Oil Film Thickness Research Articles

Optimization of lubrication characteristics of wind turbine’s transmission system based on Newton Raphson method

To improve the reliability and lifespan of wind turbines, this paper takes the two-stage fixed shaft gearbox experimental platform of wind turbines as the research object. Based on Hertz contact theory, the oil film pressure and thickness in the contact area are solved by combining the equations of elastohydrodynamic lubrication and the Newton Raphson method; And the lubrication characteristics of the transmission system were analyzed to verify the correctness of the method; At the same time, in response to partial load phenomenon caused by system coupling deformation, genetic algorithm was selected to modify the gear teeth. The results show that the max unit load on the tooth face and the maximum stress of tooth root decreased by up to 26.48 % and up to 20.35 % respectively after modification which can improve the uneven distribution of oil film and the lubrication performance of the tooth surface.

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.

TVMS Calculation and Dynamic Analysis of Cracked Gear considering Oil Film Stiffness

A time-varying meshing stiffness (TVMS) model that includes oil film stiffness in the elastohydrodynamic lubrication (EHL) line contact is proposed for tooth root cracking. This model employs the oil film thickness to estimate the stiffness of the oil film in gear contact by considering the profile variation of the oil film induced by tooth root cracks, to provide the evolution principle of TVMS in EHL line contact to study the effects of oil film stiffness of cracked gear on the TVMS. The results of the analysis reveal that the overall result of TVMS decreases owing to the stiffness of the oil film, whereas the combined TVMS depends mainly on the rotation speed of the gear system because the thickness of the oil film in the tooth crack is affected by the velocity of the entrainment. Furthermore, a six-degree-of-freedom (DOF) dynamic model is introduced to analyze the vibration behavior of the gear system using the combined TVMS results for different crack levels, and the influence of the combined TVMS on the vibration response of the tooth root crack is exhibited from the time-domain analysis, frequency-domain analysis, and statistical indicator analysis.

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.

Impact dynamics of water droplets on oil-covered dielectrowetting substrate: Effects of oil film thickness and surface wettability

Droplet impacting on solid or liquid film is a ubiquitous phenomenon in relevant processes such as spray cooling and inkjet printing on primer layers. In this study, the dynamics of water droplets impacting a solid substrate covered by a silicon oil film is investigated under the influences of the surface wettability of the dielectrowetting substrate (69.3°-117.4°) and the thickness of the silicon oil film (7.79–21.8 μm) at We=6.81. A phase diagram is established, which reflects the relationships between the impact dynamic behavior, equilibrium contact angle, and the oil film thickness. The maximum spreading factor βmax and maximum out-of-plane height Hmax/D0 for rebound of sub-droplet behaviors was smaller than 13 % and greater than 3 times than those droplet deposition behaviors, respectively. Finally, the retraction dynamics of the droplet after reaching its maximum spreading diameter is analyzed and discussed based on retraction rate γw=vr/Dmax=σw(cosθrmin-cosθeq)/fkDmax through the force balance at the three-phase contact line. Results of the study indicate that the surface wettability of the dielectrowetting substrate and thickness of the silicon oil film significantly affect the impact dynamics of water droplets on a solid substrate covered by the silicone oil film, especially in the retraction stage. This study sheds new light on controlling the dynamic impact of the droplets on silicon oil films, which is of importance to the control or optimization of processes such as inkjet printing on a primer layer.

A Study on the Oil Film Thickness Between the Lower Rail of Oil Control Ring and Lower Flank of Oil Control Ring Groove of an Engine

Abstract Lubricating oil consumption (LOC) of engines causes particulate matter in exhaust gas and abnormal combustion like pre-ignition which becomes a serious problem in hydrogen engines. Lubricating oil transports upward into the combustion chamber of an engine via the sliding surface, the gap, and the side and back of a piston ring. The target of this study was to clarify the mechanism of oil flowing between an oil control ring lower flank and the groove which was the first entrance of lubricating oil supplied from the crankshaft. Oil film thickness at the lower flank of the oil control ring was measured by laser-induced fluorescence method using optical fibers embedded in the lower flank of the ring groove. The measured oil film thickness was compared with forces acting on the lower rail of three-piece type oil control ring. The oil film thickness change was well explained using those forces and it was found that friction force at the sliding surface and pressure in the ring groove were dominant on the oil film thickness under all operating conditions tested in this study.

