A non-Newtonian model based on Ree-Eyring theory and surface effect to predict friction in elastohydrodynamic lubrication

The traction behaviour of various lubricants is investigated in elastohydrodynamic regime using a tribometre that simultaneously allows the contact visualization and the friction measurement under controlled contact kinematics. First, the film formation capability is determined: although the base oil and the polymer, via their viscosity, govern the film thickness in EHL regime, the additives control the existence of a boundary film at low entrainment speed. Second, the relative role of the additives and of the base oil on the frictional behaviour is studied for various experimental conditions: this clearly demonstrates that the piezo-viscous response of the lubricant controls the Newtonian/non-Newtonian transition and the friction level. The role of thermal effects is discussed. A strong influence of the entrainment speed, over the frictional response is unexpectedly observed, even in full film regime. A rheological model based on Ree-Eyring theory supposing a heterogeneous flow due to adsorbed surface layers, is proposed to discuss the organization of the molecules within the contact and its effect on the frictional response of the contact.     

Film Forming and Friction Properties of Overbased Calcium Sulphonate Detergents

The film-forming and friction properties of overbased calcium sulphonate (OBCaSu) detergents in rolling–sliding, thin film, lubricated contact have been investigated. All of the commercial detergents studied form thick, solid-like, calcium carbonate films on the rubbed surfaces, of thickness 100–150 nm. The films have a pad-like structure, interspersed by deep valleys in which practically no film is present. These films have the effect of increasing friction in intermediate speed conditions, an effect which is believed to occur because the pad structure of the film inhibits fluid entrainment and thus postpones the formation of an EHD film to higher entrainment speeds. Large differences were noted between the boundary friction coefficients of the various detergents tested. Two of them gave very low boundary friction coefficients, in the range 0.06–0.08, while the other two gave considerably higher friction. These differences are believed to originate from differences in the structures of the alkyl chains in the sulphonate detergent molecules. The films formed by OBCaSu detergents can be removed very effectively by treatment with EDTA solution and this shows that the films are effective in preventing wear.     

The influence of transverse roughness in thin film, mixed elastohydrodynamic lubrication

The Spacer Layer Imaging (SLIM) method has been used to investigate the influence of transverse roughness on the thickness and shape of elastohydrodynamic (EHD) films. The effects of entrainment speed and lubricant viscosity on film distribution are shown for three distinct asperity heights over a wide range of lambda ratio (ratio of lubricant film thickness, separating two contacting surfaces, to their combined RMS roughnesses). Subsequently, the behaviour of film distribution for a range of mixed rolling–sliding conditions is also studied for both thin and thick film conditions. This study provides an estimate of how and when transverse asperities decompress and an indication of conditions under which these asperities cease to affect lubricant film formation.     

Lubrication properties of non-adsorbing polymer solutions in soft elastohydrodynamic (EHD) contacts

The in-use performance and processing of many consumer products in the food, home and personal care industries are dependent on their tribological properties. A major component of these products is often a high molecular weight polymer, which is typically used to thicken aqueous systems. Polymer solutions tend to be non-Newtonian, and in particular their viscosity varies with shear rate, such that it is difficult to predict their friction or hydrodynamic film-forming behaviour. The present work relates the tribology of aqueous polymer solutions to their rheological properties in thin films in ‘soft’ contacts at high shear rates. The friction properties of three types of polymers in aqueous solution, polyethylene oxide, PEO; xanthan gum, XG; and guar gum, GG, have been studied as a function of polymer concentration over a wide range of entrainment speeds in a point contact formed between silicone rubber and steel. This has enabled the boundary lubrication and isoviscous-elastic lubrication properties of the solutions to be investigated using both hydrophilic and hydrophobic silicone surfaces.It is found that the friction vs. entrainment speed dependence follows the shape of a classical Stribeck curve. In general, a lower friction is observed with increasing polymer concentration in the mixed-regime. Using scaling factors for the entrainment speed, we have shown that this decrease in friction is likely to be due to viscous effects and that the scaling factors represent effective high shear rate viscosities. In the case of PEO and XG, and GG at low concentrations, a good correlation is found between this effective viscosity and the apparent viscosity measured at the highest shear rates attainable with the available rheometer. However, for GG at concentrations above 0.2%, the effective viscosity decreases with increasing polymer content.The three polymers do not significantly reduce friction in the boundary regime and in general give essentially the same response as water when an effective viscosity is taken into account. However, a slight increase in friction in comparison to pure water has been observed for XG and GG on hydrophobic surfaces. It is suspected that this may be due to a blocking of fluid entrainment, or possibly exclusion of polymer from the contact, due to the large hydrodynamic volume and rigid nature of the two biopolymers. Finally, for PEO solutions with full-film elastohydrodynamic conditions were reached, the measured friction coefficient of the film correlated quite well with the value calculated from the effective viscosity.     

