Lubricants

In the introduction, we present an overview of previous research on this subject in order to help the reader review possible technological solutions regarding the joining of construction materials. The original research presented in this article concerns the results of increasing the shear strength of adhesive joints of plastics using various types of surface preparation (laser texturing). Laser texturing consists in developing the surface by applying various geometric patterns of appropriate shapes and depths, as well as its density on the surface. The above parameters are currently selected in an empirical way as research is still being developed as part of a research project. The textures obtained in this way are subjected to microscopic examination. Then, a layer of glue is applied, and the samples prepared in this way, after drying, are subjected to various destructive tests, e.g., tensile, shear, and bending. In this article, we attempted to test the strength of the bonded joint of polyethylene (PE). The impact of a laser beam with ultrashort picosecond pulses was used in the research. Tools in the form of a TRUMPF TruMicro 5325c device integrated with a SCANLAB GALVO scanning head were used. This enabled ablative material removal without the presence of a heat affected zone (HAZ) in the non-laser part. Ultrashort laser pulses remove material without melting the non-exposed area by the laser beam. On the basis of the tests performed (in this article and previous research works of the authors), it was shown that the method increases the shear strength of the glued joints made in the tested construction materials. This is confirmed by laboratory results of tribological tests. The laser treatment parameters used, which are shown in this article, did not lead to the appearance of cracks in the micromachined materials. Research has shown that the connections between elements with a properly selected micropattern are characterized by a several-fold increase in the strength of joints, unlike materials without a micropattern. The presented method may be helpful for use as a technology for joining plastics. Full article

The influence of NBR Shore hardness and PTFE elastic modulus on the sealing characteristics of step rod seals is analyzed in this paper based on the developed mixed elastohydrodynamic lubrication (EHL) model. The optimized selection studies of NBR Shore hardness and PTFE elastic modulus under different operating conditions are carried out based on the principle of minimizing net leakage and friction power loss. Results show that the Shore hardness of the NBR O-ring and, in particular, the elastic modulus of the PTFE ring has a significant effect on the sealing characteristics. Although the high values of these parameters result in high friction forces, they are beneficial for leakage control. To achieve both low leakage and low friction, it is recommended that high hardness and low modulus are selected for moderate-low pressure or high speed conditions, but low hardness and high modulus are selected for high pressure or low speed conditions. Full article

With the rapid development of China’s manufacturing industry, products are changing toward better energy efficiency and precision. Reducing transmission energy waste, enhancing transmission lubrication, and increasing transmission efficiency have all become critical concerns. The moving particle semi-implicit particle approach is utilized in this study to create a high-speed rotating meshing gear lubrication model and conduct a simulation analysis of transmission gears by studying the influence law of sensitive parameter injection diameter on lubrication. The oil distribution state on the gear surface, the gear tooth surface heat dissipation effect, and the degree of gear operating stability are all calculated by computing the gear surface fluid coverage and convective heat transfer coefficient. According to the numerical simulation results, increasing the liquid injection diameter can greatly enhance fluid coverage and convective heat transfer coefficient on the gear surface, hence improving lubrication. However, when the injection diameter reaches a critical value, the contact area between the liquid and the gear is maximized, and additional increases in the injection diameter will not improve the lubricating effect. Experiments have revealed that the liquid injection diameter is the most critical factor influencing gears. The gear torque dramatically increases as the liquid injection diameter increases. According to a rigorous analysis, the gear lubrication effect is optimal when the liquid injection diameter is 2.0 mm. This provides a theoretical foundation for transmission system lubrication design. Full article

We study the mechanism of formation of the multilayer structure of the subsurface regions of WC/Mn13 steel cermets after sliding on a steel disk at speeds from 10 to 37 m/s and contact pressure of 5 MPa in order to elucidate the fundamental role of the processes of tribooxidation on a worn surface in the formation of the tribomechanical properties of a large family of similar W/Fe-containing materials. It was shown that the maximum antifriction effect of WC/Mn13 steel cermets under conditions of high-speed sliding was due to in-situ generated FeWO₄ that provided friction coefficient drop from ~0.17 to ~0.07 when sliding at 10 and 37 m/s, respectively. The sliding speed had its effect on the subsurface structure and tribolayer thickness, so micron-sized, mechanically mixed 3–4 μm-thick layers (MML) were generated in sliding at 10 and 20 m/s, whose wear occurred mainly by subsurface fracture and delamination of tile-shaped wear particles. Continuous tribolayers with 10–15 μm thickness were generated at 30–37 m/s with underlying zones containing fragmented and deformed WC grains. Such a structure provided plasticizing effect during sliding so that wear was mainly by flow of so plasticized subsurface layers. Full article

