Mixed Lubrication Conditions Research Articles

Theoretical analysis of the piston ring-pack for predicting friction and power loss in an internal combustion engine

The piston ring is considered an essential element in the operation of the internal combustion engine to improve its efficiency and reduce its emissions. It is resistant to high temperature and high-pressure gases in the combustion chamber. A one-dimensional analysis method of lubrication between piston rings and cylinder liner in mixed lubrication conditions is developed in this article by using the GT-Suite simulation software. We applied the finite difference numerical method to solve the Reynolds equation to obtain the variation during an engine cycle of the following parameters; film thickness, frictional force, and power loss. The solution results presented can be used to improve the design of the piston ring pack in internal combustion engines and is available for industry usage.

Mechanism of Wheel-Rail Adhesion Recovery during Large Sliding processes under Water Lubrication condition

The challenge of low adhesion between the wheel and rail constrains the advancement of train braking technologies, resulting in sliding during braking, increased braking distances, and even operational safety incidents. Low adhesion arises from the contamination of the rail surface by a third body, such as water or oil, significantly reducing adhesion. However, experimental studies have found that wheel-rail adhesion coefficient under water lubrication conditions possesses a recovery capability: In scenarios characterized by low adhesion in water lubrication conditions, a secondary rise in adhesion occurs when substantial wheel-rail sliding is present. This paper focuses on numerically modeling the unique phenomenon of adhesion recovery during large-sliding processes under water lubrication conditions. Considering the notable differences in frictional heating during wheel sliding, as opposed to pure rolling conditions, we construct a wheel-rail contact model under mixed lubrication conditions that incorporates the solid-liquid coupled heat transfer effect. This model achieves stable solutions for the wheel-rail contact relationship and the temperature at the wheel-rail interface. The impacts of velocity, axle load, water temperature, and slide ratio on the adhesion recovery phenomenon are discussed, revealing the underlying mechanism of adhesion recovery during large sliding processes. Finally, brake adhesion tests under water lubrication conditions are conducted on a scaled test rig to validate the proposed theoretical model.

Periodic dual-mixing method for fast and robust solving of ultra-thin fluid-structure interaction problems

This study proposes the periodic dual-mixing method (PDMM) that can rapidly and robustly solve ultra-thin fluid-structure interaction (UTFSI) problems, especially in severe mixed lubrication. The dual mixing denotes a two-step process: the first step is to mix the historical inputs and outputs separately according to optimal mixing weights; the obtained results are mixed with dynamic damping factors in the second step to predict the deformation of the next iteration. Meanwhile, the residual is injected into the predicted deformation periodically. The comparison study is carried out with the popular IQN-ILS method in general FSI, which shows the PDMM is 5.3 times faster and 5 times more robust. Furthermore, the advantages of the PDMM are more significant under harsh mixed lubrication conditions.

ZDDP Tribofilm Formation and Removal

While ZDDP tribofilm formation has been widely studied, the mechanism of ZDDP tribofilm removal during rubbing is still unclear. The study employs a ball on disc tribometer to monitor ZDDP tribofilm development in rolling-sliding, mixed lubrication conditions. It is found that when ZDDP tribofilms are formed very rapidly, as is the case with short alkyl chain, secondary ZDDPs, a large proportion of the initially-formed tribofilm is suddenly lost during rubbing. By contrast, the tribofilms that form more slowly from primary ZDDPs and longer chain secondaries are not partially lost during rubbing. XPS analysis showed that a rapidly-formed tribofilm before its partial removal has a very small Zn/O ratio, and a high BO/NBO. This suggests that such tribofilm contains a significant proportion of ultraphosphate, which is likely to have a relatively weak structure due to lack of stabilising cations. This may result in the tribofilm being partially removed when it reaches a certain thickness. By comparison, the remaining tribofilm, and also tribofilms that form slowly, have high Zn/O and low BO/NBO. This suggests that they consist of short chain polyphosphates and are thus stronger and more durable.Graphical

Evaluation of surface texturing on chrome-coated cylinder liners via deterministic mixed lubrication simulation