The Influence of Surface Roughness on the Lubrication Properties of Adsorbing and Non-Adsorbing Biopolymers

The lubrication properties of a glycoprotein (pig gastric mucin or PGM) and a high-molecular-weight hydrosoluble polymer (guar gum) have been studied. Friction has been measured over a wide range of entrainment speeds and Stribeck curves have been obtained spanning the boundary, mixed and hydrodynamic lubrication regimes. The adsorption properties of the polymers have also been assessed using evanescent wave spectroscopy. The results show that the polymer that adsorbs on solid surfaces is able to reduce friction in the boundary lubrication regime (PGM). Guar, which does not adsorb on surfaces, shows high friction in boundary lubrication but still promotes the onset of mixed lubrication; thus friction starts to fall from its boundary values at low speeds. These results can be explained in classical terms of entrainment of polymer solution into the thin film conjunction and associated shear thinning in the contact inlet. With roughened surfaces, a shift of the Stribeck curves towards high speed is observed.     

Thin lubricating films behaviour at very high contact pressure

Thin film colorimetric interferometry has been used to examine the behaviour of thin elastohydrodynamic (EHD) lubricant films under very high contact pressures of the order of 0.5–3 GPa. It has been shown that at moderate pressures, the variation of film thickness with speed follows the Hamrock and Dowson prediction down to one nanometer. As the load is increased, however, thin films behave differently from the prediction of the conventional EHD theory. For a certain lubricant and operational conditions, there is a critical rolling speed below which a reduction of film thickness is observed. This behaviour is very similar to that previously predicted computationally by Zhu.     

Lubricating film thickness measurements with bovine serum

Lubricant film thickness measurements were made for bovine serum solutions under steady state rolling and sliding. The effect of low (30 MPa) and high contact pressures (200 MPa) was examined. In the high pressure rolling tests BS initially formed films 5-50 nm thick over the speed range. However, in subsequent speed sweeps, a relatively speed independent film of 40-50 nm developed. In some cases thick (up to 100 nm) films were formed at low speeds; this behaviour was considered representative of high-viscosity surface layers rather than of solid films. At the end of each test residual boundary films of 9-19 nm were measured under static loading. These are attributed to the multilayer adsorption of protein molecules and will provide surface protection during stance or on initiation of gait. The results at low pressure showed that much thicker films (∼60-80 nm) were formed over the same speed range. Again thicker films were formed at the lower speeds. There was significant scatter in the film thickness results, possibly due to the inherent nature of the fluid, which is an inhomogeneous biological solution. The film thickness/speed behaviour was not representative of a simple Newtonian fluid and this has considerable implications for the development of predictive film thickness models and new designs of artificial hip joints.     

Influence of ionic strength on the tribological properties of pre-adsorbed salivary films

We have studied tribological properties of pre-adsorbed salivary films formed in vitro on compliant hydrophobic surfaces. The adsorbed salivary film significantly decreases boundary friction under physiological ionic strength, which is related to a hydrophilic character of the adsorbed film and its structure. Decrease in the ionic strength below physiological conditions affects film’s structure, but it does not significantly affect boundary lubrication at low loads. Applications of high loads led to a gradual loss of lubrication due to shear-induced wear of the films. The wear became more extensive as the ionic strength of the solvent was lowered below physiological conditions.     

Measurements of friction in strip drawing under thin film lubrication

Strip drawing is used to investigate the friction behaviour under thin film lubrication in metal forming with plastic deformation. Friction coefficients are measured under a wide range of tribological conditions. The surface roughness is measured on an interferometric profilometer. The results show that the friction coefficient decreases with increasing oil film thickness h_w, as estimated using a formula appropriate for smooth tool and workpiece. Measurements of the surface topography show that change in friction is associated with a change in contact ratio between the tool and strip. The effect of strip reduction, strip roughness and die roughness on the friction coefficient is also investigated.     

Effect of mechanical shear on the thin‐film properties of base oil‐polymer mixtures

The thickness and frictional characteristics of thin lubricant films are known to affect the fuel economy properties of oils. The base oil and polymer compositions of the lubricant are generally considered to be critical chemical factors that can influence these thin‐film lubricant properties in new oils. However, it is important to produce lubricants with good fuel economy properties that are maintained after the lubricant is degraded. Lubricants in use can undergo oxidation and mechanical shear degradation. The effect of oxidation degradation on thin‐film physical properties has previously been studied. This paper investigates the effect of mechanical shearing on thin‐film properties. Dispersant olefin copolymers are found to reduce thin‐film friction in simple mixtures and in fully formulated oils. In simple mixtures, shearing the dispersant olefin copolymers does not affect the friction‐reducing ability of these polymers. In fully formulated oils, even though shearing diminishes to a degree the friction‐reducing ability of dispersant olefin copolymers, these copolymers can still provide significant friction reduction.     

