Effect of wear on EHD film thickness in sliding contacts

A theoretical solution to the elastohydrodynamic (EHD) lubrication problem in sliding contacts, which takes into consideration the effect of the change in shape of the gap due to wear on the load‐carrying capacity, is presented. The model of such a contact is based on assumptions of Grubin and Ertel (von Mohrenstein). The resultant dimensionless Reynolds and film profile equations have been solved numerically for a number of cases with several values of thickness of the worn layer. Iteration of the EHD film thickness is performed by means of the secant method. Values of the calculated dimensionless film thickness are presented as a function of dimensionless wear. The conclusions concern the influence of the linear wear on the film thickness in heavily loaded sliding contacts. Copyright © 2006 John Wiley & Sons, Ltd.     

线接触零卷吸弹流条件下的急停分析

对滚珠丝杠、滚珠蜗杆、无保持架滚柱轴承中常见的零卷吸状态下的急停问题进行热弹性流体动力润滑模拟;采用不同的初始零卷吸表面速度和急停时间,探讨线接触零卷吸条件下发生急停时油膜压力、膜厚和温升的变化。结果表明：相同急停时间下,中心压力和中心膜厚在急停过程中逐渐增大,随初始零卷吸表面速度的增加而轻微减小;初始零卷吸表面速度相同时,中心压力和中心膜厚均随急停时间的增加而逐渐增加;油膜的温度峰在急停前期缓慢下降,而在急停后期急剧下降。零卷吸工况下的急停会造成运动过程中接触区中心压力的急剧增加,会导致两接触固体间的应力远超过材料的屈服极限,使两接触表面会发生塑性变形,造成表面损伤。     

A unified shear-thinning treatment of both film thickness and traction in EHD

A conclusive demonstration has been provided that the nature of the shear-thinning, that affects both film thickness and traction in EHL contacts, follows the ordinary power-law rule that has been described by many empirical models of which Carreau is but one example. This was accomplished by accurate measurements in viscometers of the shear response of a PAO that possesses a very low critical stress for shear-thinning and accurate measurements in-contact of film thickness and traction under conditions which accentuate the shear-thinning effect. The in-contact central film thickness and traction were entirely predictable from the rheological properties obtained from viscometers using simple calculations. These data should be invaluable to researchers endeavoring to accurately simulate Hertz zone behavior since the shear-thinning rheology is extensively characterized and accurate in-contact data are available to test. In addition, a new model has been introduced that may be useful for the rheological characterization of mixtures.     

Effect of proprietary oil additives on elastohydrodynamic film thickness

A study is reported of the effect on a simulated elastohydrodynamic contact of the addition of three proprietary products to the lubricating oil. Chromatic interferometry was used to study changes in lubricant film thickness. Under the conditions employed it was found that Molyslip did not affect film thickness markedly, but there is evidence that solid particles of molybdenum disulphide did enter the contact. STP and Redex both increased the film thickness as a result of increasing the viscosity, but this effect was greatly reduced at high shear rates. No evidence was found for the formation of permanent or semi-permanent surface films, although results have so far only been obtained at room temperature.     

变卷吸速度的点接触热弹流润滑分析

非稳态热弹流润滑一直是研究的热点和难点,针对变卷吸速度的点接触热弹性流体动力润滑问题,利用多重网格积分法,得到变卷吸速度的点接触热弹性流体动力润滑完全数值解。结果表明:卷吸速度的变化会引起油膜压力、膜厚和温度的变化;当卷吸速度变化到一定值时,在接触区会产生油膜的凹陷;凹陷的产生可用“温度-粘度楔”机制解释。     

Lubricant film thickness variations in frictionless bearings

The possibilities are considered of diagnostics and monitoring of the technical state of frictionless bearings on the basis of the analysis of on-line recorded and processed oscillations of the lubricant film thickness. A possibility is shown of a significant increase in the monitoring efficiency when using the technique of automated processing of the diagnostic data received by using modern microprocessor means. Implementation of the proposed methodical approach will significantly shorten the duration of the frictionless bearing tests and will make it possible to govern the operating mode of the bearings in order to prolong their operation life.     

Numerical evaluation of pressure from experimentally measured film thickness in EHL point contact

This paper is concerned with elastohydrodynamic lubrication, especially the determination of lubricant film thickness and contact pressure within a point contact of friction surfaces of machine parts. A new solution technique for numerical determination of contact pressure is introduced. The direct measurement of contact pressure is very difficult. Hence, input data of lubricant film thickness obtained from the experiment based on colorimetric interferometry are used for the calculation of pressure using the inverse elasticity theory. The algorithm is enhanced by convolution in order to increase calculation speed. The approach described in this contribution gives reliable results on smooth contact and in the future, it will be extended to enable the study of contact of friction surfaces with asperities. Copyright © 2007 John Wiley & Sons, Ltd.     

