Lubricant Film Thickness Research Articles

Electrical Impedance Spectroscopy for Precise Film Thickness Assessment in Line Contacts

In this article, we focus on utilising electrical impedance spectroscopy (EIS) for the assessment of global and contact impedances in roller bearings. Our primary objective is to establish a quantitative prediction of lubricant film thickness in elasto-hydrodynamic lubrication (EHL) and investigate the impedance transition from ohmic to capacitive behaviour as the system shifts from boundary lubrication to EHL. To achieve this, we conduct measurements of electrical impedance, bearing and oil temperature, and frictional torque in a cylindrical roller thrust bearing (CRTB) subjected to pure axial loading across various rotational speeds and supply oil temperatures. The measured impedance data is analysed and translated into a quantitative measure of lubricant film thickness within the contacts using the impedance-based and capacitance-based methods. For EHL, we observe that the measured capacitance of the EHL contact deviates from the theoretical value based on a Hertzian contact shape by a factor ranging from 3 to 11, depending on rotational speed, load, and temperature. The translation of complex impedance values to film thickness, employing the impedance and capacitance method, is then compared with the analytically estimated film thickness using the Moes correlation, corrected for inlet shear heating effects. This comparison demonstrates a robust agreement within 2% for EHL film thickness measurement. Monitoring the bearing resistance and capacitance via EIS across rotational speeds clearly shows the transition from boundary to mixed lubrication as well as the transition from mixed lubrication to EHL. Finally, we have observed that monitoring the electrical impedance appears to have the potential to perform the run-in of bearings in a controlled way.

Vibrations and film thickness in grease-lubricated deep groove ball bearings

Understanding the relevance and significance of the various replenishment mechanisms in grease-lubricated bearings is very important in choosing the appropriate lubrication strategy. This study shows that the lubricant film thickness in the ball-ring contacts of a deep groove ball bearing may increase by 10%–25% due to vibrations. The possible mechanisms behind this film thickness increase are discussed. Of the proposed contact replenishment mechanisms, the micro-lateral motion of the contact edge across the tracks caused by in-operation vibrations appears crucial. Results show that in the starved contacts, vibration plays a vital role in determining the film thickness.

Investigations on Ways to Improve the Scuffing and Wear Behavior of Oil-Free Water-Based Lubricants for Gear Applications

Abstract Today, mineral or synthetic oils that are made out of fossil raw materials are the most common lubricants in gear drive applications. Most of them are nonbiodegradable and may pose a risk to the environment. An important step to minimize the risk and the ecological footprint is the use of biodegradable and eco-friendly lubricants. Former research shows the potential of water-based lubricants in gear applications. Therefore, an oil-free, water-based lubricant was developed for this study. The base lubricant contains plant-based thickeners to generate an appropriate viscosity for a sufficient lubricant film thickness in the tooth contact. In experimental investigations, the sliding wear and scuffing performance has been examined under variation of the added polymers and additives. The scuffing tests A/8.3/RT are performed according to DIN ISO 14635-1. The wear test procedure is based on DGMK 377-01. In both scuffing tests with the sample, the failure load stage = 8 was achieved. For case-carburized gears, a “medium” to “high” amount of wear can be detected. Additional tests with nitrided gears show a “low” amount of wear. This article aims to show the great potential of water-based oils for gear lubrication and suggests operating conditions for maximum wear and scuffing carrying capacity.

Accuracy-improved ultrasonic phase algorithm for measuring lubricant film thickness

The reflected ultrasonic waves are generally used for the determination of the lubricant film thickness, which consist of a directly reflected wave at the first solid-lubricant interface and the other reflected waves passing through the oil layer. The whole reflected waves are generally utilized in current available ultrasonic algorithms. However, the directly reflected wave is independent on the lubricant film, which can be ignored for improving the measurement accuracy. In the present work, an accuracy-improved ultrasonic phase algorithm is proposed based on the reflection coefficient phase of the other reflected waves passing through the oil layer, rather than that of the whole reflected waves. Both experimental and finite element analysis results show that the proposed new algorithm possesses a high sensitivity and a robust anti-noise interference ability, which effectively improves the measurement accuracy, especially for thin films. With comparison to the current available phase algorithm, the maximum measurement error of lubricant film thickness decreased from 45 % to 6 %.

