Boundary Friction Research Articles

Frictional boundary condition for lattice Boltzmann modelling of dense granular flows

Hydrodynamic approaches that treat granular materials as a continuum via the homogenization of discrete flow properties have become viable options for efficient predictions of bulk flow behaviours. However, simplified boundary conditions in computational fluid dynamics are often adopted, which have difficulty in describing the complex stick–slip phenomenon at the boundaries. This paper extends the lattice Boltzmann method for granular flow simulations by incorporating a novel frictional boundary condition. The wall slip velocity is first calculated based on the shear rate limited by the Coulomb friction, followed by the reconstruction of unknown density distribution functions through a modified bounce-back scheme. Validation is performed against a unique plane Couette flow configuration, and the analytical solutions for the flow velocity profile and the wall slip velocity, as functions of the friction coefficient, are reproduced by the numerical model. The transition between no-slip and partial-slip regimes is captured well, but the convergence rate drops from second order to first order when slip occurs. The rheological parameters and the basal friction coefficient are calibrated further against the discrete element simulation of a square granular column collapsing over a horizontal bottom plane. It is found that the calibrated continuum model can predict other granular column collapses with different initial aspect ratios and slope inclination angles, including the basal slip and the complex internal flow structures, without any further adjustments to the model parameters. This highlights the generalization ability of the numerical model, which has a wide range of application in granular flow predictions and controls.

Tribological performance of polymeric friction modifiers under sliding rolling contact condition

AbstractThe tribological performance of two polymeric friction modifiers, one based on an ester‐based compound and another based on an ethoxylated fatty ester and an organic friction modifier, oleamide, was studied at 50, 90 and 140°C using a Mini Traction Machine equipped with optical interferometry and electrical contact resistance. The ability to form surface film is found to vary among the friction modifiers and with temperature and rubbing duration. Despite a thinner film being formed, polymeric friction modifier (PFMs) exhibited lower friction and wear than oleamide at all the studied temperatures. Further, the PFMs reduced boundary friction more effectively at higher temperature. In accordance with lower boundary friction, a smoother surface topography characterized by low wear was exhibited by PFM lubricated surfaces at higher temperatures. Scanning electron microscopy‐energy dispersive x‐ray analysis and time‐of‐flight secondary ion mass spectrometry provided insights on the tribofilm formation. The improvement in the tribological performance of PFMs is attributed to temperature‐induced conformation transition of adsorbed polymer chains on the surface. The results are corroborated by data obtained from dynamic light scattering and gel permeation chromatography.

Numerical optimisation of damage in extrusion processes

AbstractNumerical optimisation is applied to rod extrusion in order to generate optimal parameter sets which result in reduced damage accumulation. A brief overview of academic applications for damage optimisation is given. Their restrictions are reflected upon, leading to the proposed framework utilising the commercial software Abaqus FEA, which enables optimisation of industrial problems with frictional contact. The framework is setup modularly to enable arbitrary choices of design variables, such as geometric parameters, and process parameters like friction coefficients or boundary conditions. The optimisation strategy is applied to forward hollow extrusion. Compared to forward rod extrusion, an additional design variable, that is, the mandrel radius, is introduced into the forming process, which increases the design space.

Smoothed Particle Hydrodynamics Approach for Simulation of Non-Newtonian Flow of Feedstocks Used in Powder Injection Molding

The present work aims to explore the ability to simulate flow patterns and the velocity field in the powder injection molding (PIM) process using the smoothed particle hydrodynamics (SPH) method. Numerical simulations were performed using the DualSPHysics platform. A feedstock formulated from 17-4 PH stainless steel powder (60 vol. % of powder) and a wax-based binder system was prepared to experimentally obtain its rheological properties that were implemented in DualSPHysics using two different viscosity models. The numerical simulations were calibrated, and then validated with real-scale injections using a laboratory injection press. During the calibration step, the feedstock flow momentum equation in the DualSPHysics code was modified and boundary friction coefficients at different injection rates were adjusted to create a frictional effect. During the validation step, these calibrated conditions were used to simulate the flow behavior into a more complex shape, which was compared with experimental measurements. Using an appropriate boundary friction factor, both the frictional effect of the boundaries and the stability of the numerical solution were taken into account to successfully demonstrate the ability of this meshless SPH method. The flow front length and feedstock velocity obtained in a complex cavity were satisfactorily predicted with relative differences of less than 15%.

