Showing papers in "Journal of Tribology-transactions of The Asme in 2016"

A Numerical Model to Study the Role of Surface Textures at Top Dead Center Reversal in the Piston Ring to Cylinder Liner Contact

Abstract: Minimisation of parasitic losses in the internal combustion engine is essential for improved fuel efficiency and reduced emissions. Surface texturing has emerged as a method palliating these losses in instances where thin lubricant films lead to mixed or boundary regimes of lubrication. Such thin films are prevalent in contact of compression ring to cylinder liner at piston motion reversals because of momentary cessation of entraining motion. The paper provides combined solution of Reynolds equation, boundary interactions and a gas flow model to predict tribological conditions, particularly at piston reversals. The results of the analyses are validated against measurements using a floating liner for determination of in-situ friction of an engine under motored condition. Very good agreement is obtained. The validated model is then modified to include the effect of surface texturing which can be applied to the surface of the liner at compression ring reversals under fired engine conditions. The predictions show that some marginal gains in engine performance can be expected with laser textured chevron features of shallow depth under certain operating conditions.

Slurry Erosion of Pipeline Steel: Effect of Velocity and Microstructure

Abstract: Pipelines are the most flexible, economic, and convenient way for oil and gas transportation. Material degradation by slurry erosion is a common feature in oil transmission pipeline. In the present work, slurry erosion of AISI 1018, AISI 1080, API X42, and API X70 steels is investigated in terms of slurry velocity and target material microstructure. The slurry velocity and impact angle employed were 0.2, 0.29, 0.36, and 0.43 m s−1 and 90 deg, respectively. It is found that erosion rate increases with increasing slurry velocity. Scanning electron microscopy was employed to investigate the eroded surface and subsurface of the steels. Plastic deformation, microcutting, and fracture are identified as dominant erosion mechanisms. Pearlitic microstructure exhibits superior erosion resistance compared to ferrite depending upon slurry velocity and microstructural orientation.

Comparison of the Load-Carrying Performance of Mechanical Gas Seals Textured With Microgrooves and Microdimples

Abstract: The effects of microgrooves and microdimples on the load-carrying performance of mechanical gas seals are compared in this study. Numerical model based on the Reynolds equation for compressible Newtonian fluid is utilized to investigate the load-carrying performance including the hydrodynamic pressure, the load-carrying force, and gas film stiffness of the gas seals. The results indicate that both microgrooves and microdimples can improve the load-carrying performance of mechanical gas seals, particularly under a small clearance condition. Furthermore, different texture patterns achieve optimal load-carrying performance at different area density, seal clearance, and depth: microgrooves with a low area density can obtain higher load-carrying force and gas film stiffness than the dimple patterns, but with high area density, elliptical dimples yield better load-carrying performance than the groove patterns. [DOI: 10.1115/1.4031435]

Superlubricity in Gemini Hydrogels

Abstract: Gemini hydrogels have repeatedly produced low friction under conditions generally not thought to be favorable to superlubricity: low sliding speeds, low contact pressures, macroscopic contact areas, and room temperature aqueous environments. A proposed explanation for this unique behavior is that thermal fluctuations at the interface are sufficient to separate the surfaces, with solvent (water) shearing in this region being the main source of dissipation. In this paper, we demonstrate that very soft and correspondingly large mesh size Gemini hydrogels show superlubricity with the lowest measured friction coefficient being μ = 0.0013 ± 0.0006.

Quantifying Cartilage Contact Modulus, Tension Modulus, and Permeability With Hertzian Biphasic Creep

Abstract: This paper describes a new method, based on a recent analytical model (Hertzian biphasic theory (HBT)), to simultaneously quantify cartilage contact modulus, tension modulus, and permeability. Standard Hertzian creep measurements were performed on 13 osteochondral samples from three mature bovine stifles. Each creep dataset was fit for material properties using HBT. A subset of the dataset (N = 4) was also fit using Oyen's method and FEBio, an open-source finite element package designed for soft tissue mechanics. The HBT method demonstrated statistically significant sensitivity to differences between cartilage from the tibial plateau and cartilage from the femoral condyle. Based on the four samples used for comparison, no statistically significant differences were detected between properties from the HBT and FEBio methods. While the finite element method is considered the gold standard for analyzing this type of contact, the expertise and time required to setup and solve can be prohibitive, especially for large datasets. The HBT method agreed quantitatively with FEBio but also offers ease of use by nonexperts, rapid solutions, and exceptional fit quality (R2 = 0.999 ± 0.001, N = 13).

