Rolling-element fatigue life with two synthetic cycloaliphatic traction fluids

The life potential of two synthetic cycloaliphatic hydrocarbon traction fluids in rolling element fatigue was evaluated in a five ball fatigue tester. Life comparisons with a MIL-L-23699 qualified tetraester oil showed that the traction test oils had good fatigue life performance, comparable to that of the tetraester oil. No statistically significant life differences between the traction fluids and the tetraester oil were exhibited under the accelerated fatigue test conditions. Erratic operating behavior was occasionally encountered during tests with the antiwear additive containing traction fluid for reasons thought to be related to excessive chemical activity under high contact pressure. This behavior occasionally resulted in premature test termination due to excessive surface distress and overheating

Analysis of wear-debris from full-scale bearing fatigue tests using the ferrograph

The ferrograph was used to determine the types and quantities of wear particles generated during full-scale bearing fatigue tests. Deep-groove ball bearings made from AISI 52100 steel were used. A MIL-L-23699 tetraester lubricant was used in a recirculating lubrication system containing a 49 mm absolute filter. Test conditions included a maximum Hertz stress of 2.4 GPa, a shaft speed of 15,000 rpm, and a lubricant supply temperature of 74 C (165 F). Four fatigue failures were detected by accelerometers in this test set. In general, the ferrograph was more sensitive (up to 23 hr) in detecting spall initiation than either accelerometers or the normal spectrographic oil analysis. Four particle types were observed: normal rubbing wear particles, spheres, nonferrous particles, and severe wear (spall) fragments

Rolling-element fatigue life with traction fluids and automatic transmission fluid in a high-speed rolling-contact rig

Rolling-element fatigue tests were run in standard and high-speed rolling-contact rigs at bar speeds from 5000 to 50,000 rpm to determine the effects of speed and lubricant film parameter on rolling-element fatigue life. AISI 52100 test bars were tested at a maximum Hertz stress of 4.83 GPa (700,000 psi) with three traction fluids and an automatic transmission fluid. Rolling-element fatigue life increased with speed, with the greatest increases occurring from 10,000 to 50,000 rpm. The life data tended to follow published life-versus-lubricant-film-parameter data up to a film parameter of approximately 3

Elastohydrodynamic film thickness formula based on X-ray measurements with a synthetic paraffinic oil

An empirical elastohydrodynamic film thickness formula for heavily loaded contacts based upon X-ray film thickness measurements made with a synthetic paraffinic oil is presented. The deduced relation was found to adequately reflect the high load dependence exhibited by the measured minimum film thickness data at high Hertizian contact stresses, that is, above 1.04 x 10 to the ninth N/sq m (150,000 psi). Comparisons were made with the numerical results from a theoretical isothermal film thickness formula. The effects of changes in contact geometry, material, and lubricant properties on the form of the empirical model are also discussed

Design studies of continuously variable transmissions for electric vehicles

Preliminary design studies were performed on four continuously variable transmission (CVT) concepts for use with a flywheel equipped electric vehicle of 1700 kg gross weight. Requirements of the CVT's were a maximum torque of 450 N-m (330 lb-ft), a maximum output power of 75 kW (100 hp), and a flywheel speed range of 28,000 to 14,000 rpm. Efficiency, size, weight, cost, reliability, maintainability, and controls were evaluated for each of the four concepts which included a steel V-belt type, a flat rubber belt type, a toroidal traction type, and a cone roller traction type. All CVT's exhibited relatively high calculated efficiencies (68 percent to 97 percent) over a broad range of vehicle operating conditions. Estimated weight and size of these transmissions were comparable to or less than equivalent automatic transmission. The design of each concept was carried through the design layout stage

Correlation of elastohydrodynamic film thickness measurements for fluorocarbon type 2 ester, and polyphenyl ether lubricants

