Asperity Contact Research Articles

In situ analysis of flow characteristic and deformation field of metal surface in sliding asperity contact

This work uses a model in situ configuration to explore the surface flow characteristics of a soft metal surface sliding against a hard wedge, representative of surface asperity. Digital image analysis shows that a sharp wedge triggers the non-laminar flow of materials which moves the strain rate field closure to the surface, causes surface folding, and generates cracks-likes features on the slid surface. Whereas, a blunt wedge with a large tip radius promotes laminar flow and suppresses the cracks. The transition of flow from laminar to non-laminar mode is discussed in terms of the underlying deformation characteristic of sliding wedges.

Shear behavior and off-fault damage of saw-cut smooth and tension-induced rough joints in granite

The damage of rock joints or fractures upon shear includes the surface damage occurring at the contact asperities and the damage beneath the shear surface within the host rock. The latter is commonly known as off-fault damage and has been much less investigated than the surface damage. The main contribution of this study is to compare the results of direct shear tests conducted on saw-cut planar joints and tension-induced rough granite joints under normal stresses ranging from 1 MPa to 50 MPa. The shear-induced off-fault damages are quantified and compared with the optical microscope observation. Our results clearly show that the planar joints slip stably under all the normal stresses except under 50 MPa, where some local fractures and regular stick-slip occur towards the end of the test. Both post-peak stress drop and stick-slip occur for all the rough joints. The residual shear strength envelopes for the rough joints and the peak shear strength envelope for the planar joints almost overlap. The root mean square (RMS) of asperity height for the rough joints decreases while it increases for the planar joint after shear, and a larger normal stress usually leads to a more significant decrease or increase in RMS. Besides, the extent of off-fault damage (or damage zone) increases with normal stress for both planar and rough joints, and it is restricted to a very thin layer with limited micro-cracks beneath the planar joint surface. In comparison, the thickness of the damage zone for the rough joints is about an order of magnitude larger than that of the planar joints, and the coalesced micro-cracks are generally inclined to the shear direction with acute angles. The findings obtained in this study contribute to a better understanding on the frictional behavior and damage characteristics of rock joints or fractures with different roughness.

Investigation on the effect of coating properties on transient mixed lubrication of gas foil bearing

To reveal the effect of coating properties on the mixed lubrication evolution during the start–stop process of gas foil bearing (GFB), a transient gas mixed lubrication-wear model for coating surface is established. In the developed model, a method of the extended equivalent modulus by the film thickness ratio is proposed, which can extend the classic Greenwood and Tripp contact model for homogeneous materials to the coating contact involving layered materials. Moreover, a gas foil bearing start–stop experiment is conducted to verify the predicted results of the developed model. The effects of coating materials and standard deviation of coating surface on the start–stop performance of GFB are investigated. Within the scope of this article, the results show that during start-up, the gas film pressure first increases and then decreases with the increase in time, the minimum film thickness increases, while the asperity contact decreases. The opposite evolution is observed during shut-down. Compared with uncoated GFB, the friction torque and lift-off speed of GFB with polyimide (PI) and polytetrafluoroethylene (PTFE) are reduced, with PI reducing friction torque by 24.27% and PTFE by 49.03%. The minimum lift-off speed with PTFE is the smallest. The lift-off speed, friction torque, and wear volume increase with the increase in the standard deviation of coating surface. The friction torque and lift-off speed decrease as the start–stop cycle increases until both reach stability. This paper can provide theoretical guidance for the design of the top foil coating surface of GFB.

Investigation on mixed thermalelstohydrodynamic lubrication behavior of slipper/swash plate interface in water hydraulic axial piston pump

To reveal the thermal-fluid-structure interaction characteristics of water-lubricated slipper/swash plate interface, a transient mixed thermoelstohydrodynamic (MTEHD) lubrication model incorporating asperity contact, elastic deformation, heat transfer and viscosity temperature effect is originally presented. The change in fluid properties caused by cavitation is considered for solution the piston chamber pressure. Distributions of pressure, temperature, deformation and tilting state of slipper simulated by MTEHD show strong reasonableness. Effect of operating and structural parameters on energy consumption characteristics calculated by MTEHD and hydrodynamic lubrication is contrastively analyzed. The results show that energy consumption is different in delivery and suction stroke due to different degrees of MTEHD effects and transient contact. Besides, the optimal dimension for the width of studied sealing surface is determined.

