The effect of lubricant supply and frequency upon the behaviour of EHD films subjected to vibrations

Machine elements such as rolling element bearings or gears often experience vibrations due to for example geometrical inaccuracies, shock loading, rotating unbalanced masses, and others. These machine elements rely on a very thin lubricant film to protect the metallic surfaces from direct contact and eventual damage. Rapid variation of load in elastohydrodynamic contacts it is influenced by the so-called squeeze film effect, however, when both entrainment and squeeze are present, the conditions of film formation are more complex. It is expected that the lubricant film thickness is influenced by the amplitude and frequency of the vibrations. At the same time, as it is known that the film thickness is established in the inlet of the contact, it is equally important to evaluate what is the role played by the supply of lubricant to the contact under oscillatory conditions. To date there are not many studies on the effect of the oscillatory motion parameters upon the behaviour of the lubricant film. In this study the focus is on the effect of the frequency of vibrations and the supply of lubricant upon the film thickness

Study of film formation in EHD contacts using a novel method based on electrical capacitance

The elastohydrodynamic lubrication regime (EHD) is found in many machine elements, such as rolling element bearings, gears, cam/tappet, where a combination of hydrodynamic effect, elastic deformation of the surfaces and an increase of the lubricant’s viscosity with pressure create a continuous lubricant film which is capable of supporting pressures of the order of tens of thousands of atmospheres. One of the most important features of these films is their thickness, as this determines whether the bounding surfaces are completely separated, thus avoiding premature wear and failure of the contact. Consequently for many years scientists were interested in finding methods for measuring the lubricant film thickness in elastohydrodynamic conditions. One of the most versatile and widely used techniques for measuring lubricant film thickness in EHD contacts is the optical interferometry method. Apart from numerous advantages, this method has the limitation in the fact that one of the contacting surfaces must be transparent, usually glass or sapphire, thus it does not replicate real conditions found in machine elements contacts. On the other hand, the other group of methods used for studying the behaviour of elastohydrodynamic films includes a variety of electrical methods. Historically, these appeared before the optical methods, but gradually lost importance with the success of the later. Most capacitive, resistive, inductance methods developed so far use specially designed sensors for monitoring the lubricant film thickness. In the case of electrical techniques, both elements of the contact are metallic, which means that these can be used for measuring film thickness in real machine elements. One of the main disadvantages of electrical methods though, is the difficulty with which the calibration of various electrical quantities, against lubricant film thickness is obtained. This thesis describes the work carried out by the author on the application of a capacitive method for studying lubrication of elastohydrodynamic contacts. The novelty of the method used consists in the calibration of the capacitance of the contact with optical interferometry. This project started from the premises that a thicker Chromium layer will supply the phase change needed to precisely measure the lubricant film thickness by eliminating the fragile silica layer, and it has been shown that an increase in Cr thickness results in a increase in reflection of the glass–Cr interface making the resulting images hard to process. Modifications to the existing experimental rig were carried out in order to apply/collect an electrical signal from both the disc and the ball. Signal collection from the disc was quite straightforward and a graphite brush paired with a copper nut was used, as this is the oldest method of collecting/applying and electrical signal from a rotating element. Collecting an electrical signal from the ball presented quite a challenge as the ball is submerged in oil. A number of brushes was designed, made and tested and the one that provided the most stable results chosen. For calibration purposes a base oil and two additives were chosen, the additives were chosen in such a way that the improvement made to the lubrication process to be very different from one additive to the other. The chosen additives were a Viscosity Index Improver [VII] and an Organic Friction Modifier [OFM]. The VII is used by many researchers in order to obtain multigrade lubricants using the same base oil by varying its percentage in the mix. The OFM is used to provide protection between the two contacting bodies when EHD film fails and EHD lubrication is replaced by mixed lubrication by forming a boundary layer on the contacting surfaces. Optical measurements were carried out on the base oil and the two resulting lubricants from the additive mixes using the Ultra Thin Film Interferometry [UTFI] method. The measurements were used as a benchmark against which the capacitive measurements were calibrated. Tests were conducted in a number of controlled conditions for speed, temperature, load and sliding conditions. Results showed that the highest influence on the lubrication process was given by the speed, an increase in speed results in an increase in optically measured film thickness and a decrease in electrically measured film thickness. Phenomenon explained by a large amount of lubricant pushed into the contact. Another parameter that influenced the results quite significantly was temperature, a rise in temperature supplies a decrease in optically measured film thickness and an increase in capacitive measured film thickness which was explained by lubricant viscosity dropping with a rise in temperature. Three different sliding conditions were employed and a small drop in optically measured film thickness followed by a small rise in electrically measured film thickness was recorded due to a local increase in contact temperature when sliding was employed. The capacitive method developed in this project is precise enough to accurately measure lubricant film thickness down to 100nm; a model for thicknesses lower that 100nm was proposed Results from the optical and capacitive methods were compared and a good correlation was found, indicating that the developed capacitive method can be used as a tool for measuring metal on metal contacts without further calibration.EThOS - Electronic Theses Online ServiceEPSRCGBUnited Kingdo