A NEW MULTIFUNCTIONAL LUBRICANT ADDITIVE BASED ON A SULFUR-CONTAINING DERIVATIVE OF 2,6-DIMETHYLPHENOL

New dialkyldithio derivatives of 2,6-dimethylphenol have been synthesized and characterized. For the first time, the polyfunctional properties of these compounds have been studied as additives to lubricating oils in the processes of friction and wear in the boundary friction regime, as inhibitors of high-temperature oxidation of hydrocarbons, and as protectors of metal surfaces. It has been established that already with the content of synthesized additives in lubricating oils in the amount of 0.5 wt. % antiwear properties are improved more than twice. It has been shown that additives exhibit a complex antioxidant effect and high efficiency at all stages of the oxidation process, and even at ultra-low concentrations (0.005 wt. %), their ability to resist oxidation exceeds widely used analogs. New additives are of considerable interest to modern lubrication science, and they can be used in motor oil compositions and other lubricants.

Macroscale Superlubricity of Hydrated Anions in the Boundary Lubrication Regime.

Cations can achieve excellent hydration lubrication at smooth interfaces under both microscale and macroscale conditions due to the boundary layer composed of hydration shells surrounding charges, but what about anions? Commonly used friction pairs are negatively charged at the solid/solution interface. Achieving anionic adsorption through constructing positively charged surfaces is a prerequisite for studying the hydration lubrication of anions. Here we report the hydration layer composed of anions adsorbed on the positively charged polymer/sapphire interface at acidic electrolyte solutions with pH below the isoelectric point, which contributes to the hydration lubrication of anions. Strongly hydrated anions (for the case of SO42-) exhibit stable superlubricity comparable to cations, with strikingly low boundary friction coefficient of 0.003-0.007 under contact pressures above 15 MPa without a running-in period. The hydration lubrication performance of anions is determined by both the ionic hydration strength and ion adsorption density based on the surface potential and tribological experiments. The results shed light on the role of anions in superlubricity and hydration lubrication, which may be relevant for understanding the lubrication mechanism and improving lubrication performance in acidic environments, for example, in acid pumps, sealing rings of compressors for handling acidic media, and processing devices of nuclear waste.

Bentonite homogenization with technological voids upon hydration

During the construction of the nuclear waste geological repository, the inevitable creation of technological gaps will lead to the redistribution of bentonite material along the wetting path upon water intake, thus impacting its localized hydraulic and mechanical properties. It is therefore of the utmost importance to be able to understand and predict the dry density inhomogeneous distribution throughout the buffer zone. This work proposes a microscopic dynamic force balance framework, incorporating the influence of van der Waals force, diffuse double layer force, and boundary friction force, to explore the underlying mechanism of the bentonite homogenization process upon hydration. The microscopic assumption postulates that bentonite materials are an assembly of numerous parallel thin sheets with other dimensions substantially exceeding the thickness, establishing an association between the aforementioned force and the material’s volume fraction. Particular attention is directed toward exploring the mechanism of boundary friction's effects on the inhomogeneous distribution of dry density with hydration time. The application of the framework to examine the impact of engineered voids with 10% and 20% of the total volume yields a satisfactory reproduction in terms of the spatial and temporal evolution of dry density, validating the robust prediction capacity of the established model. The investigation indicates that compacted blocks in proximity to technological voids experience a rapid reduction in dry density upon hydration, leading to the homogenization process characterized by elevated values in the initial void-affected region and diminished values in the innermost area. Whereas full homogenization is yet to be achieved within the observation period of up to 2160 h, and the greater the variability of the dry density within the specimens containing larger initial voids. Further analysis reveals that as the hydration process advances, the friction force within the portion featuring the initial void exhibits a gradual increase, while emergence gradually decreases in the inner swelling zone. Notably, the high friction factor at the bentonite and steel interface allows for the maintenance of large stress gradients and the associated density gradients.