Influence of Cavitation and Shaft Deformation in the Analysis of Lubrication of the Stern Bearing

The cavitation phenomenon and shaft deformation have a significant impact on the tribological performance of the journal bearing. A mixed lubrication model is developed that takes into account surface roughness and asperity contact, as well as the effects of cavitation and deflection. The fluid–solid coupling effect in bearing deformation, asperity contact, and film pressure are investigated. The effect of boundary conditions on the lubrication regimes is discussed. The results of simulations with and without cavitation are compared under steady-state conditions. The results show that when cavitation is considered by the mixed lubrication model under a given load, the eccentricity is reduced, and the maximum oil film pressure is also reduced. The speed range of the bearing simulated with the mixed lubrication model increases after considering deflection deformation. The mixed lubrication model proposed in this paper is able to provide accurate results of pressure distribution and coefficient of friction and can be applied in the design and analysis of journal bearings.

Contacting Micro Asperity of a Deformable Surface

Abstract Deterministic contact modeling based on half-space theories has satisfied a wide range of applications. However, the half-space theories themselves do not involve shape effects of roughness on Green’s functions/influence coefficients; in deterministic rough-surface contact analyses, the roughness is considered in gap function. This approach can be called the “roughness simplification.” One needs to answer two questions about the validity of the roughness simplification: How appropriate is the roughness simplification in modeling rough-surface contacts? How accurately can the commonly included contact-plasticity behavior be captured under the roughness simplification? This work utilized a double-scale representation of an asperity—a microscopic deformable asperity stacked on a deformable half-space, to obtain their combined contact responses in both elastic and plastic regimes. The deformation and contact behaviors of asperities thus configured were obtained with finite element analysis (FEA) and rough-surface half-space contact solvers. Three stages of asperity contact were discovered: the Hertzian stage, the single-region elastoplastic stage, and the two-region elastoplastic stage where the surrounding base material also takes part in the contact. The comparisons of contact deformation and pressure results from both the finite element analysis and half-space contact solvers support the validity of the half-space theories with the roughness simplification for various ellipsoid-shape asperities with circular-bases in both elastic and elastoplastic rough-surface asperity modeling. The research also reveals that when significant plastic deformations occur, asperities with different aspect ratios can bear different maximum elastoplastic contact pressures.

Current Knowledge on Friction, Lubrication, and Wear of Ethanol-Fuelled Engines—A Review

The urgent need for drastic reduction in emissions due to global warming demands a radical energy transition in transportation. The role of biofuels is fundamental to bridging the current situation towards a clean and sustainable future. In passenger cars, the use of ethanol fuel reduces gas emissions (CO2 and other harmful gases), but can bring tribological challenges to the engine. This review addresses the current state-of-the-art on the effects of ethanol fuel on friction, lubrication, and wear in car engines, and identifies knowledge gaps and trends in lubricants for ethanol-fuelled engines. This review shows that ethanol affects friction and wear in many ways, for example, by reducing lubricant viscosity, which on the one hand can reduce shear losses under full film lubrication, but on the other can increase asperity contact under mixed lubrication. Therefore, ethanol can either reduce or increase engine friction depending on the driving conditions, engine temperature, amount of diluted ethanol in the lubricant, lubricant type, etc. Ethanol increases corrosion and affects tribocorrosion, with significant effects on engine wear. Moreover, ethanol strongly interacts with the lubricant’s additives, affecting friction and wear under boundary lubrication conditions. Regarding the anti-wear additive ZDDP, ethanol leads to thinner tribofilms with modified chemical structure, in particular shorter phosphates and increased amount of iron sulphides and oxides, thereby reducing their anti-wear protection. Tribofilms formed from Mo-DTC friction modifier are affected as well, compromising the formation of low-friction MoS2 tribofilms; however, ethanol is beneficial for the tribological behaviour of organic friction modifiers. Although the oil industry has implemented small changes in oil formulation to ensure the proper operation of ethanol-fuelled engines, there is a lack of research aiming to optimize lubricant formulation to maximize ethanol-fuelled engine performance. The findings of this review should shed light towards improved oil formulation as well as on the selection of materials and surface engineering techniques to mitigate the most pressing problems.

