Development of an interactive friction model for the prediction of lubricant breakdown behaviour during sliding wear

In this paper, a novel interactive friction-lubricant thickness model was developed to predict the evolution of coefficient of friction and the useful life of lubricant film. The developed model was calibrated by experimental results determined from pin-on-disc tests. For these experiments, a grease lubricant was applied on a Tungsten Carbide ball which slides against a disc made from AA6082 Aluminium alloy. In the pin-on-disc tests, the lubricant film thickness decreased with time during single path sliding leading to a rapid increase in the coefficient of friction. The breakdown of lubricant was divided into three stages, namely, the Stage I low and stable coefficient of friction region, Stage II region in which the coefficient of friction sees a rapid rise, and Stage III in which the coefficient of friction reaches a plateau with a value similar to that of dry sliding. In order to characterise the evolution of coefficient of friction throughout these stages, a novel interactive friction model was developed combining the effects of sliding distance, sliding speed, contact pressure and initial lubricant amount on the evolution of the coefficient of friction. This interactive friction model can be applied to situations involving lubricant breakdown in a dynamic environment such as the metal forming industry, where the use of traditional constant coefficient of friction values present limits in predictive accuracy

The formation of a modified surface layer on elastomeric materials

Surface modification of an elastomer may be formed during sliding contact with a rigid counter surface. This alteration leads to a change of mechanical properties at the surface and as a result a change in frictional behavior. Therefore, investigations related to the formation of a modified surface layer on elastomers and its effect on friction are of importance. In the present study, the formation of a modified surface layer on elastomer reinforced by silica is studied. Sliding friction is performed using a pin-on-disc tribometer. Several parameters are varied, namely contact pressure, velocity, and roughness of the counter surface. The existence of a modified surface layer is investigated by using a scanning electron microscope. The results show that the existence of a modified surface layer depends on the competition between the formation rate of the layer and the wear rate. The formation of the layer depends on the contact pressure, velocity, and sliding distance. A general formulation to calculate the volume of formation is proposed. Furthermore, a map of the formation of a modified surface layer is developed

Friction in the contact between skin and a soft counter material: Effects of hardness and surface finish

The interaction behaviour of skin with a counter surface depends strongly on the surface roughness of the counter surface. For relatively hard surfaces this effect is described in various literature, but for soft, or compliant, materials this is much less studied. Inside the contact, the protuberances on the surface will deform substantially. In order to gain insights into the effect of surface roughness and hardness on the frictional behaviour between skin and a soft counter surface a range of experiments were performed using artificial skin and various silicone compounds which are commonly used in medical devices that interact with the human skin. Using these results, a 'friction map' was created that shows the friction behaviour as a function of the elastic modulus and the surface roughness. When the surface roughness is increased the friction coefficient decreases due to the reduction in the real area of contact, which weakens the adhesion between the two surfaces. A minimum coefficient of friction was observed at a surface roughness of approximately 4 µm. For the softest compounds tested there was minimal effect of surface roughness on friction because the roughness protuberances inside the contact will be flattened. Silicone compounds with increased hardness showed a larger sensitivity of the friction to the surface roughness, because these harder surface roughness protuberances are more resistant against deformation. The friction map provides a tool when designing products that require certain frictional properties: for products that are required to adhere to skin a smooth and soft material is recommended, whereas for products that require a low coefficient of friction a harder compound with a surface roughness of approximately 4 µm is recommended

The static friction response of non-glabrous skin as a function of surface energy and environmental conditions

The (local) environmental conditions have a significant effect on the interaction between skin and products. Plasticisation of the stratum corneum occurs at high humidity, causing this layer to soften and change its surface free energy. In this work we study the effects of the micro-climate on the frictional behaviour of skin in contact with materials with varying wettability. Friction measurements are performed under a range of micro-climate conditions using four different materials with a smooth surface finish. All measurements are performed twice on a single subject in order to minimise variation in skin properties. Results show that materials with a higher wettability show a larger increase in friction coefficient when exposed to warm, moist conditions. The friction force is modelled using the skin micro-relief, the elastic properties of the different skin layers, the surface chemistry of both skin and counter surface, and the environment, as input parameters

Spatiotemporal mapping for in-situ and real-time tribological analysis in polymer-metal contacts

Spatiotemporal mapping (SMA) is a graphical technique to visualise the evolution of data with time and space during a process. This paper discusses the benefits of SMA in the field of polymer tribology via two highly different polymer/metal sliding systems. The SMA is found useful for the qualitative and quantitative characterisation and analysis of the transfer phenomena at the contact interface during repeated sliding, e.g., the slide-roll mechanism of transfer lumps, the severe-to-mild wear transition due to the tribo-chemical reaction of PTFE, the accumulation of wear debris, and the formation of friction-reducing back-transfer polyimide films. Additionally, the SMA helps spot various abnormal tribological behaviours, such as the local removal of oxides on a misaligned disc that would otherwise be overlooked

Understanding the occurrence of a wavy wear track on elastomeric materials

Elastomeric materials are used in daily applications, such as tires and conveyor belts. Sliding friction of elastomeric materials often produces a unique periodic wear pattern. In general, the periodic wear pattern has to be prevented because it generates surface instabilities and, as a result, vibration. Sliding contact between an elastomer and a rigid ball may cause the development of a periodic wear pattern like a wave on the elastomer surface, called a wavy wear track. The present study has investigated the occurrence of the wavy wear track on the elastomers under several operating conditions. The elastomers used were a Styrene-Butadiene Rubber (SBR) and Butadiene Rubber (BR) reinforced with two types of fillers, i.e., highly dispersible silica and short-cut aramid fiber. A pin-on-disc tribometer was used to study the wavy wear track of the materials under several operating conditions. An analytical model was used to predict the wave length of the wear pattern and to study the occurrence of the wavy wear track. The results show that the occurrence of the wavy wear track depends on the mechanical properties of the elastomer, the operating conditions (such as sliding velocity and force), the inertia mass of the counter surface frame and the circumferential length of the wear track. The analytical model is in good agreement with the experimental results

Tool-life prediction under multi-cycle loading during metal forming: a feasibility study

In the present research, the friction and wear behaviour of a hard coating were studied by using ball-on-disc tests to simulate the wear process of the coated tools for sheet metal forming process. The evolution of the friction coefficient followed a typical dual-plateau pattern, i.e. at the initial stage of sliding, the friction coefficient was relatively low, followed by a sharp increase due to the breakdown of the coatings after a certain number of cyclic dynamic loadings. This phenomenon was caused by the interactive response between the friction and wear from a coating tribo-system, which is often neglected by metal forming researchers, and constant friction coefficient values are normally used in the finite element (FE) simulations to represent the complex tribological nature at the contact interfaces. Meanwhile, most of the current FE simulations consider single-cycle loading processes, whereas many metal-forming operations are conducted in a form of multi-cycle loading. Therefore, a novel friction/wear interactive friction model was developed to, simultaneously, characterise the evolutions of friction coefficient and the remaining thickness of the coating layer, to enable the wear life of coated tooling to be predicted. The friction model was then implemented into the FE simulation of a sheet metal forming process for feasibility study

A finite element approach to modeling abrasive wear modes

Machine components operating in sandy environments will wear because of the abrasive interaction with sand particles. In this work, a method is derived to predict the amount of wear caused by such abrasive action, in order to improve the maintenance concept of the components. A finite element model is used to simulate various tips scratching a smooth surface. The model is verified by comparing the obtained results with a set of experiments performed earlier (M. Woldman, et al., 2013, Wear, 301(1–2), pp 76–81)