Influence of surface roughness features on mixed‐film lubrication

An optical technique (three‐dimensional spacer layer imaging) has been developed to map accurately lubricant film thickness in thin‐film elastohydrodynamic (EHD) contacts. This experimental technique has been used to study the influence of surface roughness features, asperity height, and slope on EHD film thickness and pressure. Single ridges transverse to the entrainment direction were used to represent asperities. It was found that the ridges with lower slopes generate films of greater minimum thickness. Below a certain entrainment speed, the minimum film thickness declined at a rate dependent on the ridge slope. At low speeds, the ridges with higher slopes entrapped a larger volume of lubricant ahead of the ridge and along the entrainment direction. For all speeds, the highest ridges entrapped the most lubricant. Both ridge slope and ridge height had a negligible effect on mean film thickness in the contact. Asperity pressure increased with higher ridge slope, but was not influenced by entrainment speed. An increase in pressure was found where lubricant is entrapped upstream of a ridge.     

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.     

Friction of Poly(n-Alkyl Methacrylates)

The friction coefficient of solid poly(n-alkyl methacrylates) decreases progressively with increasing length of the alkyl group. This behavior parallels the behavior of adsorbed films of these polymers from solution on solid surfaces. Durability of thin films of these polymers (approximately 3,500 Å thick) increases with increasing length of alkyl group. For example, when the alkyl is C₂₂ the durability is four times greater than when the alkyl is C₁₂ (polymer film on a 1020 steel substrate). The film durability is strongly substrate dependent, e.g., durability of poly(n-dodecyl methacrylale) is three times greater on glass than on 1020 steel when rubbed with a 440 C rider. The friction and durability are attributed to side chain crystallinity of the polymer. Side chain crystallinity has been observed by others using x-ray and other techniques when the alkyl group is at least 10 or 12 carbons long. Friction measurements may be a more sensitive way of detecting side chain crystallinity. The friction behavior of adsorbed films from solution of the poly(n-alkyl methacrylates) suggests that side chain crystallinity also pertains to suck adsorbed films.     

Oscillations induced in EHD film thickness by a step in entrainment speed

Transient elastohydrodynamic (EHD) lubrication conditions occur in the contacts of many machine elements, such as gears, cams, and reciprocating devices, as a result of their working cycles. These conditions also occur in rolling‐element bearings at the onset or cessation of motion. The aspect of film thickness in elastohydrodynamically lubricated contacts subjected to a very rapid change in entrainment speed has not received much attention from researchers, probably because it is seen as less problematic than a sudden fall of the entrainment speed, which theoretically can lead to film failure. For a sudden stop, however, it has been shown previously that the lubricant forms an entrapment, which is able to protect the contact in many cases when the motion resumes. In this paper, EHD film behaviour under sudden acceleration is investigated; the study covers three cases ‐ starting from zero film, starting from an entrapped film, and starting from a continuous, steady film.     

The Formation of Viscous Surface Films by Polymer Solutions: Boundary or Elastohydrodynamic Lubrication?

The film-forming properties of a range of polymer solutions have been studied down to very thin film thickness using ultrathin film interferometry.

It has been found that, at very slow rolling speeds, some polymers generate much thicker films than predicted from theory. It appears that these polymers form adsorbed layers between three and 15 nanometers thick on the two solid surfaces. These layers have a viscosity many times higher than that of the bulk solution. Therefore, under slow speed, low film thickness conditions, the contact effectively operates within a viscous boundary layer, generating an elastohydrodynamic-type film much thicker than predicted from the viscosity of the bulk lubricant. As the speed is raised the contact emerges from this boundary layer and reverts to elastohydrodynamic behavior based upon the viscosity of the bulk polymer solution.     

The Frictional Properties of Newtonian Fluids in Rolling–Sliding soft-EHL Contact

A combined experimental and numerical study has been carried out to explore friction in rolling–sliding, soft-EHL contact. Experimental work has employed corn syrup solutions of different concentrations in water to provide a range of lubricant viscosities and has measured Couette friction in mixed rolling–sliding conditions over a wide range of entrainment speeds. A Stribeck curve has been generated, ranging from the boundary to full film, isoviscous-elastic lubrication regime. In the latter regime, friction coefficient is approximately proportional to the product of (entrainment speed × viscosity) raised to the power 0.55. Numerical solution of the isoviscous-elastic lubrication regime has been used to derive predictive equations for both Couette and Poiseuille friction in circular, soft-EHL contacts. This shows that in soft-EHL the Poiseuille or “rolling” friction can have magnitude comparable to the Couette friction. The calculated Poiseuille friction coefficient can be predicted from non-dimensional load and speed using a simple power law expression similar to that used for film thickness. However accurate prediction of calculated Couette friction coefficient requires a two-term power law expression. Comparison of experimental and numerical Couette friction coefficients shows quite good agreement between the two, with a similar non-dimensional speed dependence, but slightly lower predicted than measured values.     