Using electrical impedance spectroscopy to identify equivalent circuit models of lubricated contacts with complex geometry: In-situ application to mini traction machine

Electrical contact resistance or capacitance as measured between a lubricated contact has been used in tribometers, partially reflecting the lubrication condition. In contrast, the electrical impedance provides rich information of magnitude and phase, which can be interpreted using equivalent circuit models, enabling more comprehensive measurements, including the variation of lubricant film thickness and the asperity (metal-to-metal) contact area. An accurate circuit model of the lubricated contact is critical as needed for the electrical impedance analysis. However, existing circuit models are hand derived and suited to interfaces with simple geometry, such as parallel plates, concentric and eccentric cylinders. Circuit model identification of lubricated contacts with complex geometry is challenging. This work takes the ball-on-disc lubricated contact in a Mini Traction Machine (MTM) as an example, where screws on the ball, grooves on the disc, and contact close to the disc edge make the overall interface geometry complicated. The electrical impedance spectroscopy (EIS) is used to capture its frequency response, with a group of load, speed, and temperature varied and tested separately. The results enable an identification of equivalent circuit models by fitting parallel resistor-capacitor models, the dependence on the oil film thickness is further calibrated using a high-accuracy optical interferometry, which is operated under the same lubrication condition as in the MTM. Overall, the proposed method is applicable to general lubricated interfaces for the identification of equivalent circuit models, which in turn facilitates in-situ tribo-contacts with electric impedance measurement of oil film thickness – it does not need transparent materials as optical techniques do, or structural modifications for piezoelectric sensor mounting as ultrasound techniques do.

Flow and thermo-hydrodynamic characteristics in supercritical CO2 lubrication

Supercritical CO2 is used as an important lubricant in Brayton cycle turbomachinery, and the study of lubricant flow and heat transfer mechanisms plays a crucial role in the lubrication performance of Supercritical CO2. To improve the thermal environment and load capacity performance of lubrication in turbomachinery, the turbulence models and real gas models were used in this work to numerically simulate the evolution of lubrication flow and thermal characteristics of CO2 from low pressure to supercritical condition. Simulations were conducted under various operating parameters and lubrication conditions. The rarefaction effect, viscous heat, compression heat and tribological performance were analyzed. The findings indicate that the lubrication film temperature characteristics of low operating pressure depended on the viscous heat dissipation. Under the effect of rarefaction, the CO2 lubrication pressure maximum decreased of 3.0 %. As the operating pressure increased to the supercritical condition, the compression heat effect of SCO2 lubricating film increased and dominated the temperature distribution characteristics of the lubricating film. High operating pressure enhanced the pressure and load capacity of the lubrication film, and reduced the maximum lubrication temperature by 7.2 K. However, it was observed that near the critical temperature, fluctuations in the load capacity and friction torque of the lubricating film damaged the stable operation of the rotor. The change in lubrication film thickness has a significant impact on the load capacity and viscous heat dissipation, with variations as high as 81.4 % and 82.6 %, respectively. The research results provide guidance for the selection of operating pressure and temperature within the lubrication film, thereby improving the thermal working environment and operational stability of the rotor and stator.

Effects of a typical shear dependent viscosity on analytical elastohydrodynamic lubrication film thickness predictions: A critical issue for the classical approach

Many engineering estimates of the film thickness in the concentrated contacts of real machines have come from extrapolations of measurements of elastohydrodynamic lubrication film thickness performed in glass on steel elastohydrodynamic rigs. Such estimates are likely to have large errors due to shear dependence of viscosity. The classical film thickness formulas employed have not been validated except for some Newtonian reference liquids at room temperature because the real pressure-viscosity response measured in viscometers has been ignored. A blend of polyalpha olefin base oils with mild shear-thinning has been employed in a line contact calculation to assess the effects of shear-dependent viscosity on the power-law exponents of the classical film thickness formula. The exponents on the pressure-viscosity coefficient and on the elastic modulus of the solids are not sensitive to the non-Newtonian effect. The exponents on ambient pressure viscosity and velocity are slightly reduced by shear-thinning. The exponents on pressure and scale are substantially increased by the shear dependence. The usual practice of measuring film thickness in an elastohydrodynamic rig to obtain an effective “[Formula: see text]-value” to use in a classical Newtonian film thickness formula will overstated the film thickness of a liquid which is shear dependent in the elastohydrodynamic lubrication inlet.

