点接触润滑状态转化的实验观察

利用球-盘接触润滑油膜厚度的光干涉测量法,通过卷吸速度或载荷的改变实验研究了弹性流体动力润滑与流体动力润滑转化过程中油膜厚度的变化规律。实验结果显示这2种润滑状态之间存在明显的过渡区。与已有的理论一致,在弹性流体动力润滑区和流体动力润滑区,油膜厚度与卷吸速度或载荷在对数坐标中呈直线关系。在两者的过渡区,固体表面的弹性变形量随卷吸速度或载荷的变化发生明显的变化,油膜厚度与速度或载荷的关系不再为对数坐标中简单的线性关系。使用已有的润滑状态区理论不能得到实验观测到的润滑状态的转化过渡区。     

Film Formation by Colloidal Overbased Detergents in Lubricated Contacts

It has been reported in the literature that overbased detergents can possess good antifriction and antiwear properties although the origins of these properties are not fully clear. In practice, over-based detergents are colloidal dispersions and this may be important in determining their properties and mechanism of action.

In the current study, the lubricating properties of commercial, overbased magnesium and calcium sulfonates were measured in thin film, lubricated conditions and compared to a neutral sulfonate additive. A range of techniques was employed to evaluate the tribological performance of solutions of these additives. Film thickness measurements were carried out using optical interferometry and in-contact visualization, while friction and wear measurements complemented the study.

It has been found that, when operating in thin film conditions, overbased detergents deposit solid-like boundary films on the rubbing surfaces. These films form in both rolling and mixed rolling/sliding conditions and, unlike many other colloidally-formed boundary films, are able to survive in high speed, thick film conditions. During formation, the film rapidly reaches a thickness corresponding to one colloid particle diameter, between 10 and 20 nm. After prolonged rubbing, however, the film thickness reaches the equivalent of three particle diameters. No such thick boundary films are observed with the neutral sulfonate.

The boundary films formed by overbased detergents produce a significant reduction in wear. However, for the very smooth surfaces used in this study, they also result in an effective roughening of the very smooth surfaces studied. This leads to an increase in friction in the intermediate speed region by promoting solid-solid contact in thin fluid film conditions.     

Traction of Lubricated Rolling Contacts between Thin-Film Coatings and Steel

Tribological thin-film coatings can enhance the performance of mechanical components such as bearings and gears. Although a lubricant is present in most applications, the interactions of the lubricant with the coated surfaces are not always well understood. In the present study, Stribeck curves (i.e., traction coefficient vs. dimensionless film thickness λ) were generated for lubricated rolling contact between coated and uncoated surfaces. Chromium nitride, tungsten carbide–reinforced amorphous hydrocarbon, and silicon-incorporated diamond-like carbon coatings were evaluated. Compositions, hydrogen concentrations, Raman spectra, and surface energies are reported for the films. A ball-on-flat test configuration was used in 5%, 50%, and 100% slide-to-roll conditions. The test lubricant was a polyalphaolefin containing rust and oxidation inhibitor additives only. Differences in traction performance were observed for different coating types. Traction coefficients decreased at high λ with increased hydrocarbon content in the coating. Coating micro-texture and composition were believed to influence traction as λ became small.     

Elastohydrodynamic Lubrication of Circular Contacts at Impact Loading with Generalized Newtonian Lubricants

In this article, pure squeeze elastohydrodynamic lubrication (EHL) motion of circular contacts with power law model lubricant is explored at impact loading. The coupled transient modified Reynolds, the elasticity deformation, and the ball motion equations are solved simultaneously, thus obtaining the transient pressure profiles, film shapes, normal squeeze velocities, and accelerations. The simulation results reveal that the greater the flow index (n), the earlier the pressure spike and the dimple form, while the maximum pressure and the film thickness increase, and the diameter of the dimple, the maximum value of the impact force, the rebounding velocity, and the acceleration decrease. Further, this analysis numerically demonstrates that the contact central pressure for a ball impacting and rebounding from a lubricated surface reached two peaks during the total impact period. As the flow index increases, the primary and the secondary peak increase, and the first and second peaks form earlier; as the total impact time decreases. Moreover, the phase shift between the time of the peak value of the squeeze acceleration and the zero value of the squeeze velocity increase with increasing flow index.     