Effect of nanoscale surface roughness on sliding friction and wear in mixed lubrication

Surface roughness is significant to friction and wear. However, the influence remains elusive, especially at the nanoscale. This study aimed to explore the effect of the nanoscale surface roughness on sliding friction and wear. For bearing steel tribo-pairs, the surface roughness can affect the lubrication state transition. The lower the surface roughness is, the easier it is to enter mixed lubrication and full film lubrication. Moreover, reducing the surface roughness can decrease friction and wear in mixed lubrication. At 94 mm/s sliding speed, as the surface roughness Sq decreases from 769.7 nm to 21.1 nm, the average friction coefficient first remains unchanged and then decreases by 20%, while the wear rate decreases by 85%. However, further reducing the surface roughness may result in friction failure, raising friction and wear. At 10 mm sliding radius, about 20∼40 nm Sq can lead to the minimal friction and wear. For the mechanism, as the surface roughness decreases, the asperity contact diminishes. Therefore, friction and wear decrease. However, when the surface roughness passes the critical point, asperities cannot fully accommodate the interfacial wear debris. Consequently, friction failure occurs. The findings may provide an enhanced understanding of the role of surface roughness in tribology.

Failure mechanisms of diamond like carbon coatings characterised by in situ SEM scratch testing

In situ SEM scratch testing of DLC and Si-doped DLC deposited on Si < 100> wafers has been conducted using sharp 1 and 5 μm radii diamond asperities, enabling the stages of deformation and wear of DLC coatings to be evaluated in real time. With increasing load, initial plastic deformation and tensile cracking in the scratch track progresses to the propagation of radial and lateral cracks, and full coating spallation. In situ SEM imaging reveals nucleation of radial cracks in the DLC coating around the front and side of the moving asperity, followed by lateral crack propagation both ahead of, and behind, the asperity contact zone. Post-mortem FIB cross sectioning reveals microcracking and lateral cracks in the silicon substrate below DLC coatings prior to coating spallation. The DLC failure mechanisms are influenced by asperity geometry, with notable DLC coating lift up/delamination events occurring during the smaller 1 μm radius asperity scratch tests. The sharper 1 μm radius asperity required ∼20% of the applied load, and higher contact pressure, to initiate spallation during scratching compared the larger 5 μm asperity, indicating that smaller radii asperities are significantly more likely to cause DLC coating spallation, although the spallations they generate were observed to be, on average, smaller.

Numerical simulation on startup performance of thrust bearing under different acceleration scenarios

PurposeThis paper aims to study the startup performance of thrust bearing. The effects of acceleration scenarios, roughness, the area ratio of texture and texture depth on the transient startup performance of the thrust bearing were analyzed.Design/methodology/approachThe lubrication model is solved by the Reynolds equation with the mass-conservation boundary condition. The Greenwood and Tripp contact model is used to predict asperity contact load. The finite volume method is used to discretize the governing equations.FindingsBy studying the bearing performance with different acceleration functions, it was found that the higher the acceleration at the beginning of the startup, the faster the thrust bearing operates under the hydrodynamic lubrication regime in the start stage. It appears that the friction and contact time of asperity increase with the increasing roughness. The optimal area ratio of texture is within 30%–50%. The depth of texture ranging from 1 to 2 is the best.Originality/valueThis paper proposes a transient mixed lubrication analysis model of the thrust bearing. This model can be used to analyze the variations of tribological performance and lubrication regime of the thrust bearing under different acceleration scenarios.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-09-2022-0268/