Transforming sustainable plant proteins into high performance lubricating microgels

With the resource-intensive meat industry accounting for over 50% of food-linked emissions, plant protein consumption is an inevitable need of the hour. Despite its significance, the key barrier to adoption of plant proteins is their astringent off-sensation, typically associated with high friction and consequently poor lubrication performance. Herein, we demonstrate that by transforming plant proteins into physically cross-linked microgels, it is possible to improve their lubricity remarkably, dependent on their volume fractions, as evidenced by combining tribology using biomimetic tongue-like surface with atomic force microscopy, dynamic light scattering, rheology and adsorption measurements. Experimental findings which are fully supported by numerical modelling reveal that these non-lipidic microgels not only decrease boundary friction by an order of magnitude as compared to native protein but also replicate the lubrication performance of a 20:80 oil/water emulsion. These plant protein microgels offer a much-needed platform to design the next-generation of healthy, palatable and sustainable foods.

Modeling of disc springs based on energy method considering asymmetric frictional boundary

Disc springs have excellent ability to absorb and dissipate energy, and are widely used as basic vibration isolation units in the design of vibration isolators for naval power systems. Focusing on the effect of friction on disc springs, a mechanical model of disc springs considering asymmetric frictional boundary is developed. The additional load to overcome the Coulomb friction damping is derived analytically by the energy method. Finite element analysis of disc springs is carried out and the results for large and small frictional conditions are compared with the theoretical results. Quasi-static experiments on disc springs are carried out and the proposed method is further validated. The results show that the analytical model based on energy method can describe the load–displacement characteristics of disc springs and their combinations under symmetric and asymmetric frictional boundaries accurately. Based on the analytical solution, the influence of the structural parameters of the disc springs on the damping effect is investigated. The stiffness and damping of disc springs are linearly related to the friction coefficient. In addition, the magnitude of the effect of asymmetry of the boundary friction on the mechanical properties of the disc springs varies with the structural parameters.

Effects of Diamond-like Carbon and Tungsten-Carbide Carbon Coatings on Tribological Performance of Cam–Tappet Conjunction

Cam–tappet contacts are responsible for ~7.5% of the internal combustion engine’s (ICE) total frictional losses. The application of coatings can improve the tribological performance of these contacts. In this paper, the application of a WC-C coating as a novel approach for cam–tappets in comparison with DLC coating is investigated. The tribological performance of the coated contacts are evaluated by a novel model comprising combined implicit analytical and explicit numerical methods. This model considers the coupled tribo-dynamic behaviour whilst obtaining detailed tribological performance. The combined approach provides a computationally efficient platform. The results show that application of DLC or WC-C can improve the film thickness value by up to 41%. They can improve boundary friction, whilst increasing the viscous friction.

Modeling surface wave dynamics in upper Delaware Bay with living shorelines

Living shorelines gain increasing attention because they stabilize shorelines and reduce erosion. This study leverages physics-based models and bagged regression tree (BRT) machine learning algorithm to simulate wave dynamics at a living shoreline composed of constructed oyster reefs (CORs) in upper Delaware Bay. The physics-based models consist of coupled Delft3D-FLOW and SWAN in four-level nested domains. The model accuracy converges with increasing mesh resolution. The simulated wave-induced current circulation substantiates the effectiveness of CORs in trapping sediments. The simulated yearly-averaged wave power correlates qualitatively with historical shoreline retreat rates. BRT is adopted to improve the model accuracy, identify key processes responsible for simulation errors in wave height (Hs) and wave period (Tp), and quantify their importance. In the CORs sheltered area, BRT reveals that simulation errors of wind seas mainly arise from wind forcing, wave breaking and wave triad interactions. Wave breaking is seven times more important than wind forcing for simulating Hs, while wind forcing and triad interactions are of equal importance for simulating Tp. Simulation errors of swells mostly stem from bottom friction and offshore wave boundary conditions. Results from this study can help the assessment and adaptive management of CORs-based living shoreline restoration projects under climate change.

