Optical measurements in elastohydrodynamic rolling-contact bearings

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Grease

Everybody has made use of grease in their daily lives. The word “grease” originates from the early Latin word “crassus,” meaning fat. For our purposes, in this Special Issue, we will be focusing on lubricating grease, for publication in the eponymous journal Lubricants. According to ASTM, lubricating grease may be defined as “a solid-to-semi-fluid product of dispersed thickening agents in a liquid lubricant”. Other functional ingredients, such anti-wear and extreme pressure additives, may be included, with the overall goal of inducing special properties/functionalities. Grease is a very complex lubricant. We have never had a Special Issue focusing on this key product, and lubricating greases are often underrepresented in the technical literature. In recent years, there has been significant progress in research on greases, ranging from the specific chemical formulation of greases for special applications to how grease interacts with various surfaces, tribological advances in grease properties, new techniques for grease property measurements, etc. Recently, greases have also been evolving, as they and play a key role in the lubrication of electric vehicles. We aim to select the top research avenues and papers worldwide related to lubricating greases to form this compilation. This Special Issue wishes to be the first of its kind, and we plan to make this an annual exercise, where our compendium aims to discuss the latest developments worldwide encompassing all areas related to greases

Developments for the calculation of heavily loaded journal bearings

This thesis describes the development of an ElastoHydroDynamic (EHD) bearing calculation. The effect of body forces is shown to be important for highly loaded bearings in reciprocating internal combustion engines. Extension of the program to rotating machinery includes an examination of instability in the shaft bearings of a turbocharger. The development of a parameter to predict cavitation damage in a bearing is promising. Several calculation results using the program are shown. These are engine main bearing and connecting rod big-end bearings and full floating bearings for a turbocharger. The calculations on the big-end bearing if a racing engine show why the designers were having difficulty understanding the correct location for the oil feed hole position. Effects of elastic deformation, thermal deformation and manufacturing/assembly deformation all have a significant effect on the extent of the oil film. A novel calculation for a cavitation damage parameter is demonstrated successfully for a heavily loaded diesel engine bearing. The importance of body forces on the oil film due to high accelerations on certain bearings is shown to be theoretically important but not yet demonstrated. The program was written with the intention to be incorporated into the sponsoring company’s range of engine design software. A part of that development process included carrying out calculations to demonstrate to customers and present papers at conferences. The results of some of these calculations have been included in this thesis. Results of a study on the effect of crankshaft geometry on racing engine viscous friction losses were reported in a paper presented at the IDETC conference in Long Beach, 2005. This study used the first version of the software which only included Rigid Hydro Dynamics (RHD) at the time but was usable. Results of a study on stability of shaft motion in high speed turbocharger bearings were reported in a paper at the 8th International Turbocharger conference in London, 2006. At this time the program was still only capable of RHD calculations but could now solve for multiple oil films simultaneously and sweep through the speed range. The studies on the effects of body forces and the development of a cavitation parameter will be presented in papers in the near future

