A Computer Thermal Model of Mixed Lubrication in Point Contacts

2004 ◽  
Vol 126 (1) ◽  
pp. 162-170 ◽  
Author(s):  
Wen-Zhong Wang ◽  
Yu-Chuan Liu ◽  
Hui Wang ◽  
Yuan-Zhong Hu
Keyword(s):  
Surface Temperature ◽  
Thermal Model ◽  
Reynolds Equation ◽  
Equation System ◽  
Mixed Lubrication ◽  
Successful Implementation ◽  
Asperity Contact ◽  
Point Contacts ◽  
Wide Range ◽  
Lubrication Conditions

This paper presents a transient thermal model for mixed lubrication problems in point contacts. The model deterministically calculates pressure and surface temperature by simultaneously solving a system of equations that govern the lubrication, contact and thermal behaviors of a point contact interface. The pressure distribution on the entire computation domain is obtained through solving a unified Reynolds equation system without identifying hydrodynamic or asperity contact regions. The point heat source integration method is applied to determine the temperature distributions on contact surfaces. The interactions between pressure and temperature are considered through incorporating viscosity-temperature and density-temperature relations in the Reynolds equation, then solving the equation system iteratively. With the successful implementation of an FFT-based algorithm (DC-FFT) for calculation of surface deformation and temperature rise, the numerical analysis of lubricated contact problems, which used to involve a great deal of computation, can be performed in acceptable time. The model enables us to simulate various lubrication conditions, from full film elastohydrodynamic lubrication (EHL) to boundary lubrication, for a better understanding of the effect of surface roughness. Numerical examples are analyzed and the results show that the present model can be used to predict pressure and surface temperature over a wide range of lubrication conditions, and that the solution methods are computationally efficient and robust.

scholarly journals Contact stiffness and damping of spiral bevel gears under transient mixed lubrication conditions

Friction ◽  
2021 ◽  
Author(s):  
Zongzheng Wang ◽  
Wei Pu ◽  
Xin Pei ◽  
Wei Cao
Keyword(s):  
Contact Stiffness ◽  
Mixed Lubrication ◽  
Asperity Contact ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Dry Contact ◽  
Spiral Bevel ◽  
Stiffness And Damping ◽  
Lubrication Conditions ◽  
Film Lubrication

AbstractExisting studies primarily focus on stiffness and damping under full-film lubrication or dry contact conditions. However, most lubricated transmission components operate in the mixed lubrication region, indicating that both the asperity contact and film lubrication exist on the rubbing surfaces. Herein, a novel method is proposed to evaluate the time-varying contact stiffness and damping of spiral bevel gears under transient mixed lubrication conditions. This method is sufficiently robust for addressing any mixed lubrication state regardless of the severity of the asperity contact. Based on this method, the transient mixed contact stiffness and damping of spiral bevel gears are investigated systematically. The results show a significant difference between the transient mixed contact stiffness and damping and the results from Hertz (dry) contact. In addition, the roughness significantly changes the contact stiffness and damping, indicating the importance of film lubrication and asperity contact. The transient mixed contact stiffness and damping change significantly along the meshing path from an engaging-in to an engaging-out point, and both of them are affected by the applied torque and rotational speed. In addition, the middle contact path is recommended because of its comprehensive high stiffness and damping, which maintained the stability of spiral bevel gear transmission.

A Full Numerical Solution to the Mixed Lubrication in Point Contacts

1999 ◽  
Vol 122 (1) ◽  
pp. 1-9 ◽  
Author(s):  
Yuan-Zhong Hu ◽  
Dong Zhu
Keyword(s):  
Numerical Solution ◽  
Reynolds Equation ◽  
Surface Deformation ◽  
Full Range ◽  
Computing Time ◽  
Numerical Procedure ◽  
Elastohydrodynamic Lubrication ◽  
Asperity Contact ◽  
Point Contacts ◽  
Severe Condition

A full numerical solution for the mixed elastohydrodynamic lubrication (EHL) in point contacts is presented in this paper, using a new numerical approach that is simple and robust, capable of handling three-dimensional measured engineering rough surfaces moving at different rolling and sliding velocities. The equation system and the numerical procedure are unified for a full coverage of all the lubrication regions including the full film, mixed and boundary lubrication. In the hydrodynamically lubricated areas the Reynolds equation is used. In the asperity contact areas, where the film thickness is zero, the Reynolds equation is reduced to an expression equivalent to the mathematical description of dry contact problem. In order to save computing time, a multi-level integration method is used to calculate surface deformation. Sample cases under severe condition show that this approach is capable of analyzing different cases in a full range of λ ratio, from infinitely large down to nearly zero (less than 0.03). [S0742-4787(00)00101-6]

scholarly journals Identification of a Material–Lubricant Pairing and Operating Conditions That Lead to the Failure of Porous Journal Bearing Systems

