Minimum Film Research Articles

Multi-objective optimization of tribological properties of camshaft bearing pairs using DNN coupled with NSGA-II algorithm and TOPSIS

PurposeThis study aims to propose an optimization framework using deep neural networks (DNN) coupled with nondominated sorting genetic algorithm II and technique for order preference by similarity to an ideal solution method to improve the tribological properties of camshaft bearing pairs of internal combustion engine.Design/methodology/approachA lubrication model based on the theory of elastohydrodynamic lubrication and flexible multibody dynamics was developed for a V6 diesel engine. Setting DNN model as fitness function, the multi-objective optimization genetic algorithm and decision-making method were used to optimize the bearing pair structure with the goal of minimizing the total friction loss and the difference of the average values of minimum oil film thickness.FindingsThe results show that the lubrication state corresponding to the optimized bearing pair structure is elastohydrodynamic lubrication. Compared with the original structure, the optimized structure significantly reduces the total friction loss.Originality/valueThe optimized performance and corresponding structural parameters are obtained, and the optimization results were verified through multibody dynamics simulation.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2023-0417/

Analysis of Influence of Different Running Speeds on Lubrication Performance of Plain Bearings

Abstract Given the influence of the running speed of rotating machinery on the lubrication performance of sliding bearings, based on the hydrodynamic lubrication theory, a numerical analysis model of hydrodynamic lubrication of rolling bearings is established and solved by the finite difference method. The lubrication characteristics of rolling bearings, such as oil film pressure, oil film temperature, oil film thickness, and temperature rise at different running speeds (10 r/min, 30 r/min, 120 r/min, 160 r/min), are obtained. The results show that the sliding bearing shows different trends at different rotational speeds, the maximum oil film temperature is 70.49℃, the film thickness ratio corresponding to the minimum oil film thickness is much more than 3, and the maximum oil film pressure and temperature rise meet the allowable requirements.

Understanding the Influences of Multiscale Waviness on the Elastohydrodynamic Lubrication Performance, Part II: The Partial-Film Condition

This paper is the second part of a two-part report studying the responses of a typical point-contact elastohydrodynamic lubrication (EHL) system to multiscale roughness mimicked by wavy surfaces. The wavy surfaces are defined by three key parameters: amplitudes, frequencies, and directions. The previous Part I paper focuses on the full film lubrication condition, while the current paper focuses on the partial film regime where asperity contacts occur. A transient thermal EHL model simulates lubrication problems with different waviness parameters, loads, and speeds. The total number of simulations is 1600. Performance parameters, including the asperity contact ratio, minimum film thickness, maximum pressure, central point film thickness, central point pressure, mean film thickness, coefficient of friction (COF), and the maximum temperature rise, are obtained for each simulation. These performance parameters are post-processed in the same manner as those in the previous Part I paper. The influences of the waviness parameters, load, and speed values on the eight performance parameters are discussed.

Effect of textured shapes on slot entry hybrid conical journal bearing with ER lubricant behavior

This article investigates the influence of textured shapes and electrorheological fluid (ERF) behavior on slot entry hybrid conical journal bearing system (HCJBs). The slot entry restrictor is used as a compensating element to supply the lubricant in the clearance space. Spherical, rectangular, and triangular textured shapes over the surface of conical bearings have been employed. Furthermore, the intelligent properties of ERF on the behavior of textured slot entry HCJBs have been analyzed. The finite element method (FEM) and the successive iteration-based Gauss-Seidel method have been used to solve the modified Reynolds equation. The results drawn from this study show different influences on the bearing performance for different textured shapes. Using textured surfaces and ERF improves the minimum fluid film thickness, stability, and bearing stiffness compared to the non-textured bearing.

Parametric investigation of flow and heat transfer on the reflooding quenching of a cylinder rod in forced convection

A reflooding quenching boiling experiment in forced convection was conducted to investigate the flow and heat transfer performance of a FeCrAl cylindrical rod under various subcooling degrees and flow rates. Employing image processing and inverse heat conduction problem (IHCP) methods, the research provides insights into vapor film thickness, quenching front propagation, wall temperature cooling rate and minimum film boiling temperature. Key observations include the presence of numerous extremely small bubbles dispersing around the rod and a third quenching front appears in the middle of the rod under higher subcooling condition at 25 °C, attributed to a thinner vapor film, smaller bubbles resulting from film rupture and the inertia of fluid flow. Within the experimental range, the impact of the subcooling degree on the fluid flow and heat transfer performance during the quenching boiling process is more pronounced than that of the coolant flow rate. The evolution of the vapor film indicates a substantial reduction of 78.76 % in film thickness and a significant increase of 185.71 % in propagation velocity with an increase in subcooling degree, while an elevation in flow rate lead to a 29.84 % decrease in film thickness and a 45 % increase in propagation velocity. Heat transfer performance benefits from increased subcooling degrees throughout the entire quenching boiling process, whereas flow rate impacts the heat transfer performance of film boiling alone. Furthermore, by incorporating the impact of flow velocity, a predictive formula for Tmin is established with an error margin within ±5 %.