This study investigates the mixed lubrication performance of various surface texture configurations in the piston ring/cylinder liner conjunction of a two-stroke internal combustion engine using a deterministic mixed lubrication model. The numerical model simultaneously solves the Reynolds equation with mass-conserving cavitation to calculate inter-asperity hydrodynamic pressures and an elastic, perfectly plastic, rough contact model to determine contact pressures at each asperity interaction. Gaussian Mixture Model clustering was employed to enhance surface characterization. The deterministic simulation approach considers the full-scale representation of the cylinder liner topography to accurately capture the influence of surface features on the hydrodynamic support and friction under mixed lubrication conditions. The investigated cylinder liners were initially hard-chrome-coated and honed, resulting in a stochastic arrangement of surface pores, and then deterministic patterns of surface pockets were created by micro electrodischarge machining (EDM). Surface measurements were performed using laser interferometry, providing input for the mixed lubrication simulations. The study also explored the virtual removal of ridges formed around the pockets by the EDM technique. Key findings indicate that the stochastic texture outperformed the hybrid texture (stochastic + deterministic) in the boundary and mixed lubrication regimes, showing higher hydrodynamic support at low separations but increased hydrodynamic shear stresses at higher speeds. Conversely, deterministic textures exhibited a significant decrease in average hydrodynamic shear stress at high velocities. These results highlight the critical role of surface texture in tribological behavior and suggest that localized textures on cylinder liners can potentially optimize engine performance. The study recommends further exploration of a broader range of texture geometries, densities, and distribution patterns to enhance engine design strategies.

Wear Performance Evaluation of Polymer Overlays on Engine Bearings.

Modern engine bearing materials encounter the challenge of functioning under conditions of mixed lubrication, low viscosity oils, downsizing, start-stop engines, potentially leading to metal-to-metal contact and, subsequently, premature bearing failure. In this work, two types of polymer overlays were applied to the bearing surface to compensate for extreme conditions, such as excessive loads and mixed lubrication. Two different polymer overlays, created through a curing process on a conventional engine bearing surface with an approximate thickness of 13 µm, were investigated for their friction and wear resistances under a 30 N load using a pin-on-disc setup. The results indicate that the newly developed polymer overlay (NDP, PAI-based coating) surface has a coefficient of friction (COF) of 0.155 and a wear volume loss of 0.010 cm3. In contrast, the currently used polymer overlay (CPO) in this field shows higher values with a COF of 0.378 and a wear volume loss of 0.024 cm3, which is significantly greater than that of the NDP. It was found that, in addition to accurately selecting the ratios of solid lubricants, polymer resins, and wear-resistant hard particle additives (metal powders, metal oxides, carbides, etc.) within the polymer coating, the effective presence of a transfer film providing low friction on the counter surface also played a crucial role.

Study on the mixed lubrication of rough planar extrusion considering surface texture

Surface texture plays a crucial role in fluid dynamic lubrication. The non-Newtonian thermal elastohydrodynamic lubrication problem involving rough surfaces with texture has not been investigated to date. In this paper, a model for non-Newtonian thermal elastohydrodynamic lubrication incorporating rough surfaces and texture morphology is developed, focusing on the problem of mixed lubrication in planar extrusion with texture. The model builds upon the Reynolds equation with flow factor introduced. It considers the effects of rough surface texture, thermal effects, and non-Newtonian effects. The Reynolds equation is numerically solved using the Semi-System method to calculate the oil film pressure in full film region and contact pressure in dry contact area. The DC-FFT algorithm is employed to calculate surface elastic deformation. Comparing the calculated friction coefficient of the present model with the measured values in literature experiments, the average error is only 6.94%. Furthermore, the study investigates the effects of texture, temperature, and non-Newtonian on interfacial lubrication performance under mixed lubrication conditions. It’s found that compared to untextured surface, the average film thickness of textured surface increased by a maximum of 10.8%, and the friction coefficient decreased by a maximum of 67.4%; Compared to Newtonian fluids, shear thinning fluids reduce temperature by 0.18%, and shear thickening fluids are more conducive to improving mixed lubrication performance. A stepped pit texture is designed based on the dynamic pressure mechanism of the texture, indicating that the circular stepped pit texture has the best load-bearing capacity improvement.

Influence of ZDDP tribofilm on micropitting formation and progression

This paper presents insights into how Zinc Dialkyl Dithiophosphate (ZDDP) influences the formation and progression of micropitting. Experimental investigations were conducted using a twin-disc tribometer in rolling-sliding contacts under mixed or boundary lubrication conditions, focusing on the impact of ZDDP on micropitting in bearing steel samples. Results show that ZDDP reduces wear and increases surface friction by forming a tribofilm. This facilitates micropitting formation, but also retards the progression of micropitting. It highlights that understanding the chemical and mechanical interactions at the tribological interface is essential for designing effective mitigation strategies for managing micropitting and avoiding related issues in bearing applications.