一个表面带单粗糙峰的线接触时变微弹流润滑数值分析

通过数值求解研究了一个固体表面的单粗糙峰对两固体形成的线接触时变弹流润滑区压力、膜厚分布曲线的影响。结果表明：粗糙峰的出现，使其对应位置上的压力、膜厚发生急剧变化；粗糙峰的移动，对压力和膜厚的变化、固体表面的凹陷现象以及Hertz接触区的出口颈缩均有不同的影响；另外，压力峰和油膜形状随着粗糙峰幅值和半波长的变化而变化。结果亦表明：准稳态解比时变解过高地估计粗糙峰对压力和膜厚的影响。     

A numerical analysis of the elastohydrodynamic line contact film formation at motion start-up

A mathematical model is proposed of the process of formation of the elastohydrodynamic (EHD) lubricant layer between resilient cylinders that begin to rotate in the lubricating material medium from the resting state. The model assumes division of the whole contact region into three zones: the zone within which dry motion is described by the equations of the elastohydrodynamic theory of lubrication, the transient zone, and the dry contact zone. The method of the numerical solution of this system of equations is presented. The calculations are performed for the lubricating material that was used in the published experimental study of the process of formation of the EHD lubricating layer between the resilient ball and the flat resilient base. It is shown that the calculation results well agree with the experimental data both qualitatively and quantitatively providing that the transient region dimensions are adequately selected. The function of the pressure distribution, the lubricating layer thickness, the lubricating material flow, the rate of approach of the surfaces over the contact region at different moments of time, the time dependencies of the lubricating layer thickness at different points of the contact region, and the coordinates of the boundary points of the dry contact region is also presented.     

Numerical multilevel investigation for the evaluation of pressure distribution in ehl circular contacts from film thickness measurements

An analysis of circular contacts under elastohydrodynamic lubrication using a hybrid technique is presented. In particular, attention has been focused on the pressure distribution calculation. A versatile code has been developed to evaluate the pressure distribution starting from three‐dimensional film thickness maps obtained from the analysis of interferometric images. The code has been developed in C++ and is based on the multigrid technique. This hybrid technique has a basic advantage over the full numerical approach in that the pressure is obtained without making any assumptions about the lubricant itself. The main drawback of the method is that high‐resolution interferometric images are required.     

加载条件下零卷吸凹陷油膜分布的试验研究

为探究加载过程中零卷吸工况下油膜的变化情况,使用球-盘光干涉试验机进行PAO100润滑油润滑下的摩擦实验。实验过程中通过伺服电机驱动钢球和蓝宝石盘以等值反向速度稳定转动,同时匀速加载;采用工业相机拍摄球-盘之间的油膜图像,实验后使用双光干涉法测量接触区中截面油膜厚度。实验发现：在加载情况下,当表面速度较低时且载荷较小条件下,油膜规律性不强,只有当载荷增加到一定程度,“温度-黏度楔”效应才会起作用,形成中央凹陷油膜;中央凹陷出现的时间随着表面速度的增加而提前;在速度较高条件下,中央小凹陷会迅速演化为大凹陷;与稳态结果的对比显示,时变效应会延迟“温度-黏度楔”效应的作用。     

High-Speed Elastohydrodynamic Lubrication by a Dilute Oil-in-Water Emulsion

When a concentrated contact is lubricated at low speed by an oil-in-water emulsion, a film of pure oil typically separates the surfaces (stage 1). At higher speeds, starvation occurs (stage 2) and the film is thinner than would be expected if lubricated by neat oil. However, at the very highest speeds, film thickness increases again (stage 3), though little is known for certain about either the film composition or the mechanism of lubrication, despite some theoretical speculation.

In this article, we report the film thickness in a ball-on-flat contact, lubricated by an oil-in-water emulsion, at speeds of up to 20 m/s, measured using a new high-speed test rig. We also investigated the sliding traction and the phase composition of the film, using fluorescent and infrared microscopy techniques.

Results show that, as the speed is increased, starvation is followed by a progressive change in film composition, from pure oil to mostly water. At the highest speeds, a film builds up that has a phase composition similar to the bulk emulsion. This tends to support the “microemulsion” view rather than the “dynamic concentration” theory.     

A simplified calculus method for a grease-lubricated Rayleigh step bearing

The paper presents a simplified method for the analytical calculus of a grease-lubricated infinitely large Rayleigh step bearing. The principal problem of the grease flow through a Rayleigh step bearing is the shape of the stagnant core in the step region. This shape is determined using Navier-Stokes equations resolved by the finite method element. The theoretical results are compared with those obtained experimentally by visualisation of the grease flow using the reflecting tracer method. The conclusion of the simplified method is that a Rayleigh step bearing lubricated with grease is equivalent to one lubricated with oil, but with a different configuration of the convergent interstice.     