Skidding behavior of lubricated rolling element bearings under the influence of oil film and radial clearances

Skidding is an inevitable phenomenon in rolling element bearing but accelerates the bearing wear and shortens the bearing life. Recognizing skidding behavior under different clearances will benefit to bearing health monitoring. In this study, an improved bearing dynamic model is developed to investigate its vibration characteristics and skidding behavior taking into all bearing structure components, time-varying oil film characteristics and bearing clearances. A novel method is proposed to include time-varying oil film stiffness and thickness under different clearances into the bearing dynamic model. A fast algorithm is adopted through interpolation during the model solving process. Furthermore, vibration responses and skidding behavior under different clearances are analyzed. Finally, a designed synchronous differential encoder (SDE) system tests the skidding behavior of bearings and verifies the proposed model through measuring the angular velocity of cage transformed by distance test. Numerical result shows that both RMS and ball pass frequency of outer race (BPFO) increase with bearing clearances. The slip ratio represents growth with the increase of bearing clearances, which is verified by the designed experiment with good consistency with the simulation. It can be foreseen that this novel dynamic model with SDE system can be well performed for bearing skidding detection and fault detection.

The 1 μm wear particles entrainment in situ observation via fluorescent staining silica particles by silane coupling with Rhodamine B

Observing wear debris during friction is crucial for comprehending the wear behavior of lubrication systems. Despite various techniques attempted for observation, a persistent challenge is the oversight of wear debris with a diameter less than 1 μm, mainly due to limitations in measurement systems. Consequently, we still lack a comprehensive understanding of whether these small particles can infiltrate contact points and serve as abrasives. In this study, we conducted in-situ friction tests to investigate the entrainment of imitation wear particles at the contact point under boundary lubrication conditions. These imitation wear particles were glass beads with diameters of approximately 0.8 μm, 1.0 μm, and 3.0 μm, respectively. To address optical limitations, we stained these particles using silane coupling to attach Rhodamine B to the glass beads. We examined the effect of particle diameter on entrainment numbers under varying outside oil film thicknesses. The results showed that the entrainment number was highest when the outside oil film thickness matched the particle diameter. This clearly indicated that the outside oil film thickness significantly influenced the entrainment of particles.

Effect of chevron-shaped wetting patterns on oil film thickness in cylinder-on-disc contact under starved lubrication or limited lubricant supply

This study addresses the oil starvation problem in roller bearing line contacts and proposes a novel Chevron-shaped wetting/oleophilic pattern on the bearing track to enhance oil replenishment. Validation through optical cylinder-on-disc lubrication film tests reveals the impact of the pattern on inlet oil supply and film thickness. Notably, a Chevron pattern oriented opposite to disc movement significantly increases film thickness. Wetting is more pronounced in oleophilic areas (Chevron pattern), forming an inverted V-shaped "virtual wall" that directs lubricant backflow toward the center and reduces side leakage. A pattern length equal to the bearing track width was found to be more effective compared to smaller sizes, as the oil side ridges are located on the oleophobic and oleophilic boundaries, which capitalizes the wettability step effect more effectively. This research provides a basis for designing oleophobic surfaces with improved anti-wear and anti-friction properties.

Influence of Glyceryl Monostearate Adsorption on the Lubrication Behavior of a Slider Bearing

Glyceryl monostearate (GMS) was used as an organic friction modifier (OFM) and added to the base oil (PAO10, polyα-olefin) in this study. The film thickness and friction coefficient of the base oil added with GMS (PAO10G) under different slider inclinations and loads were investigated experimentally by using a slider-on-disc contact lubricant film measurement system, and the effect of the adsorption of GMS on the friction behavior of lubricant was studied. Contact angle hysteresis (CAH) was used to evaluate the wettability of the solid–liquid interface, and its correlation with the coefficient of friction was analyzed. The results show that CAH is in good agreement with the wettability of the solid–liquid interface. Compared with the base oil, the wettability of POA10G is weak, which can effectively reduce the coefficient of friction. However, different from the classical lubrication theory, the film thickness of PAO10G is higher than that of PAO10; this unusual phenomenon is preliminarily explained by the interface slippage in this paper.

Study on vibration suppression of an aero-engine rotor system with adjustable oil film thickness driven by piezoelectric actuator through critical speed

The squeeze film damper (SFD) is difficult to meet the vibration control requirements of the rotor at both the critical speed and other rotor speeds at the same time due to the fixed structural parameters. The control method of piezoelectric ceramic actuator (PZT) actively changing the SFD oil film gap is proposed to suppress the critical amplitude of the rotor system. The dynamic model of the rotor system with PZT is established. The mechanical controllable characteristics of SFD are revealed, and the vibration damping performance of the controllable SFD (CSFD) is studied at critical speed. Both experiment and theory show that the proposed method can effectively suppress the critical amplitude of the rotor system with different imbalance.