To increase the power density of the electromechanical drive train of wind turbines, journal bearings can be used as planetary gear bearings instead of rolling bearings. This technological change presents new challenges. For example, wind turbine drive systems are subject to dynamic and low-speed operating conditions, which can lead to accelerated abrasive wear of the journal bearings. In addition, oil supply failure or peak loads due to wind gusts and grid and power converter faults could potentially result in catastrophic failure due to adhesive wear in a very short time. Such operating characteristics are, therefore, critical regarding the journal bearing wear lifetime and must be considered in the design. The successful implementation of journal bearings in wind turbines depends on a reliable estimation of adhesive and abrasive wear. In this paper, five different models for the wear calculation of journal bearings are evaluated regarding their suitability for the wear calculation of planetary gear bearings in wind turbines. For this purpose, the following evaluation criteria were defined: parameter uncertainty, parametrization effort, in particular number of parameters, parameterization method, load case dependency of parameters and calculation effort. In order to be able to evaluate the wear models, the wear models are numerically implemented, and the wear of a test journal bearing is exemplarily calculated under load conditions, which are comparable to load conditions in a wind turbine. Relevant influences from the wind turbine system, such as lubricant, material and manufacturing-dependent surface influences, such as roughness and hardness, are considered. The wear models are evaluated with respect to their fulfillment of the defined criteria. The resulting evaluation allows the selection of a wear model that can be used to calculate the wear of planetary gear journal bearings in wind turbines, considering the available input variables. Full article

Ni-based alloys are among the materials of choice in developing high-quality coatings for ambient and high-temperature applications that require protection against intense wear and corrosion. The current study aims to develop and characterize NiCrBSi coatings with high wear resistance and improved adhesion to the substrate. Starting with nickel-based feedstock powders, thermally sprayed coatings were initially fabricated. Prior to deposition, the powders were characterized in terms of microstructure, particle size, chemical composition, flowability, and density. For comparison, three types of powders with different chemical compositions and characteristics were deposited onto a 1.7227 tempered steel substrate using oxyacetylene flame spraying, and subsequently, the coatings were inductively remelted. Ball-on-disc sliding wear testing was chosen to investigate the tribological properties of both the as-sprayed and induction-remelted coatings. The results reveal that, in the case of as-sprayed coatings, the main wear mechanisms were abrasive, independent of powder chemical composition, and correlated with intense wear losses due to the poor intersplat cohesion typical of flame-sprayed coatings. The remelting treatment improved the performance of the coatings in terms of wear compared to that of the as-sprayed ones, and the density and lower porosity achieved during the induction post-treatment had a significant positive role in this behavior. Full article

In order to investigate the turbulent lubrication performance of a textured hydrodynamic journal bearing (THJB), a model of turbulent lubrication was established in this paper. The variations in the Reynolds number, oil film thickness, oil film pressure, bearing capacity, attitude angle, and side leakage flow with structural and working parameters were studied, and the axis whirl orbit was further analyzed. The results show that turbulent lubrication is suitable for the actual operating conditions of THJBs. The Reynolds number decreases with the eccentricity ratio in the pressure-bearing zone but increases with rotational speeds, whereas the variation in the maximum oil film pressure increases and the minimum oil film thickness decreases with the eccentricity ratio under various Reynolds numbers. The bearing capacity decreases with the dimple diameter, depth, oil film thickness, and clearance ratio but increases with the length/diameter ratio and dimple spacing. As the eccentricity ratio increases, the attitude angle decreases, but the side leakage flow increases. In addition, the system tends to be unstable as the rotational speed and length/diameter ratio increase, and the friction and wear on the surface are three-body friction. This work not only helps in analyzing the characteristics of a THJB under actual operating conditions but also provides support for research on the simulation of THJB’s lubrication mechanism of THJB via computational fluid dynamics. Full article

This paper develops a coupling model of cam-roller contact and roller-pin contact considering thermal effects based on the exhaust cam-roller unit of an internal combustion engine. For the steady/startup running processes, the skidding and the lubrication performance are obtained in a complete cam rotation cycle, and the effects of oil viscosity or modified load are also discussed. The results show that the most significant effect of skidding on the cam-roller unit is the increase in friction between the cam and the roller. In a cam rotation cycle, the slide-roll ratio is not constant, and its value may even be negative. Compared with the steady running process, skidding is more pronounced during the startup running process, especially at the beginning of the acceleration stage (0–18°). Reducing oil viscosity or increasing modified load can effectively reduce the skidding situation, and its effect is more obvious in the steady running process than in the startup running process. Full article