Effect of Cu and Ni Inclusion on Tribological Performance of Tribocatalytically Active Coatings in Hydrocarbon Environments

Protective coatings are important for enhancing tribological behavior, preventing surface degradation, and reducing friction-induced energy losses during the operation of mechanical systems. Recently, tribocatalytically driven formation of protective carbon films at the contact interface has been demonstrated as a viable approach for repairing and extending the lifetime of protective coatings. Here, we study the effect of catalytic metals, specifically their composition and amount, on the tribocatalysis process. To achieve this, we test the tribological performance of electro-deposited amorphous CoNiP and CoCuP coatings in different hydrocarbon-rich environments. Our results indicate that the tribocatalytic repair of wear-induced damage is optimal when Ni and Cu are included in the Co-P matrix at 5 wt% Ni and 7 wt% Cu, respectively. Characterization of the wear tracks suggests that among the considered samples, the tribofilms formed on the surface of Co7CuP have the highest concentration of graphitic carbon, leading to a more significant reduction in the COF and wear rate. The carbon tribofilm formation was more pronounced in decane and synthetic oil than in ethanol, which is attributed to the difference in the length of the hydrocarbon molecules affecting viscosity and the lubricant film thickness during boundary lubrication sliding.

Effect of Grease Filling on the Film Thickness in Deep-Groove Ball Bearings

Determining the film thickness during the bleeding phase of grease lubrication in a bearing is difficult due to the various replenishment and loss mechanisms involved. An additional factor that could influence the film thickness is the amount of grease in the bearing. In this study, film thickness is measured in deep-groove ball bearings using two different greases, each with initial grease filling percentages of 7.5%, 15%, and 30% of the bearing’s free volume. Film thickness is measured during the early stage of the bleeding phase at various loads and speeds using the electrical capacitance method. Results show that, after churning, values of temperature and film thickness are similar for the three different filling quantities. This indicates that bulk grease flow or oil bleed from the reservoirs formed in the unswept region does not impact the lubricant film thickness in the early stage of bearing operation.

Investigation of oil emission mechanisms in a marine medium-speed dual-fuel engine

Pilot-ignition Otto marine engines are known for greatly reduced emissions of air pollutants (sulphur oxides, nitrogen oxide, particulates) compared to marine diesel engines. However, lubricating oil emissions still are about one order of magnitude higher than in land-based systems. To identify reduction potentials, a better understanding of oil emission mechanisms has to be gained. For this purpose, mass spectrometric oil emission measurements and fluorescence lubricating film thickness measurements were performed on a medium-speed marine engine. With the fluorescence measuring system, the varying lubricating oil film on the cylinder wall can be visualised and analysed in sub-crank-angle resolution. By applying the developed calibration method to the measurement data, the oil film thickness can be determined in µm. It is shown that the oil film left by the piston rings on the liner as it moves down is almost halved after ignition compared to during intake stroke. The authors have further been able to detect and time operating point dependent ring rotation and investigations show a connection between ring rotation and cylinder liner temperature distribution. Aligning ring gaps allow blow-by to happen. This and other high intensity events such as engine knock, load shedding or the transition from diesel-mode to gas-mode, heavily disturb the oil layer and cause peaking oil emissions.

Effect of Oil Dispersion on Lubricating Film Thickness Generation under Oil Droplet Supply Conditions

Oil–air lubrication has proven to be very effective for high-speed bearings because the oil supply in the form of droplets can be precisely controlled. This work uses optical interferometry to study the mechanism of lubricating film formation in rolling point contact with oil droplet lubrication. The effect of a double oil drop pair, where two oil droplets are positioned in mirror images about the central axis of the lubricated track, is examined. The process by which pairs of oil droplets approach and lubricate a bearing contact is analysed. This study also covers the effect of multiple oil droplets supplied in a tailored or a random dispersion pattern. Additionally, the effects of oil viscosity, entrainment velocity, and droplet distribution on starvation are also investigated.

Machine Learning for Film Thickness Prediction in Elastohydrodynamic Lubricated Elliptical Contacts

This study extends the use of Machine Learning (ML) approaches for lubricant film thickness predictions to the general case of elliptical elastohydrodynamic (EHD) contacts, by considering wide and narrow contacts over a wide range of ellipticity and operating conditions. Finite element (FEM) simulations are used to generate substantial training and testing datasets that are used within the proposed ML framework. The complete dataset entails 915 samples; split into an 823-sample training dataset and a 92-sample testing dataset, corresponding to 90% and 10% of the combined dataset samples, respectively. The proposed ML model consists of a pre-processing stage in which conventional EHD dimensionless groups are used to minimize the number of inputs into the model, reducing them to only three. The core of the model is based on Gaussian Process Regression (GPR), a powerful ML regression tool, well-suited for small-sized datasets, producing output central and minimum film thicknesses, also in dimensionless form. The last stage is a post-processing one, in which the output film thicknesses are retrieved in dimensional from. The results reveal the capabilities and potential of the proposed ML framework, producing quasi-instantaneous predictions that are far more accurate than conventional film thickness analytical formulae. In fact, the produced central and minimum film thickness predictions are on average within 0.3% and 1.0% of the FEM results, respectively.

