Microplastohydrodynamic Lubrication Research Articles

A new method for determining lubrication regimes of piston ring-cylinder liner tribosystem

The time-varying lubrication regime is a unique feature of the piston ring-cylinder liner tribosystem. This study proposes a new method for comparing oil film thickness with critical values, consisting of characteristic topographic parameters (Rpk, Rk, and Rvk, etc.), to determine the lubrication regime. The lubrication regime could be determined as hydrodynamic lubrication, micro-plasto-elastohydrodynamic lubrication, micro-plastohydrodynamic lubrication, thin film lubrication, boundary lubrication, or mixed lubrication. The influence of thermal effects and oil-feed conditions on the lubrication regime is discussed. It is found that the friction coefficient alone is not entirely suitable for evaluating the lubrication regime of the piston ring-cylinder liner tribosystem. Nevertheless, this new method is capable of determining the lubrication regime under different operation conditions.

Complementary Approaches for the Numerical Simulation of the Micro-Plasto-Hydrodynamic Lubrication Regime

This paper presents recent investigations in the field of lubricant escapes from asperities. This phenomenon, named Micro Plasto Hydrodynamic Lubrication (MPHL), induces friction variation during metal forming processes. A better understanding of MPH lubrication would lead to a better management of friction, which is a central element in most sheet metal forming processes. To fulfil that goal, experiments were conducted in plane strip drawing using a transparent upper tool in order to observe lubricant flow around macroscopic pyramidal cavities. These experiments were then numerically reproduced with two complementary Finite Element models. The numerical results are discussed in this paper and show good agreement with experimental measurements.

Micro-Plasto-Hydrodynamic Lubrication a Fundamental Mechanism in Cold Rolling

This paper presents recent investigations in Micro-Plasto-Hydrodynamic (MPH) lubrication. Industrial evidences of the existence of MPH lubrication mechanism for cold rolling processes are presented. A new lubrication model developed for strip drawing processes is then applied to predict the MPH lubrication initiation and MPH lubrication extension along the tool-piece solid contacts initially in boundary lubrication regime. Finally, it is shown how this new MPH lubrication model can be implemented in a cold rolling model to maximize mills capabilities, determine optimum rolling oils properties and predict roughness transfer.

Effects of cold rolling process variables on final surface quality of stainless steel thin strip

In cold rolling some surface defects, known as pits, are due to lubricant that, entrapped in the deep valleys of the surface roughness, is nearly incompressible and acts like an inclusion avoiding microcavity elimination. During the rolling process, when specific favorable conditions can be set up, the lubricant may be expelled by the microplasto-hydrodynamic lubrication (MPHL) mechanism and pits may be recovered. In this paper the Λm parameter, index of the MPHL, is investigated together with the neutral point position to better understand the practical process recommendations for surface defect recovery. By means of finite element analysis of a Sendzimir’cold rolling process, the sensitivity of these objective functions are studied by means of a design of experiment analysis changing the major process variables like back tension, friction coefficient, reduction parameter, initial thickness, and roll diameter.

Surface Defect Generation and Recovery in Cold Rolling of Stainless Steel Strips

Previously, researchers investigated the mechanism of surface defect evolution in rolling. It was highlighted how the lubricant plays an essential role for the final strip surface quality. In some cases the lubricant can be entrapped in pits or in other defects where hydrostatic pressure tends to prevent its elimination; however, when some favorable conditions are satisfied, the lubricant can be drawn out by hydrodynamic actions and defects can be recovered. This mechanism has been described as microplastohydrodynamic lubrication (MPHL) and recent studies report a suitable parameter (the ratio of the oil drawn out from the pit to the initial pit volume) as MPHL characterization coefficient. The present paper deals with the recovery of isolated surface defects in the Sendzimir rolling process of AISI 304 stainless steel; the analyses have been conducted on two rolling conditions, which although quite similar, regularly showed opposite capability of defect recovery, moreover, with a trend that is in contrast with the predictions made by standard MPHL. Two effects, which are usually ignored in literature modeling, have been considered in this work: The former is the back-tension, which has relevant outcome on the contact pressure and the latter is the position of the neutral point, which cannot be assumed to lie at the end of the roll bite. The analytical treatment was supported by FEM simulations, which permitted to put realistic data into the MPHL equations, thus, to explain the experimental behavior. The analysis was then validated with two further rolling schedules that seem to confirm the proposed approach.