In order to study the oil–gas two-phase flow characteristics of an aero-engine bearing chamber and improve the scavenge effect of lubricating oil, the two-phase flow solution model of a bearing chamber based on the Euler–Euler method was established. Three improvement schemes were proposed for the ventilation structure and scavenge structure of the bearing chamber. The flow characteristics and scavenge characteristics of a conventional bearing chamber and three improvement schemes under different working conditions were analyzed in depth. The results show that after the conventional bearing chamber ventilation structure is embedded (Embed) and improved, with the increase in the embedding depth, the oil in the cavity is further blocked in the cavity, the amount of oil flowing out from the vent is further reduced, and the scavenge efficiency is further improved. After the slope improvement of the scavenge structure of the conventional bearing chamber, due to the increase in the depth of the oil return groove, the drag effect of the air shear force in the cavity on the oil in the oil return groove is further weakened, and the oil accumulation area on the right side of the scavenge port is further suppressed. The volume fraction of the oil in the cavity is further reduced, and the scavenge efficiency is further improved. The combined improvement scheme (ES) can take into account the advantages of embedding and slope improvement schemes, and further improve the scavenge efficiency. Compared to the conventional bearing chamber, when the oil flow rate is 200 L/h and the speed is 15,000 r/min, the oil return efficiency of the embedded (h = 12 mm), slope (l = 56 mm) and combined improvement schemes are increased by 20.19%, 13.43%, and 37.94%, respectively. Full article

In hot stamping of aluminium, the need for efficient methods to evaluate, compare, and rank lubricants based on their tribological performance is critical in the early stages of selection. Pilot and simulative testing can be costly, time-consuming, and complex, making it inefficient for initial benchmarking. This work aims to develop a test methodology to assess lubricant performance for hot stamping under key operating conditions without fully simulating the forming process. The proposed method distinguishes the impact of temperature on lubricant degradation, friction, wear response, and cleanability. The tests utilised a conventional hot work tool steel and a 6010S aluminium alloy with two commercially available lubricants: a polymeric lubricant and a lubricant containing graphite. The tribological tests involved a reciprocating, sliding flat-on-flat configuration at two temperatures (100 °C and 300 °C). The methodology showed that the graphite-containing lubricant exhibited over a four times lower friction coefficient than the polymer-based lubricant at 10 wt.% concentration and 300 °C. At 100 °C, both lubricants provide lubrication and can be cleaned, but increasing temperature led to a significant decline of both aspects. The observed temperature range where the lubricants degrade was between 120 °C and 170 °C. Full article

This study investigates the structure and corrosion behavior of the Al_0.8CrFeCoNiCu_0.5 high-entropy alloy prepared using non-consumable vacuum arc melting. XRD analysis identified BCC1 and BCC2 phases corresponding to (Fe-Cr) and Al-Ni, respectively, while the FCC phase aligned with Cu. SEM and EBSD observations confirmed an equiaxed grain structure with fishbone-like morphology at grain boundaries and modulated structures within the grains. The alloy exhibited minimal residual stress and strain. The alloy demonstrated a preferred orientation of grain growth along the <001> direction. Electrochemical testing in a 3.5% NaCl solution revealed a corrosion potential of −0.332 V and a corrosion current density of 2.61 × 10⁻⁶ A/cm². The intergranular corrosion regions exhibited significant depletion of Al and Cu elements, with the corrosion products primarily consisting of Al and Cu. Al and Cu elements are susceptible to corrosion. The wear scar width of Al_0.8CrFeCoNiCu_0.5 high-entropy alloy is 1.65 mm, which is less than 45# steel, and high-entropy alloy has more excellent wear resistance. Given its unique attributes, this high-entropy alloy could find potential applications in high-end manufacturing industries such as the aerospace engineering, the defense industry, energy production, and chemical processing where high corrosion resistance and wear resilience are crucial. Full article

As the speed of the new generation of high-speed electric multiple units (EMU) increases, the requirements for vibration and noise reduction in traction gear trains are becoming higher and higher. Although most researchers have focused on the vibration mechanics analysis of gears, the actual noise has the most direct impact on passenger experience and safety. To address this problem, a new type of curved cylindrical gear is proposed to analyze the dynamic characteristics of the gear pair and predict its radiated noise based on the acoustic-vibration coupling theory using the finite element-boundary element method. Parametric modeling of the gear pair using CREO and assembly motion analysis were performed. ANSYS was used to analyze the stress distribution, inherent frequency, and inherent vibration pattern of the gear pair, and harmonic response analysis was performed using the modal superposition method to solve the displacement frequency response curve and vibration characteristics. ACTRAN was used to construct the free-field model, create acoustic excitation based on the acoustic-vibration coupling equation, set the field points, and predict radiated noise. The research results show that the noise is mainly concentrated in the tooth meshing area, and the root mean square RMS range of its sound pressure level value is 91–100 dB. Its dynamic characteristics and noise values are in line with the traction requirements of high-speed EMU, providing a new idea for improving the noise prediction of traction gears for new generation high-speed EMU, which in turn strongly support the noise control of high-speed EMU stock and thus improve the passenger experience and driving environment. Full article