基于Carreau流变模型的圆柱滚子轴承热混合润滑分析*

为了研究圆柱滚子轴承接触区的混合润滑性能,建立基于Carreau非牛顿流体的热混合润滑模型,求解非牛顿流体线接触热混合润滑数值解。研究滑滚比、卷吸速度及载荷对线接触混合润滑特性的影响,并与相同工况下牛顿流体热混合润滑的结果进行对比。结果表明：随着滑滚比、卷吸速度及载荷的增大,油膜温度都会升高,Carreau非牛顿流体的温度要低于牛顿流体的温度;油膜厚度随着滑滚比、载荷的增大而减小,随着卷吸速度的增大而增大,Carreau非牛顿流体与牛顿流体膜厚相差不大;随着滑滚比的增大,2种流体的平均摩擦因数均增大,随着卷吸速度和载荷的增大,2种流体的载荷比均减小。     

Film Forming Behavior of Greases Under Starved and Fully Flooded EHL Conditions

Improving knowledge on the film forming behavior of greases is essential to be able to develop efficient greases. This article examines how operating conditions (e.g., temperature, lubrication condition [fully flooded/starved]) and base oil viscosity influence the film forming properties of greases by comparing the behavior of two lithium-based greases and their respective base oils in rolling point contact. It is found that the onset and degree of starvation is controlled by speed (u) × viscosity (ν)/load (W) factor (uν/W) and temperature and that low uν/W values promote entrainment of thickener into contact. Thus, grease with low base oil viscosity shows significant thickener entrainment in the low speed region compared to the one with high base oil viscosity, which leads to the formation of thickener-rich viscous material during extended running with the low base oil viscosity grease. The results suggest that the shape of the film thickness versus speed curve is viscosity and uν/W range dependent. Furthermore, for the test conditions used in this study, grease-lubricated contacts appear to shift from the initial fully flooded condition to starved condition over a prolonged running of 2 h. The results from this study concur with those reported in the literature that fully flooded oil elastohydrodynamic lubrication (EHL) theory or film thickness cannot be directly applied or taken as a guideline in grease-lubricated contacts.     

The Design of Boundary Film-Forming PMA Viscosity Modifiers

Previous research has shown that some viscosity modifier additives are able to adsorb from oil solution on to metal surfaces to produce thick, viscous boundary films. These films enhance lubricant film formation in slow-speed and high temperature conditions and thus produce a significant reduction in friction. This article describes a systematic study of this phenomenon, which makes use of the versatile nature of polymethacrylate (PMA) chemistry. Dispersant polymethacrylates with a range of different functionalities, molecular weights, and architectures have been synthesized using controlled radical polymerization techniques. The influence of each of these features on boundary film formation and friction has been explored using optical interferometry and friction versus speed measurement. From the results, guidelines have been developed for designing PMAs having optimal boundary lubricating and, thus, friction-reducing properties.     

Si3N4 as a biomaterial and its tribo‐characterization under water lubrication

Hip implant wear is recognised as the main cause of hip implant failure therefore has been widely investigated both experimentally and clinically, demonstrating the coexistence of abrasive, adhesive, fatigue and corrosive wear. Many clinical in vivo and bulk material wear rate data from published literature have been presented for non‐oxide ceramic implants. Several studies have shown that the coefficient of friction of self‐mated silicon nitride in water decreases from an initially high value to about 0.002 after a certain run‐in period. Since the worn surfaces become extremely smooth, the low friction is attributed to the initiation of hydrodynamic lubrication by a thin water film at the interface. The possibility of mixed lubrication, i.e. hydrodynamic lubrication by water and boundary lubrication due to the presence of colloidal silica on the wearing surfaces, has also been proposed. Influence of load, speed and surface roughness on the duration of the run‐in period of silicon nitride under water lubrication was investigated in this study. The results confirmed that a low coefficient of friction is obtained following a run‐in period when a wear scar of sufficient size is developed to reduce the contact stress. The run‐in period, during which the coefficient of friction is fairly high, is shorter for smoother surfaces and at higher loads and speeds. The striations that appeared to be associated with the high‐friction spikes can be formed as a result of surface film breakdown. Although the results are consistent with the proposed mechanisms of hydrodynamic lubrication or mixed lubrication, it is proposed that the low‐friction behaviour may also be related to fundamental interactions between two hard and elastically deforming surfaces covered with hydrogen‐terminated oxide films. Copyright © 2016 John Wiley & Sons, Ltd.