A General Case of a Line Contact Lubricated by a Non-Newtonian Giesekus Fluid

A steady plane hydrodynamic problem of lubrication of a lightly loaded contact of two parallel cylinders lubricated by a non-Newtonian fluid with Giesekus rheology is considered. The advantage of this non-Newtonian rheology is its ability to properly describe the real behavior of formulated lubricants at high and low shear stresses. The problem is solved by using a modification of the regular perturbation method with respect to the small parameter α, characterizing the degree to which the polymeric molecules of the additive to the lubricant follow the streamlines of the lubricant flow. It is assumed that the lubricant relaxation time and the value of α are of the order of the magnitude of the ratio of the characteristic gap between the contact surfaces and the contact length. The obtained analytical solution of the problem is analyzed numerically for the dependencies of the problem characteristics such as contact pressure, fluid flux, lubrication film thickness, friction force, energy loss in the lubricated contact, etc., on the problem input parameters.

Deterministic surface roughness effects on elastic material contact with shear thinning fluid media

Abstract The formation of lubrication films is described using the hydrodynamic lubrication theory, which is based on the Reynolds equation that includes shear thinning behaviors of lubricant. Contacting surfaces are considered to undergo elastic deformation owing to concentrated contact pressures that exceed 1.0 GPa in most engineering applications. Under the contact condition of a high load on a relatively small contact area, elastic deformation of contacting bodies directly influences the formation of the lubricated film. Elastohydrodynamic lubrication (EHL) analysis is applied to correctly analyze the lubricated contact. Under an EHL contact, the scale of the lubrication film thickness is frequently less than that of the surface roughness that results from either the manufacturing or running-in processes. In this work, surface roughness is considered in detail, and two-dimensional surface roughness is measured as that characterizing general engineering surface roughness. The deterministic method regarding the surface roughness is considered for computing EHL film formation under several contact conditions such as load, contact velocity, and elasticity of contacting materials.

Investigation of Lubricant Oil Film Thickness on Workpiece under Minimum Quantity Lubrication Milling Process

Investigation of Lubricant Oil Film Thickness on Workpiece under Minimum Quantity Lubrication Milling Process

Effects of Drilling Parameters and Mud Types on Wear Factors and Mechanisms of SM2535 Casings

This work aims to explore the impact of side loads, drill-pipe tool-joint (DP-TJ) speed (rpm), and mud type on the austenitic stainless steel SM2535-110 casing wear characteristics. Actual field drill pipe tool joints, casings, and drilling muds are used in this study. The results of the study show that under both types of lubrication, the wear volume increased with radial load and DP-TJ speed. SM2535-110 casing specimens tested under oil-based mud (OBM) lubrication had higher casing wear volumes than those obtained under water-based mud (WBM) lubrication. This unexpected behavior is mainly due to the increase in the surface hardness of the casing specimens tested under WBM. The results also show that the specific wear rate or wear factor (K) (which is defined as the volume loss per unit load per unit distance sliding) values of specimens tested under WBM are in general two to four times higher than those obtained under OBM. While K values under WBM increase with both the side load and rpm, those under OBM show a sharp decrease with rpm. This behavior under OBM is due to this lubricant’s higher viscosity and the change of lubrication regime from thin film to thick film lubrication at higher rpm. Scanning electron microscopy (SEM) and the digital microscopic imaging (DMI) of SM235-110 casing specimens show that an aggressive combination of adhesive, abrasive, and plastic deformation was observed under WBM, while the dominant wear mechanism under OBM is abrasive wear.