Experimental results and analytical film thickness predictions in EHD rolling point contacts

In this work, we consider several types of lubricants—including non-Newtonian fluids—that were studied in EHD pure rolling point contacts under various operating conditions, leading us to explore a wide range of dimensionless parameters. The experimental results are compared with predictions given by the usual analytical EHL relationships and by more recently developed models. This broad comparison conducted with particular emphasis on minimum film thickness (h_m) showed a fair agreement between experimental data and a few predictions including some obtained from extended models. Commonly used elastohydrodynamic lubrication (EHL) models did not systematically give accurate h_m estimation, whereas minimum film thickness not only is a yield value but also serves as a key parameter in estimating lubrication regimes.     

Thermal effects in cylindrical journal bearings of high‐speed gearboxes

The high rotational speeds and loads of gears operating in acceleration gearboxes causes problems related to the correct choice and design of journal or rolling bearings. In the case of journal bearings, these problems are connected with thermoelastohydrodynamic lubrication theory and the dynamics of the bearing system. However, of major importance is the problem of thermal effects in journal bearings. This has been considered for bearings used in a double‐helical gearbox with the pinion and output shaft operating in cylindrical journal bearings. The oil film pressure, temperature, viscosity distributions, and maximum and mean oil film temperatures have been determined. In calculations, laminar adiabatic and turbulent adiabatic models of oil films have been applied. The results of the calculations can be used in the design of cylindrical or other types of journal bearing in rotating machinery, including acceleration or reduction gearboxes.     

A finite element approach of thin film lubrication in circular EHD contacts

So far, most of the numerical studies concerning elastohydrodynamic point contact lubrication have been realized using finite differences. This paper describes a finite element approach for the modelling of both, thick and thin film lubrication in circular contacts under isothermal elastohydrodynamic regime. Multigrid techniques are used to accelerate the convergence and reduce calculation time. The use of the finite element method (FEM) offers two advantages: first, the existence of high level ready-to-use Finite Element commercial software which reduces the time spent in implementing the method and second, the easier adaptability to different and various physical models such as lubricant rheology, starvation effects, thermal effects, non-Newtonian behaviour, etc. The numerical model is presented in detail and an example of its adaptation taking into account non-Newtonian effects is shown. Finally, a comparison is made between Newtonian and non-Newtonian solutions, exhibiting differences obtained when using both models, especially at high shear rates where the film thickness and the friction coefficients are overestimated by a Newtonian approach.     

Calculation of pressure distribution in EHD point contacts from experimentally determinated film thickness

In lubrication studies, film thickness is measured since 1963 using optical interferometry, but pressure distribution is also of great interest. Unfortunately, this parameter is very difficult to measure. This paper presents a new method for pressure evaluation based on an inverse elastic approach. This latter uses the film thickness field known precisely (±3 nm) by computerised treatment of interferograms. We present here the whole process, from the image to the pressure field. A complete error analysis is conducted: the pressure field is known within 5% and the spatial resolution is 3 grid steps, i.e. 6 μm.     

The influence of thin boundary films on real surface roughness in thin film, mixed EHD contact

The behaviour of thin viscous boundary films in the rough surface rolling–sliding point contact operated under thin film lubrication conditions have been observed by thin film colorimetric interferometry. Changes in film thickness distribution within the lubricated contact between steel ball and glass disc were studies with both mineral base oil and mineral oil formulated with non-functionalized polyalkylmethacrylate (PAMA). Recent studies by other researchers showed that this polymer-containing viscosity index improver exhibits some friction-reducing capabilities even though it forms only very thin boundary films on rubbing surfaces. Results obtained in the current study proved that thin viscous boundary films formed on rubbing surfaces can reduce asperities interactions of rubbing surfaces under very thin film conditions. Even though these boundary films do not separate rubbing surfaces completely, they still can provide some protection of contacting bodies against excessive friction and wear.     

Effects of thermally induced inhomogeneous shear and surface thermal boundary conditions on the shear stress in sliding elastohydrodynamic contacts

Numerous research work has shown that significant thermally induced cross‐film inhomogeneous shear or thermal shear localisation may be developed in sliding elastohydrodynamic lubrication (EHL) contacts with pronounced consequences. This paper uses the theoretical framework established in previous research to further analyse the effects of the shear localisation on the lubricant shear stress and thus the EHL traction. Results obtained suggest that the shear localisation significantly accelerates the thermally induced reduction of the shear stress in sliding EHL contacts. The study also shows dramatic reduction of the shear stress in EHL contacts with one‐insolated surface, which is significantly attributed to the more intensified thermal shear localisation near the insolated surface. The practical significance of the dramatic shear stress reduction is discussed. Copyright © 2009 John Wiley & Sons, Ltd.     

A theoretical simulation of thermal elastohydrodynamic lubrication for a Newtonian fluid in impact motion

In this work, the thermal elastohydrodynamic lubrication (TEHL) in an impact motion is explored using multigrid (MG) method and column by column scanning techniques. A steel ball impacts onto an infinite steel plane lubricated with a thin layer of oil. The study starts from a smooth contact problem and the results are compared with the corresponding isothermal ones. Then surface waviness is imposed on the steel ball surface to check the fluctuation in the oil film.