Tribo-dynamic analysis of hypoid gears in automotive differentials

Torsional vibrations in differentials of Rear Wheel Drive vehicles are of major importance for the automotive industry. Hypoid transmissions, forming the motion transfer mechanism from the driveshaft to the wheels, suffer from severe vibration issues. The latter are attributed to improper mesh between the mating gear flanks due to misalignments, variation of contact load and shifting of the effective mesh position. For certain operating conditions, the gear pair exhibits high amplitude motions accompanied with separation of the mating surfaces. Ultimately, single or even double-sided vibro-impact phenomena evolve, which have been related to noise generation. This thesis attempts to address these issues by effectively analysing the dynamic behaviour of a hypoid gear pair under torsional motion. The case study considered is focused on a commercial light truck. The major difference of the employed mathematical model to prior formulations is the usage of an alternative expression for the dynamic transmission error so that the variation of contact radii and transmission error can be accounted for. This approach combined to a correlation of the resistive torque in terms of the angular velocity of the differential enables the achievement of steady state, stable periodic solutions. The dynamic complexity of systems with gears necessitates the identification of the various response regimes. A solution continuation method (software AUTO) is employed to determine the stable/unstable branches over the operating range of the differential. The ensuing parametric studies convey the importance of the main system parameters on the dynamic behaviour of the transmission yielding crucial design guidelines. A tribo-dynamic investigation aims at expanding the dynamic model from pure dry conditions to a more integrated elastohydrodynamic (EHL) approach. Analytical and extrapolated solutions are applied for the derivation of the film thickness magnitude based on the kinematic and loading characteristics of the dynamic model. The temperature rise is governed mainly by conduction due to the thin lubricant films. The generated friction is also computed as a function of the viscous shear and asperity interactions. The effective lubricant viscosity is greatly affected by the pressure increase due to the resonant behaviour of the contact load. The final part of this work is involved with a feasibility study concerning the application of Nonlinear Energy Sinks (NES) as vibration absorbers, exploiting their ability for broadband frequency interaction. Response regimes associated with effective energy absorption are identified and encouraging results are obtained, showing the potential of the method

Measurement of film thickness in lubricated components using ultrasonic reflection.

Many everyday objects are used without consideration of the fact that they rely on a tiny layer of lubricant as thin as 1/1000th of the thickness of a human hair in order to operate correctly. However, without the lubricant, problems are quickly noticed: door hinges squeaking, wear in engines or failure of hip implants. This thesis documents the application of ultrasound to the measurement of this layer of lubricant

Rolling element skew measurement in a spherical roller bearing utilizing a CPD probe

This thesis incorporates an array of Contact Potential Difference (CPD) sensors to measure and monitor the degree of skew in the rolling elements of a spherical roller bearing. Skewing is the motion of a roller as it turns about an axis normal to the roller race interface. Roller skew is generated as part of the kinematic effects of roller bearings. Skew monitoring is important for bearing design as it is an indirect measure of bearing life. For the purpose of this thesis, roller skew was measured utilizing multiple pairs of CPD probes located around the bearings outer raceway at varying points of the loading zone. These CPD probes are not in direct contact with the rollers, but in close proximity to their surface (through the bearing outer ring). The skew angle measured is related to different operating conditions such as applied load, shaft speed, and lubrication. The pair of CPD probes detected a signal as the roller surface passed by and the phase difference between the two distinct signals measured the skew angles in the range of 0.016 to 1.10. The shaft is rotated both clockwise and counterclockwise to capture any probe misalignment which was in the range of 0.5 up to 2.0 . This thesis also provides a model for the probe signal as a spherical roller surface passes the probe surface.M.S.Committee Chair: Steven Danyluk; Committee Member: David Sanborn; Committee Member: Shreyes Melkot