Mixed lubrication performances of misaligned stern bearing considering turbulence and elastic deformation

PurposeThis study aims to investigate mixed lubrication performances of stern bearing in a misaligned state considering turbulence and bearing deformation impacts.Design/methodology/approachA mixed lubrication model of stern bearing is established. The generalized average Reynolds equation governing the turbulent flow of lubricant is analyzed by considering the interaction of bearing elastic deformation, asperity contact pressure and film pressure. The bearing behaviors including minimum film thickness, hydrodynamic pressure, asperity friction force and frictional coefficient are studied under different models. The correctness of this model is verified by comparing it with that of the published data.FindingsNumerical results indicate that elastic deformation noticeably decreases the maximum film pressure, the asperity contact force and the friction coefficient in the mixed lubrication stage. The effect of elastic deformation and turbulence reduces the transition speed from mixed to liquid lubrication.Originality/valueThis model includes both turbulence and bearing deformation impacts on journal bearing performances. It is expected that the numerical results can provide useful information to establish a stern bearing exposed to mixed lubrication conditions.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-11-2022-0352/

Manufacturing error and misalignment effect on the transient lubrication behavior of dynamically loaded journal bearing with micro-groove

The novelty of this paper is to numerically investigate the effect of manufacturing error and misalignment on the transient lubrication behavior of dynamically loaded journal bearings with micro-groove. Based on the average Reynolds equation considering the mass conservation cavitation algorithm, the asperity contact model, and the force balance equation, the mixed lubrication model under time-varying dynamic loads is developed. Meanwhile, mathematical functions are given for the bearings with different surface profiles, including the circumferential and axial manufacturing errors of the bearing, the horizontal and vertical deflection angles of the journal, and the micro-grooves with different distribution forms. According to this model, the lubrication characteristics of the bearing are systematically investigated at different horizontal and vertical deflection angles, amplitudes, spatial numbers, and phase angles of the circumferential waviness, as well as shape profiles of the axial error. In addition, the performance parameters of dynamically loaded journal bearings with ideal and actual surfaces under different micro-groove distributions are comparatively evaluated. Numerical results show that manufacturing errors and misalignment have a remarkable effect on the transient behavior of dynamically loaded journal bearings, and the coupling effect will be more consistent with practical engineering. It can be found that the distribution form of the micro-groove surface directly affects the friction reduction effect of bearing systems. The numerical model can serve as a meaningful guideline for the optimum design of dynamically loaded journal bearing with micro-groove.

Experimental and numerical investigations of the wear behavior and sealing performance of PTFE rotary lip seals based on the elasto-hydrodynamic analysis with considerations of the asperity contact

Sealing performances of Polytetrafluoroethylene (PTFE) rotary lip seals could be deteriorated due to wear behaviors, objective investigations of the potential leakage are therefore demanded in the early design stage. Numerical assessments based on the elasto-hydrodynamic analysis proposed in the authors’ recent work in conjunction with the Greenwood and Williamson contact model are presented. The asperity contact pressure is calculated and implemented into the modified Archard wear model to estimate the wear depth of the seal lip under the lubricated operation. Current analysis procedures can fairly estimate evolutions of the seal lip geometry under both the dry and lubricated operation, and a sign of the reverse pumping rate is further verified as an effective index of the leakage.

Application of Load-Sharing Concept to Mechanical Seals

Mechanical seals are mechanisms that are used to prevent fluid leakage. Since the seal surfaces are in contact with one another, hydrodynamic and contact forces are functions of surface roughness. Additionally, since the lubrication regime under specific operating conditions such as low speed or high load causes the seal to operate in the mixed lubrication regime, thus the contact of asperities plays an important role. The primary purpose of this paper is to apply the load-sharing concept to study the behavior of a mechanical seal in a mixed lubrication regime. The predicted results are compared to the published data from the literature, showing acceptable accuracy. The model presented in this paper can predict the performance of the mechanical seal system in a short execution time while providing acceptable accuracy by considering the surface roughness effect.