Strategic surface topographies for enhanced lubrication in sheet forming of stainless steel

Strategic stainless steel surfaces have been developed for which the tribological properties are significantly improved for sheet-metal forming compared with the as-received surfaces. The improvements have been achieved by modification of the surface to promote Micro-Plasto Hydrodynamic Lubrication (MPHL) by increasing the ratio of closed lubricant pockets and modifying the pocket geometry. These factors influence the retention and subsequent escape of lubricant during forming thus enhancing lubricant permeability to the contact between flattened workpiece asperities and contacting tool. The technique, which has been developed, is based on an electrochemical treatment changing the topography of the stainless steel surface. Comparative testing of the new surface topographies in ironing and deep drawing of stainless steel sheet shows significant improvements and possibilities of replacing chlorinated paraffin oils with environmentally friendly plain mineral oil.

Effects of die surface patterning on lubrication in strip drawing

Strip-drawing tests with annealed stainless steel samples involving small strains were used to investigate the effect of surface texturing in tribological applications involving mixed lubrication and plastic deformation. Dies were prepared with surface patterns composed of circular pockets and parallel grooves, and comparison tests were performed with highly polished dies. The effects of surface texturing were detected by friction force measurements and examination of the deformed strip surfaces, under conditions of oil lubrication. Surface patterns consisting of circular pockets with very low area coverage did not improve the tribological performance. For grooves with larger area coverage (≈25%), significant effects were observed on the friction between the dies and the strip, which were reflected in the drawing force. The performance was strongly influenced by the relative orientation between the grooves and the drawing direction. For grooves perpendicular to the drawing direction, the friction was greatly reduced; the grooves were believed to act as lubricant reservoirs and to induce microplastohydrodynamic lubrication. On the other hand, when the grooves were oriented parallel to the drawing direction, the friction was much greater and the strip surface finish became poorer; these grooves were believed to allow the lubricant to escape from the contact.

Evolution of Surface Pits on Stainless Steel Strip in Cold Rolling and Strip Drawing

Theoretical models are presented for describing the evolution of pits in the inlet and work zone during cold rolling and strip drawing of shot-blast stainless steel under ‘mixed’ lubrication. Results shows that the rough shot-blast surface is flattened rapidly in a short inlet zone, thereby entrapping the lubricant in surface pits. The subsequent evolution of these surface pits in the work zone can be explained by micro-plasto-hydrodynamic-lubrication (MPHL) models described previously. A development of these models is presented which takes into account the effects of the oil film entrained in the inlet, an oil film penetrating from adjacent pits and the finite depth of the pits. The role of an inlet oil film and penetrating MPHL oil film is to limit the potential reduction of pit size. Lubrication regime maps are constructed which describe the evolution of the surface pits for a range of pit geometries. Results explain the experimental observation that some pits survive even after a multi-pass schedule. Predictions of the pit area show good agreement with measurements on samples obtained in strip drawing or rolled under industrial conditions.

Modeling of Micro-Pit Evolution in Rolling or Strip-Drawing

The micro-plasto-hydrodynamic lubrication (MPHL) model of pit evolution is extended to account for the variation of sliding speed and strain rate in rolling and drawing processes. Results show that all of the following factors are important: pit angle, lubricant viscosity and pressure viscosity coefficient, material yield stress and sliding speed. Theoretical predictions for the change in pit area during the deformation process are well correlated by a non-dimensional group of these parameters. The model agrees reasonably with the measured change in pit volume and area from drawing experiments on cold rolled stainless steel strip containing both artificial and stochastic roughness.