Effect of picosecond laser texturing on the friction behavior of silicon carbide in hybrid ceramic bearings under dry and water lubrication

Hybrid ceramic bearings consisting of silicon carbide (SiC) and GCr15 steel have a wide range of applications. However, under unlubricated and water lubricated conditions, friction between SiC and GCr15 steel inevitably occurs due to interfacial contact (e.g. dry friction and boundary friction). Laser surface texturing, as a promising surface modification technique, has a significant impact on the material friction and wear characteristics aspects. In this paper, the UV picosecond laser was used to process a groove-textured structure on the surface of silicon carbide ceramics with the aim of comparatively investigating the effect of frictional properties of textured SiC surfaces and untextured SiC surfaces under dry friction and water lubrication conditions. The results showed that the picosecond laser successfully machined surface textures on the hard-to-process SiC surface, and the picosecond laser texturing had a significant effect on the tribological behavior of SiC ceramics. Under dry friction conditions, the coefficient of friction (COF) of picosecond laser-textured SiC with GCr15 steel increased (from 0.249 to 0.296) due to the micro-cutting effect and high surface roughness caused by the texture. In contrast, the COF of picosecond laser-textured SiC with GCr15 was significantly reduced under water-lubricated conditions (from 0.22 to 0.167), due to the facilitated frictional chemical reaction on the laser-textured surface, which favors the improved tribological properties of the silicon carbide friction interface.

PLASMA-ELECTROLYTIC MODIFICATION OF STEEL AND TITANIUM SURFACES BY COMBINING CATHODIC NI-TRIDING AND ANODIC POLISHING

The possibility of increasing the wear resistance of steel 45 surfaces by 19.9 times and titanium alloy VT6 by 3.6 times after cathodic electrolytic plasma nitriding in a solution of ammonium chloride and ammonia and subsequent anodic electrolyte-plasma polishing in a solution of ammonium sulfate. A positive effect on wear resistance was revealed reducing surface roughness and removing the outer part of the oxide layer using anodic electrolytic plasma polishing and increasing the hardness of the surface layer as a result of cathodic nitriding. The wear mechanism is defined as fatigue upon plastic contact and boundary friction.

The recognition method for the fractal and the dynamic on the tool flank of a high-energy-efficiency milling cutter

The friction contact boundary between the tool flank of the milling cutter and the machining transition surface is important indicator to reveal the third deformation zone tool contact relationship and assessing the frictional wear performance of milling cutter. The existing models for friction boundary identification pay attention to the maximum width of accumulated friction and wear on the tool flank, ignoring the variability of the overall and local morphology of the friction boundary on the flank. Aimed at the influence of milling vibration on the instantaneous position of the cutter teeth and the machining transition surface, the solution and discrimination for the instantaneous position vector on the flank was proposed. Based on the mutagenicity of the instantaneous temperature and stress distribution, the influence of the instantaneous contact, extrusion, and deformation between the tool flank and the machined transition surface on the friction area was recognized. The calculation model of friction boundary of the flank was established. The irregularities of the distributions of the friction boundaries of the tool flank were revealed. The fractal recognition methods for instantaneous and cumulative friction boundary of the flank were proposed. And response was studied and verified with experiments. The results showed that it could effectively identify the irregular distribution of the friction boundary on the flank with the use of the above models. The formation and evolution of the friction boundary on the tool flank of the high-energy efficiency milling cutters were revealed.

