Lubricants

Cold welding refers to an effect related to space (vacuum). The heavy vibrations during a launch subject interfaces (hold down points) to oscillating motions which may lead to formation of a kind of “friction weld”. If so, these mechanisms may get stuck, and deployment will be hindered. This may endanger the functionality of the mission (instruments) or even the whole spacecraft (if solar panels do not open). Several studies have been done to characterize material combinations (including coatings) for their ability to cold welding in space. Meanwhile, also during launch grease free contacts are demanded. If grease hat to be omitted, the risk of cold welding under fretting was found to increase (when testing in high vacuum). To rate this risk under launch conditions, the test method was recently extended for testing under launch conditions. The new tests procedure consists of fretting applied in the sequence in air, low vacuum and high vacuum. The paper shall present first results gained with this new method of testing in launch conditions and compare them to previous studies done in vacuum. Following the need of space industry on mechanisms for launch and in-orbit life, a first set of combinations of materials and coatings were selected for this new test sequence where fretting is now applied in a sequence of air, low vacuum and high vacuum. Under this sequence, the measured levels of adhesion and it’s evolvement was found to differ strongly from tests done formerly. The paper outlines these first results and compares them to existing data. Full article

Recently, cycloidal drives have been increasingly used due to their beneficial features, such as the implementation of a large transmission, efficiency, and high performance density. Production accuracy is inevitable in order to ensure the dynamically proper and smooth operation of the drive. Smaller backlash and minimal transmission fluctuations can only be achieved by improving the production accuracy, reducing the number of production failures, and shrinking the tolerance zone. This research primarily focuses on the investigation of the tolerable production accuracy of small-series and individually manufactured drives. The analysis of load distribution was calculated on the cogs of a planetary gear made with a wire EDM machine. On the other hand, we investigate how production failures affect transmission fluctuations and the backlash of a drive. The novelty of this research is based on the determined analytical equations, which can help engineers to find the right tolerances to a given gear ratio fluctuation. Full article

The cutting fluids applied to the machining processes by the MQL process aim to reduce the machining temperatures and tool wear as well as improve the surface and dimensional finishing of the parts. To increase the efficiency of these fluids, graphene lubricating platelets are added. This work investigated the performance of three different cutting fluids with graphene sheets added and applied via MQL, considering the tool life, wear, and wear mechanisms acting on TiAlN-coated cemented carbide cutting tools in the end milling of AISI 1045 steel. We evaluated two vegetable- (MQL15 and LB1000) and one mineral-based (MQL14) neat oils and the same fluids with the addition of 0.05 and 0.1%wt graphene nanoplatelets. Dry cuts were also performed and investigated for comparison. The experiments were conducted under fixed cutting conditions (v_c = 250 m/min, f_z = 0.14 mm/tooth, a_p = 1 mm, and a_e = 20 mm). The end-of-tool-life criterion followed the guidelines of ISO 8688-1 (1989). To analyze the results, ANOVA and Tukey’s test were applied. The addition of graphene sheets in the vegetable-based cutting fluids effectively increased the lubricating properties, partially reducing the wear mechanisms acting on the tools. In addition, there was a predominance of thermal fatigue cracks and mechanical cracks as well as adhesive and abrasive wear mechanisms on the tools used in the cutting with the MQL15 and MQL14 fluids, indicating greater cyclical fluctuations in temperature and surface stresses. Full article

Surface Force Balance (SFB) experiments have been performed in a dry atmosphere and across an ionic liquid, combining the analysis of surface interactions and deformations, and illustrate that the mechanical deformations of the surfaces have important consequences for the force measurements. First, we find that the variation of the contact radius with the force across the ionic liquid is well described only by the Derjaguin–Muller–Toporov (DMT) model, in contrast with the usual consideration that SFB experiments are always in the Johnson–Kendall–Roberts (JKR) regime. Secondly, we observe that mica does not only bend but can also experience a compression, of order $1\mathrm{nm}$ with $7\mathsf{\mu }\mathrm{m}$ mica. We present a modified procedure to calibrate the mica thickness in a dry atmosphere, and we show that the structural forces measured across the ionic liquid cannot be described by the usual exponentially decaying harmonic oscillation, but should be considered as a convolution of the surface forces across the liquid and the mechanical response of the confining solids. The measured structural force profile is fitted with a heuristic formulation supposing that mica compression is dominant over liquid compression, and a scaling criterion is proposed to distinguish situations where the solid deformation is negligible or dominant. Full article