An Experimental Investigation of Surface Pit Evolution During Cold-Rolling or Drawing of Stainless Steel Strip

This paper presents an experimental investigation of the mechanisms of pit elimination in strip drawing and rolling of stainless steel strips. Strip drawing tests with artificial indents confirm the role of micro-plasto-hydrodynamic lubrication (MPHL) in allowing pits to be reduced in size and depth. The similarity of results for two oils, which differ in viscosity by a factor of 10, is attributed to the fact that oil is drawn out of the pits rather easily, so that the behavior tends to the unlubricated case. Similar behavior is observed for strip drawing of shot blast white hot band. For much smoother bright anneal strip, it is suggested that the presence of an oil film in the unpitted region prevents generation of pressure differences between the pits and the unpitted regions. A comparison of strip-drawn and cold-rolled stainless steel samples show that the change in pit area and Rq roughness varies with overall reduction in a remarkably similar way. The reason for such similar behavior is attributed to the absence of hydrodynamic action in preventing pit elimination, albeit for opposite reasons. The similar rate of pit evolution in both cases confirms the usefulness of the strip drawing rig as a tool to model the change of surface topography during rolling, as long as care is taken in matching the regimes of lubrication.

Influence of Workpiece Surface Topography on the Mechanisms of Liquid Lubrication in Strip Drawing

The workpiece surface topography is an important factor controlling the mechanisms of lubrication in metal forming processes. In the present work, the microscopic lubrication mechanisms induced by lubricant trapped in pockets of the surface in strip drawing are studied. The experiments are performed with macroscopic model pockets in the surface studying the influence of the shape of the pockets on the lubrication mechanisms. A large radius of curvature on the rear edge and a small angle to the edge of the lubricant pocket induce a large area of backward escape of lubrication caused by microplasto hydrodynamic lubrication (MPHDL). On the other hand, when the radius on the edge is small MPHDL is impeded and microplasto hydrostatic lubrication appears instead implying forward escape of the lubricant. The occurrence of these mechanisms are quantitatively explained by a mathematical model combining a slab method of analysis of the strip drawing process and an analysis of lubricant escape by Reynolds equation.

A Theoretical Model of Micro-Pool Lubrication in Metal Forming

A model of a secondary hydrodynamic lubrication mechanism, which is called micro-pool or micro-plasto hydrodynamic lubrication, has been developed. It shows that, with sufficiently high viscosity and sliding speed, the lubricant trapped in the micro-pools between the tool and workpiece can be drawn into the interface. The friction force is either increased or decreased, depending on the viscosity and sliding speed. Without bulk stretching, the product of the lubricant viscosity and sliding velocity can be used as an index to indicate whether or not micro-pool lubrication will occur. Stretching the workpiece may make a strong influence not only on the thickness of the permeating film but also on the asperity contact area.

A Study of Mechanisms of Liquid Lubrication in Metal Forming

Applying a transparent tool technique the lubrication in plane strip drawing of aluminium sheet is studied providing the strip with surface pockets for entrapment of lubricant. The compression and eventual escape of trapped lubricant by Micro Plasto HydroDynamic Lubrication (MPHDL) as well as Micro Plasto Hydrostatic Lubrication (MPHSL) is observed and quantified experimentally with varying lubricant viscosity, drawing speed, reduction, die angle, back tension, workpiece material and friction conditions All these parameters are shown to influence the mechanisms of lubricant escape in an explicable way. Theoretical models for the two observed mechanisms of lubricant escape, i.e. backward escape by MPHDL and forward escape by MPHSL are established combining a continuum mechanic analysis of the pressure distribution in the tool/workpiece interface with fluid mechanic analyses of the lubricant escape. Experimental observations of oscillations in the drawing force are quantitatively shown to be caused by the two mechanisms of lubricant escape.