The influence of temperature on viscoelastic friction properties

Viscoelastic friction strongly depends on temperature, which determines the material stiffness and, therefore, given a constant load, the volume that is deformed and dissipates energy. We compare the results obtained by a numerical approach introduced by Carbone and Putignano (2013) [1] with measurements that separate viscoelastic losses from Coulomb contribution. This is done for a range of temperatures. We show that viscoelastic friction curves for different temperatures can be arranged into a single master curve using a frequency shift coefficient, which can be found from the characterization of the viscoelastic material response. This shows that it is possible to accurately (a) use dynamic material analysis data to extrapolate viscoelastic friction measurements to values outside the tested range, and (b) use a tribometer to obtain fundamental viscoelastic material properties

A new approach for the measurement of film thickness in liquid face seals

Face seals operate by allowing a small volume of the sealed fluid to escape and form a thin film between the contacting parts. The thickness of this film must be optimized to ensure that the faces are separated, yet the leakage is minimized. In this work the liquid film is measured using a novel ultrasonic approach with a view to developing a condition monitoring tool. The trials were performed in two stages. Initially tests were based on a lab simulation, where it was possible to compare the ultrasonic film thickness measurements with optical interference methods and capacitance methods. A direct correlation was seen between ultrasonic measurements and capacitance. Where ultrasonic and optical methods overlap, good correlation is observed; however, the optical method will not record film thickness above 0.72 m. A second set of trials was carried out, where the film thickness was monitored inside a seal test apparatus. Film thickness was successfully recorded as speed and load were varied. The results showed that while stationary the film thickness varied noticeably with load. When rotating, however, the oil film remained relatively stable around 2 m. During the normal operation of the seal, both sudden speed and load changes were applied in order to initiate a seal failure. During these events, the measured film thickness was seen to drop dramatically down to 0.2 m. This demonstrated the ability of the technique to predict failure in a face seal and therefore its aptitude for condition monitoring

Thermal conductivity and flash temperature

The thermal conductivity is a key property in determining the friction-induced temperature rise on the surface of sliding components. In this study, a Frequency Domain Thermoreflectance (FDTR) method is used to measure the thermal conductivity of a range of tribological materials (AISI 52100 bearing steel, silicon nitride, sapphire, tungsten carbide and zirconia). The FDTR technique is validated by comparing measurements of pure germanium and silicon with well-known values, showing discrepancies of less than 3%. For most of the tribological materials studied, the thermal conductivity values measured are reasonably consistent with values found in the literature. However the measured thermal conductivity of AISI 52100 steel (21 W/mK) is less than half the value cited in the literature (46 W/mK). Further bulk thermal conductivity measurements show that this discrepancy arises from a reduction in thermal conductivity of AISI 52100 due to through-hardening. The thermal conductivity value generally cited and used in the literature represents that of soft, annealed alloy, but through-hardened AISI 52100, which is generally employed in rolling bearings and for lubricant testing, appears to have a much lower thermal conductivity. This difference has a large effect on estimates of flash temperature and example calculations show that it increases the resulting surface temperatures by 30 to 50%. The revised value of thermal conductivity of bearing steel also has implications concerning heat transfer in transmissions

The Use of Triboemission Imaging and Charge Measurements to Study DLC Coating Failure

We present a study on the simultaneous evolution of the electron emission and surface charge accumulation that occurs during scratching tests in order to monitor coating failure. Steel discs coated with a diamond-like-carbon (DLC) film were scratched in both vacuum (~10−5 Torr) and atmospheric conditions, with electron emission and surface charge being measured by a system of microchannel plates and an electrometer, respectively. The results highlight a positive correlation between emission intensity values, surface charge measurements and surface damage topography, suggesting the effective use of these techniques to monitor coating wear in real time

Using acoustic emission to characterize friction and wear in dry sliding steel contacts