Progressive Mesh Densification Method for Numerical Solution of Mixed Elastohydrodynamic Lubrication

Abstract: Numerical solution of mixed elastohydrodynamic lubrication (EHL) is of great importance for the study of lubrication formation and breakdown, as well as surface failures of mechanical components. However, converged and accurate numerical solutions become more difficult, and solution process with a fixed single discretization mesh for the solution domain appears to be quite slow, especially when the lubricant films and surface contacts coexist with real-machined roughness involved. Also, the effect of computational mesh density is found to be more significant if the average film thickness is small. In the present study, a set of sample cases with and without machined surface roughness are analyzed through the progressive mesh densification (PMD) method, and the obtained results are compared with those from the direct iteration method with a single fixed mesh. Besides, more numerical analyses with and without surface roughness in a wide range of operating conditions are conducted to investigate the influence of different compound modes in order to optimize the PMD procedure. In addition, different initial conditions are used to study the effect of initial value on the behaviors of this transient solution. It is observed that, no matter with or without surface roughness considered, the PMD method is stable for transient mixed EHL problems and capable of significantly accelerating the EHL solution process while ensuring numerical accuracy.

Fully Coupled Resolution of Heterogeneous Elastic–Plastic Contact Problem

Abstract: The recent development of semi-analytical methods (SAM) has led to numerous improvements in their capabilities in terms of phenomena that can be accounted for and numerical efficiency. They now allow to perform fast and robust simulations of contact between inelastic—with either elastic–plastic or viscoelastic behavior—and anisotropic or heterogeneous materials. All effects may be combined, with either coating, inclusions, cavities, or fibers as inhomogeneities. The coupling between local and global scales remains numerically difficult. A framework is proposed here for contact problems considering the effect of elastic heterogeneities within an elastic–plastic matrix. The mutual interactions among heterogeneities and their surrounding plastic zone as well as the interactions between them and the contact surface through which the load is transmitted should be accounted for. These couplings are outside the validity domain of the Eshelby’s equivalent inclusion method (EIM) that assumes a uniform stress field in an infinite space far from the inhomogeneity. In the presence of heterogeneities close to the surface or located at the Hertzian depth, the yield stress can be reached locally due to the additional stress it generates, whereas the stress and strain state would remain purely elastic for a matrix without inclusion. It is well known that for rolling element bearing and gear applications, the ruin of components is often linked to cracks initiated in the vicinity of large or hard inclusions that act as stress raisers. It turned out that plastic strains tend to reduce the stress generated by the contact pressure while hard heterogeneities will increase it. As plastic strain accumulation can provide the basis for fatigue damage criteria, the second half of the paper will illustrate how the method can be used to identify and rank geometrical and material parameters that influence the location and magnitude of the maximal plastic strain.

Generalized Three-Dimensional Mathematical Models for Force and Stiffness in Axially, Radially, and Perpendicularly Magnetized Passive Magnetic Bearings With “n” Number of Ring Pairs

Abstract: This work deals with generalized three-dimensional (3D) mathematical model to estimate the force and stiffness in axially, radially, and perpendicularly polarized passive magnetic bearings with “n” number of permanent magnet (PM) ring pairs. Coulombian model and vector approach are used to derive generalized equations for force and stiffness. Bearing characteristics (in three possible standard configurations) of permanent magnet bearings (PMBs) are evaluated using matlab codes. Further, results of the model are validated with finite element analysis (FEA) results for five ring pairs. Developed matlab codes are further utilized to determine only the axial force and axial stiffness in three stacked PMB configurations by varying the number of rings. Finally, the correlation between the bearing characteristics (PMB with only one and multiple ring pairs) is proposed and discussed in detail. The proposed mathematical model might be useful for the selection of suitable configuration of PMB as well as its optimization for geometrical parameters for high-speed applications.