The Effect of Soft Nanoparticle Size and Concentration on Wear Behavior in Mixed Lubrication Conditions

The Effect of Soft Nanoparticle Size and Concentration on Wear Behavior in Mixed Lubrication Conditions

TRIBOLOGICAL PROPERTIES OF THERMOPLASTIC ELASTOMER USED IN 3D PRINTING TECHNOLOGY

The use of thermoplastic elastomers (TPE) in 3D printing technology enables the use of this technology to produce prototype seals with an unusual shape or design solution. Tribological tests were carried out on a pin-on-disc test stand. The influence of contact pressure and sliding velocity on the friction coefficient of the TPE-steel friction pair under mixed lubrication conditions was analyzed. Based on the obtained tribological test results, it was found that the coefficient of friction of the thermoplastic TPE elastomer on steel in the presence of hydraulic oil (mixed lubrication) at a sliding velocity below 1 m/s does not exceed μ = 0.25. The obtained friction coefficient values are comparable to the results for other elastomeric materials used for technical seals. It was found that the influence of contact pressure on the value of the friction coefficient in the tested friction pairs is varied and depends, for example, on the sliding velocity. It was recommended to carry out research on the assessment of durability (wear intensity) and structure (porosity) of the material in elements manufactured using 3D printing to obtain full knowledge of the possibility of using these materials in the area of technical aircraft seals.

Numerical study on mixed lubrication performance of misaligned microgroove water-lubricated bearings considering cavitation and turbulence effects

This study presents a mixed lubrication model for misaligned microgroove water-lubricated bearings (WLBs). The model considers the effects of cavitation and turbulence to assess the mixed lubrication performance of WLBs with various microgroove morphologies. The equations are discretized using the control volume method (CVM) and solved by using the Fischer–Burmeister–Newton–Schur method for dealing with the constrained system. A comparison of the experimental data from the published literature demonstrates the model and methodology's validity. On this basis, the effects of rotational speed, load, and misalignment angle on the mixed lubrication performance of microgroove WLBs are investigated. The numerical results indicate that the left-triangular microgroove exhibits the best-mixed lubrication performance. Under elastohydrodynamic lubrication and mixed lubrication conditions, there are significant discrepancies in microgroove morphology. However, this discrepancy diminishes with increasing misalignment angles. The edge contact problem resulting from journal misalignment can be efficiently mitigated by selecting the proper microgroove morphology. This study provides useful guidance for the optimal design and mixed lubrication performance improvement of WLBs.

Tribology behaviour of graphene-modified nanostructured Al2O3/3 % TiO2 coatings under boundary and mixed lubrication conditions

This study is focused on the preparation of a self-lubricating coating via thermal spraying. This coating was designed to control friction and lubrication in both boundary lubrication (BL) and mixed lubrication (ML) regimes. We aimed to compare the tribological behaviour of nanostructured Al2O3/3 % TiO2 and modified nanostructured Al2O3/3 % TiO2 incorporating 3 % GNPs coatings deposited by Oxygen-Fuel (OF). The critical conditions for the transition from BL to ML were experimentally studied using a fundamental tribological concept known as the Stribeck curve. A lubricating film consisting of detached GNPs, Al2O3 nanoparticle debris, and a conventional lubricant effectively covers the surface material and improves the mechanochemical interactions between the surface material and lubricating oil, thereby enhancing the tribological performance. The introduction of GNPs is found to play an effective role in the lubrication regime, leading to an increase in microhardness, a decrease in the friction coefficient and wear volume of the Al2O3/3 % TiO2 coating, and the steel counterpart disc. It noticeably improved the critical load-carrying capacity at different speeds during the transition from BL to ML regimes. The tribo-layer formed on the worn surfaces controls the tribological properties of the Al2O3/3 % TiO2 + 3 % GNPs coatings.

Friction Reduction Achieved by Ultraviolet Illumination on TiO2 Surface.

