Effect of Base Oil Structure on Elastohydrodynamic Friction

The EHD friction properties of a wide range of base fluids have been measured and compared in mixed sliding–rolling conditions at three temperatures and two pressures. The use of tungsten carbide ball and disc specimens enabled high mean contact pressures of 1.5 and 2.0 GPa to be obtained, comparable to those present in many rolling bearings. The measurements confirm the importance of molecular structure of the base fluid in determining EHD friction. Liquids having linear-shaped molecules with flexible bonds give considerably lower friction than liquids based on molecules with bulky side groups or rings. EHD friction also increases with viscosity for liquids having similar molecular structures. Using pure ester fluids, it is shown that quite small differences in molecular structure can have considerable effects on EHD friction. The importance of temperature rise in reducing EHD friction at slide–roll ratios above about 5% has been shown. By measuring EHD friction at several temperatures and pressures as well as EHD film thickness, approximate corrections to measured EHD friction data have been made to obtain isothermal shear stress and thus EHD friction curves. These show that under the conditions tested most low molecular weight base fluids do not reach a limiting friction coefficient and thus shear stress. However, two high traction base fluids appear to reach limiting values, while three linear polymeric base fluids may also do so. Constants of best fit to a linear/logarithmic isothermal shear stress/strain rate relationship have been provided to enable reconstruction of isothermal EHD friction behaviour for most of the fluids tested.     

Comparison between rubber–ice and sand–ice friction and the effect of loose snow contamination

The application of sand particles is a common method to improve the friction of aircraft tires on snow or ice covered runways. Hence, an understanding of the prevailing rubber–ice and sand–ice friction mechanisms is of practical interest. Rubber–ice and sand–ice friction measurements were made with a British Pendulum Tester at temperatures between ?22 and 0 °C and the effect of loose snow contamination on top of the ice was investigated. The results (the response of the instrument) were expressed in a sliding length averaged friction coefficient μ_BP. Close to the melting point the friction of rubber on ice was low and increased with decreasing ice temperature. Below ?5 °C, reasonably high friction levels (0.2<μ_BP<0.5) were obtained between rubber and ice, but the friction level dropped drastically by the presence of a very thin layer of snow. The sand–ice friction level was less dependent on ice temperature and clearly not as much affected by the presence of snow, compared to rubber–ice friction. The micromechanisms involved in rubber–ice and sand–ice frictions were investigated by the application of etching and replicating technique (ERT) developed for the examinations of the dynamics of dislocations in ice during deformation.     

Investigations on the effects of friction modeling in finite element simulation of machining

Accurately predicting the physical cutting process variables, e.g. temperature, velocity, strain and stress fields, plays a pivotal role for predictive process engineering for machining processes. These predicted field variables, however, are highly influenced by workpiece constitutive material model (i.e. flow stress), thermo-mechanical properties and contact friction law at the tool-chip-workpiece interfaces. This paper aims to investigate effects of friction modeling at the tool-chip-workpiece interfaces on chip formation process in predicting forces, temperatures and other field variables such as normal stress and shear stress on the tool by using advanced finite element (FE) simulation techniques.For this purpose, two distinct FE models with Arbitrary Lagrangian Eulerian (ALE) fully coupled thermal-stress analyses are employed to study not only the effects of FE modeling with different ALE techniques but also to investigate the influence of limiting shear stress at the tool-chip contact on frictional conditions, which was never done before. A detailed friction modeling at the tool-chip and tool-work interfaces is also carried by coupling sticking and sliding frictions. Experiments and simulations have been performed for machining of AISI 4340 steel using tungsten carbide tooling and the simulation results under increasing limit shear stress have been compared to experiments. The influence of limiting shear stress on the tool-chip contact friction was explored and validity of friction modeling approaches was examined. The results presented in this work not only provide a clear understanding of friction in FEM modeling of machining but also advance the process knowledge in machining.     

Finite element simulation of high-pressure water-jet assisted metal cutting

Experimental studies have shown that improved metal cutting efficiency can be obtained when a high-pressure water/coolant jet is injected at the tool–chip interface. The pressure exerted on the chip face by the jet is expected to reduce, for example, friction along the tool–chip interface, temperature rise in the chip and the workpiece, the cutting force, and residual stress in the finished workpiece, leading to a longer tool life and a better surface integrity for the finished workpiece. This paper presents the results of finite element simulations of high-pressure water-jet assisted orthogonal metal cutting, in which the water jet is injected directly into the tool–chip interface through a small hole on the rake face of the tool. The mechanical effect of the high-pressure water jet is approximated as a pressure loading at the tool–chip interface. The frictional interaction along the tool–chip interface is modeled by using a modified Coulomb friction law. Chip separation is modeled by a nodal release technique and is based on a critical stress criterion. The effect of temperature, strain rate and large strain is considered. Cooling effect of the high-pressure jet on the temperature distribution is modeled with a convective heat-transfer coefficient. The effect of water jet hole position and pressure is studied. Contour plots showing the distributions of steady-state temperature and stress and the residual stress are presented. The simulation results show a reduction in temperature, the cutting force and residual stresses for water-jet assisted cutting conditions. The mechanical effect of the water jet is found to reduce the contact pressure and shear stress along the tool–chip interface and also the contact zone length for certain water jet hole locations.     

