFM) as functions of the applied load and the sliding velocity. The SAM coated DLC surfaces showed lower friction than the unlubricated DLC surfaces and the friction coefficient decreased by about 15% compared to the unlubricated DLC surfaces. Scratch tests revealed that the critical load of the DLC film increased due to the SAM deposition. These results are attributed to the hydrophobic nature of the SAM coated surface. On the other hand, even though the water contact angle of the SAM coated surface was larger than the 2 nm thick PFPE coated surface, the friction of the SAM coated surface was larger than that of the PFPE coated surface. Also, the critical load of the SAM coated DLC surface in scratch test was lower than the PFPE coated surface. These results indicate that the hydrophobic nature of the surface is not the only factor which determines the friction characteristics in the nano-lubricating system, and it is attributed to the mobile characteristic of PFPE lubricant.