Controlling friction by light field is a low-cost, low-energy, non-polluting method. By applying ultraviolet light on the surface of photosensitive materials, the properties of the friction pairs or lubricant can be influenced, thus achieving the purpose of reducing friction. In this study, TiO2, an inorganic photosensitive material, was selected to investigate the modulating effect of light fields on friction lubrication when using polyalphaolefin (PAO) base oil as a lubricant, and the modulation law of light fields on the friction lubrication behavior was investigated under different loads (1-8 N), different speeds (20-380 mm/s), and different viscosities (10.1-108.6 mPa·s) of PAO base oil. The experimental results showed that light treatment could reduce the friction coefficient of PAO4 base oil lubrication from 0.034 to 0.016, with a reduction of 52.9% under conditions of 3 N-load and 56.5 mm/s-speed, and the best regulation effect could be achieved under the mixed lubrication condition. After TiO2 was treated with ultraviolet light, due to its photocatalytic property, PAO molecules were oxidized and adsorbed on the TiO2 surface to form an adsorption layer, which avoided the direct contact of rough peaks and thus reduced the friction coefficient. This study combines photosensitivity, photocatalysis, and friction, presenting a method to reduce the friction coefficient by applying a light field without changing the friction pairs or lubricants, which provides a new direction for friction modulation and gives new ideas for practical applications.

Insights into modeling approaches for boundary- and mixed-lubricated conditions

PurposeTribological research is complex and multidisciplinary, with many parameters to consider. As traditional experimentation is time-consuming and expensive due to the complexity of tribological systems, researchers tend to use quantitative and qualitative analysis to monitor critical parameters and material characterization to explain observed dependencies. In this regard, numerical modeling and simulation offers a cost-effective alternative to physical experimentation but must be validated with limited testing. This paper aims to highlight advances in numerical modeling as they relate to the field of tribology.Design/methodology/approachThis study performed an in-depth literature review for the field of modeling and simulation as it relates to tribology. The authors initially looked at the application of foundational studies (e.g. Stribeck) to understand the gaps in the current knowledge set. The authors then evaluated a number of modern developments related to contact mechanics, surface roughness, tribofilm formation and fluid-film layers. In particular, it looked at key fields driving tribology models including nanoparticle research and prosthetics. The study then sought out to understand the future trends in this research field.FindingsThe field of tribology, numerical modeling has shown to be a powerful tool, which is both time- and cost-effective when compared to standard bench testing. The characterization of tribological systems of interest fundamentally stems from the lubrication regimes designated in the Stribeck curve. The prediction of tribofilm formation, film thickness variation, fluid properties, asperity contact and surface deformation as well as the continuously changing interactions between such parameters is an essential challenge for proper modeling.Originality/valueThis paper highlights the major numerical modeling achievements in various disciplines and discusses their efficacy, assumptions and limitations in tribology research.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2023-0076/

Study on the performance of reciprocating seals under the coupling effect of elastohydrodynamic lubrication and rubber wear

Due to the lack of research on the sealing performance of reciprocating combined seals under the coupling of elastohydrodynamic lubrication and rubber wear, this paper uses the UMESHMOTION user subroutine and the improved Archard model to realize the dynamic wear process of the combined seals and the adaptive meshing of the local area to simulate the wear of the seals. At the same time, combined with the elastohydrodynamic lubrication model of the toothed slip ring combined seal ring, the sealing performance of the reciprocating combination under mixed lubrication conditions is studied. Finally, the accuracy of the model is verified by building a two-cylinder reciprocating seal test bench with more accurate measurement. The results show that the influence of the change of fluid pressure on the wear of the seal lip is greater in the fast wear stage than in the stable wear stage. The influence of the change of interference on the wear of the sealing lip is small at different wear stages. The wear of the sealing lip has a significant effect on the sealing performance of the instroke, but has little effect on the sealing performance of the outstroke.

Prediction of ball-on-plate friction and wear by ANN with data-driven optimization

For training artificial neural network (ANN), big data either generated by machine or measured from experiments are used as input to “learn” the unspecified functions defining the ANN. The experimental data are fed directly into the optimizer allowing training to be performed according to a predefined loss function. To predict sliding friction and wear at mixed lubrication conditions, in this study a specific ANN structure was so designed that deep learning algorithms and data-driven optimization models can be used. Experimental ball-on-plate friction and wear data were analyzed using the specific training procedure to optimize the weights and biases incorporated into the neural layers of the ANN, and only two independent experimental data sets were used during the ANN optimization procedure. After the training procedure, the ANN is capable to predict the contact and hydrodynamic pressure by adapting the output data according to the tribological condition implemented in the optimization algorithm.

An improved mixed lubrication model for revealing the mechanism of high speed and frictional heat on sealing performance

This study presents a numerical model that incorporates the actual micro morphology of sealing lip and rotating shaft to elucidate the sealing behavior in high-speed rotating lip seals operating under mixed lubrication conditions. The model explores the intricate interplay between hydrodynamics at the interface, macro-scale solid mechanics, micro-contact mechanics of surfaces, and the heat generated by friction at the lip. Based on this model, this paper quantitatively predicts the leakage rates and friction torque under various operating conditions and lip seal structural parameters, shedding light on the influence of high-speed frictional heat on sealing performance.