자동차용 판재성형 해석 적용을 위한 다중 스케일 마찰 모델 개발 및 평가

학위논문(박사) -- 서울대학교대학원 : 공과대학 재료공학부, 2022.2. 이명규.Sheet metal forming of advanced high strength steels (AHSS) has drawn significant attentions in automotive industry for their improved fuel efficiency by lightweightness and passenger safety by higher strength. However, the manufacturing of automotive parts with the AHSS accompanies inferior springback and formability compared to the conventional lower strength steels, which results in more time consuming trial and error in the tool design stage. To overcome this challenges in applying the AHSS to the automotive parts, finite element simulations have been commonly used as a numerical tool for predicting springback and formability of sheet metal parts prior to real try-out. Accurate modeling of finite element simulation in sheet metal forming process requires reliable numerical techniques, constitutive models, realistic boundary conditions, etc. Among these, the friction is one of important factors to determine the accuracy of the simulation, but it has been overlooked in most simulations. The frictional behavior in sheet metal forming is known to be very complex and depend on various parameters such as surface roughness, contact pressure, sliding velocity, lubrication condition, etc. However, it is a common practice to use the simplest Coulomb friction law in the finite element modeling. In the present study, a microscale asperity based friction model is further modified by imposing new model parameters for satisfying force equilibrium between contact surfaces. In addition, a geometrical shape model of the tool surface is newly proposed to determine the plowing effect of the friction. The tool geometry is modeled based on primary summits in tool height distribution determined by the measured wavelength, rather than the summits dependent on the resolution of surface measurement instrument. The friction models are required not only in the preceding boundary lubrication condition, but also in the mixed-boundary lubrication condition where sufficient lubrication exists in non-contacting surface valleys. The hydrodynamic friction model uses a load-sharing concept that considers the lubrication area and metal-to-metal contact separately. In this study, the hydrodynamic friction model is combined with the boundary lubrication friction model to account for the friction in the mixed lubrication domain. The lubricant film thickness, calculated as the volume of non-contacting surface valleys, is used to realize the coupling. The film lubrication behavior is implemented by the finite element coding of the Reynolds equation, which enables the calculation of the hydrodynamic pressure. To validate the boundary lubrication friction model, the calculated friction coefficient and the measured friction coefficient are compared according to the contact pressure under boundary lubrication conditions. Also, the boundary lubrication friction model is verified by the finite element simulation that is applied to the U-draw/bending process. Finally, the boundary lubrication friction model and the mixed boundary lubrication friction model are applied to the finite element simulation of the newly developed press-forming process, which represents the influence of various variables such as contact pressure, sliding speed and lubrication. The results of the validations show that the developed multi-scale friction models and their implementation can be efficiently used to the sheet metal forming simulations where the frictional behavior is critical for the quality of the automotive parts.AHSS(고장력강판)의 판금 성형은 경량화에 의한 연비 향상과 고강도화에 의한 승객 안전으로 자동차 산업에서 큰 주목을 받고 있습니다. 그러나 AHSS를 이용한 자동차 부품 제조는 기존의 저강도 강재에 비해 스프링백 및 성형성이 좋지않기에 툴 설계 단계에서 시행착오가 더 많이 발생하게 됩니다. 자동차 부품에 AHSS를 적용할 때 이러한 문제를 극복하기 위해 유한 요소 시뮬레이션은 실제 시험 전에 판재 성형 부품의 스프링백 및 성형성을 예측하기 위한 수치해석적 도구로 일반적으로 사용되었습니다. 판재 성형 공정에서 유한 요소 시뮬레이션의 정확한 모델링은 신뢰할 수 있는 수치해석적 기술, 구성 방정식, 정확한 경계 조건 등이 필요합니다. 이 중 마찰은 시뮬레이션의 정확도를 결정하는 중요한 요소 중 하나이지만 대부분의 시뮬레이션에서 간과되어 왔습니다. 