A minimum films thickness correlation applicable to heavily loaded elastohydrodynamic (EHD) contacts was formulated from experimental data obtained by an X-ray transmission technique. The correlation, based on data generated with fluorocarbon, type II ester, and polyphenyl ether lubricants, extends a previous analysis developed from data for a synthetic paraffinic oil. The resulting correlation represents the data of the four lubricants reasonably well over a large range of operating conditions. Contained within the derived relation is a factor to account for the high-load dependence displayed by the measurements beyond that which is provided for by the theory. Thermal corrections applied to a commonly used film thickness formula showed little improvement to the general disagreement that exists between theory and test. Choice of contact geometry and material are judged to have a relatively mild influence on the form of the semiempirical model

Young's Moduli of Cold and Vacuum Plasma Sprayed Metallic Coatings

Monolithic metallic copper alloy and NiCrAlY coatings were fabricated by either the cold spray (CS) or the vacuum plasma spray (VPS) deposition processes. Dynamic elastic modulus property measurements were conducted on these monolithic coating specimens between 300 K and 1273 K using the impulse excitation technique. The Young's moduli decreased almost linearly with increasing temperature at all temperatures except in the case of the CS Cu-23%Cr-5%Al and VPS NiCrAlY, where deviations from linearity were observed above a critical temperature. It was observed that the Young's moduli for VPS Cu-8%Cr were larger than literature data compiled for Cu. The addition of 1%Al to Cu- 8%Cr significantly increased its Young's modulus by 12 to 17% presumably due to a solid solution effect. Comparisons of the Young s moduli data between two different measurements on the same CS Cu- 23%Cr-5%Al specimen revealed that the values measured in the first run were about 10% higher than those in the second run. It is suggested that this observation is due to annealing of the initial cold work microstructure resulting form the cold spray deposition process

A seeded ambient temperature ferrit process for the treatment of AMD waters: Magnetite formation in the presence and absence of calcium ions under steady state operation

An ambient temperature ferrite process has been developed for the removal of iron and non-ferrous metals from AMD waters. The process involves the controlled formation of magnetite (Fe3 O4 ) that has the capacity to substitute divalent and trivalent cations as part of the lattice, thus forming a stable easy-to-separate ferrite. This paper reports on continuous operations of the process in the absence and presence of Ca2+, which is well known to impede ferrite formation. In the first instance, the process involves the precipitation of hydroxy-metals at pH 10.5 and their subsequent adsorption onto magnetite seed in a contact stabilisation reactor. Second, liquid-solid separation is effected and the solid fraction is subsequently treated in an oxidising reactor in which a fraction of the ferrous species is oxidised to an intermediate ferric precipitate. Finally, both ferrous and ferric species undergo crystalchemical processing and are incorporated into stable magnetite. Results indicate that Ca2+ interference can be overcome by maintaining a high ratio of precipitated ferrous species to dissolved Ca2+. It was found that in order to attain the required high Fe2+:Ca2+ ratio, the solid ferrous-hydroxy species concentration in the oxidation reactor should be maintained at above 1 200 mg Fe/l. Ferrous to calcium ratios greater than 3 were found to favour magnetite formation. In the absence of Ca2+, a solid ferroushydroxy species concentration of approximately 500 mg/l was sufficient for magnetite formation. Operating the process at ferroushydroxy concentrations of lower than 1 200 and 500 mg/l in the presence and absence of calcium respectively enhanced the formation of other iron oxides, primarily goethite. In all experiments the iron concentration in the effluent was less than 1 mg/l, the sludge volume index (SVI) extremely low (< 4 ml/g) and the percentage of ferrous-hydroxy species in the sludge can be reduced to about 1%. These features, together with the potential to incorporate heavy metals into a stable compound, make the process very promising for AMD treatment

Tribology: The Story of Lubrication and Wear

Topics addressed include: lubrication and design of high speed rolling element bearings, high speed gears, and traction drives

Sulphate measurement in organic-rich solutions: Carbonate fusion pretreatment to remove organic interferences

Sulphate measurement using a barium sulphate turbidimetric method in solutions with high concentrations of organic material is shown to be problematic. The organics give background colour, which introduces a positive error to the measured absorption, and inhibit the barium sulphate precipitate, which results in a negative error. A carbonate fusion pretreatment of the sample results in the removal of the organic matter and associated interferences. With this pretreatment, excellent sulphate recoveries were obtained (100%). Rigorous testing of the method shows that reproducible and accurate results are obtainable