Effect of Stiff Coatings on EHL Film Thickness in Point Contacts

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
Yuchuan Liu ◽  
Q. Jane Wang ◽  
Dong Zhu
Keyword(s):  
Film Thickness ◽  
Coating Thickness ◽  
Performance Enhancement ◽  
Point Contact ◽  
Elastohydrodynamic Lubrication ◽  
Thickness Variation ◽  
Grand Challenge ◽  
Maximum Increase ◽  
Wide Range ◽  
Minimum Film Thickness

Coatings are widely used for interface performance enhancement and component life improvement, as well as for corrosion prevention and surface decoration. More and more mechanical components, especially those working under severe conditions, are coated with stiff (hard) thin coatings. However, the effects of coatings on lubrication characteristics, such as film thickness and friction, have not been well understood, and designing coating for optimal tribological performance is a grand challenge. In this paper, the influences of coating material properties and coating thickness on lubricant film thickness are investigated based on a point-contact isothermal elastohydrodynamic lubrication (EHL) model developed recently by the authors. The results present the trend of minimum film thickness variation as a function of coating thickness and elastic modulus under a wide range of working conditions. Curve fitting of numerical results indicates that the maximum increase in minimum film thickness, Imax, and the corresponding optimal dimensionless coating thickness, H2max, can be expressed in the following forms: Imax=0.769M0.0238R20.0297L0.1376exp(−0.0243ln2L) and H2max=0.049M0.4557R2−0.1722L0.7611exp(−0.0504ln2M−0.0921ln2L). These formulas can be used to estimate the effect of coatings on film thickness for EHL applications.

Effect of Stiff Coatings on EHL Film Thickness in Point Contacts

2007 ◽  
Author(s):  
Yuchuan Liu ◽  
Q. Jane Wang ◽  
Dong Zhu
Keyword(s):  
Film Thickness ◽  
Working Conditions ◽  
Coating Thickness ◽  
Point Contact ◽  
Thickness Variation ◽  
Point Contacts ◽  
Lubricant Film Thickness ◽  
Wide Range ◽  
Minimum Film Thickness ◽  
Coating Material Properties

This study investigates the influences of coating material properties and coating thickness on lubricant film thickness based on a point-contact isothermal EHL model developed recently by the authors. The results present the trend of minimum film thickness variation as a function of coating thickness and elastic modulus under a wide range of working conditions. Numerical results indicates that the increase in minimum film thickness, Imax, and the corresponding optimal dimensionless coating thickness, H2, can be expressed in the following formulas: Imax=0.766M0.0248R20.0296L0.1379exp(−0.0245ln2L)H2=0.049M0.4557R2−0.1722L0.7611exp(−0.0504ln2M−0.0921ln2L) These formulas can be used to estimate the effect of a coating on EHL film thickness.

Numerical Solution of Mixed Thermal Elastohydrodynamic Lubrication in Point Contacts With Three-Dimensional Surface Roughness

2016 ◽  
Vol 139 (1) ◽  
Author(s):  
Xiaopeng Wang ◽  
Yuchuan Liu ◽  
Dong Zhu
Keyword(s):  
Surface Roughness ◽  
Film Thickness ◽  
Three Dimensional ◽  
Point Contact ◽  
Elastohydrodynamic Lubrication ◽  
Lubricant Film ◽  
Operating Conditions ◽  
Thickness Variation ◽  
Wide Range ◽  
Film Lubrication

Elastohydrodynamic lubrication (EHL) is a common mode of fluid-film lubrication in which many machine elements operate. Its thermal behavior is an important concern especially for components working under extreme conditions such as high speeds, heavy loads, and surfaces with significant roughness. Previous thermal EHL (TEHL) studies focused only on the cases with smooth surfaces under the full-film lubrication condition. The present study intends to develop a more realistic unified TEHL model for point contact problems that is capable of simulating the entire transition of lubrication status from the full-film and mixed lubrication all the way down to boundary lubrication with real machined roughness. The model consists of the generalized Reynolds equation, elasticity equation, film thickness equation, and those for lubricant rheology in combination with the energy equation for the lubricant film and the surface temperature equations. The solution algorithms based on the improved semi-system approach have demonstrated a good ability to achieve stable solutions with fast convergence under severe operating conditions. Lubricant film thickness variation and temperature rises in the lubricant film and on the surfaces during the entire transition have been investigated. It appears that this model can be used to predict mixed TEHL characteristics in a wide range of operating conditions with or without three-dimensional (3D) surface roughness involved. Therefore, it can be employed as a useful tool in engineering analyses.

The Elastohydrodynamic Lubrication of Elliptical Point Contacts Operating in the Isoviscous Region

1995 ◽  
Vol 209 (4) ◽  
pp. 225-234 ◽  
Author(s):  
C J Hooke
Keyword(s):  
Film Thickness ◽  
Elastohydrodynamic Lubrication ◽  
Operating Conditions ◽  
Radius Ratio ◽  
Point Contacts ◽  
Reasonable Estimate ◽  
Wide Range ◽  
Minimum Film Thickness

The elastohydrodynamic lubrication of point contacts is examined and results for the minimum film thickness are presented for a wide range of radius ratios and operating conditions. The results are compared with the predictions of the appropriate regime formulae. Although these formulae give a reasonable estimate of the contact's behaviour, the actual clearances are often substantially different, particularly close to the regime boundaries. Interpolation equations for seven values of radius ratio are given and these should be sufficient to allow the minimum clearance to be estimated for most isoviscous point contacts.