판재 성형에서 마찰 거동은 매우 복잡하고 표면 거칠기, 접촉 압력, 미끄럼 속도, 윤활 조건 등과 같은 다양한 매개변수에 따라 달라지는 것으로 알려져 있습니다. 그러나, 대부분의 유한 요소 해석에서 가장 간단한 쿨롱 마찰 법칙을 사용하는 것이 일반적입니다. 본 연구에서는 접촉면 사이의 힘 평형을 만족시키기 위해 새로운 모델 매개변수를 부과하여 마이크로 스케일 돌기 기반 마찰 모델을 추가로 수정했습니다. 또한 마찰의 쟁기질 효과를 결정하기 위해 툴 표면의 기하학적 형상 모델이 새로 제안되었습니다. 툴 형상은 표면 측정 장비의 분해능에 의존하는 정점이 아니라 측정된 파장에 의해 결정되는 툴표면 높이 조도의 서밋을 기반으로 모델링됩니다. 마찰모델은 경계윤활조건뿐만 아니라 충분한 윤활이 존재하는 혼합경계윤활조건에서도 필요하다. 유체역학적 마찰 모델은 윤활 영역과 금속 대 금속 접촉을 별도로 고려하는 하중 공유 개념을 사용합니다. 본 연구에서는 유체역학적 마찰 모델을 경계 윤활 마찰 모델과 결합하여 혼합 윤활 영역의 마찰을 설명합니다. 비접촉 표면 밸리의 부피로 계산된 윤활유 필름 두께는 커플링을 구현하는 데 사용됩니다. 필름 윤활 거동은 유체역학적 압력의 계산을 가능하게 하는 Reynolds 방정식의 유한 요소 방법을 사용해 구현됩니다. 경계 윤활 마찰 모델을 검증하기 위해 경계 윤활 조건에서 접촉 압력에 따라 계산된 마찰 계수와 측정된 마찰 계수를 비교합니다. 또한 경계 윤활 마찰 모델은 U-draw/bending 과정에 적용된 유한 요소 시뮬레이션을 통해 검증되었습니다. 마지막으로 경계 윤활 마찰 모델과 혼합 경계 윤활 마찰 모델을 새로 개발된 프레스 성형 공정의 유한 요소 시뮬레이션에 적용했는데, 이는 접촉 압력, 미끄럼 속도 및 윤활과 같은 다양한 변수의 영향을 나타냅니다. 검증 결과는 개발된 다중 스케일 마찰 모델과 그 구현이 마찰 거동이 자동차 부품 품질에 중요한 판재 성형 시뮬레이션에 효율적으로 사용될 수 있음을 보여줍니다.1. Introduction 1 1.1. Sheet metal forming and deep drawing process 1 1.2. Motivation and objective 2 1.3. Literature review 5 1.3.1. Friction modeling on the boundary lubrication condition 6 1.3.2. Friction modeling on the mixed-boundary lubrication condition 22 2. Friction model in boundary lubrication 35 2.1. Framework of friction model in boundary lubrication 35 2.2. Statistical contact model for describing surface deformation 38 2.2.1. Assumptions for modeling 39 2.2.2. Flattening of workpiece asperity due to normal load 41 2.2.3. Flattening of workpiece asperity due to normal load and sliding 48 2.2.4. Flattening of workpiece asperity due to normal load and bulk strain 50 2.3. Friction model through a new approach 53 2.3.1. An elliptical paraboloid asperity model 53 2.3.2. A tool geometry model 56 3. Friction model in mixed-boundary lubrication 65 3.1. Overview of the mixed-boundary friction model (Hol [106]) 67 3.2. Finite element modeling for film fluid behavior 71 3.3. Verification of the developed finite element modeling 75 4. Application of boundary lubrication and mixed-boundary lubrication friction model to sheet metal forming process 82 4.1. Friction model parameters 82 4.1.1. Material properties 82 4.1.2. Surface data 83 4.1.3. Friction experiments 86 4.2. Application to sheet metal forming processes under non-lubrication conditions 91 4.2.1. Application to U-draw/bending simulation 94 4.2.2. Application to prototype press-forming process without lubricant 105 4.3. Application to sheet metal forming processes under lubrication conditions 116 5. Conclusions 129 Reference 134박

Advances in Bearing Lubrication and Thermal Sciences

This reprint focuses on the hot issue of bearing lubrication and thermal analysis, and brings together many cutting-edge studies, such as bearing multi-body dynamics, bearing tribology, new lubrication and heat dissipation structures, bearing self-lubricating materials, thermal analysis of bearing assembly process, bearing service state prediction, etc. The purpose of this reprint is to explore recent developments in bearing thermal mechanisms and lubrication technology, as well as the impact of bearing operating parameters on their lubrication performance and thermal behavior

Modeling and simulation in tribology across scales: An overview

This review summarizes recent advances in the area of tribology based on the outcome of a Lorentz Center workshop surveying various physical, chemical and mechanical phenomena across scales. Among the main themes discussed were those of rough surface representations, the breakdown of continuum theories at the nano- and micro-scales, as well as multiscale and multiphysics aspects for analytical and computational models relevant to applications spanning a variety of sectors, from automotive to biotribology and nanotechnology. Significant effort is still required to account for complementary nonlinear effects of plasticity, adhesion, friction, wear, lubrication and surface chemistry in tribological models. For each topic, we propose some research directions