Image Acquisition and Image Processing Algorithms for Movement Analysis of Bearing Cages

Abstract: Movement analyses of ball bearings with regard to stable and unstable cage motion behavior are often conducted by simulations, typically by investigating the cage whirl. Some experimental studies exist in which the cage is modified in order to capture its movement with sensors. This paper presents an image-based approach for investigating the cage motion without modifications, which in turn allows a cage motion analysis of an angular contact ball bearing under operation condition. Two new image evaluation algorithms are presented in detail and their suitability is verified by experiments on a bearing test rig.

Real Area of Contact in a Soft Transparent Interface by Particle Exclusion Microscopy

Abstract: Soft matter mechanics are characterized by high strains and time-dependent elastic properties, which complicate contact mechanics for emerging applications in biomedical surfaces and flexible electronics. In addition, hydrated soft matter precludes using interferometry to observe real areas of contact. In this work, we present a method for measuring the real area of contact in a soft, hydrated, and transparent interface by excluding colloidal particles from the contact region. We confirm the technique by presenting a Hertz-like quasi-static indentation (loading time > 1.4 hrs) by a polyacrylamide probe into a stiff flat surface in a submerged environment. The real contact area and width were calculated from in situ images of the interface processed to reduce image noise and thresholded to define the perimeter of contact. This simple technique of in situ particle exclusion microscopy (PEM) may be widely applicable for determining real areas of contact of soft, transparent interfaces.

Lubricity from Entangled Polymer Networks on Hydrogels

Abstract: Structural hydrogel materials are being considered and investigated for a wide variety of biotribological applications. Unfortunately, most of the mechanical strength and rigidity of these materials comes from high polymer concentrations and correspondingly low polymer mesh size, which results in high friction coefficients in aqueous environments. Recent measurements have revealed that soft, flexible, and large mesh size hydrogels can provide ultra low friction, but this comes at the expense of mechanical strength. In this paper, we have prepared a low friction structural hydrogel sample of polyhydroxyethyl-methacrylate (pHEMA) by polymerizing an entangled polymer network on the surface through a solution polymerization route. The entangled polymer network was made entirely from uncrosslinked polyacrylamide (pAAm) that was polymerized from an aqueous solution and had integral entanglement with the pHEMA surface. Measurements revealed that these entangled polymer networks could extend up to similar to 200 mu m from the surface, and these entangled polymer networks can provide reductions in friction coefficient of almost two orders of magnitude (mu > 0.7 to mu < 0.01).

Influence of the hip joint modeling approaches on the kinematics of human gait

Abstract: The first and third authors express their gratitude to the Portuguese Foundation for Science and Technology for the PhD grants SFRH/BD/76573/2011 and SFRH/BD/64477/2009, respectively. The authors would like to thank to the Portuguese Foundation for Science and Technology through the project UID/EEA/04436/2013. The authors are also gratefully acknowledge the financial support from QREN (Quadro de Referencia Estrategico Nacional - National Strategic Reference Framework), for this study “INOVSHOES - Padronizar para Customizar Calcado Ortopedico”, project n.o 2010/12032.

Tribological Properties of Laser Microtextured Surface Bonded With Composite Solid Lubricant at High Temperature

Abstract: A combination technology of the solid lubricant and the laser surface texturing (LST) can significantly improve the tribological properties of friction pairs. The plate sample was textured by fiber laser and composite lubricant of polyimide (PI) and molybdenum disulfide (MoS2) powders were filled in the microdimples. Sliding friction performances of micron-sized composite lubricant and nano-sized composite lubricant were investigated by ring-plate tribometer at temperatures ranging from room temperature (RT) to 400 °C. On the one hand, the results of the micron-sized composite lubricant show that the friction coefficient of the textured surface filled with composite lubricant (TS) exhibits the lowest level and the highest stability compared to a textured surface without solid lubrication, smooth surface without lubrication, smooth surface burnished with a layer of composite solid lubricant. The better dimple density range is 35-46%. The friction coefficients of the sample surface filled with micron-composite solid lubricant with the texture density of 35% are maintained at a low level (about 0.1) at temperatures ranging from RT to 300 °C. On the other hand, the results of the nano-sized composite lubricant show that these friction properties are better than those of MoS2-PI micron-sized composite. The friction coefficients of MoS2-PI-CNTs nano-sized composite solid lubricant are lower than those of the MoS2-PI composite lubricant at temperatures ranging from RT to 400 °C. In addition, the possible mechanisms involving the synergetic effect of the surface texture and the solid lubricant are discussed in the present work.