Next-Gen Lubrication: Water-cooled thrust bearings in conjunction with nano fluid lubricant

Thrust bearing finds application as a key element for heavy duty machines such as hydro-power plants (vertical shaft), submarines, steam engines, cement plant-ball mills (horizontal shaft) etc. Bearing temperature is a primary factor that affects the performance of hydrodynamic thrust bearings. Thermal deformation, misalignment, reduction in minimum oil film thickness and subsequent drop in load carrying capacity, are some of the manifestations related to high bearing temperatures. The present study attempts to decrease the bearing temperature by utilizing novel hybrid bearing set up. It involves the integration of water-cooled pads coupled with nanoparticle-infused lubricant films. This approach represents a convergence of two key technologies aimed at addressing the thermal effects linked with elevated temperatures generated during the operation of bearings. This study utilizes computational simulations to evaluate the effect of integrated thrust pad design on performance characteristics like pressure, temperature, and thermal deformation of a thrust bearing. The simulation results of new integrated design confirm (i) enhancement in pressure values e.g. maximum pressure increases from 5.6 MPa to 6.5 MPa (ii) reduction of pad temperature values e.g. maximum pad temperature value reduces from 85℃ to 70℃ (iii) reduction of pad thermal deformation values e.g. maximum pad thermal deformation value reduces from 36.5 µm to 22.3 µm. By leveraging the direct cooling effect of embedded cooling circuitry and the enhanced thermophysical properties of nanoparticles, this novel configuration promises to unlock new levels of efficiency and reliability in thrust bearing operation.

The research on the failure mechanism and dynamic reliability of lubricated clearance

In the operation of mechanisms with lubricated clearances, uncertain parameters such as the temperature of lubricant, driving speed, and clearance value will lead to dynamic variations for oil film thickness of lubricated clearance. The lubrication may fail when the oil film thickness of bearing surfaces is insufficient, thereby significantly affecting the performance of the mechanism. This paper presents a novel method for the dynamic reliability of lubricated clearances by improved response surface method (IRSM). Firstly, the mathematical model of lubricated clearance is established, and the oil film load of lubricated clearance is defined, then the dynamic model of mechanism considering lubricated clearances is built through Lagrange method. Secondly, considering the failure mechanism of the lubricated clearance, the surrogate model is established using the IRSM with minimum oil film thickness as the failure criterion. Finally, taking the 9-link mechanism with multiple lubricated clearances as a numerical example, the dynamic minimum oil film thickness of the lubricated clearance considering uncertain parameters is computed. The reliability of the lubricated clearance is investigated by the surrogate model, and the applicability of the model is verified by the Monte Carlo method (MCM). The results demonstrate that the IRSM has higher accuracy compared to the traditional response surface method (TRSM). This paper provides a theoretical basis for the study of failure mechanism and reliability of lubricated clearances, and also has practical significance for engineering applications.

Hydrodynamic Thrust Bearing Test Rig with Novel Bearing Alignment System

Abstract This study presents the design and development of a new hydrodynamic thrust bearing test rig with a novel (patent pending) hydrodynamic pressure feedback bearing alignment control system. The bearing alignment system maintains even distribution of thrust load across the bearing thrust pads using active hydrodynamic pressure as input to manipulate bearing orientation with stepper motors. The test rig is used to conduct performance evaluation of fixed geometry hydrodynamic thrust bearings with variable taper depths. The influence of helical taper angle, rotational speed, and applied load on key performance characteristics including minimum oil film thickness (MOFT), hydrodynamic pressure distribution, and bearing temperature is presented and analyzed. A numerical model based on the Reynolds equation is used to support the experimental results obtained. Trends in performance established by the numerical analysis show mutually agreeable results compared to experimental data. The average percent deviation of the experimentally gathered change in MOFT as load is increased with respect to the numerically predicted values is 24%. Comparison of experimental to numerical pressure distribution data shows an overall average percent deviation of 32%.