Analysis of frictional phenomena in friction welding of mild steel

A dynamical analysis of the “equilibrium phase” of friction welding is presented. The fundamental idea is that the observed phenomena are controlled by the behaviour of a viscous layer of plasticised metal at the rubbing surfaces. This layer is postulated to obey a constitutive equation relating shear stress to rate of strain which is similar to the well-known “Bingham plastic” model. Formulae are thus obtained which predict the external driving torque, as well as the thickness and temperature distribution of the plasticised layer. A comparison is made between the theoretical results and a number of experiments which have been carried out on mild steel tubular specimens, over a range of conditions. Good agreement is found in all cases. Preliminary results are presented for the apparent viscosity of plasticised mild steel.     

Thermal activation in boundary lubricated friction

The friction coefficients for copper pairs lubricated with fatty acids and fluorinated fatty acids have been measured over a wide range of sliding speeds and temperatures. Sliding speeds in the range 10⁻⁷−10⁻² m s⁻¹ and temperatures in the range 4.2–300 K were used. The friction coefficients near 300 K are generally low and increase with sliding speed, while the friction coefficients at low temperatures are markedly higher and relatively independent of velocity. Each lubricant's friction vs. velocity behavior over the temperature range 150–300 K can be described by a friction-velocity master curve derived from a thermal activation model for the lubricant's shear strength. The activation energies deduced from this friction model are identical to those obtained in the same temperature range for a vibrational mode associated with low temperature mechanical relaxations in similarly structured polymers. These results suggest that thermally activated interfacial shear is responsible for the fatty acids' positive-sloped friction vs. velocity characteristics at low sliding speeds near room temperature.     

Possibility of slip in hydrodynamic oil films under sliding contact conditions

In hydrodynamic lubrication theory, the oil film thickness build‐up increases with increasing sliding speed or oil viscosity, and the viscous resistance or shear stress also increases, both without limit. The entraining force forming the oil film is given by the moving surfaces, or by the adhesive force of the oil molecules on the rubbing surfaces and the interaction force between them. Therefore, the maximum friction force and maximum oil film thickness will be limited by the operating conditions, such as oil properties, rubbing materials, sliding speed, and load. In this study, friction tests were conducted using a plate‐on‐cylinder sliding contact apparatus. It was found that a critical shear stress existed, above which the friction force and oil thickness decreased from theoretical values. Slip in an oil film seems to occur when the theoretical shear stress exceeds the critical value of the oil, according to test conditions. The occurrence of slip in an oil film is responsible for the reduction in the oil film and friction force from theoretical values, leading to the lower‐viscosity components of the oil selectively passing through the conjunction zone.     

Nonlinear thermodynamic model of boundary friction

Melting of an ultrathin lubricant film confined between two atomically flat surfaces is studied. An excess volume parameter is introduced, the value of which is related to the presence of defects and inhomogeneities in the lubricant. Via minimization of the free energy, the Landau-Khalatnikov kinetic equation is obtained for this parameter. The kinetic equation is also used for relaxation of elastic strains, which in its explicit form contains the relative shear velocity of the rubbing surfaces. With the numerical solution of these equations, a phase diagram with domains corresponding to the sliding and dry stationary friction regimes is built at a fixed shear velocity. A simple tribological system is used to demonstrate that in the dynamic case, three friction regimes can occur, namely, dry, stick-slip, and sliding friction. It is shown that a lubricant can melt when the shear velocity exceeds a critical value and with elevation of its temperature. The dependence of the dynamic friction force on the pressure applied to the surfaces, the temperature of the lubricant, and the shear velocity is considered. It is shown that growth of pressure leads to the forced ordering and solidification of the lubricant.     

Elementary results of dimensional analysis for friction and wear in steady state sliding

The combination of a dimensional analysis and the recognition of surface roughness (asperity) dimensions as dependent rather than independent variables in a steady state of wear leads to some interesting results. Functional forms for the friction coefficient, wear rate and the geometry of the wear surface are seen to provide surprisingly strong restrictions (such as no effect of the speed of sliding on the coefficient of friction) in some instances and surprisingly little in others. The roles of load, rubbing speed, elastic and plastic properties of rubbing surfaces, surface energy, critical stress intensities, microstructural dimensions, heat conductivity and strain rate sensitivity are touched upon briefly.     