A Mixed Lubrication Deterministic Model of an Elastic Support Water-Lubricated Tilting Pad Thrust Bearing

In order to study the effect of surface roughness on lubrication performance of an elastic support water-lubricated tilting pad thrust bearing, a mixed lubrication (ML) deterministic model is hereby presented based on a unified Reynolds equation model. This very model incorporates the elastic–plastic deformation of asperities and polymer matrix of the thrust pad, as well as the elastic deformation of the rubber support. The randomly distributed surface roughness of the thrust pad is generated by a mathematical model and shares the same distribution characteristics as the measured surface roughness. The Greenwood and Williamson asperity contact model and thin plate deformation model are combined to solve the asperities contact stress and deformation. Meanwhile, the bearing ML performance is compared with the results calculated by a thermohydrodynamic (THD) lubrication model and a thermo-elasto-hydrodynamic (TEHD) lubrication model, while the film thickness is also compared with measurements. The results show that the water film thickness calculated by the ML model is smaller than that by the THD model and the TEHD model, but the water film temperature is higher. The roughness has a great influence on the contact area ratio and the lubrication state, but little effect on the average film thickness. A higher roughness indicates a higher rotational speed required for the bearing to achieve full hydrodynamic lubrication. The film thickness calculated by the mixed lubrication model is closer to the measured results. Overall, it is proved that the mixed lubrication model can more accurately predict the lubrication performance of bearings. Compared to the thin plate deformation model, the elastic deformation simulation based on the half-infinite space model severely overestimates the elastic deformation of the pad surface, making it unsuitable for calculating the elastic deformation of the polymer matrix of the thrust pad under contact force or water film pressure. This ML deterministic model provides an effective means for high-precision prediction of the lubrication performance of the elastic supported water-lubricated thrust bearings coupled with multi-layer soft materials.

Finite element modeling and simulation of mixed elastohydrodynamic lubrication for the finite line contact under tilting loads

Misalignment is a prevalent problem in rotor machinery. This paper proposes a numerical analysis for the mixed EHL of finite-line contacts considering tilting loads based on FEM. The Reynolds and linear elasticity equations, and Greenwood-Tripp contact model are coupled in an iterative process to solve the fluid-solid/solid-solid interaction under the compound external force and moment. Lubrication characteristics at both ends of the cylinder are analyzed and an asymmetric profile design scheme is presented to improve the lubrication performance at the cylinder's lower end. It is found that proper profile parameters can reduce EHL pressure by 40%, increasing the minimum oil film thickness by up to 100%, and thus reduce asperity contact pressure by up to 50%.

Numerical Simulation of the Lubricant-Solid Interface Using the Multigrid Method

Solid asperity interactions are common and inevitable under severe loading conditions for any lubricated contact. Heavy-duty machine components (gears, bearings, etc.) generally operate under Mixed Lubrication (ML), where uneven surface features contact each other when the generated fluid pressure is not enough to support the external load. The Reynolds equation is commonly used to simulate smooth lubricated contacts numerically. In rough lubricated interfaces where opposite surface asperities make contact, the Reynolds equation alone cannot accurately predict pressure using the traditional numerical simulation method. In this paper, lubrication–contact interface conditions (LCICs) have been implemented and extended to solve the multiple asperity contact problem using the full-multigrid approach. The developed novel algorithm has significantly accelerated the solution process and improved the accuracy and efficiency of pressure calculation for fluid–solid sub-interactions that can occur in ML regions. The results of the finite difference method (FDM) results have been compared with those of computational fluid dynamics (CFD) simulation to validate the newly developed model. Hence, the proposed optimized solution method will provide valuable insight to researchers and industry engineers interested in simulating the ML problem where the effect of the fluid–solid interface can be captured effectively to improve reliability in the calculation of the life expectancy of the lubricated parts.