The effect of turbulence on the minimum thickness of a liquid film flowing down a vertical tube

When a liquid flows down a vertical tube at a low flowrate, it may not be able to completely cover the surface as a film, and the flow will comprise a number of rivulets separated by unwetted areas. Predictions of the minimum film thickness and corresponding minimum flowrate below which films cannot be sustained are needed in many industrial heat and mass transfer operations. In this paper a model is developed using the minimum energy method to calculate the minimum film thicknesses that can be maintained for flows down a vertical tube. It is concluded that inclusion of the effect of turbulence in the model can significantly increase the values of the calculated minimum film thicknesses. In these calculations (for 100⁰C water flowing down a 6 mm inside diameter tube) the effect of turbulence increased as the tube to liquid contact angle increased. For a flow at the highest contact angle of 90⁰, the minimum film thickness increased by 22% above the laminar value and the corresponding minimum flowrate increased by 75%. The model presented in this paper can be used to calculate the thermal performance of falling film evaporators over the whole range of flowrate.

Quantitative Elastohydrodynamic Lubrication—Seventeen Years In

Abstract Seventeen years have passed since the first full elastohydrodynamic lubrication (EHL) simulation employed the real pressure and shear dependence of viscosity measured in viscometers to accurately predict film thickness and friction. This is the appropriate time to enumerate the advances in understanding brought on by the application of high-pressure rheology to the EHL problem. The pressure dependence of the low-shear viscosity, which has been measured in viscometers for nearly a century, differs from the narratives taught to tribology students and often used to justify inaccurate models. The central film thickness often depends on the shear-thinning at low pressure and time–temperature–pressure superposition demands that the same shear dependence be active at the high pressure where friction is generated. In this article, some of the revelations resulting from quantitative EHL are reviewed. For example, it has been discovered that the minimum film thickness in point contacts depends upon the viscosity at the highest pressures of the contact. This explains the errors in the classical formulas, which were based upon the fictional narratives concerning piezoviscous response, and the assumption of film thickness governed by inlet conditions. Quantitative EHL provides quantitative predictions of contact behavior.

Dynamic Characterization of Grease-Lubricated Ball Screws

According to the lubrication characteristics of grease and lubrication mechanism, concerning the Hamrock-Dowson minimum film thickness formula, this paper analyses the trend and size of oil film thickness change of grease-lubricated ball screw sub under different aviation working conditions to identify the lubrication status. ABAQUS software is used to carry out dynamic simulation and the friction coefficient is selected according to the lubrication state and Stribeck curve to define the contact conditions to obtain the friction torque change curve and the fluctuation curve of axial velocity of the nut under different aerospace working conditions. Finally, a test bench is set up to test and calculate the friction torque of grease-lubricated ball screws to analyze the influence of different aviation working conditions on the dynamic characteristics of grease-lubricated ball screws and to investigate the reasons for the change of dynamic characteristics.

Time in DNB experimental study on Cr coated zircaloy cladding

Since the Fukushima-Daiichi accident effort has been put in by the nuclear community to develop Accident Tolerant Fuel (ATF) cladding materials to reduce the risk of clad oxidation and, consequently, hydrogen generation and potential major accidents. Among designed materials, the use of a chromium coating on top of zirconium-alloy cladding showed reasonable results in preliminary tests, being a favorable cladding solution for Pressurized Water Reactors. This paper provides highly detailed temperature data obtained during time in departure from nucleate boiling (DNB) experiments under prototypical reactor conditions of temperature, pressure, mass flux, and heat flux profile on a Cr-coated zirconium-alloy cladded heater rod simulating the fuel pin. Data were obtained at mass fluxes from 1300 to 1700 kg/m2s, pressure of 16 MPa, and inlet temperature of 333 °C (subcooling degree of 14.4 °C). The change in dry time was obtained by increasing the spike in wall temperature necessary to shut down the power. These tests showed that increasing the spike in temperature to characterize the critical heat flux from 50 °C to 400 °C resulted in variations of the departure from nucleate boiling measured value within the uncertainty range of their measurements, hence, validating the use of a spike of 50 °C, a commonly used value in this kind of study, as an indicator of the critical heat flux. Within the dry region, the temperature was found to increase along the direction of the flow for a very short length, reaching a peak, from which it reduces linearly until the surface reaches a temperature that is no longer able to sustain a dry patch. It was noticed that the dry region can grow against the flow direction due to the cosine profile of the heat flux, and that small dryout events can occur without leading to departure from nucleate boiling, i.e., being fully suppressed. However, two consecutive events may sum up and cause the critical heat flux. Rewet time was found to increase with peak cladding temperature and decrease with mass flux. A maximum peak cladding temperature of 844 °C was found, with the surface remaining dry for approximately 14.1 s. The minimum film boiling temperature was measured during the rewet process, showing absolute values of around 580 °C, and difference between wall and inlet temperatures of about 240 °C. A post-inspection using microscope and X-ray images showed no damage to the cladding and heater structure, differently than what was noticed for the bare zircaloy in a previous study. This indicated that the presence of chromium coated cladding can improve the oxidation resistance of the cladding not only in short critical heat flux transients but also in longer events associated with major accidents, like a Loss of Coolant Accident.