Study on Heat Transfer Characteristics of High-Speed Herringbone Gear in Meshing Process Under Oil Injection Lubrication

Abstract To quantify the relationship between the total frictional heat and the absorbed heat by the oil film in the herringbone gear transmission, this article investigates the lubrication status and thermal characteristics of the tooth meshing point under the fuel injection condition. First, the contact analysis of the herringbone gears is carried out—studying the variation pattern of the maximum pressure, highest temperature rise, and minimum film thickness of different oil films at various mesh points along the meshing line. Second, the friction coefficient and frictional power for the meshing points on the tooth surface are calculated to determine the ratio of oil film pressure to total pressure distribution. This completes the allocation of frictional power for the meshing points of the driving and driven gears. Finally, by comparing the total heat generated by frictional shear with the heat absorbed by the oil film, the numerical relationship between the two can be quantified.

Investigation of the leakage in the flow distribution pair of radial piston hydraulic motors through CFD analysis and experiments

The internal leakage of a radial piston motor (RPM) is an unavoidable structural characteristic, and the amount of internal leakage has a critical effect on the volumetric efficiency of the motor. Using the distribution plate as the force body, an equation for the balance between the preload spring force and the hydrodynamic force is analytically derived, the variation range of the clearance of the flow distribution pair (FDP) is determined, and a model for the internal leakage flow of the FDP is developed. Based on computational fluid dynamics (CFD) simulations, the effects of the oil film thickness, inlet pressure, motor speed, and oil temperature on the leakage volume are investigated. An efficiency test system for RPMs is built and tests are performed on motor prototypes. The experimental results show that the error between experimental and simulation results decreases gradually with increasing motor speed. When the motor runs at the rated speed, the error is stable within 5%. The experimental results verify the correctness of both the theoretical and CFD models. The CFD analysis method can be used as a technical means to optimize the motor volumetric efficiency and the preload spring design.

Experimental and numerical study on the dynamic and lubrication characteristics of the rotor-bearing-frame system in a variable-speed scroll compressor

The variable-speed scroll compressors can adapt to the various demands of heating and cooling capacity, and the rotational speeds significantly influence the rotor dynamic and bearings lubrication, which might cause performance and reliability issues. In this paper, numerical models for the rotor-bearing-frame system are developed by coupling the Reynolds equation, rotor dynamic equation, and the flexibility equation of the frame. The experimental apparatus is also established to directly measure the journal displacement response in the hermetic high-pressure shell of the compressor. The predicted journal center trajectories are compared with the experimental results and they show good agreement. Results show that the whirl radius decreases with the increase of rotational speed at the measuring point, while the opposite tendency can be observed at the bottom of the main bearing. Transient dynamic analysis of the rotor shows that the tilting and deformation of the rotor vary with respect to different rotational speeds. The displacement of the crank part could lead to the separating tendency between orbiting and fixed scrolls through the coupled orbiting bearing, especially at the lower rotational speed, due to the pull of main balance weight. The numerical results also reveal that the distribution of oil film pressure is dominated by the squeeze effect due to the relatively stable magnitude but the variable direction of loads on the shaft. The influence of the deformation of the cantilevered bearing frame on the oil film thickness is significant but the maximum deformation moves downward at the higher rotational speed.

Micro Lubrication and Heat Transfer in Wedge-Shaped Channel Slider with Convex Surface Texture Based on Lattice Boltzmann Method

Hydrodynamic lubrication is widely used between two relatively moving objects, and the effect of fluid flow state and temperature distribution on lubrication performance in wedge-shaped gaps is a popular topic to study. In this paper, the incompressible double-distribution lattice Boltzmann method (LBM) is applied to study the effect of micro convex surface texture on micro lubrication and heat transfer in wedge-shaped channels. By comparing this model with the analytical solution of an infinitely wide wedge slider, the maximum pressure calculated by LBM is 0.1081 MPa, and the maximum pressure calculated by the Reynolds equation is 0.1079 MPa. The error of the maximum pressure is 1.11%, and the Reynolds equation result is slightly smaller. The reason is that the Reynolds equation ignores the influence of fluid inertia force on oil film pressure. The results indicate that the application of LBM can be used to study lubrication problems. Compared with the Reynolds equation, LBM can calculate the velocity field and pressure field in the film thickness direction, and can also observe precise flow field details such as vortices. Three micro convex texture shapes were established to study the effects of different convex textures on micro lubrication and oil film temperature distribution, and the velocity distribution, temperature distribution and oil film pressure along the oil film thickness direction were given. Under the same conditions, comparing the oil film pressure with and without surface texture, the results show that the maximum oil film pressure with surface texture 3 is increased by about 4.34% compared with that without surface texture. The slightly convex texture can increase the hydrodynamic lubrication effect and obtain greater load-bearing capacity, helping to reduce the possibility of contact friction. The results show that the convex surface texture can improve the hydrodynamic lubrication performance, increase the load carrying capacity and reduce the possibility of contact friction, and the convex surface texture can influence the temperature distribution of the oil film. At 3.6 mm in the slider length direction and 7.5 μm in the oil film thickness direction, the temperature of surface texture 1 is 402.64 K, the temperature of surface texture 2 is 403.31 K, and the temperature of surface texture 3 is 403.99 K. The presence of vortices is captured at a high convergence ratio.