2020 ◽  
Vol 68 (4) ◽  
Author(s):  
Guido Boidi ◽  
Stefan Krenn ◽  
Stefan J. Eder
Keyword(s):  
Mixed Lubrication ◽  
Operating Conditions ◽  
Maximum Temperature ◽  
Asperity Contact ◽  
Operational Conditions ◽  
Practical Applications ◽  
Custom Made ◽  
Wide Range ◽  
Lab Test ◽  
Wear Tests

AbstractIn this study, we perform accelerated wear tests with porous journal bearings (PJBs) on a lab test rig, providing statistically reliable results under realistic operational conditions. To this end, a custom-made tribometer consisting of 5 mechanically independent but centrally controlled units was used to test five identical bearings in parallel. The test parameters were tuned to promote enough wear under mixed lubrication by increasing the clearance gap and the radial load, while minimizing the bidirectional rotational speed. A wide range of lubricant and material combinations were evaluated, the vast majority of which performed excellently (i.e., negligible wear and low friction). Only one notable combination of a low-density iron bearing paired with a standard PAO-based lubricant failed when operating at low rotational speeds, exhibiting highly unstable frictional behavior and 10–20 times the typical wear in practical applications. An analysis of Stribeck curves, recorded periodically during the wear tests as a diagnostic tool, proved that this particular combination of materials and parameters failed to run in properly, with deteriorating tribological behavior over time. A direct relation between the total wear and the maximum temperature in the tribocontact during testing helped identify this pairing as the only one operating solely under mixed lubrication (high asperity contact), explaining the excessive wear. Graphical Abstract

Modeling of Mixed Lubrication Conditions in a Heavy Duty Piston Pin Joint

2006 ◽  
Author(s):  
Vladimir Fridman ◽  
Ilya Piraner ◽  
Kent Clark
Keyword(s):  
Contact Pressure ◽  
Hydrodynamic Pressure ◽  
Mixed Lubrication ◽  
Production Test ◽  
Asperity Contact ◽  
Connecting Rod ◽  
Test Analysis ◽  
Pressure Distributions ◽  
Contact Formulation ◽  
Lubrication Conditions

A piston pin joint in a modern diesel engine operates under extreme loading and lubrication conditions. High load in combination with low relative surface velocities and limited lubrication makes this joint prone to localized wear and sudden failure. The analysis of this joint is also complicated with the pin motion, which defines surface velocities in the pin bore to pin and the pin to connecting rod interfaces. Therefore, the entire joint needs to be analyzed as a system of two bearings. Also, the hydrodynamic pressure in this joint at times may not be sufficient to balance the force applied to the joint and has to be complemented by the asperity contact pressure. The latter causes an additional deformation of the bearing. To address this problem a mixed lubrication model has been developed based on spectral EHD and nonlinear Greenwood and Trip statistical asperity contact formulation. Contact pressure distributions calculated with this model showed a pattern similar to the wear pattern in the bushing after production test. Analysis of the heat generated in the bearing was found to be a good indicator for the severity of the regime. Analysis of the bushing and piston bore with different geometry showed that asperity contact pressure and heat generated in the joint can be significantly reduced by modifications in local shape of the contacting surfaces.

A Mixed Elastohydrodynamic Lubrication Model With Asperity Contact

1999 ◽  
Vol 121 (3) ◽  
pp. 481-491 ◽  
Author(s):  
Xiaofei Jiang ◽  
D. Y. Hua ◽  
H. S. Cheng ◽  
Xiaolan Ai ◽  
Si C. Lee
Keyword(s):  
Contact Pressure ◽  
Contact Area ◽  
Rough Surfaces ◽  
Elastohydrodynamic Lubrication ◽  
Load Ratio ◽  
Mixed Lubrication ◽  
Successful Implementation ◽  
Asperity Contact ◽  
Contact Ratio ◽  
Lubrication Performance