Film Thickness and Asperity Load Formulas for Line-Contact Elastohydrodynamic Lubrication With Provision for Surface Roughness

2012 ◽  
Vol 134 (1) ◽  
Author(s):  
M. Masjedi ◽  
M. M. Khonsari
Keyword(s):  
Surface Roughness ◽  
Film Thickness ◽  
Reynolds Equation ◽  
Surface Deformation ◽  
Elastohydrodynamic Lubrication ◽  
Load Ratio ◽  
Material Surface ◽  
Line Contact ◽  
Wide Range ◽  
Minimum Film Thickness

Three formulas are derived for predicting the central and the minimum film thickness as well as the asperity load ratio in line-contact EHL with provision for surface roughness. These expressions are based on the simultaneous solution to the modified Reynolds equation and surface deformation with consideration of elastic, plastic and elasto-plastic deformation of the surface asperities. The formulas cover a wide range of input and they are of the form f(W, U, G, σ¯, V), where the parameters represented are dimensionless load, speed, material, surface roughness and hardness, respectively.

scholarly journals Analysis of Starvation Effects on Hydrodynamic Lubrication in Nonconforming Contacts

1982 ◽  
Vol 104 (3) ◽  
pp. 410-417 ◽  
Author(s):  
D. E. Brewe ◽  
B. J. Hamrock
Keyword(s):  
Film Thickness ◽  
Hydrodynamic Lubrication ◽  
Three Dimensional ◽  
Point Contact ◽  
Sharp Decrease ◽  
Reduction Factor ◽  
Wide Range ◽  
Minimum Film Thickness ◽  
Contour Plots ◽  
Starvation Effects

Numerical methods were used to determine the effects of lubricant starvation on the minimum film thickness under conditions of a hydrodynamic point contact. Starvation was effected by varying the fluid inlet level. The Reynolds boundary conditions were applied at the cavitation boundary and zero pressure was stipulated at the meniscus or inlet boundary. The analysis is considered valid for a range of speeds and loads for which thermal, piezoviscous, and deformation effects are negligible. It is applied to a wide range of geometries (i.e., from a ball-on-plate configuration to a ball in a conforming groove). Seventy-four cases were used to numerically determine a minimum-film-thickness equation as a function of the ratio of dimensionless load to dimensionless speed for varying degrees of starvation. From this, a film reduction factor was determined as a function of the fluid inlet level. Further, a starved fully flooded boundary was defined and an expression determining the onset of starvation was derived. As the degree of starvation was increased, the minimum film thickness decreased gradually until the fluid inlet level became critical. Reducing the fluid inlet level still further led to a sharp decrease in the minimum film thickness. An expression determining the critically starved fluid inlet level was derived. The changes in the inlet pressure buildup due to changing the available lubricant supply are presented in the form of three-dimensional isometric plots and also in the form of contour plots.

EHL Circular Contact Film Thickness Correction Factor for Shear-Thinning Fluids

2008 ◽  
Vol 130 (4) ◽  
Author(s):  
Punit Kumar ◽  
M. M. Khonsari
Keyword(s):  
Film Thickness ◽  
Correction Factor ◽  
Point Contact ◽  
Elastohydrodynamic Lubrication ◽  
Shear Thinning ◽  
Correction Factors ◽  
Shear Thinning Fluids ◽  
Pure Rolling ◽  
Wide Range ◽  
Circular Contact

An extensive set of full elastohydrodynamic lubrication point contact simulations has been used to develop correction factors to account for the effect of shear-thinning lubricant behavior on the central and minimum film thickness in circular contacts under pure rolling condition. The film thickness for a shear-thinning lubricant can be easily obtained by dividing the corresponding Newtonian film thickness by the appropriate correction factor. Comparisons of the film thickness values obtained using the correction factors have been matched with the published experimental results pertaining to shear-thinning lubricants with a variety of realistic flow and piezoviscous properties under a wide range of operating speed. The good agreement between them establishes the validity and versatility of the correction factors developed in this paper.

Non-Newtonian Elastohydrodynamic Lubrication of Point Contact

1991 ◽  
Vol 113 (4) ◽  
pp. 703-711 ◽  
Author(s):  
Kyung Hoon Kim ◽  
Farshid Sadeghi
Keyword(s):  
Film Thickness ◽  
Point Contact ◽  
Elastohydrodynamic Lubrication ◽  
Two Dimensional ◽  
Point Contacts ◽  
Dimensionless Velocity ◽  
Simultaneous System ◽  
Elasticity Equations ◽  
Minimum Film Thickness ◽  
Pressure Spike

A numerical solution to the problem of isothermal non-Newtonian elastohydrodynamic lubrication of rolling/sliding point contacts has been obtained. The multigrid technique is used to solve the simultaneous system of two-dimensional modified Reynolds and elasticity equations. The effects of various loads, speeds, and slide to roll ratios on the pressure distribution, film thickness, and friction force have been investigated. Results for the dimensionless load W = 4.6 × 10−6 and 1.1 × 10−6, and the dimensionless velocity U = 3 × 10−10 and 3 × 10−11 are presented. The results indicate that slide to roll ratio has negligible effect on the minimum film thickness, however, it significantly reduces the pressure spike.