Solid Film Deposition and Non-Sacrificial Boundary Lubrication

This paper reports the results of studying various approaches in non-sacrificial boundary lubrication in which the deposition of a beneficial surface layer is the result of a chemical reaction involving one or more components in the lubricating fluid but not the metal surface itself. This is in contrast to the conventional approach which involves the rubbing surfaces as reactants with the components in the lubricant and usually promotes wear as the result of chemical change of the surfaces. The most interesting findings show that a reaction between a molybdenum complex and a mixture of zinc dialkylphosphorodithioates produced in situ deposition of MoS₂ and some other unidentified crystalline material. Effective reductions in friction and wear were obtained. Electron diffraction patterns of the worn metal surface established the presence of MoS₂.     

In Situ Pressure and Film Thickness Measurements in Rolling/Sliding Lubricated Point Contacts

The physical conditions—pressure, temperature, shear stress—generated in an elastohydrodynamic contact govern the rheological behavior of the lubricant within the contact, and thus its tribological performance.This paper presents in situ measurements of pressure and film thickness in EHD point contacts using respectively Raman microspectrometry and differential colorimetric interferometry. A model lubricant—a polyphenylether oil (5P4E)—is used. The influence of load, temperature and sliding speed at different mean entrainment speeds on pressure and film thickness distributions is investigated. The analysis is based upon the relative values taken by the Moes dimensionless parameters M and L. In all cases, the pressure peak tends to increase and to move towards the center of the contact when the slide to roll ratio increases. When the sliding speed reaches large values (100 to 180%), several cases are encountered: When M > L, the pressure peak softens and moves towards the outlet; The Petrusevich peak disappears and the pressure profile remains almost constant as M and L are close to each other; When M < L, the peak disappears along with a strong modification of the pressure distribution. The maximum value is significantly reduced and the area of contact increases.Measured film thickness profiles confirm these tendencies. Increasing the slide to roll ratio leads to an important film thickness reduction and modifies the position of the constriction. Furthermore, film increase localized between the contact center and the constriction region is observed. This indicates the presence of important thermal effects within the contact and is discussed in the light of recently published papers.     

Boundary Layer Behaviour in Circular EHL Contacts in the Elastic-Piezoviscous Regime

The solution of elastohydrodynamically lubricated contacts at high loads and/or low speeds can be described as a Hertzian pressure with inlet and outlet boundary layers: zones where significant pressure flow occurs. For the soft lubrication regime (elastic-isoviscous), a self-similar solution exists in the boundary layers satisfying localized equations. In this paper, the boundary layer behaviour in the elastic-piezoviscous regime is investigated. The lengthscale of the boundary layers and the scaling of pressure and film thickness are expressed in non-dimensional parameters. The boundary layer width scales as \(1/\sqrt{M}\) (equivalent to \({\bar{\lambda }}^{3/8}\) ), the maximum pressure difference relative to the Hertzian solution as \(1 / \root 3 \of {M}\) (equivalent to \({\bar{\lambda }}^{1/4}\) ) and the film thickness as \(1/\root 16 \of {M}\) (equivalent to \({\bar{\lambda }}^{3/64}\) ) with \(M\) the Moes non-dimensional load and \({\bar{\lambda }}\) a dimensionless speed parameter. The Moes dimensionless lubricant parameter \(L\) was fixed. These scalings differ from the isoviscous-elastic (soft lubrication) regime. With increasing load (decreasing speed), the solution exhibits an increasing degree of rotational symmetry. The pressure varies less than 10 % over an angle less than 45 degrees from the lubricant entrainment direction. The results provide additional fundamental understanding of the nature of elastohydrodynamic lubrication and give physical rationale to the finding of roughness deformation depending on the “inlet length”. The findings may contribute to more efficient numerical solutions and to improved semi-analytical prediction methods for engineering based on physically correct asymptotic behaviour.     