Experimental Analysis of Rolling Torque and Thermal Inlet Shear Heating in Tapered Roller Bearings

The investigation in this article focuses on the rolling resistance torque and thermal inlet shear factor in tapered roller bearings (TRBs) through systematic experiments using a modular test setup. TRBs typically operate under Elastohydrodynamic Lubrication (EHL) conditions. At sufficiently high speeds, the majority of rolling friction is due to a significant shift of the pressure centre in the EHL contact. While at lower speeds, sliding friction in the roller-rib contact becomes dominant, which operates under mixed lubrication conditions. Limited literature exists on the impact of inlet shear heating on effective lubricant temperature (Tin_c) and rolling friction in TRBs. To fill this gap, experimental measurements of the total frictional torque under axial loading at different speeds and oil temperatures are performed. With existing models for different friction contributions described in the literature, the rolling resistance due to EHL has been determined for various operating conditions. The effects of dimension-less speed (U), material (G), and load (W) parameters have also been investigated. Under fully flooded conditions, it was observed that the influence of material (G) and load (W) parameters on rolling friction is minor, while the impact of velocity (U) is significant. In the context of rolling resistance, the heating due to shear of the lubricant in the inlet zone plays a significant role. For higher rotational velocities, the estimated rotational torque reduction resulting from inlet shear heating was found to be approximately 6–8%.

Tribological characteristics of hard-to-hard matching materials of cylinder block/valve plate interface in electro-hydrostatic actuator pumps

Axial piston pumps, serving as the essential power component in electro-hydrostatic actuators (EHA), play a crucial role in achieving advanced actuation by ensuring high efficiency and reliability. The cylinder block/valve plate interface, which is the greatest contact area inside the axial piston pump, significantly affects both leakage and energy dissipation. The interface experiences significant friction loss and severe wear in aerospace applications, primarily due to the rapidly changing mixed and boundary lubrication conditions under a wide range of speed and pressure. Therefore, to improve the efficiency and reliability of electro-hydrostatic actuators, strengthening the cylinder block/valve plate interface is a key problem to overcome. Previous studies have demonstrated that the utilization of soft-to-hard matching materials enhances the friction characteristics of the interface, but it also results in relatively severe wear on the soft material. Therefore, in this study, we propose the concept of employing hard-to-hard matching materials as a strategy to mitigate wear in axial piston pumps. An optimized friction simulation test apparatus is adopted, which contains a simulated piston structure to take the piston stirring effect into consideration. Experimental results show that the implementation of hard-to-hard materials leads to a substantial improvement in the wear resistance of the interface under a wide range of rotational speed (300–6000 rpm). The wear depths of the TiAlN/TiAlN (hard-to-hard) matching material are only 28.6%~34.7% of the tin bronze/TiAlN (soft-to-hard) matching material. Besides, compared with traditional tin bronze/nitrided (soft-to-hard) matching material, the hard-to-hard matching materials improve both friction and wear performance. The hard-to-hard matching materials provide a novel approach to reinforce the cylinder block/valve plate interface, and thus to promote volumetric efficiency and extend the service life of the axial piston pump.

Analysis of the Rolling Interface Contact Characteristics in Mixed Lubrication Based on Gaussian Distribution Theory.

To reveal the influence of surface morphology characteristics in mixed lubrication on the contact characteristics of the rolling interface, a random three-dimensional rough surface model based on Gaussian distribution theory was established. The model utilizes the finite element method (FEM) to simulate the regular contact and tangential sliding behavior of micro-asperities at the rolling interface in mixed lubrication conditions. The connection bearing capacity of models with varied roughness in mixed lubrication was studied. Furthermore, the effect of various sliding and normal indentation amounts on the normal and friction stress was investigated. The simulation result reveals that the roughness of the surface influences the distribution of the lubricating oil film. The lubricating oil layer between the interfaces with a lower roughness has a higher bearing capacity due to its more uniform distribution of peaks and valleys. An increase in the normal indentation amount raises the friction stress and normal stress. In contrast, an increase in sliding lowers the normal pressure, substantially impacting the fluctuation of the friction coefficient dramatically. Finally, the random three-dimensional rough surface model is verified by comparing it with the experimental data in the related literature.