An Examination of Thermionic Emission Due to Frictionally Generated Temperatures

The emission of electrons from a surface due to heating-referred to as thermionic emission-is examined theoretically for sliding contact. High local temperatures generated by friction at the contacts between rubbing surfaces can activate the emission of electrons and influence tribochemical reactions. A thermal model previously developed by Vick and Furey [1,2] for sliding contact is used to predict the temperature rise over the surface. This predicted temperature rise, along with the bulk temperature of the material, is used in the Richardson--Dushman equation for thermionic emission to predict the current density from the surface. The total current discharged from the surface is obtained from an integration of the current density. Results demonstrate that high local temperatures generated by friction at the contacts between rubbing surfaces can activate the emission of electrons, with local spikes in the current density occurring in the vicinity of the peak temperature. In addition, relatively large changes in both current density and total current result from relatively small changes in either material properties or sliding conditions, such as velocity or applied load. Since the true area of contact is likely to evolve in a highly dynamic fashion, a study using time varying, multiple contacts was also conducted. Results suggest that the locations of high local temperatures and thermionic activity are likely to be short lived and random.     

MATERIAL PROPERTY NEEDS IN MODELING METAL MACHINING

Different laws of how flow stress varies with strain, strain rate, and temperature, from different authors, are reviewed and compared for their predictions of behavior in the primary and secondary shear conditions of metal machining. Despite differences in their structure, the laws give similar numerical values of flow stress in primary shear conditions, but show large differences in secondary shear. Friction laws are also discussed. There is a need to develop secondary shear yield and friction laws.     

History,Origins and Prediction of Elastohydrodynamic Friction

There is currently considerable debate concerning the most appropriate rheological model to describe the behaviour of lubricant films in rolling–sliding, elastohydrodynamic contacts. This is an important issue since an accurate model is required to predict friction in such contacts. This paper reviews the origins of this debate, which primarily concerns a divergence of views between researchers using high pressure, high shear rate viscometry and those concerned with the measurement and analysis of elastohydrodynamic friction; the former advocate a Carreau-based shear stress/strain rate model while the latter generally favour an Eyring-based one. The crucial importance of accounting for shear heating effects in analysing both viscometric and friction data is discussed. The main criticisms levied by advocates of a Carreau-based model against Eyring’s model are discussed in some detail. Finally, the ability of both types of rheological model to fit elastohydrodynamic friction measurements for a quite simple, well-defined base fluid is tested, using previously measured pressure–viscosity behaviour for the fluid. Both models appear to fit the experimental data over a wide temperature range quite well, though fit of the Eyring model appears slightly closer than that of the Carreau–Yasuda model. Friction data from a wider range of well-defined fluid types are needed to identify categorically the most appropriate model to describe elastohydrodynamic friction.     

MATERIAL PROPERTY NEEDS IN MODELING METAL MACHINING

ABSTRACT

Different laws of how flow stress varies with strain, strain rate, and temperature, from different authors, are reviewed and compared for their predictions of behavior in the primary and secondary shear conditions of metal machining. Despite differences in their structure, the laws give similar numerical values of flow stress in primary shear conditions, but show large differences in secondary shear. Friction laws are also discussed. There is a need to develop secondary shear yield and friction laws.     

Low-Temperature Friction in the XPS Analytical Ultrahigh Vacuum Tribotester

In this work, we present the capability of ultrahigh vacuum analytical tribometry for studying mechanisms of friction at low temperatures. We investigated the low-temperature frictional behavior of two different materials: ice and polyethylene (PE). We successfully formed a thin layer of ice on a steel surface, at temperature as low as 123 K in an ultrahigh vacuum. The surface characterization technique used for this study was X-ray photoelectron spectroscopy (XPS). We investigated the frictional behavior of such a thin ice layer. The changing friction as a function of temperature indicates that the ice might undergo pre-melting even at temperatures below 123 K. A polyethylene (PE) film previously deposited on a metal surface also showed changing friction as a function of temperature in the range 123 to 400 K. As there is no change in the nature of the surface chemistry of the polymer, as indicated by XPS, the results are therefore interpreted in terms of change in ductile-to-brittle transition of the polymer film over the temperature range. This work enables the fundamental investigation of friction at low temperatures with the help of surface analysis.     

