Transient experimental and modelling studies of laser-textured micro-grooved surfaces with a focus on piston-ring cylinder liner contacts

This paper presents a comparison between the results from numerical modelling and experiments to shed light on the mechanisms by which surface texture can reduce friction when applied to an automotive cylinder liner. In this configuration, textured features move relative to th e piston-liner conjunction and to account for this our approach is to focus on the transient friction response to individual pockets as they pass through, and then leave, the sliding contact. The numerical approach is based on the averaged Reynolds’ equat ion with the Patir & Cheng’s flow factors and the p- θ Elrod- Adams mass-conserving cavitation model. The contact pressures that arises from the asperity interactions are solved simultaneously to the fluid flow solution using the Greenwood and Tripp method. The experimental data is produced using a pin-on -disc set up, in which laser textured pockets have been applied to the disc specimen. Under certain conditions in the mixed and boundary lubrication regime s, both model and experimental results show i ) an increase in friction as the pocket enters the contact, followed by ii ) a sharp decrease as the pocket leaves the contact, and then iii ) a gradual decay back to the pre-entrainment value. From the evidence obtained for the first time from the proposed combined modelling and experimental investigation conducted under carefully controlled conditions, w e suggest that these three stages occur due to the following mechanisms: i ) a reduction in fluid pressure due to the increased inlet gap, ii ) inlet suction as the cavitated fluid within the pocket draws lubricant into the contact, and iii ) film thickness decay as oil is squeezed out of the contact. The interplay of these three mechanisms is shown to control the response of micro-textured surfaces under all lubrication regimes

Experimental validation of a mixed-lubrication regime model for textured piston-ring-liner contacts

Recent experiments have shown that automotive piston-liner friction may be reduced by up to 50 % if the surface of the liner is laser textured with certain configurations of micro-pockets. It is important to model this behavior to understand and optimize the friction reduction mechanisms that are occurring. However, until now, very few models that predict the lubrication performance of textured surfaces have been successfully validated against experimental data. This is because of the requirement for them to: (1) reproduce experimental configurations with a certain degree of fidelity, (2) conserve mass properly, and (3) account for transient, boundary lubrication conditions. To address this, the current paper presents a comparison between the results from a numerical model, which fulfils these criteria, and an experimental test rig operating under the same conditions. The mathematical modeling is based on the averaged Reynolds’ equation with Patir and Cheng’s flow factors and the p − θ Elrod–Adams mass-conserving cavitation model. Simultaneously to the fluid flow solution, the contact pressures that arise from the asperity interactions are also included into the calculations through the well-known stochastic Greenwood and Tripp model for rough contacts. The experimental data is produced using a reciprocating tribometer, whose contact conditions are closely controlled and accurately mimic those found in an automotive piston–liner conjunction. Data is presented in terms of friction force versus stroke angle, and the similarities and differences between the model and experiment are discussed

A general finite volume method for the solution of the reynolds lubrication equation with a mass-conserving cavitation model

This contribution presents the development of a general discretization scheme for the solution of Reynolds equation with a mass-conserving cavitation model and its application for the numerical simulation of lubricated contacts to be discretized using irregular grids. Such scheme is based on a hybrid-type formulation, here named as element-based finite volume method that combines the flexibility of the FEM to deal with unstructured grids, while preserving the local and global fluid-flow conservation aspect of the FVM throughout the discretized domain. The accuracy and robustness of the method are successfully tested using several benchmark cases proposed in the recent literature. Simulations of fully or partially textured sliding bearings are finally employed to show the advantages of being able to adopt irregular meshes both in terms of flexibility for the discretization of complex surface features and computational speed

Partitioned fluid-structure interaction techniques applied to the mixed-elastohydrodynamic solution of dynamically loaded connecting-rod big-end bearings

The present contribution proposes different partitioned techniques, which are commonly used in fluid-structure interaction (FSI) applications, in the context of tribological simulations of the transient mixed-elastohydrodynamic problem of dynamically loaded connecting-rod bearings. With the premise that the FSI framework developed is general, in the current work the fluid flow effects have been considered through the averaged Reynolds equation by Patir & Cheng and the mass-conserving Elrod-Adams cavitation model. The multiphysics simulation framework developed has been used to simulate the connecting-rod big-end bearings of both heavy-duty diesel and high-speed motorcycle engines. In the latter case, the influence of polymer concentration in VM-containing oils with similar HTHS150 values on the bearing power loss is investigated and discussed in details

The use of Powder Metallurgy for promoting friction reduction under sliding-rolling lubricated conditions

This work exploits the use of different sintering manufacturing techniques for obtaining superior performances in lubricated point contacts. Disc and ball specimens were manufactures varying porosity and pore characteristics. The effect of surface pores in sintered materials was evaluated based on the frictional behaviour under different sliding-rolling conditions and lubrication regimes. Furthermore, lubricant film thicknesses were measured using interferometric technique. Test results showed that the decrease of porosity generally improves tribological performance. Low porosity surfaces can promote friction reduction compared to non-porous reference materials in specific configurations and operating with similar specific lubricant thickness values. This work contributes to an improved understanding of how randomly distributed micro-irregularities could change lubrication conditions, potentially increasing the efficiency of lubricated mechanical systems

Fast laser surface texturing of spherical samples to improve the frictional performance of elasto-hydrodynamic lubricated contacts

Textured surfaces offer the potential to promote friction and wear reduction by increasing the hydrodynamic pressure, fluid uptake, or acting as oil or debris reservoirs. However, texturing techniques often require additional manufacturing steps and costs, thus frequently being not economically feasible for real engineering applications. This experimental study aims at applying a fast laser texturing technique on curved surfaces for obtaining superior tribological performances. A femtosecond pulsed laser (Ti:Sapphire) and direct laser interference patterning (with a solid-state Nd:YAG laser) were used for manufacturing dimple and groove patterns on curved steel surfaces (ball samples). Tribological tests were carried out under elasto-hydrodynamic lubricated contact conditions varying slide-roll ratio using a ball-on-disk configuration. Furthermore, a specific interferometry technique for rough surfaces was used to measure the film thickness of smooth and textured surfaces. Smooth steel samples were used to obtain data for the reference surface. The results showed that dimples promoted friction reduction (up to 20%) compared to the reference smooth specimens, whereas grooves generally caused less beneficial or detrimental effects. In addition, dimples promoted the formation of full film lubrication conditions at lower speeds. This study demonstrates how fast texturing techniques could potentially be used for improving the tribological performance of bearings as well as other mechanical components utilised in several engineering applications

Towards optimum additive performance: A numerical study to understand the influence of roughness parameters on the zinc dialkyldithiophosphates tribofilm growth

In recent years, several theoretical models to predict the triboreactive film thickness of zinc dialkyldithiophosphates (ZDDP) have been developed. Although these models are not complete and are approximate in nature, they provide a framework which can be used to evaluate the factors impacting the tribofilm growth. In this paper, rough surfaces with different roughness parameters were numerically generated and used to calculate the tribofilm growth. The simulation results show that lower negative skewness, higher kurtosis, and larger autocorrelation length values give thicker ZDDP tribofilms with skewness and autocorrelation values having a greater effect on the tribofilm growth. Based on the simulation results, it is found that these parameters influence the tribofilm growth by changing the contact ratio which eventually changes the dynamic growth of tribofilm and wear of substrate. The results presented in this paper have bigger implications for industry in designing surface textures that promote the anti‐wear action