Tribological properties and synergetic self-lubricating mechanism of PS-PAO based nanocapsules with MoDTC addtives

With development of encapsulation technology, analysis of dependent nano-scaled microcapsule is significant to intensively understand self-lubrication behavior. In this paper, polystyrene (PS)-poly alpha olefin (PAO) capsules were synthesized with PAO as core and PS as shell. The diameter, shell thickness and encapsulated rate of PS-PAO4 were 381.51 ± 25.44 nm, 40 nm and 43.29 wt.%. The friction coefficient (COF) of PS-PAO4 by SRV friction test was 0.089, which played intermediate between PS nanosphere and PAO oil. Comprehensive analysis with Hamrock-Dowson equation and classical Stribeck curve manifested that the PS-PAO nanocapsules and PS nanospheres stayed in mixed lubrication regime, and PAO oil stayed in the boundary lubrication regime. Due to the absence of lubrication, PS dry friction and asperities contact status were more significant to determine the lubrication state of PS-PAO4 sample. The influence factors including load, operating temperature, PAO types and molybdenum dithiocarbamate (MoDTC) addtives were respectively investigated. A three-stage decline curve of PS-PAO4/MoDTC was found with final COF of 0.015, which the COF value decreased by 83.15% compared by PS-PAO4. The synergetic self-lubricating mechanism was mainly determined by asperity contacts, PS debris grinding, FeS tribofilm formation of MoDTC additives and counterparts, transfer film and third body formation by PS, MoDTC, PAO oil and counterparts. This work provides intensive understanding of nanocapsules for mixed lubrication regime and is expected to apply in ultrathin coating, liquid lubricant additives and functional polishing abrasives under heavy-duty and low speed conditions.

Analysis and Experimental Verification of the Sealing Performance of PEM Fuel Cell Based on Fractal Theory

Aiming to accurately predict the leakage rate of the sealing interface, this work proposes a two-dimensional finite element model of a proton exchange membrane fuel cell, which includes the microscopic surface morphology and the asperity contact process of the components. First of all, we constructed the surface morphology of the seal by the two-dimensional W-M (Weierstrass–Mandelbrot) fractal function and explored the influence of fractal dimension (D) and scale parameter (G) on the surface profile. Furthermore, the finite element method and Poiseuille fluid theory were adopted to obtain the deformation variables of the asperity under different clamping pressures and leakage rates. Moreover, we quantitatively analyzed the impact of surface roughness on the clamping pressure and leakage rate. It was found that both the surface amplitude and surface roughness are positively correlated with G and negatively correlated with D. Surface morphology is proportional to D but has no relationship with G. Additionally, the deformation asperity decreases exponentially with growing clamping pressure, and the leakage rate is consistent with the experimental values at a clamping pressure of 0.54 MPa. With the same leakage rate, when the seal surface roughness value is less than 1 μm, a doubled roughness value leads to an increase of 31% in the clamping pressure. In contrast, when the surface roughness of the seal is greater than 1 μm, a doubled roughness value induces an increase of 50% in the corresponding clamping pressure.

Lubrication failure analysis of camshaft bearings in V6 diesel engine

This contribution investigates the lubrication characteristics and failure causes of camshaft bearings belong to a V6 diesel engine. Numerical simulation based on the theory of elastohydrodynamic lubrication and flexible multibody dynamics is performed to analyse the lubrication characteristics of camshaft bearings. The results reveal that lubrication performance of different bearings of camshaft shows great differences. For a certain bearing, the mixed lubrication state and elastohydrodynamic lubrication state alternately occur in one engine cycle. The duration of mixed lubrication varies greatly in different bearings. For the bearing closest to the timing drive gear, the total pressure is dominated by the asperity contact pressure, and the predicted safety factors of the asperity contact pressure, hydrodynamic pressure and oil film thickness are less than 1, which means that this bearing will have lubrication failure.