Substrate-Assisted Laser-Induced Breakdown Spectroscopy Combined with Variable Selection and Extreme Learning Machine for Quantitative Determination of Fenthion in Soybean Oil

The quality and safety of edible vegetable oils are closely related to human life and health, meaning it is of great significance to explore the rapid detection methods of pesticide residues in edible vegetable oils. This study explored the applicability potential of substrate-assisted laser-induced breakdown spectroscopy (LIBS) for quantitatively determining fenthion in soybean oils. First, we explored the impact of laser energy, delay time, and average oil film thickness on the spectral signals to identify the best experimental parameters. Afterward, we quantitatively analyzed soybean oil samples using these optimized conditions and developed a full-spectrum extreme learning machine (ELM) model. The model achieved a prediction correlation coefficient (RP2) of 0.8417, a root mean square error of prediction (RMSEP) of 167.2986, and a mean absolute percentage error of prediction (MAPEP) of 26.46%. In order to enhance the prediction performance of the model, a modeling method using the Boruta algorithm combined with the ELM was proposed. The Boruta algorithm was employed to identify the feature variables that exhibit a strong correlation with the fenthion content. These selected variables were utilized as inputs for the ELM model, with the RP2, RMSEP, and MAPEP of Boruta-ELM being 0.9631, 71.4423, and 10.06%, respectively. Then, the genetic algorithm (GA) was used to optimize the parameters of the Boruta-ELM model, with the RP2, RMSEP, and MAPEP of GA-Boruta-ELM being 0.9962, 11.005, and 1.66%, respectively. The findings demonstrate that the GA-Boruta-ELM model exhibits excellent prediction capability and effectively predicts the fenthion contents in soybean oil samples. It will be valuable for the LIBS quantitative detection and analysis of pesticide residues in edible vegetable oils.

The Prediction of Wear Depth Based on Machine Learning Algorithms

In this work, ball-on-disk wear experiments were carried out on different wear parameters such as sliding speed, sliding distance, normal load, temperature, and oil film thickness. In total, 81 different sets of wear depth data were obtained. Four different machine learning (ML) algorithms, namely Random Forest (RF), K-neighborhood (KNN), Extreme Gradient Boosting (XGB), and Support Vector Machine (SVM) were applied to predict wear depth. By analyzing the performance of several ML algorithms, it is demonstrated that ball bearing wear depth can be estimated by ML models by inputting different parameter variables. A comparative analysis of the performance of the different models revealed that XGB was more accurate than the other ML models at anticipating wear depth. Further analysis of the attribute of feature importance and correlation heatmap of the Pearson correlation reveals that each input feature has an effect on wear.

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.

Experimental study on the effect of sloping substrate on the spill fire in a well-confined ship engine room

Fuel leakage in the ship engine room tends to form the dynamically evolving spill fires instead of pool fires, which are full of danger and have been scarcely concerned. In this work, one-dimensional spill fire experiments with different fuel leakage rates and substrate slopes are tentatively conducted in a well-confined model-scale ship engine room to reveal their fire dynamics characteristics. It is found that the development of spill fires in the ship engine room is quite different from that in open space, and it, to a great extent, depends on the specific leakage rate and substrate slope. Typically, the spill fire in the ship engine room can be divided into five stages: continuous spreading, steady burning, burning shrinkage, quasi-steady burning, and decay stages, while the steady or quasi-steady stage does not always appear for all cases. In the quasi-steady burning stage, the thickness of the critical oil film is between 0.97 and 1.55 mm, smaller than that in the open space. The special fire phenomena are mainly attributed to the confined boundary condition, where the competing mechanisms of fuel control and ventilation control effects will collectively influence the development of the spill fire in the ship engine room. Characteristic parameters of spill fires in ship engine room, including flame spread rate, burning area, burning rate, and flame height, are also quantitatively analyzed.