The Slow-Speed Wear Behavior of Case-Carburized Gears Lubricated with NLGI 00 Grease under Boundary Lubrication Conditions

NLGI 00 greases are often used to lubricate gears running at low pitch line velocities, such as, for example, in large open gear drives. At low pitch line velocities, sliding wear, which under these operating conditions is referred to as slow speed wear, is often the limiting factor to gear lifetime. A thorough knowledge of the effect of different grease components on the wear behavior is therefore important when selecting a grease to effectively reduce gear wear in a given gear drive. In order to systematically investigate and analyze the influence of different grease components on the slow-speed wear behavior of case-carburized gears, systematic gear tests using the Gear Research Center's (FZG) back-to-back gear test rig were conducted. Primarily, the focus of the experimental investigations is on the influence of the base oil viscosity and type, the additive type, and also the type of soap thickener on the gear wear behavior at low pitch line velocities. To experimentally determine the influence of these different grease components on the wear behavior of case-carburized gears, a modified, more stringent wear test, based on the standard DGMK slow-speed wear test for gear oils, was developed. Different NLGI 00 greases with base oil viscosities between ν₄₀ = 70 and 1,200 mm²/s were investigated.

Base oil type and base oil viscosity were shown to have only a minor effect on the wear behavior under boundary lubrication conditions. On the other hand, the thickener type and especially the additive type play an important role in determining the wear behavior.     

Porosity Effect of Sintered Steel on the Frictional Performance of Conformal and Nonconformal Lubricated Contacts

Abstract

The effect of surface topography on lubricated systems plays a crucial role in terms of friction performance, because surface micro-irregularities can improve the load-carrying capacity of mechanical parts in lubricated conformal and nonconformal contacts. Sintered materials, which can be applied to manufacturing several mechanical components such as gears, axial thrust bearings, and disc brake pads, are interesting candidates, because they present pores that could be somewhat compared to microcavities produced by surface texturing techniques. This work aims at studying the influence of surface pores originated from the sintering process on the frictional performance of lubricated contacts under different lubrication regimes and slide-to-roll ratios (SRR). The research contributes to understanding how random micro-irregularities could change lubrication conditions and promote effects similar to those of more expensive and precise surface features produced by texturing techniques. The experimental results showed that a decrease in porosity led to a reduction in the coefficient of friction. Furthermore, less porous samples promoted friction reduction compared to nonporous materials due to the probable additional load support caused by small-scale surface pores. Therefore, in addition to the traditional appeal of the use of sintered materials to reduce production costs, the present contribution reveals that this type of material could also be used to reduce friction in contacting mechanical components operating under certain tribological conditions.     

Tribological Behavior of Self-mated Ti3SiC2 in Short-Chain n-Alcohols,Glycol and Glycerol under Boundary Lubrication

The tribological behavior of self-mated Ti₃SiC₂ in bath of alcohols are investigated at sliding velocity ranging from 0.005 to 0.3 m/s. The results show that the friction coefficient and wear rates of self-mated Ti₃SiC₂ are reduced greatly under lubrication of alcohols compared to that under dry condition. In alcohols, smooth worn surfaces of Ti₃SiC₂ can be obtained. The mechanical wear is inhibited and the oxidized Ti and Si species on the worn surface are TiO₂ and silica gel. The friction coefficients decrease with carbon numbers and sliding velocity in the n-alcohols. The friction coefficient decrease with sliding velocity in glycol and glycerol as well. The decrease is determined by the increase of the viscosity of alcohols. In glycerol, at 0.1 m/s and 5 N, the friction coefficient of self-mated Ti₃SiC₂ is 0.08 which is the lowest in this paper. The lubrication regimes are calculated according to classical lubrication theory. At velocity from 0.005 to 0.3 m/s, in all of the alcohols except glycerol, the λ are below 1 which indicates that the lubrication regime is BL. While in glycerol, the lubrication regimes vary from BL to BL and EHL, then to EHL as the velocity increases.     

A New Method for Measuring the Film Thickness of Mixed Lubrication in Line Contacts

In the present paper, an optical method, called frustrated total reflection (FTR), for measuring the film thickness of mixed lubrication in line contacts is proposed. The principles of FTR are analyzed. The relationship between the reflectivity and the film thickness is derived. The measuring methods and procedures are described.     