Bio-based lubricant with additives: tribological performances in hydrodynamic journal bearing

PurposeThe purpose of this paper is to investigate the performance of bio-based lubricants (BBL), namely, palm mid-olein (PMO) enriched with an antioxidant agent, tertiary-butylhydroquinone (TBHQ) and a viscosity improver, ethylene-vinyl acetate (EVA), in journal bearing (JB) applications.Design/methodology/approachSamples of the BBL were prepared by blending it with TBHQ and EVA at various blending ratios. The oxidative stability (OS) and viscosity of the BBL samples were examined using differential scanning calorimetry and a viscometer, respectively. Meanwhile, their performance in JB applications was evaluated through the use of a JB test rig with a 0.5 length-to-diameter ratio at various operating conditions.FindingsIt was found that the combination of PMO + TBHQ + EVA demonstrated a superior oil film pressure and load-carrying capacity, resulting in a reduced friction coefficient and a smaller attitude angle compared to the use of only PMO or VG68. However, it was observed that the addition of TBHQ and EVA to the PMO did not have a significant impact on the minimum oil film thickness.Practical implicationsThe results would be quite useful for researchers generally and designers of bearings in particular.Originality/valueThis study used PMO as the base stock, and its compatibility with TBHQ and EVA was investigated in terms of its OS and viscosity. The performance of this treated BBL was evaluated in a hydrodynamic JB.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-11-2023-0363/

Stochastic uncertain lubrication in gear transmission subjected to tribodynamic loading

A stochastic uncertain tribodynamic model is established for a spur gear pair for the first time. The stochastic uncertainty of pinion rotation speed propagated to lubrication performance is investigated. The probability density function of the minimum lubricant film thickness hmin evolves over time periodically at interval of an engagement process. Correspondence between abrupt increase in meshing force and amplification of hmin uncertainty is found. Robust and reliable lubrication performance can be achieved by suppressing the hmin uncertainty and decreasing the lubrication failure probability. This can be done by increasing lubricant viscosity, and decreasing input torque and uncertainty level of input rotation speed. This work lays a solid foundation for robust and reliability based optimization for tribodynamic gear system.

Enhancing the Elastohydrodynamic Lubrication and Vibration Behavior of Rolling Bearings Using a Hybrid Bio-Grease Blended with Activated Carbon Nanoparticles

In recent years, bio-lubricants have received a growing interest for industrial applications. Still, a full-scale implementation in machinery lubrication requires a thorough evaluation of their performance through tribological and operational tests to stand upon their performance. Additionally, the promising outcomes achieved by nanoadditives in improving the performance of synthetic lubricants have prompted research efforts to identify suitable nanoadditives for bio-grease. This paper introduces a bio-grease from a hybrid vegetable oil and glycerol monostearate as a thickener for the lubrication of rolling bearings. Activated carbon nanoparticles (ACNPs) as nanoadditives were synthesized, characterized, and incorporated into the bio-grease at concentrations of 0.5, 1, and 2% by weight. Tribo-tests were conducted on these bio-grease blends, and running tests were carried out using 6006 ball bearings on a custom test rig. Throughout a 30-min test run under a radial load of 10% of the bearing’s dynamic load rating, mechanical vibrations and power consumption were measured and analyzed for each bearing. The bio-grease with ACNPs exhibited a substantial reduction in wear scar diameter (WSD) and coefficient of friction (COF), achieving improvements of up to 73.6 and 65%, respectively, in comparison to lithium grease. Furthermore, the load carrying capacity was enhanced by 200%. The study revealed a strong correlation between measured vibration amplitudes and the viscosity of the bio-grease. The absence of high frequency resonant bands in vibration spectra indicated that the test grease samples satisfied the conditions of elastohydrodynamic lubrication, and these findings were corroborated through calculations of the minimum oil film thickness.