Electrolytic coating of iron-chromium alloy of sulphate-chloride electrolyte in machine parts recovery process modelling

Introduction. The technological process of restoring a part should provide more than 80% of the resource and no more than 50% of the cost of a new part. The wear resistance of the applied coating determines the resource of the restored part operating under waterjet and boundary friction. The microhardness of an iron-based electrolytic coating is one of the key indicators of wear resistance. The study of the results of statistical processing and the factors most affecting the increase in the microhardness of the iron-based coating will make it possible to recommend and optimize the deposition conditions for obtaining the most wear-resistant coatings.Materials and methods. The studies on equipment that let to obtain the necessary data with the required accuracy were carried out. The mathematical processing using modern statistical data processing tools that excluded possible errors, let to obtain the dependence of factors with the necessary accuracy was carried out.Results. During the study of the developed sulfate-chloride electrolyte for the deposition of an iron–chromium coating, it became necessary to determine the effect of deposition conditions – ‘factors’ (temperature, acidity of the electrolyte, cathode current density) on the microhardness of the coating – ‘response’. It was found that the combination of the factors ‘temperature’ and ‘cathode current density’ in the coded values of 1.5. 2.0 and -2 are the most significant. The deposition conditions in order to obtain a coating with maximum microhardness are optimized.Discussion and conclusions. As a result of the conducted studies for the effect of the deposition conditions of the Fe-Cr alloy from the sulfate-chloride electrolyte on the microhardness of the coating, it was found that in order to obtain high-quality coatings of the iron-chromium alloy with high microhardness, it is necessary to strictly comply with the requirements of the deposition conditions and acidity to a greater extent. As the current density and temperature of the electrolyte, compared with the acidity of the electrolyte, iron baths are installed and regulated by equipment.

Tribological Effects of Metalworking Fluids in Cutting Processes

An understanding of the proper application of metalworking fluids (MWFs) is necessary for their implementation in efficient production processes. In addition, the knowledge of the process-related aspect of chip transport and the macroscopic cooling effect, the characteristics and properties of lubricant film formation, and the cooling conditions in the secondary shear zone on the chip surface, i.e., in the direct vicinity of the material separation, represent a combined fundamental scientific issue within production engineering. The aim is to transfer methods from the field of tribology of machine elements, which have already led to a considerable gain in knowledge in this discipline, to machining and to couple them with already established approaches to machining. In the case of roller bearings, the contact pressure is in the range as the pressure in the contact zone between the cutting insert and chip. Due to this, established methods might be transferred to the cutting process. In addition to classical pin-on-plate and pin-on-ring friction investigations, film thickness measurements were carried out and compared to machining tests. The coefficient of friction determined in the planing test rig is 0.48 for dry cutting, while it is 0.47 for wet cutting. These two values are much larger than the CoF with MWFs measured on the two tribometers. It is shown that the boundary friction of MWF especially influences the machining process. Thus, additives in MWF might have a high significance in machining.

New experimental methodology to evaluate lubrication properties of synovial fluid containing worn tissue particles in osteoarthritis patients

Studying the lubrication properties of osteoarthritis (OA) synovial fluid (SF) enables an understanding of the boundary lubrication joint, mobility, and friction. However, tribology has never been combined with the clinical reality of the presence of worn particles within the synovial fluid and how they affect the osteoarthritic joints. Part of the problem relates to the tribology methods studying friction by applying inadequate pin-on-disc techniques. In this study, synovial fluid with and without worn particles was studied using a customized tribometer. This method enables opening the contact at the end of each cycle and simulates better contact conditions of a natural knee joint and can thus be applied for evaluating the severity of joint OA and the treatment given to the patient.