Constant power-continuously variable transmission (CP-CVT) : optimisation and simulation

A novel continuously variable transmission has previously been designed that is capable of addressing a number of concerns within the automotive industry such as reduced emissions. At the commencement of this research, the design was in the early stages of development and little attempt had been previously made to optimise the design to meet specific measurable targets. This thesis utilises and modifies several design approaches to take the design from the concept stage to a usable product. Several optimisation techniques are adapted and created to analyse the CVT from both a design and tribological prospective. A specially designed optimisation algorithm has been created that is capable of quickly improving each critical component dimension in parallel to fulfil multiple objectives. This algorithm can be easily adapted for alternative applications and objectives. The validity of the optimised design is demonstrated through a simulation-tool that has been created in order to model the behaviour of the CVT in a real automotive environment using multiple fundamental theories and models including tire friction and traction behaviour. This powerful simulation tool is capable of predicting transmission and vehicular behaviour, and demonstrates a very good correlation with real-world data. A design critique is then performed that assesses the current state of the CVT design, and looks to address some of the concerns that have been found through the various methods used. A specific prototype design is also presented, based on the optimisation techniques developed, although the actual creation of a prototype is not presented here. Additional complementary research looks at the accuracy of the tire friction models through the use of a specially design tire friction test rig. Furthermore, a monitoring system is proposed for this particular CVT design (and similar) that is capable of continuously checking the contact film thickness between adjacent elements to ensure that there is sufficient lubricant to avoid metal-on-metal contact. The system, which is based around capacitance, requires the knowledge of the behaviour of the lubricant’s permittivity at increased pressure. This behaviour is studied through the use of a specially-designed experimental test rig.EThOS - Electronic Theses Online ServiceThomas Gerald Gray Charitable TrustGBUnited Kingdo

The behaviour of lubricated EHD contacts subjected to vibrations

Machine components containing contacts working in elastohydrodynamic (EHD) conditions are often subjected to vibrations. These may be originated from the mechanism or machine the contact is part of, the surrounding environment and within the contact itself. The influence of vibrations upon the behaviour of elastohydrodynamic films has been studied experimentally in a number of papers, but a comprehensive study of the effect of the parameters of the oscillatory motion upon the film thickness has not been carried out yet. In this study the authors evaluate the effect of the frequency of the oscillatory motion upon the EHD film thickness. Optical interferometry is used to measure lubricant film thickness in a ball-on-flat disc arrangement. A high – speed camera records the interferometric images for later analysis and conversion into film thickness maps. The disc runs at a constant angular velocity while the ball is driven by the traction forces developed in the EHD film. In steady state conditions, this would ensure pure rolling conditions, however in the present investigation the ball is subjected to harmonic vibrations in a direction perpendicular to the plane of the film. The contact under study is lubricated by basic oils and the temperature is kept at a constant value of 60°C. The aim of this paper is to understand how vibrations influence the lubricant film formation