Research on the Optimal Design Approach of the Surface Texture for Journal Bearings

Aiming to improve the comprehensive performance of the journal bearing system, this paper presents a multi-objective adaptive scale texture optimization design approach. A mixed lubrication model for the textured journal bearing system is established by considering the effects of cavitation and roughness. The geometrical parameters of the textures were co-optimized using a multi-objective grey wolf optimizer to obtain the optimal texture schemes that are suitable for different operating conditions. Through this approach, the influences of different texture schemes under transient operating conditions can be investigated. According to the results, it was found that different texture schemes result in different friction reduction effects. Proper surface texture is beneficial in increasing the minimum oil film thickness and reducing the possibility of asperity contact. The adaptive scale texture exhibits strong adaptability and achieves significant hydrodynamic effects. Therefore, the developed approach provides valuable insights for the optimization design of journal bearing systems.

Study on electric erosion in grease lubrication using optical interference method

Protecting bearings from electrical environments is crucial as modern industry evolves. With increasing exposure to electrical conditions, the risk of bearing failure due to electric erosion becomes a significant concern. To better understand how lubrication interacts with electric discharge in rolling bearings, an optical ball-on-disc tribometer was modified to measure film thickness under elastohydrodynamic lubrication (EHL) with electric discharge. The results of the study revealed that an electrical potential difference between the surfaces separated by the lubrication film leads to a reduction in film thickness, which can be attributed to the generation of Joule heating. As the electrical potential difference increases, the film thickness decreases even further, ultimately resulting in destructive electric discharge. Interestingly, sporadic discharge was observed in the region of minimum film thickness as the entrainment velocities increased prior to the occurrence of destructive discharge. In addition, the study also investigated the use of grease with a conductive additive, a double trifluoro-sulfonate ionic liquid. It was found that incorporating this ionic liquid into the grease can decrease the energy during discharge, thereby mitigating bearing electric erosion.

The effect of fluid viscoelasticity in soft lubrication

This study explores the influence of fluid viscoelasticity in soft lubrication, in which elastohydrodynamic lubrication (EHL) plays an important role. Our findings reveal that introducing polymers can significantly reduce the friction coefficient, particularly for high Deborah numbers, i.e., the ratio between the polymer relaxation time and the flow residence time, due mainly to an increased minimum film height. This augmented film thickness reduces the Newtonian pressure contributions, lowering friction. The study highlights the non-linear relationship between Deborah numbers, load, and viscoelasticity effects, as well as the complex interplay between these factors in the Pipkin space analysis. These insights provide a comprehensive understanding of the fluid viscoelasticity in soft lubricated contacts.

Modeling and analysis of elastohydrodynamic lubrication of orthogonal face gear with installation errors

Installation error is one of the most prominent factors affecting the lubrication of face gear. To analyze the lubrication performance of the face gear with installation errors, the installation error model of the orthogonal face gear transmission system is established. Then, the contact path, equivalent curvature radius, load distribution and entrainment velocity are studied using the face gear loaded tooth contact analysis (LTCA). On this basis, the lubrication governing equations of the face gear are established according to the elastohydrodynamic lubrication (EHL) theory. In addition, the oil film thickness, oil film pressure and coefficient of friction in the process of face gear drives are calculated using the method of progressive mesh densification (PMD). Finally, the effects of axis intersection angle error, axis intersection error and axial displacement error on lubrication characteristics are analyzed. The results reveal that when the axial intersection angle error and axial displacement error are negative and the axial intersection error is positive, the minimum oil film thickness of the face gear tooth surface is less than that without error. When the error values are the same, the minimum oil film thickness and coefficient of friction have larger changes with the axial displacement error than with the axis intersection error, and the contact path has a bigger movement range.

A fully coupled finite element solution for the mixed elastohydrodynamic lubrication of finite line contacts

A fully coupled FE model for mixed EHL of finite line contacts is proposed, integrating all of the governing equations into a monolithic system. The solution reveals the fully coupled model achieves 5% higher accuracy and 50% greater efficiency compared to the weakly coupled one. Additionally, there is evidence to support the assertion that profiling contributes to the mitigation of surface roughness contact. Logarithmic profiling can increase the minimum film thickness by a factor of 30, resulting in a reduction of up to 64.6% in the maximum asperity contact pressure, and thus, the boundary friction force is decreased by more than 19%, under heavy-load low-velocity condition. This contributes to the reduction of abrasive wear.