This study was designed to examine the effects of a trimethylolpropane trioleate (TMPTO)-based lubricant on thrust force and torque under the high-speed drilling of Al-6061 as an effective environmentally friendly cutting fluid. The tribological performance of three lubricant blends was evaluated based on ASTM standards. TMPTO base oil, notably enhances load-carrying capacity under extreme pressure conditions, with a seizer load of 7848 N. The best-performing oil was further optimized using a Taguchi-based design experiment to investigate the effect of different additive concentrations on thrust force and torque under actual contact conditions. Experiments were conducted using three critical machining parameters: additive concentration, spindle speed, and feed rate. The results of the ANOVA analysis reveal that spindle speed contributes most substantially (62.99%) to torque, with feed rate (23.72%) and additive concentration (7.74%) also showing significant impacts. On the other hand, thrust force is primarily influenced by feed rate (73.52%), followed by spindle speed (16.82%), and additive concentration (6.28%). Furthermore, a machine learning model was developed to predict and compare a few significant aspects of high-speed drilling machinability, including thrust force and torque. Three different error metrics were utilized in order to assess the performance of the predicted values, namely the coefficient of determination (R2), mean absolute percentage error (MAPE) and mean square error (MSE), which are all based on the coefficient of determination. Compared to other models, decision tree produces more accurate prediction values for cutting forces. The present study provides a novel approach for evaluating the most promising biodegradable lube oils and predicting cutting forces by formulating a perfect blend. Full article

This study has investigated the influence of journal bearing wear on the dynamic behaviour of a flexible rotor with a central disc. Rotors supported on journal bearings are susceptible to self-excited whirling, leading to unstable conditions. Prior knowledge of the stability limit speed is important to avoid the excessive vibration of rotating machines. For the study in this paper, journal bearings were lubricated with powder owing to high-temperature applications where conventional oil lubricants would fail to perform. The governing equations for lubrication were derived using a simplified grain theory based on the theory of dense gases. The rotor shaft was discretized considering Timoshenko beam elements. Modal analysis was conducted to obtain the system’s natural frequencies, mode shapes, damping factors, stability limit speed, and unbalance response. This study has also evaluated the influence of wear depth on the dynamic behaviour of the rotor shaft system and found that bearing wear significantly affects the stiffness and damping characteristics of lubricating film. Consequently, free and forced vibration behaviour is also affected. It has been found that increased wear depth improves stability limit speed but has little influence on the unbalance response. Full article

The key objective of the presented study was to use a commercially feasible and scalable approach to modifying surfaces to reduce friction. In an industrial setting, surface grinding is commercially viable and scalable as compared to other surface modifying processes like laser surface texturing, plasma, or ion beam milling. Frictional force plots are generated from the lubricated contact interface between a flat-faced aluminum pin and a reciprocating stainless steel countersurface driven by a scotch yoke follower mechanism. Using a surface grinder and selecting coated abrasive sheets, different stainless steel surface specimens, classified as P320, P1200, and mirror were prepared and tested in this study. The frictional force encountered by the pin was recorded using a data acquisition system at discrete intervals in the reciprocating path and averaged along the sliding cycles. The shape of the frictional force plots thus generated were found to be different from each other. Various mechanisms of friction prevalent at the contact were presumed to influence the shape of these frictional plots. These mechanisms were tested by varying the sliding speeds, lubricating oil viscosities, and using tribofilm-forming additives. We used Group 1 base oil of two different viscosities in our tests. At lower speeds, the frictional force plot for the mirror-finished surface seemed to conform to the Stribeck curve, while in the same scale of reference, the P1200 surface had a force plot that was nearly flat and of very low magnitude. At the contact interface, there seemed to be a fine balance existing between adhesion and abrasion phenomena, while oil retention was promoted to achieve extremely low sliding friction. Full article