Experimental investigation on rolling contact wear in grease lubricated spherical roller bearings using microcomputed tomography (μCT)

This study presents a novel and non-destructive method for quantitatively analysing grease lubricated bearing wear by using X-ray microcomputed tomography (μCT). The efficacy of μCT to measure rolling contact wear via wear debris analysis was demonstrated, as was quantifying grease contamination and wear debris identification. Test rig experiments of grease lubricated spherical roller bearings, were performed to simulate rolling contact wear. Six grease samples were collected from two bearings at three different intervals to investigate wear progression. Results showed μCT measured wear volume increased exponentially with increasing bearing operation times. Grease cleanliness (particle counts per ml) worsened nonlinearly due to the exponential growth of wear debris over longer bearing operational times. Comparing the conventional ISO281 bearing assembly and operating condition assessment, a particle-count based method via μCT analysis provided a less subjective and dynamic assessment for quantifying grease contamination. Grease contamination was found to increase with longer operational timeframes due to the combination of wear debris growth and decreased lubrication film thickness. Finally, laminar, chunk and spherical wear particles, associated with rolling contact wear, were identified by the morphometric parameters measured by μCT. This study highlights the potential of μCT as a wear monitoring and grease quality assessment technique for railway bearing applications.

Surface modification effect of aluminium block on the tribological performance for super olein

PurposeThe purpose of this study is to investigate the use of micro-pits technology to the problem of tribological performance in a sliding motion.Design/methodology/approachVegetable oil is a sustainable and economically viable alternative to both mineral and synthetic oils, offering significant savings in both the cost of research and manufacturing. To solve the depriving issue and boost lubrication film thickness, the micro-pits on the surface may function as reservoirs that provide the oil to the contact inlet area. In this research, an aluminium block is used as the workpiece material in an evaluation of a through pin-on-disc tribotester. Lubricating oil in the form of super olein (SO) was used in the experiment.FindingsThe results show that the friction performance during a rubbing process between a hemispherical pin and an aluminium block lubricated with SO using aluminium alloy materials, AA5083, was significantly improved.Originality/valueIn this study, a material that breaks down called SO, which is derived from the fractionation of palm olein, was used to use a modified aluminium micro-pit sample that will serve as a lubricant reservoir in pin-on-disc tribotester.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2023-0200/

Investigation of Programmable Friction with Ionic Liquid Mixtures at the Nano- and Macroscales

Non-mechanical stimuli are used to directly control or program the friction properties of tribosystems. For this purpose, an ionic liquid is used as a lubricant that affects and controls the friction in the presence of external triggers. Here, it is shown that the friction behavior of two surfaces in sliding contact can be controlled and permanently changed by applying an electrical potential to an ionic liquid mixture (ILM). This change in the friction properties was demonstrated both at the nanoscale using an atomic force microscopy (AFM)-based friction force microscopy (FFM) and at the macroscale using a specially designed tribo-setup cell. In tribology, the linking of these two scales of magnitude represents one of the greatest obstacles between basic research and the step towards application-oriented system development and is therefore of fundamental importance. In addition, other parameters affecting the tribological behavior of the system, such as roughness, lubricant film thickness, and wear behavior, were investigated as a function of the electrical potentials. The correlation between the structure of surface-bound ionic liquid layers and the friction behavior can be used to control friction, thus enabling a first step towards tribosystems that automatically adapt to changing conditions.

Thermal characteristics and distribution rule of lubrication film of full ceramic ball bearing under different service condition

PurposeThe study aims to the distribution rule of lubricating oil film of full ceramic ball bearing and improve its performance and life.Design/methodology/approachThe paper established an analysis model based on the fluid–solid conjugate heat transfer theory for full ceramic ball bearings. The distribution of flow, temperature and pressure field of bearings under variable working conditions is analyzed. Meanwhile, the mathematical model of elastohydrodynamic lubrication (EHL) of full ceramic ball bearings is established. The numerical analysis is used to study the influence of variable working conditions on the lubricant film thickness and pressure distribution of bearings. The temperature rise test of full ceramic ball bearing under oil lubrication was carried out to verify the correctness of simulation results.FindingsAs the speed increased, the oil volume fraction in full ceramic ball bearing decreased and the surface pressure of rolling element increased. The temperature rise of full ceramic ball bearings increases with increasing speed and load. The lubricant film thickness of full ceramic ball bearing is positively correlated with speed and negatively correlated with load. The pressure of lubricating film is positively correlated with speed and load. The test shows that the higher inner ring speed and radial load, the higher the steady-state temperature rise of full ceramic ball bearing. The test results are in high agreement with simulation results.Originality/valueBased on the fluid–solid conjugate heat transfer theory and combined with Reynolds equation, lubricating oil film thickness formula, viscosity temperature and viscosity pressure formula. The thermal analysis model and EHL mathematical model of ceramic ball bearings are established. The flow field, temperature field and pressure field distribution of the full ceramic ball bearing are determined. And the thickness and pressure distribution of lubricating oil film in the contact area of full ceramic ball bearing were determined.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0126/