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Research Papers: Elastohydrodynamic Lubrication

Numerical Prediction of Surface Wear and Roughness Parameters During Running-In for Line Contacts Under Mixed Lubrication

[+] Author and Article Information
Yazhao Zhang

State Key Laboratory of Tribology,
Tsinghua University,
Beijing 100084, China
e-mail: zhang-yz14@mails.tsinghua.edu.cn

Alexander Kovalev

State Key Laboratory of Tribology,
Tsinghua University,
Beijing 100084, China
e-mail: akovalev@tsinghua.edu.cn

Noriyuki Hayashi

Machinery Research Department,
Research & Innovation Center,
Mitsubishi Heavy Industries Ltd.,
5-717-1, Fukahori-machi,
Nagasaki 851-0392, Japan

Kensuke Nishiura

Machinery Research Department,
Research & Innovation Center,
Mitsubishi Heavy Industries Ltd.,
5-717-1, Fukahori-machi,
Nagasaki 851-0392, Japan

Yonggang Meng

State Key Laboratory of Tribology,
Tsinghua University,
Beijing 100084, China
e-mail: mengyg@tsinghua.edu.cn

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received November 8, 2017; final manuscript received March 13, 2018; published online May 7, 2018. Assoc. Editor: Wang-Long Li.

J. Tribol 140(6), 061501 (May 07, 2018) (13 pages) Paper No: TRIB-17-1426; doi: 10.1115/1.4039867 History: Received November 08, 2017; Revised March 13, 2018

A stochastic model for predicting the evolutions of wear profile and surface height probability density function (PDF) of initial line contacts during running-in under mixed lubrication condition is presented. A numerical approach was developed on the basis of stochastic solution of mixed lubrication, which combined the Patir and Cheng's average flow model for calculation of the hydrodynamic pressure and the Kogut and Etsion's (KE) rough surface contact model for calculation of the asperity contact pressure. The total friction force was assumed to be the sum of the boundary friction at the contact asperities and the integration of viscous shear stress in the hydrodynamic region. The wear depth on the contact region was estimated according to the modified Archard's wear model using the asperity contact pressure. Sugimura's wear model was modified and used to link the wear particle size distribution and the variation of surface height PDF during wear. In the wear process, the variations of profile and surface height PDF of initial line contacts were calculated step by step in time, and the pressure distribution, friction coefficient, and wear rate were updated consequently. The effect of size distribution of wear particles on the wear process was numerically investigated, and the simulation results showed that the lubrication condition in which small wear particles are generated from the asperity contact region is beneficial to reduce friction coefficient and wear rate, and leads to a better steady mixed lubrication condition.

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Figures

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Fig. 1

Wear process of initial line contact at the mixed lubrication regime: (a) friction pairs of smooth stationary plate and a sliding rough cylinder and (b) schematic of geometric profile variation and roughness change

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Fig. 2

Flowchart for mixed lubrication model

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Fig. 3

The change of surface height distribution during time t∼t+Δt

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Fig. 4

An exponential PDF of particle thickness fw(w) with σw=1 μm and a corresponding density function ψ(w)

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Fig. 5

Calculation flowchart of mixed lubrication and evolution of statistical surface parameters

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Fig. 6

Wear particle thickness distributions

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Fig. 7

Variation of cylinder profile during the wear process with different lubrication conditions: (a) lubrication condition with σw/σ0=0.3, (b) lubrication condition with σw/σ0=1.0, and (c) lubrication condition with σw/σ0=3.0

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Fig. 8

Changes of height PDF during the lubrication process: (a) lubrication condition with σw/σ0=0.3, (b) lubrication condition with σw/σ0=1.0, and (c) lubrication condition with σw/σ0=3.0

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Fig. 9

Variation of roughness parameters during wear process: (a) standard deviation Sq, (b) skewness Ssk, and (c) kurtosis Sku

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Fig. 10

Variation of pressure distribution of σw/σ0=1.0 condition along with sliding distance: (a) 0 m, (b) 300 m, (c) 1000 m, and (d) 1800 m

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Fig. 11

Variation of contact load ratio during wear process

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Fig. 12

Changes of friction coefficient during wear process

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Fig. 13

Changes of wear rate and wear loss during wear process

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Fig. 14

Surface profiles and wear particle

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Fig. 15

The composite profile and changes due to wear

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