This article presents a test stand with a model high-speed spindle equipped with a system of active control of the preload of the bearings. This preload was changed by means of three piezo actuators. The work presents the results of tests during which the commercial Abacus measuring equipment from Data Physics was used. Its application has shown that the spindle system with angular contact ball bearings is responsive to changes in the preload value of these bearings. The change preload resulted in a change in the value of the resonant frequency of the system and its amplitude. This article presents the dependence between the variable value of the preload of the bearings and the corresponding values of the resonance frequency and amplitude of the spindle system. The use of the Abacus measuring equipment for testing allowed for the preparation of a model showing the dynamic behavior of the spindle. The system was forced by a signal with known parameters, and the response to this excitation was recorded at eleven points located on the surface of the entire spindle. Full article

In the context of targeted improvements in energy efficiency, secondary rolling bearing contacts are gaining relevance. As such, the elastohydrodynamically lubricated (EHL) roller face/rib contact of tapered roller bearings significantly affects power losses. Consequently, this contribution aimed at numerical optimization of the pairing’s macro-geometric parameters. The latter were sampled by a statistical design of experiments (DoE) and the tribological behavior was predicted by means of EHL contact simulations. For each of the geometric pairings considered, a database was generated. Key target variables such as pressure, lubricant gap and friction were approximated by a meta-model of optimal prognosis (MOP) and optimization was carried out using an evolutionary algorithm (EA). It was shown that the tribological behavior was mainly determined by the basic geometric pairing and the radii while eccentricity was of subordinate role. Furthermore, there was a trade-off between high load carrying capacity and low frictional losses. Thereby, spherical or toroidal geometries on the roller end face featuring a large radius paired with a tapered rib geometry were found to be advantageous in terms of low friction. For larger lubricant film heights and load carrying capacity, spherical or toroidal roller on toroidal rib geometries with medium radii were favorable. Full article

The motivations for the move to electrified vehicles are discussed with reference to their improved energy efficiency, their potential for lower CO₂ emissions (if the electricity system is decarbonized), their lower (or zero) NO_x/particulate matter (PM) tailpipe emissions, and the lower overall costs for owners. Some of the assumptions made in life-cycle CO₂ emissions calculations are discussed and the effect of these assumptions on the CO₂ benefits of electric vehicles are made clear. A number of new tribological challenges have emerged, particularly for hybrid vehicles that have both a conventional internal combustion engine and a battery, such as the need to protect against the much greater number of stop-starts that the engine will have during its lifetime. In addition, new lubricants are required for electric vehicle transmissions systems. Although full battery electric vehicles (BEVs) will not require engine oils (as there is no engine), they will require a system to cool the batteries—alternative cooling systems are discussed, and where these are fluid-based, the specific fluid requirements are outlined. Full article

Many researches are focused on the tribological performances of pure vegetable oil in order to replace the conventional mineral engine oils. This work investigates the influence of local moringa oil (noted VO) on the performances of lubricants formed from a blend of dodecane and graphite particles at ambient temperature. In a first part, a reduction of about 50% of friction properties of dodecane is observed when adding small amounts of moringa oil (VO), which is intended to be used as a bio-base performance additive in lubricant formulations. The friction properties of their blends with graphite, generally employed as solid lubricant additive, showed an adsorption effect of fatty acid molecules. The more promising results were obtained for the blend containing 2 w% of VO. Physicochemical characterizations of the tribofilms evidence the good antiwear properties of the lubricant. Full article

TiAlCrSiN thin films were deposited on K20 WC–Co substrates using the co-sputtering method. The silicon content in the deposited coatings were varied by modifying the number of silicon pieces (1, 2, or 3) on the Cr target. The morphology, semi-quantitative chemical composition, and microstructure were investigated using scanning electron microscopy (SEM), energy disperse spectroscopy (EDS), and X-ray diffraction (XRD), respectively. Modified ASTM B611 abrasive wear and nano-hardness tests were used to evaluate the tribological and mechanical properties of the different coatings, respectively. The results showed that the addition of Si promotes an increased hardness and elastic modulus. Also, mass loss in wear tests decreased as Si increased, due to the growth in hardness related to the microstructural refinement produced by the blocking of sliding bands by the grain boundaries. Full article