SPH modeling of biomass granular flow: Theoretical implementation and experimental validation

The commercialization of biomass-derived energy is impeded by flowability challenges arising from the feeding and handling of granular biomass materials in full-scale biorefineries. To overcome these obstacles, a robust and accurate model to simulate the flow of granular biomass is indispensable. However, conventional mesh-based numerical codes are limited by inherent mesh distortion in simulating large deformation that commonly occurs in granular biomass handling. In this study, we propose a graphics processing unit (GPU)-accelerated meshless Smoothed Particle Hydrodynamics (SPH) code to model the flow of granular biomass materials. A modified void ratio-based mass conversation, a hybrid particle-to-particle/surface frictional boundary treatment, and a hypoplastic constitutive model are implemented. Four numerical examples, an elastic block sliding on inclined planes, sand column collapse, Angle of Repose, and axial compression tests for pine chips, were simulated using the developed SPH code. The results demonstrate good agreement between numerical predictions and analytical and experimental data for all four examples, validating the SPH code and increasing confidence that it can be applied to simulate more complex granular biomass handling processes, such as hopper feeding or auger conveyance.

Correlation between Lubricating Oil Characteristic Parameters and Friction Characteristics

In order to help one to judge the friction properties of lubricating oils without tests, this paper intends to establish the correlation between the characteristic parameters of lubricating oils and the friction properties. The elastohydrodynamic and boundary friction properties of poly alpha olefin (PAO) synthetic oil, polyol ester oil and paraffin-based mineral oil were tested using a Mini-Traction Machine. Fourier transform infrared microscopy is used to identify material changes before and after friction tests. The kinematic and dynamic viscosities of the three lubricating oils were measured using a petroleum product viscosity tester and a rotating rheometer. The results show that the kinematic viscosity does not directly determine the COF (coefficient of friction) of the lubricating oil, but the higher the dynamic viscosity, the higher the COF of the lubricating oil. The higher the viscosity-pressure coefficient, the lower the viscosity index (the worse the viscosity-temperature performance), and the higher the COF of the lubricating oil, which is related to the adaptability of the molecular structure of lubricating oils to pressure and temperature. PAO synthetic oils and polyol ester oils have excellent friction properties resulting from their strong adaptability to temperature and pressure variations due to the presence of linear chains and flexible groups.

Increasing Hardness and Wear Resistance of Austenitic Stainless Steel Surface by Anodic Plasma Electrolytic Treatment

The results of modifying the surface of austenitic stainless steel by anodic plasma electrolytic treatment are presented. Surface treatment was carried out in aqueous electrolytes based on ammonium chloride (10%) with the addition of ammonia (5%) as a source of nitrogen (for nitriding), boric acid (3%) as a source of boron (for boriding) or glycerin (10%) as a carbon source (for carburizing). Morphology, surface roughness, phase composition and microhardness of the diffusion layers in addition to the tribological properties were studied. The influence of physicochemical processes during the anodic treatment of the features of the formation of the modified surface and its operational properties are shown. The study revealed the smoothing of irregularities and the reduction in surface roughness during anodic plasma electrolytic treatment due to electrochemical dissolution. An increase in the hardness of the nitrided layers to 1450 HV with a thickness of up to 20–25 μm was found due to the formation of iron nitrides and iron-chromium carbides with a 3.7-fold decrease in roughness accompanied by an increase in wear resistance by 2 orders. The carburizing of the steel surface leads to a smaller increase in hardness (up to 700 HV) but a greater thickness of the hardened layer (up to 80 μm) due to the formation of chromium carbides and a solid solution of carbon. The roughness and wear resistance of the carburized surface change are approximately the same values as after nitriding. As a result of the boriding of the austenitic stainless steel, there is no hardening of the surface, but, at the same time, there is a decrease in roughness and an increase in wear resistance on the surface. It has been established that frictional bonds in the friction process are destroyed after all types of processing as a result of the plastic displacement of the counter body material. The type of wear can be characterized as fatigue wear with boundary friction and plastic contact. The correlation of the friction coefficient with the Kragelsky–Kombalov criterion, a generalized dimensionless criterion of surface roughness, is shown.