Influence of surface roughness on friction and scuffing behaviour of cast iron under sparse lubrication

Friction and scuffing behaviour of grey cast iron as influenced by the surface roughness under sparse lubrication conditions is studied. The studies are carried out on a three-shoe-on-disc machine under the conditions of parallel sliding. The experiments were conducted at three oil supply rates of 0.10, 0.22 and 0.36 μg/cm² per contact obtained through a mist oiling system and with specimens of cast iron shoes of different roughness values, Ra, between 0.04 and 2.0 μm against a 0.55% C steel disc. In a step load procedure, the friction torque at the end of each load step and the scuffing load are the major parameters measured. Results of friction and scuffing behaviour as a function of roughness and oil supply rates have been discussed.     

Reduction of Friction by Functionalised Viscosity Index Improvers

A range of functionalised polymethacrylate copolymers have been synthesised with different functionalities, polymer architecture and molecular weight. It is shown that appropriately functionalised block copolymers give enhanced film thickness and greatly reduced friction under low entrainment speed conditions, even with polymer concentration as low as 1% wt. This behaviour almost certainly results from the formation of an adsorbed brush-like film of thickness ca 20 nm on each polar surface. These films provide a highly viscous inlet that promotes fluid entrainment and thus maintains a separating film down to very low entrainment speed. The adsorbed polymer films are also able to maintain separation in stationary contact conditions. Randomly distributed copolymers do not show this type of behaviour. The friction reduction observed is more effective in unidirectional, mixed sliding–rolling than in reciprocating, sliding conditions. However, it is found that functionalised polymers and conventional organic and molybdenum-based friction modifiers can be combined to provide effective friction reduction over the whole range of rubbing conditions.     

Controlled microtribology of a metal oxide surface

The rational control of the friction and wear (damage) of engineering, as opposed to model, surfaces under practical conditions such as high contact pressures has long been a technological challenge with much fundamental interest. Lubricant fluids and physisorbed surfactant monolayers (boundary lubricants) are effective friction modifiers but often fail at high loads. We show that the chemisorption of a suitably designed single-chained phosphonate surfactant onto crystalline α-alumina surfaces produces robust protective monolayers that significantly reduce the friction forces and wear even at high loads. The mechanisms are explained, which point to some general principles that offer a basis for scale-up in many different engineering systems. This revised version was published online in June 2006 with corrections to the Cover Date.     

A parallel computing application of the genetic algorithm for lubrication optimization

This study investigated the performance of parallel optimization by means of a genetic algorithm (GA) for lubrication analysis. An air-bearing design was used as the illustrated example and the parallel computation was conducted in a single system image (SSI) cluster, a system of loosely network-connected desktop computers. The main advantages of using GAs as optimization tools are for multi-objective optimization, and high probability of achieving global optimum in a complex problem. To prevent a premature convergence in the early stage of evolution for multi-objective optimization, the Pareto optimality was used as an effective criterion in offspring selections. Since the execution of the genetic algorithm (GA) in search of optimum is population-based, the computations can be performed in parallel. In the cases of uneven computational loads a simple dynamic load-balancing scheme is proposed for optimizing the parallel efficiency. It is demonstrated that the huge amount of computing demand of the GA for complex multi-objective optimization problems can be effectively dealt with by parallel computing in an SSI cluster.     

Effects of lubricant additives on the performance of hydrodynamically lubricated journal bearings

A non-Newtonian rheological model to investigate theoretically the effects of lubricant additives on the steady state performance of hydrodynamically lubricated finite journal bearings is introduced. In this model, the non-Newtonian behavior resulting from blending the lubricant with polymer additives is simulated by Stokes couple stress fluid model. The formed boundary layer at the bearing surface is described through the use of a hypothetical porous medium layer that adheres to the bearing surface. The Brinkman-extended Darcy equations are utilized to model the flow in the porous region. A stress jump boundary condition is applied at the porous media/fluid film interface. A modified form of the Reynolds equation is derived and solved numerically using a finite difference scheme. The effects of bearing geometry, and non-Newtonian behavior of the lubricant on the steady-state performance characteristics such as pressure distribution, load carrying capacity, side leakage flow, and coefficient of friction are presented and discussed. The results showed that lubricant additives significantly increase the load carrying capacity and reduce both the coefficient of friction and the side leakage as compared to the Newtonian lubricants.     

Determination of load carrying ability of chemical films developed in sliding point contact

It has already been known for many years that the use of some extreme-pressure (EP), antiwear or friction modifier (FM) additives in mineral oils can produce different kind of boundary or chemical reaction films on sliding contact surfaces of some kinds of steel in boundary lubrication conditions. Using a sliding ball-on-disc configuration lubricated with some kinds of EP or FM, the wear scars on the balls can always reach the same limit size at a specified applied load and sliding velocity. From the fact that the limit sizes of wear scars decrease as sliding speed is increased or applied load is decreased, the load carrying ability of a chemical film can be obtained by extrapolating the data to the condition of zero sliding speed and is so defined that if the contact pressure is greater than this load carrying ability, the contact surfaces will continuously be worn; if the contact pressure is smaller than it, no more wear will occur on the surfaces. Based on this load carrying ability, the hydrodynamic effect of sliding pairs can also be identified. Therefore, the limit size of wear scar at specified sliding speed and applied load can also be predicted in a mixed lubrication condition.     

高速轴承缺油(脂)润滑的分析和预测

本文从摩擦学-接触润滑出发，通过理论和实验分析，论述了微型轴承润滑机理、成膜能力、缺油开始速度以及影响因素，并且提出相应的防止缺油的对策。     

Molecular basis of lubrication

The advent of micro-electromechanical devices (MEMs), sensors, actuators, microsystems, and nanotechnology have called to attention the effect of friction on moving parts in nano/micro devices. To take full advantage of the opportunity to sense, compute, and actuate in real time, fast-moving parts are often necessary or desirable. As the scales of the components shrink, adhesion, stiction, friction, and wear become a significant technological barrier for the successful deployment of durable devices. Most current devices in production avoid such contacts.The nature of the surface contacts, as component scale moves from macro to micro to nano, is dominated by surface forces that normally are dwarfed by mechanical loading. Therefore nanolubrication needs to take into account different factors than conventional lubrication concepts. This paper compares traditional lubrication concepts and those necessary for nanolubrication and proposes various nanometer scale thick lubricating film designs as a means to control the surface properties of surfaces at nano/micro scales.Many of the concepts derive their origin from studies and observations from the magnetic hard disk technology where a “monolayer” of lubricant protects the system and has proven to be robust and safe. Examples from magnetic hard disks will be used to illustrate some of the concepts.     

The Boundary Lubrication Properties of Model Esters

The friction of three chemically distinct esters was measured in order to determine how molecular architecture influences friction. The friction coefficients of mica surfaces separated by a thin film (<2 nm) of -chlorodecyl benzoate, -chlorodecyl pentafluoro benzoate, and -chlorodecyl perfluoro hexanoate were measured to be 0.15±0.015, 0.13±0.012, and 0.12±0.02, respectively. The friction coefficients for the esters are lower than the previously measured friction coefficients of simple hydrocarbon liquids such as n-tetradecane (=0.8), but are comparable to the friction coefficients of surfactant monolayer coated surfaces (=0.001–0.2). The results suggest that the ester molecules adsorb onto the mica surface with the (phenyl or hexyl) carbonyl next to the surface and the hydrocarbon tail pointing away from the surface. Hence, the friction is controlled by the packing density and properties of the hydrocarbon tail. Changes in the chemistry and structure of the carboxylic acid portion of the ester only give rise to small changes in the friction coefficient.