This study highlights how the results from an artificial engine oil aging method compare to used engine oil samples collected from a vehicle fleet. Additionally, this paper presents the effect of contaminating the oil during aging with synthetic fuel alternatives on the physical and chemical properties of artificially aged engine oil samples. A laboratory-scale artificial thermo-oxidative aging experiment was conducted on multiple samples of commercially available formulated fully-synthetic SAE 0W-30 engine oil. The goal of the experiment was to establish the validity of the artificially aged samples as well as the validity of the underlying process in reproducibly fabricating small batches of aged engine oil with comparable chemical and physical properties to real-life used oils. Eight samples were subjected to distinct load cases (temperature, air flow rate, sample volume and aging time). Six additional samples were subjected to an intermediate load case, with five of them contaminated with selected conventional fuels and novel automotive fuel candidates. Conventional oil analysis was conducted on each sample to determine oxidation, residual additive content, kinematic viscosity and total base number. Additionally, analysis results were compared to in-use engine oil samples through PCA. The resulting oil condition after aging is in accordance with independently published results in terms of zinc dialkyldithiophosphate content and kinematic viscosity. Contaminated aging with OME _3-5 resulted in a drop in antioxidant content and elevated kinematic viscosity. Based on the comparison with in-use samples, artificial aging of 200 mL engine oil at 180 °C with 1 L/min air flow for 96 h can produce similar oil conditions as mixed vehicle use for 7000 km. Full article

Hydrogen is the cleanest fuel available because its combustion product is water. The internal combustion engine can, in principle and without significant modifications, run on hydrogen to produce mechanical energy. Regarding the technological solution leading to compact engines, a question to ask is the following: Can combustion engine systems be lubricated with hydrogen? In general, since many applications such as in turbomachines, is it possible to use the surrounding gas as a lubricant? In this paper, journal bearings global parameters are calculated and compared for steady state and dynamic conditions for different gas constituents such as air, pentafluoropropane, helium and hydrogen. Such a bearing may be promising as an ecological alternative to liquid lubrication. Full article

The lifespan of journal bearings is directly related to the operating conditions they have to face and reducing their maintenance intervals allows one to have a clear idea about their performance when issues occur. The presence of scratches on one of its surfaces degrades the performance of a journal bearing. These effects have already been assessed in experiments; however, numerical studies on this subject are still scarce. This work develops a numerical thermohydrodynamic (THD) program using the finite volume method to simulate the effects of scratches on the performance of journal bearings. To test the validity of the program, the numerical results are compared with the scientific literature and with experimental measurements conducted using the Pprime Institute journal bearing test rig. Some minor discrepancies are observed, but the overall results are in good agreement. Full article

Within renewable energy, challenging climates can impose great limitations on power generation. In wind energy, rain erosion on turbine blades can create major disruptions to air flow over the aerofoil, reducing the efficiency of the blade and immediately affecting the power output of the turbine. The defects in the materials that cause these inefficiencies are known and can be observed on turbines that have been in operation for extended periods. This work explores the transitions between different wear states for G10 Epoxy Glass under laboratory simulated wind turbine conditions in operation and measures the wear periodically to identify a progression of erosion. Mass loss data and micrographic analysis revealed samples at 45° and 6$0°$ displayed increasing erosion when examining erosion performance for angles between 1$5°$ and 9$0°$ over various exposure and velocities. Erosion maps were constructed, showing the variation of wastage and identifying the performance window of conditions where degradation is minimised. Full article

Greased bearings in electric motors (EMs) are subject to a wide range of operational requirements and corresponding micro-environments. Consequently, greases must function effectively in these conditions. Here, the tribological performance of four market-available EM greases was characterized by measuring friction and wear of silicon nitride sliding on hardened 52100 steel. The EM greases evaluated had similar viscosity grades but different combinations of polyurea or lithium thickener with mineral or synthetic base oil. Measurements were performed at a range of temperature and surface roughness conditions to capture behavior in multiple lubrication regimes. Results enabled direct comparison of market-available products across different application-relevant metrics, and the analysis methods developed can be used as a baseline for future studies of EM grease performance. Full article

A new method of material and lubricant testing is demonstrated with a planar contact fretting wear tribometer under typical fretting wear conditions. The usual abstraction of contact geometries with an easy-to-align point or line contacts is deliberately dispensed to do justice to the frequently flat contacts of machine elements (shaft-hub connection, bearing seats, etc.). For the study, a new method of targeted observation of the contact surfaces during the test is used, which allows a time-lapse animation of the fretting wear progress of solid lubricant mixtures. Thus, the formation of possible transfer film build-up and the type of wear mechanism occurring can be visualized. This technique represents, in conjunction with additional analytical methods such as microscopy and SEM/EDX, a powerful tool to provide a better insight into the mechanisms of solid lubricant action under fretting conditions. To demonstrate the potential of this approach, a time to damage study is performed on commercial and self-prepared pastes from solid lubricants and white oil, where calcium hydroxide is a commonly employed solid lubricant for the avoidance of fretting wear is compared to other materials. Full article