Most machine elements, such as gears and bearings, are operated in the mixed lubrication region. To evaluate lubrication performance for these tribological components, a contact model in mixed elastohydrodynamic lubrication is presented. This model deals with the EHL problem in the very thin film region where the film is not thick enough to separate the asperity contact of rough surface. The macro contact area is then divided into the lubricated area and the micro asperity contact areas by the contacted rough surfaces. In the case when asperity to asperity contact is present, Reynolds equation is only valid in the lubricated areas. Asperity contact pressure is determined by the interaction of two mating surfaces. The applied load is carried out by the lubricant film and the contacted asperities. FFT techniques are utilized to calculate the surface displacement (forward problem) by convolution and the asperity contact pressure (inverse problem) by deconvolution for non-periodic surfaces. With the successful implementation of FFT and multigrid methods, the lubricated contact problem can be solved within hours on a PC for the grids as large as one million nodes. This capability enables us to simulate random rough surfaces in a dense mesh. The load ratio, contact area ratio and average gap are introduced to characterize the performance of mixed lubrication with asperity contacts. Discussions are given regarding the asperity orientation as well as the effect of rolling-sliding condition. Numerical results of real rough topography are illustrated with effects of velocity parameter on load ratio, contact ratio, and average gap.

Effects of Speed on Scuffing in Mixed Lubrication

1994 ◽  
Vol 208 (4) ◽  
pp. 269-279 ◽  
Author(s):  
D A Kelly ◽  
C G Barnes
Keyword(s):  
Thermal Model ◽  
Elastohydrodynamic Lubrication ◽  
Mixed Lubrication ◽  
Engineering Practice ◽  
General Criterion ◽  
Sliding Direction ◽  
Lubrication Regime ◽  
Surface Finishes ◽  
Mixed Lubrication Regime ◽  
Lubrication Conditions

Theories of failure of elastohydrodynamic lubrication are briefly reviewed, but none that relate to scuffing per se and no general criterion that accounts for the sensitivity of scuffing to rolling as well as sliding speed are found. A theoretical investigation of micro-EHL by Baglin, for surface finishes with a lay parallel to the sliding direction, predicts boundaries in the operating condition domain to a regime of mixed lubrication in which little elastic deformation of asperities by micro-EHL is expected. A new thermal model incorporating salient features of scuffing in mixed lubrication conditions is described. It is shown to give the form of a boundary in the sliding/rolling speed domain above which localized temperatures close to melting may be expected and below which lower temperatures suggest running-in without scuffing may be expected. Results of scuffing tests on circumferentially ground discs, at sliding and rolling speeds in the range 3-10 m/s, are reported and shown for surfaces with a distinguishable mainscale wavelength in their topography, (a) to provide further support for the location of the boundaries to the mixed lubrication regime in the operating domain predicted by Baglin and (b) to match the form of the thermal model in the speed domain. Implications for engineering practice are briefly discussed.

A Generalized Thermal EHL Model for Point Contact Problems

2008 ◽  
Author(s):  
Yuchuan Liu ◽  
Q. Jang Wang ◽  
Dong Zhu ◽  
Fanghui Shi
Keyword(s):  
Surface Temperature ◽  
Thermal Model ◽  
Reynolds Equation ◽  
Energy Equation ◽  
Point Contact ◽  
Elastohydrodynamic Lubrication ◽  
Contact Problems ◽  
Three Dimensions ◽  
Thermal Ehl ◽  
Generalized Reynolds Equation

A generalized thermal elastohydrodynamic lubrication (TEHL) model for point contact problems is developed based on an isothermal generalized Newtonian elastohydrodynamic (EHL) model recently developed. The thermal model couples FDM for lubricant energy equation and the DC-FFT method for surface temperature integration. A generalized Reynolds equation is derived considering the change of viscosity with respect to temperature, pressure and shear in three dimensions. Numerical cases are conducted to verify the model.

A Mixed-TEHD Model for Journal-Bearing Conformal Contacts—Part I: Model Formulation and Approximation of Heat Transfer Considering Asperity Contact

1998 ◽  
Vol 120 (2) ◽  
pp. 198-205 ◽  
Author(s):  
Fanghui Shi ◽  
Qian (Jane) Wang
Keyword(s):  
Heat Transfer ◽  
Mixed Lubrication ◽  
Integrated System ◽  
Asperity Contact ◽  
Model Formulation ◽  
Roughness Effect ◽  
Elastic Process ◽  
Numerical Process ◽  
Large Eccentricity ◽  
Lubrication Conditions

A mixed-TEHD (thermal elastohydrodynamic) model was developed for journal bearings working at large eccentricity ratios in order to facilitate a better understanding of mixed-lubrication phenomena for conformal-contact elements. The model consists of a mixed-lubrication process that considers the roughness effect and asperity contact, a thermal process for temperature analyses, and a thermal-elastic process for deformation calculations. In this model, the interactive journal, lubricant, and bearing were treated as an integrated system. Finite-element, finite-difference, and influence-function methods were utilized in the numerical process. The overall solution was achieved by the iteration method. Analyses of a simulated bearing-lubricant-journal system working under mixed-lubrication conditions were conducted, and the influence of the changes of lubricant flows as a result of the asperity contact on the system heat transfer and temperature distributions was numerically investigated.