在刀-屑界面持续润滑刀具切削45钢的性能及润滑机理

为提高刀具润滑性能,尽量减少切削液的使用,制备出在刀屑界面持续润滑的新型刀具,能够将切削液通过微通道直接输送到刀屑接触界面内部。采用该新型刀具与普通刀具在干切削和浇注切削液条件下分别进行切削45钢试验,测量了切削三向力,对刀具前刀面磨损面进行SEM微观形貌分析及元素检测,分析了刀具的摩擦磨损特性及润滑机理。试验结果表明,与普通刀具在干切削和浇注切削液条件下相比,刀屑界面持续润滑刀具能够有效减少切削过程中的摩擦磨损,而切削液用量只有传统浇注式切削的1/120。分析前刀面的元素可知,切削液能够更加深入到离主切削刃更近的区域,并能持续供给,这是该刀具具有更好的减摩抗磨效果的主要原因。尽管新型刀具的黏结情况大大缓解,但刀具的磨损机理仍然以黏结磨损和氧化磨损为主。     

A Film Thickness Correction Formula for Double-Newtonian Shear-Thinning in Rolling EHL Circular Contacts

Lubricants which contain a polymeric thickener will often display a second Newtonian plateau in measured flow curves. Like other manifestations of shear-dependent viscosity, this shear response will lead to an inaccurate prediction when the classical film-thickness formulas are employed. A correction formula has been developed from numerical experiments for a range of parameters of the double-Newtonian modified Carreau equation. The parameters of this shear-thinning model were selected from measurements for real lubricants obtained in Couette viscometers and a capillary viscometer. In addition, a full EHL film thickness formula has been derived from the same numerical experiments. The correction formula and the full formula were successfully validated using published film thickness data and published viscosity data for an EHL reference liquid, a polymer solution. Clearly, viscometer measurements of shear-dependent viscosity which contain the inflection leading to the second Newtonian are essential for a film-thickness calculation when a high-molecular-weight component of the lubricant is present.     

An In Situ Method for Simultaneous Friction Measurements and Imaging of Interfacial Tribochemical Film Growth in Lubricated Contacts

Tribological investigations of macroscopic lubricated sliding contacts are critical for a wide range of industrial applications including automotive engines, gears, bearings, and any other contacting surfaces in relative motion. However, the inability of existing techniques to access buried sliding interfaces with high spatial resolution inhibits the development of fundamental insights into the tribological processes at play. Here we demonstrate a novel and general in situ method, based on atomic force microscopy (AFM), in which micrometer-scale spherical probes are attached to a standard microfabricated AFM cantilever which is then slid over a substrate while immersed in a liquid lubricant. In this case, steel colloidal probes and steel substrates were used, and the contact was immersed in a commercial polyalphaolefin oil with zinc dialkyl dithiophosphate (ZDDP) additive at both room temperature and 100 °C, but the method can be used for a broad range of material combinations, lubricants, and temperatures. We demonstrate that the in situ measurements of friction force and the morphological evolution of the tribochemical films on the substrate can be simultaneously achieved with nanometer-level spatial resolution. In addition, we demonstrate that the sliding zone is readily accessible for further characterization with higher spatial resolution using standard AFM probes with nanometer-scale tip radii. Ex situ characterization of the micrometer-scale probe and the sample is also feasible, which is demonstrated by acquiring high-resolution AFM topographic imaging of the final state of the probe.     

Boundary Lubrication of Steel Surfaces with Borate,Phosphorus, and Sulfur Containing Lubricants at Relatively Low and Elevated Temperatures

Prolonging the life of engineering components through lubricant formulation to achieve better wear resistance and higher oxidation stability is of paramount importance to many mechanical systems, such as automotive gears and bearings. This can be accomplished with formulated lubricants that limit the generation of wear debris causing severe abrasion and protect the contacting surfaces through the formation of wear-resistant tribofilms. In this study, a ball-on-disk tribometer was used to characterize the friction and wear properties of steel surfaces slid in the boundary lubrication regime. An experimental scheme was developed to allow the statistical screening of various lubricant formulations. Sliding experiments were performed in baths of different lubricants at relatively low and elevated temperatures, approximately 32 and 100°C, respectively, under conditions of constant load and sliding speed. Surface profilometry, optical microscopy, and scanning electron microscopy were used to characterize the dominant friction and wear mechanisms. The tribological properties were found to strongly depend on the temperature and the additives (e.g., borate, phosphorus, and sulfur) present in the blended lubricants. The superior high-temperature wear performance of the lubricant with the higher borate content is indicative of the formation of a durable tribofilm that reduces metal-to-metal adhesion, material transfer, and surface plowing by wear debris.     