Measurement of the Rheology of Lubricant Films Within Elastohydrodynamic Contacts

There is growing need for a reliable model of the rheological response of lubricants in elastohydrodynamic (EHD) contacts, not only to predict behaviour in full-film EHD conditions, but also for use in modelling mixed-film lubrication. One barrier to developing such a model is that measurements of friction actually represent averaged values over the whole, lubricated contact under study. However the fluid film conditions of temperature, pressure and strain rate generally vary over such contacts, which makes it difficult to determine constitutive shear-stress equations from friction measurements. This paper examines the various different techniques used to study the origins of EHD friction and the underlying film rheology. It then describes and applies a technique for obtaining the temperature rise maps of both solid surfaces in a rolling-sliding EHD contacts and thus shear-stress and friction maps. The work shows that the shear stress of the traction fluid studied increases approximately linearly with pressure and decreases approximately linearly with temperature in the high-pressure central region of EHD contacts.     

考虑摩擦因数与滑动速度相关时的轮轨滚动接触有限元分析

使用与滑动速度相关的摩擦因数替代库伦摩擦定律中的常系数,结合mixed Lagrangian/Eulerian方法建立轮轨滚动接触有限元模型,分析牵引力主导的蠕滑工况下的干燥状态的轮轨滚动接触特性。通过与摩擦因数取值为常数的轮轨滚动接触分析结果对比发现:与滑动速度相关的摩擦因数对轮轨滚动接触最大接触应力和接触斑面积影响不大,均在1%以内;但是对轮轨接触斑内最大Mises应力、最大纵向切应力、最大横向切应力和最大等效塑性应变影响较大,特别是对最大纵向切应力影响幅度近20%;更需要引起注意的是对轮轨滚动接触摩擦力矢量分布和切向塑性应变分布影响明显,这对轮轨滚动接触疲劳损伤分析非常重要。     

Microstructural investigation of ice surfaces after rubber–ice and sand–ice sliding friction tests

The dual process of etching and replicating technique revealing lattice dislocations, dislocation cells, grain and sub-grain boundaries, etc., in ice has been applied to investigate the microstructure of freshly deformed ice surfaces after rubber–ice and sand–ice sliding friction tests. Features related to the generation, multiplication and mobility of dislocations were observed in ice subjected to rubber–ice friction even at high speeds and high ice temperatures, involving low friction. During sand–ice friction, deformation took place at the surfaces as well as deeper within the ice by ploughing sand particle, and was accompanied with recrystallization. The deformation features in ice found in the laboratory were also observed in full-scale tire–ice interactions on ice covered runway pavements.     

磨粒磨损中微观接触过程的有限元分析

分析了磨粒压入被磨损材料表面、磨粒在材料表面滑动和卸载脱离接触的过程,研究了这三个接触阶段材料表层的应力应变、接触压力和接触摩擦切应力特征。结果表明,微观接触过程不仅存在材料的非线性作用和摩擦接触的状态非线性作用,而且存在着由于材料表面变形引起的几何非线性作用,被磨损材料表层的应力应变和接触压力的分布和大小与材料表面变形过程有关。     

A Molecular Dynamics Study of the Transition from Ultra-Thin Film Lubrication Toward Local Film Breakdown

The transition from ultra-thin lubrication to dry friction under high pressure and shear is studied using molecular dynamics: the quantity of lubricant in the confined film is progressively reduced toward solid-body contact. A quantized layer structure is observed for n-alkanes confined between smooth, wettable walls, featuring an alternation of well-layered, low friction configurations, and disordered ones, characterized by high friction, and heat generation. The molecular structure influences the ordering of the fluid and the resulting shear stress. In fact, Lennard-Jones fluids are characterized by low friction due to the absence of interlayer bridges, opposed to the always entangled states and high shear stresses for branched molecules. Surface geometry and wettability also affect the behavior of the confined lubricant. The presence of nanometer-scale roughness frustrates the ordering of the fluid molecules, leading to high friction states. Furthermore, local film breakdown can be observed when the asperities come into contact, with strong wall–wall interactions causing the maximum in shear stress. Finally, friction is limited to a small, constant value by the presence of smooth, non-wettable surfaces in the system due to the occurrence of wall slip.     

磨削加工中的尺寸效应机理研究

从比切削能和比摩擦能的大小变化与磨削参数的关系出发,研究了磨削加工中的尺寸效应问题,结果认为：比切削能的尺寸效应是金属剪切流动应力的尺寸效应和磨粒顶端钝圆影响的综合作用结果;当磨削深度或工件进给速度减小时,平均未变形切屑厚度减小,金属材料的剪应变效应和剪应变率效应增强,而热软化效应减弱,从而金属材料的剪切流动应力增大;当未变形切屑厚度减小时,磨粒顶端钝圆的影响增大;比摩擦能的尺寸效应是由于工件和砂轮的实际接触面积与磨削深度之间存在非线性关系及工件和砂轮间的摩擦因数的速度效应造成的;当工件进给速度减小时,工件与砂轮磨损平面间的摩擦因数增大。