Simulations and Measurements of Sliding Friction Between Rough Surfaces in Point Contacts: From EHL to Boundary Lubrication

2007 ◽  
Vol 129 (3) ◽  
pp. 495-501 ◽  
Author(s):  
Wen-zhong Wang ◽  
Shun Wang ◽  
Fanghui Shi ◽  
Yu-cong Wang ◽  
Hai-bo Chen ◽  
...  
Keyword(s):  
Shear Stress ◽  
Boundary Lubrication ◽  
Fluid Shear Stress ◽  
Sliding Friction ◽  
Rough Surfaces ◽  
Numerical Approach ◽  
Mixed Lubrication ◽  
Engineering Practice ◽  
Asperity Contact ◽  
Point Contacts

This paper presents a numerical approach to simulate sliding friction between engineering surfaces with 3D roughness in point contacts. The numerical approach is developed on the basis of the deterministic solutions of mixed lubrication, which is able to predict the locations where the asperity contacts occur, and the pressure distribution over both lubrication and contact areas. If the friction coefficients over the contacting asperities have been determined, total friction force between the surfaces can be calculated by summing up the two components, i.e., the boundary friction contributed by contacting asperities and the shear stress in hydrodynamic regions. The frictions from asperity contact were determined in terms of a limiting shear stress or shear strength of boundary films while the fluid shear stress in the lubrication areas was calculated using different rheology models for the lubricant, in order to find which one would be more reliable in predicting fluid tractions. The simulations covered the entire lubrication, regime, including full-film Elastohydrodynamic Lubrication (EHL), mixed lubrication, and boundary lubrication. The results, when being plotted as a function of sliding velocity, give a Stribeck-type friction curve. This provides an opportunity to study friction change during the transition of lubrication conditions and to compare friction performance on different rough surfaces, which is of great value in engineering practice. Experiments were conducted on a commercial test device—universal material tester (UMT) to measure friction at a fixed load but different sliding velocities in reciprocal or rotary motions. The results also give rise to the Stribeck friction curves for different rough surfaces, which are to be compared with the results from simulations. The samples were prepared with typical machined surfaces in different roughness heights and textures, and in point contacts with steel ball. Results show that there is a general agreement between the experiments and simulations. It is found that surface features, such as roughness amplitude and patterns, may have a significant effect on the critical speed of transition from hydrodynamic to mixed lubrication. In the regime of mixed lubrication, rougher samples would give rise to a higher friction if the operation conditions are the same.

IMPROVEMENT OF INNOVATIVE ACTIVITY OF THE ENTERPRISE

2017 ◽  
Author(s):  
Nataliya Stoyanets ◽  
◽  
Mathias Onuh Aboyi ◽  
Keyword(s):  
Value Chain ◽  
Net Present Value ◽  
Successful Implementation ◽  
Innovative Development ◽  
Technological Equipment ◽  
Alliance Partner ◽  
Innovation Potential ◽  
Wide Range ◽  
Technological Platform ◽  
The Cost

The article defines that for the successful implementation of an innovative project and the introduction of a new product into production it is necessary to use advanced technologies and modern software, which is an integral part of successful innovation by taking into account the life cycle of innovations. It is proposed to consider the general potential of the enterprise through its main components, namely: production and technological, scientific and technical, financial and economic, personnel and actual innovation potential. Base for the introduction of technological innovations LLC "ALLIANCE- PARTNER", which provides a wide range of support and consulting services, services in the employment market, tourism, insurance, translation and more. To form a model of innovative development of the enterprise, it is advisable to establish the following key aspects: the system of value creation through the model of cooperation with partners and suppliers; creating a value chain; technological platform; infrastructure, determine the cost of supply, the cost of activities for customers and for the enterprise as a whole. The system of factors of influence on formation of model of strategic innovative development of the enterprise is offered. The expediency of the cost of the complex of technological equipment, which is 6800.0 thousand UAH, is economically calculated. Given the fact that the company plans to receive funds under the program of socio-economic development of Sumy region, the evaluation of the effectiveness of the innovation project, the purchase of technological equipment, it is determined that the payback period of the project is 3 years 10 months. In terms of net present value (NPV), the project under study is profitable. The project profitability index (PI) meets the requirements for a positive decision on project implementation> 1.0. The internal rate of return of the project (IRR) also has a positive value of 22% because it exceeds the discount rate.

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