Surface texturing is an effective method to reduce friction without the need to change materials. In this study, surface textures were transferred to rubber samples in the form of dimples, using a novel laser surface texturing (LST)—based texturing during moulding (TDM) production process, developed within the European Project MouldTex. The rubber samples were used to experimentally determine texture-induced friction variations, although, due to the complexity of manufacturing, only a limited amount was available. The tribological friction measurements were hence combined with an artificial intelligence (AI) technique, i.e., Reduced Order Modelling (ROM). ROM allows obtaining a virtual representation of reality through a set of numerical strategies for problem simplification. The ROM model was created to predict the friction outcome under different operating conditions and to find optimised dimple parameters, i.e., depth, diameter and distance, for friction reduction. Moreover, the ROM model was used to evaluate the impact on friction when manufacturing deviations on dimple dimensions were observed. These results enable industrial producers to improve the quality of their products by finding optimised textures and controlling nominal surface texture tolerances prior to the rubber components production. Full article

This paper presents a formulation of point contact elastohydrodynamic lubrication analysis for an isothermal, non-Newtonian flow. A coordinate system of the pressure gradient was employed herein. A Couette flow and a Poiseuille flow were considered along the directions of the zero and non-zero pressure gradients, respectively. The Poiseuille flow velocity was assumed to be represented by a 4th-order polynomial of z along the film thickness direction. The Couette flow velocity was assumed to be represented by a linear function of z. Subsequently, the modified Reynolds equation, which contains an equivalent viscosity, was obtained. Using Bauer’s rheological model, the formulation presented in this study was applied to a grease that has been previously experimented upon. The results of previous studies were compared with those of the present study and a reasonable agreement was noted. The distribution of the equivalent viscosity showed a notable difference from that of Newtonian flow. The formulation can be incorporated easily to the usual elastohydrodynamic lubrication calculation procedure for Newtonian flow. The method can be easily applied to other non-Newtonian rheological models. The equivalent viscosity can be calculated using the one-parameter Newton-Raphson’s method; as a result, the calculation can be performed within a reasonable time. Full article

Even though the behavior of aerostatic bearings has for long been the topic of extensive research, there are still many aspects that require further investigation. Among these, the identification of the discharge coefficients is one the most crucial. This paper presents a hybrid method to identify the discharge coefficients of aerostatic bearing orifices. The method is termed as hybrid since it exploits experimental data and the equations of the analytical model of a circular and centrally fed aerostatic pad. The obtained results demonstrate the accuracy of the method. The proposed method further offers practical advantages compared to the conventional methods. Full article

Wear of nonstandard involute gears with two types of coatings, AlCrN and CrAlSiN, was studied. The coatings were applied by cathodic arc deposition. The gears were tested using a Niemann tester at a graduated load up to the 12th load stage and were compared to noncoated gears. Both Biogear S150 gear oil and PP90 universal hydraulic oil were applied during these tests. The thickness of deposited coatings and wear of gear teeth were studied by SEM and their chemical compositions were determined by EDS analysis. Maximal contact pressure of 1350 MPa was calculated in the region of the tooth flank at the 12th load stage. Maximal frictional stress was also calculated on the tooth flank. The resistance against wear of gears was evaluated based on the critical weight loss and mainly based on the critical surface roughness of gears. The critical roughness was exceeded at the 10th load stage for noncoated gears. For the gears with AlCrN and CrAlSiN coatings, the critical roughness was exceeded at the 11th load stage. Wear of AlCrN and CrAlSiN coatings was nonuniform along the height of tooth. Wear on the tooth flank was characterized by fragmentation of thin coatings and subsequent detaching of fragments from the steel substrate. The steel substrate was worn by microcutting, which caused the highest roughness on the tooth surface. On the tooth pitch, surface protrusions of coatings were smoothed, and coatings cracked and locally detached subsequently. On the tooth face, surface protrusions were also smoothed but coatings remained compact without crack initiations. Both experimental oils, Biogear S150 and PP90, proved to be suitable during Niemann tests as their temperatures did not exceed the limit value of 80 °C. Full article