Elastohydrodynamic lubrication of a circular point contact for a compliant layered surface bonded to a rigid substrate Part 2: Numerical results

2000 ◽  
Vol 214 (3) ◽  
pp. 281-289 ◽  
Author(s):  
Z. M. Jin
Keyword(s):  
Film Thickness ◽  
Layer Thickness ◽  
Poisson’S Ratio ◽  
Point Contact ◽  
Elastohydrodynamic Lubrication ◽  
Poisson's Ratio ◽  
Contact Radius ◽  
Rigid Substrate ◽  
Circular Point ◽  
Wide Range

Both the theoretical formulation and the numerical analysis of the elastohydrodynamic lubrication problem of a circular point contact of a compliant layered surface firmly bonded to a rigid substrate have been present in the earlier paper, Part 1. The numerical method is applied, in this paper, to a compliant layered surface firmly bonded to a rigid substrate. The results of the film thickness and pressure distribution are presented for a wide range of ratios of the contact radius to the layer thickness and Poisson's ratio. It has been shown that the film thickness for a layered surface can be predicted from the semi-infinite solid assumption when the ratio of the contact radius to the layer thickness is less than or equal to 0.25. Furthermore, it has been demonstrated that, for a layered surface with Poisson's ratio equal to 0.4, the elastohydrodynamic solutions based on the simple constrained column model are reasonably accurate when the contact radius is larger than or equal to the layer thickness. General non-dimensional solutions of the minimum and central film thicknesses have been presented using the Moes load and film thickness parameters as a function of the ratio of the contact radius to the layer thickness and Poisson's ratio. All the numerical solutions of both the central and the minimum (along the centre of contact in the entraining direction) film thicknesses have been curve fitted using a least-squares technique. A normal human hip joint has been chosen as an example to illustrate the application of the present study.

scholarly journals Misalignment-Induced Micro-Elastohydrodynamic Lubrication in Rotary Lip Seals

Lubricants ◽  
2020 ◽  
Vol 8 (2) ◽  
pp. 19 ◽  
Author(s):  
F. Xavier Borras ◽  
Matthijn B. de Rooij ◽  
Dik J. Schipper
Keyword(s):  
Film Thickness ◽  
Contact Pressure ◽  
Elastohydrodynamic Lubrication ◽  
Hydrodynamic Pressure ◽  
Thickness Variation ◽  
Hydrodynamic Action ◽  
Static Contact ◽  
Model Predictions ◽  
Minimum Film Thickness ◽  
Lip Seals

In literature the lubrication of rotary lip seals is explained by hydrodynamic action on a microscopic scale. This theory assumes perfect concentricity between the seal and the shaft which in reality seldomly occurs. Focusing on the stern tube seals application, an analysis is performed on the phenomena distorting the axisymmetric operation of rotary lip seals. Radial and angular shaft misalignments together with pressure and temperature gradients have been modelled. The model predictions are validated using a dedicated setup. Additionally, applying the soft-EHL film thickness expressions at the asperity level, an equivalent film thickness along the circumferential direction is estimated. The Reynolds PDE is solved to predict the misalignment-induced hydrodynamic pressure build-up. The film thickness variation derived and accompanying non-uniform contact pressure distribution was shown to be sufficient for hydrodynamic action and, depending on the minimum film thickness, the hydrodynamic pressure build-up can exceed the static contact pressure. Additionally, significant differences were observed between the radial and angular misalignment configurations.

scholarly journals A thermal resistances-based approach for thermal-elastohydrodynamic calculations in point contacts

2017 ◽  
Vol 232 (11) ◽  
pp. 2088-2102 ◽  
Author(s):  
Eduardo de la Guerra Ochoa ◽  
Javier Echávarri Otero ◽  
Enrique Chacón Tanarro ◽  
Benito del Río López
Keyword(s):  
Friction Coefficient ◽  
Film Thickness ◽  
Thermal Effects ◽  
Good Accuracy ◽  
Computational Cost ◽  
Point Contact ◽  
Elastohydrodynamic Lubrication ◽  
Point Contacts ◽  
New Approach ◽  
Ball On Disc

This article presents a thermal resistances-based approach for solving the thermal-elastohydrodynamic lubrication problem in point contact, taking the lubricant rheology into account. The friction coefficient in the contact is estimated, along with the distribution of both film thickness and temperature. A commercial tribometer is used in order to measure the friction coefficient at a ball-on-disc point contact lubricated with a polyalphaolefin base. These data and other experimental results available in the bibliography are compared to those obtained by using the proposed methodology, and thermal effects are analysed. The new approach shows good accuracy for predicting the friction coefficient and requires less computational cost than full thermal-elastohydrodynamic simulations.

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