In this work, laser processing technology was utilized to fabricate micro-textures on the surface of 42CrMo steel to improve its wear resistance under high load conditions and provide an effective method to solve the wear of tooth plates in oil drilling wellhead machinery. Firstly, the friction process of the textured components was conducted by finite element analysis. Additionally, various forms of textures were compared and measured by this method to optimize the shape and parameters of the patterns. Secondly, three types of texture shapes, such as micro-dimples, micro-grooves, and reticular grooves, were created on the surface of 42CrMo steel. Lastly, the tribological characteristics of the micro-textures were analyzed in the dry friction experiments. Compared with the untextured surface, the wear resistance of the textured 42CrMo steel has been improved, and the anti-wear property of the micro-dimples was better than micro-grooves and reticular grooves. Along the direction of friction sliding, the wear of the front end is more worn than the rear end. Micro-dimples with a diameter of 0.8 mm, a spacing of 1.2 mm, and an area occupancy of 34.8% were fabricated at an output power of 200 W and a frequency of 5 Hz. The wear of the textured surface has been reduced by more than 80% in the process of ring-block dry friction with a load of 50 N, a rotation speed of 35 r/min, and a time of 15 min. The wear mechanism is mainly abrasive wear. The results showed that the hardness of the surface could be improved by laser hardening. In addition, micro-dimples on 42CrMo steel can store abrasive particles, mitigate the formation of furrows and reduce the abrasive wear of tooth plates. Full article

Lubricant is vital to improve energy efficiency and workpiece durability for the moving counterpart. High-temperature lubricants are important for the hot rolling process to reduce the rolling force and protect the roller and the strips. The current paper concerns eco-friendly sodium metasilicate as a high-temperature lubricant. A hot rolling mill is employed to evaluate the lubrication effect of sodium metasilicate. The influence of crucial factors of concentration of lubricant and descaling is discussed; the rolled surface was analyzed by scanning electron microscopy, energy dispersive spectroscopy, and 3D profilometer. The results depict that the sodium metasilicate can reduce the rolling force by about 7.8% when the concentration of sodium metasilicate is 18% and above, and descaling of the hot stripe makes the lubrication effect more effective, which can reach a 12.7% reduction in the rolling force. This lubrication is attributed to the formed melts of the sodium silicate layer that offers an easy shearing interface. For the un-descaled samples, the lubricant will be compacted and mixed with the oxide scale, and weakens the lubrication effect. This work suggests that sodium metasilicate can be a high-temperature lubricant for hot rolling; descaling is vital, not only for the quality of the product but also for the efficiency of the lubricant. This work will also be useful for the concentration selection of glass lubricant. Full article

Surface quality has a significant impact on the service life of machine parts. Grinding is often the last process to ensure surface quality and accuracy of material formation. In this study, a high-quality surface was developed by determining the coefficient of friction in grinding a quartz fiber-reinforced silica ceramic composite. By processing the physical signals in the grinding process, a multi-objective function was established by considering grinding parameters, i.e., surface roughness, coefficient of friction, active energy consumption, and effective grinding time. The weight vector coefficients of the sub-objective functions were optimized through a multi-objective evolutionary algorithm based on the decomposition (MOEA/D) algorithm. The genetic algorithm was used to optimize the process parameters of the multi-objective function, and the optimal range for the coefficient of friction was determined to be 0.197~0.216. The experimental results indicated that when the coefficient of friction tends to 0.197, the distribution distance of the microscopic data points on the surface profile is small and the distribution uniformity is good. When the coefficient of friction tends to 0.216, the surface profile shows a good periodic characteristic. The quality of a grinding surface depends on the uniformity and periodicity of the surface’s topography. The coefficient of friction explained the typical physical characteristics of high-quality grinding surfaces. The multi-objective optimization function was even more important for the subsequent high-quality machining of mechanical parts to provide guidance and reference significance. Full article

Nowadays, due to the carcinogenic effects of chrome, replacing the hard chromium used for hydraulic components like rods and cylinders is becoming increasingly requested. Thermally sprayed coatings are a solution to the problem; however, proper understanding and characterisation of their tribological behaviour are essential for the successful exploitation of surface engineering. Thus, the main aim of this study is to evaluate the abrasive wear characteristics of two metal sprayed layers, tungsten carbide (WC) deposited through the high-velocity oxygen fuel coating (HVOF) method and Fe alloy coating deposited through thermal spraying with an electric arc with a wire-electrode G3Si1, and compare the results with those of an electrochemically deposited hard chromium layer. Their wear resistance is then related to their hardness. The results highlight the tribological performances of the thermally sprayed coatings. The HVOF WC10Co4Cr coating has a wear coefficient and a material wear volume that are hundreds of times lower than those of the other two coatings. Full article