Acoustic emission (AE) was recorded during tribological tests on 52,100 steel specimens under different loads. AE signals were transformed to the frequency domain using a Fast Fourier Transform and parameters such as power, RMS amplitude, mean frequency, and energy were analyzed and compared with friction coefficient and wear volume measurements. Results show that certain acoustic frequencies reflect friction while others reflect wear. If frequencies are chosen optimally, AE and friction signals are highly correlated (Pearson coefficients >0.8). SEM and Raman analysis reveal how plastic deformation and oxide formation affect friction, wear and AE simultaneously. AE recordings contains more information than conventional friction and wear volume measurements and are more sensitive to changes in mechanism. This all demonstrates AE's potential as a tool to monitor tribological behavior.This work was supported by the Overseas Study Program of Jiangsu Higher Education Institutions; the Natural Science Foundation of Jiangsu Province, China (Grant no. BK20160353); the Natural Science Foundation of Jiangsu Higher Education Institutions (Grant no. 16KJB460032); the Key Laboratory of Suzhou (SZS201815); the Top-notch Academic Programs Project of Jiangsu Higher Education Institutions (TAPP) (Grant no. PPZY2015B186) and the Scientific Research Foundation of SIIT (Grant no. 2017kyqd015)

The phase shift of an ultrasonic pulse at an oil layer and determination of film thickness

An ultrasonic pulse incident on a lubricating oil film in a machine element will be partially reflected and partially transmitted. The proportion of the wave amplitude reflected, termed the reflection coefficient, depends on the film thickness and the acoustic properties of the oil. When the appropriate ultrasonic frequency is used, the magnitude of the reflection coefficient can be used to determine the oil film thickness. However, the reflected wave has both a real component and an imaginary component, and both the amplitude and the phase are functions of the film thickness. The phase of the reflected wave will be shifted from that of the incident wave when it is reflected. In the present study, this phase shift is explored as the film changes and is evaluated as an alternative means to measure oil film thickness. A quas i-static theoretical model of the reflection response from an oil film has been, developed. This model relates the phase shift to the wave frequency and the film properties. Measurements of reflection coefficient from a static model oil film and also from a rotating journal bearing have been recorded. These have been used to determine the oil film thickness using both amplitude and phase shift methods. In both cases, the results agree closely with independent assessments of the oil film thickness. The model of ultrasonic reflection is further extended to incorporate mass and damping terms. Experiments show that both the mass and the internal damping of the oil films tested in this work have a negligible effect on ultrasonic reflection. A potentially v ery useful application for the simultaneous measurement of reflection coefficient amplitude and phase is that the data can be used to negate the need for a reference. The theoretical relationship between phase and amplitude is fitted to the data. An extrapolation is performed to determine the values of amplitude and phase for an infinitely thick layer. This is equivalent to the reference signal determined by measuring the reflection coefficient directly, but importantly does not require the materials to be separated. This provides a simple and effective means of continuously calibrating the film measurement approach

Exact analytical solution to ultrasonic interfacial reflection enabling optimal oil film thickness measurement

The ultrasonic reflection from a lubricated interface has been widely analyzed to measure fluid film thickness, with different algorithms being applied to overcome measurement accuracy and resolution issues. Existing algorithms use either the amplitude or the phase angle of the ultrasonic interfacial reflection. In this paper, a new algorithm (named the “exact model – complex”) that simultaneously utilizes both the amplitude and the phase of the complex ultrasonic reflection coefficient is proposed and mathematically derived. General procedures for theoretical analysis in terms of measurement accuracy and uncertainty are proposed and applied to the new algorithm, the beneficial features of which (as compared to other existing algorithms) can be summarized as: 1) a direct calculation, instead of an iterative approximation, 2) guaranteed maximum measurement accuracy, and 3) acceptable measurement uncertainty. None of the existing methods have showed this combination of benefits. Moreover, two groups of raw data from previous experimental studies are utilized to further validate the practical feasibility of the new algorithm. Overall, the proposed “exact model – complex” algorithm fully exploits the potential of ultrasonic reflection for oil film thickness measurement, with an accurate and a convenient calculation suited to practical implementation

Electrical impedance spectroscopy enabled in-depth lubrication condition monitoring

Electrical contact resistance or capacitance as measured between two interfaces of a lubricated contact has been used in tribometers, partially reflecting the lubrication condition. In contrast, the electrical impedance spectroscopy (EIS) provides rich information of magnitude/phase spectrum, which is thoroughly investigated using a combination of electrical circuit models (equivalent to the lubricated contact) and in-situ measurements with a ball-on-disc contact. Results indicate a promising potential of EIS in lubrication condition monitoring, including the variation of lubricant film thickness as estimated using high-frequency magnitude response; the transition between full-film, mixed, and boundary lubrication regimes, as differentiated using extracted electrical resistance together with phase spectrum; the forming of anti-wear boundary film, where extra resistor/capacitor are added; and the degradation of lubricant, such as fuel dilution, oil oxidization, and water emulsifying