Influence of Carbon Nanotubes on Conductive Capacity and Tribological Characteristics of Poly(ethylene Glycol-Ran-Propylene Glycol) Monobutyl Ether as Base Oil of Grease

Abstract: Carbon black (CB) and three kinds of carbon nanotubes (CNTs) including multiwalled CNTs (MWCNTs), carboxyl multiwalled CNTs (CMWCNTs), and single-walled CNTs (SWCNTs) were doped as conductive additives in poly(ethylene glycol-ran-propylene glycol) monobutyl ether (denoted as PAG) to afford conductive greases in the presence of polytetrafluoroethylene (PTFE) as the thickener and acetone as the polar dispersant. The effects of the conductive additives on the conductive capacity and tribological characteristics of the PAG grease were investigated, and the tribological action mechanisms of the conductive additives were analyzed in relation to worn surface analyses by scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS). Results indicate that the SWCNTs can reduce the volume resistivity of the base grease by over 10,000 times. In the meantime, the CB and the three kinds of CNTs as conductive additives can improve the tribological characteristics of the base grease to some extent, and the CNTs are advantageous over the CB in improving the friction-reducing and antiwear abilities of the base grease. The reason lies in that CNTs with a small size and a large specific surface area can be easily adsorbed on sliding steel surfaces to form a surface protective film.

Influence of Minimum Quantity Lubrication on Friction Characterizing Tool–Aluminum Alloy Contact

Abstract: The possibility to reduce the amount of cutting fluids from machining processes is actively studied by the industrials and researchers. Minimum Quantity Lubrication (MQL) is a solution towards cutting fluids reduction. This article investigates the consequences on friction coefficient induced by the use of MQL. A tribometer is used in order to simulate experimentally the tribological conditions encountered during machining. As the cutting speed increases a lower amount of oil is deposited on the rough surfaces. Depending on the MQL operating conditions and sliding velocities it is plausible to reach starvation by leaving the real rough contact partly dry. A model computing a starvation percentage by filling an estimated oil amount in a deformed topography correlates with the experimental results. © 2015 by ASME

Squeal Noise of Friction Material With Groove-Textured Surface: An Experimental and Numerical Analysis

Abstract: In this work, an experimental and numerical study is performed to understand squeal generation and suppression of a pad-on-disk friction system. Several friction material specimens having various orientation degrees of grooves cut on their surfaces are tested. Numerical studies using the methods of complex eigenvalue analysis and dynamic transient analysis are conducted to simulate the experimental process with the finite element (FE) software abaqus. Both experimental and numerical results show that surface modifications of friction material specimens have a significant influence on the squeal instability: cutting a 45 deg or 90 deg groove on the material surface can significantly reduce squeal noise, cutting a 135 deg groove just reduces squeal noise moderately and cutting a 0 deg groove cannot reduce squeal noise. Moreover, the contact pressure distributions for the original surface and modified surfaces are studied to provide a physical explanation of the noise phenomenon. The major finding that friction-induced noise can be reduced by means of suitable structural modifications of the contact interface is expected to have important and much wider applications.

Modeling of the Friction Behavior in Metal Forming Process Considering Material Hardening and Junction Growth

Abstract: In various plastic forming processes of metals, friction has been revealed to play an important role in the determination of the material flow, fracture, and surface quality. The precise description of friction behavior is thus a critical issue for the accurate prediction and analysis of these formability indicators. Generally, the friction behavior is inevitably affected by material hardening and junction growth. However, few of the previous models have taken both of them into consideration, especially for the nonlinear hardening materials. In this study, the classical contact model was modified to include the power-law hardening material, and the general friction law combined with Tabor's equation was employed to estimate the friction stress with the junction growth of asperities. An asperity-based friction model for rough surfaces in metal forming process was then obtained by summarizing the normal and tangential stresses of all the asperities on the surface using Greenwood and Williamson (GW) method. The model was validated by comparing to the finite element (FE) results and the experimental results. And its comparison with Kogut and Etsion (KE) model and Cohen's model revealed a wider range of application for the present model. It was also found to be able to predict the friction coefficient and the real contact area of nonlinear hardening materials under various contact conditions. This work is helpful to understand the friction behavior and further guide the simulation and optimization of forming processes.