Improved Substrate Protection and Self-Healing of Boundary Lubrication Film Consisting of Polydimethylsiloxane with Cationic Side Groups

The substrate protection and self-healing capability of a cationic polymer lubricant (CPL) on a silicon oxide surface were tested with a pin-on-disc tribometer and atomic force microscopy (AFM). CPL was made of low molecular weight polydimethylsiloxane (PDMS) containing covalently attached quaternary ammonium cations and iodide counter-anions. CPL was spin-coated on the silicon oxide surface to form a 3–4 nm thick bound-and-mobile lubricant layer. The CPL film capable of binding to the SiO₂ surface through ionic interactions is superior in substrate protection than the neutral PDMS film which cannot form the bound layer. The mobile component in the CPL film readily flows into the lubricant-depleted sliding contact region from the surrounding film. The self-healing capability of CPL via lateral flow is slightly enhanced in humid environments due to water uptake in the film. The 3–4 nm thick CPL film on silicon oxide takes 30–40 s to flow into a ~50 μm wide track, which corresponds to an apparent spreading rate of 2–3 × 10⁻¹¹ m²/s.     

Boundary Tribological Behaviors of Untreated and Surface-Modified M50 Steel Lubricated by Fuel JP-10

To explore the possibility of using advanced surface engineering techniques (ASETs) to solve the wear problems caused by the poor lubricity of pure, low-viscosity aviation fuel JP-10, polished M50 bearing steel sample surfaces were treated with nitrogen ion implantation, TiAlN coating deposition, and Ta coating deposition followed by high current pulsed electron beam (HCPEB) irradiation, respectively. Boundary tribological behaviors of these ASET-treated and untreated steel samples sliding in pure JP-10 against a Si₃N₄ ball (ball-on-disc model) were investigated under 2.0 GPa in the atmosphere and the friction tests indicated that significant, reductions, although to different extents, in friction and wear were achieved by these modified surfaces. Simultaneously considering the tribological performance and potential pollution caused by wear debris to JP-10, HCPEB-treated Ta coating with a lowest average friction coefficient of 0.11 and a specific wear rate of around zero was the fittest to offset the inadequate lubricity of JP-10 itself under the laboratory condition.     

钢蜗轮摩擦副边界润滑状态判断及润滑油添加剂选择

使用Johnson和Hooke编制的润滑状态区域图,对实验所用的中心距为120mm钢蜗轮减速器摩擦副的润滑状态进行了计算与判断,根据润滑类型,合理选择了润滑油添加剂。     

A Dual Experimental/Numerical Approach for Film Thickness Analysis in TEHL Spinning Skewing Circular Contacts

Studies on the behaviour of rolling bearings show that the position as well as the loading of the rolling element at the flange roller-end contact depends on the momentum created on the roller track caused by local friction variability. This situation is characterized by a skew angle that varies within a limited range in the application influenced also by the clearance in the cage pockets. This paper provides some elements which contribute to increase the understanding of the physical phenomena occurring in lubricated spinning contacts under skew. An experimental investigation is carried out using a unique in-house test rig called Tribogyr, dedicated to large size-contacts with spinning and skewing kinematics. Alongside the experiments, a numerical analysis is conducted, based on a finite element approach, aiming to take into account the multiphysics aspect of this thermo-elastohydrodynamic problem. The model and the experiments show a good agreement. The skew effects on film thickness of spinning flange/roller-end contacts are characterized by a global decrease of central film thickness, mainly due to high shear of the lubricant, involving thermal thinning. The shallow dimple captured by the in situ measurements of film thickness can be explained as a consequence of the viscosity wedge due to different thermal conductivities between glass and steel. The dual experimental–theoretical approach was a useful method that help to study separate phenomena which are naturally coupled each other.