Research Papers: Elastohydrodynamic Lubrication

A Mixed-TEHL Analysis of Cam-Roller Contacts Considering Roller Slip: On the Influence of Roller-Pin Contact Friction

[+] Author and Article Information
Shivam S. Alakhramsing

Laboratory for Surface Technology and
Faculty of Engineering Technology,
University of Twente,
P.O. Box 217,
Enschede 7500 AE, The Netherlands
e-mail: s.s.alakhramsing@utwente.nl

Matthijn B. de Rooij, Aydar Akchurin, Dirk J. Schipper

Laboratory for Surface Technology and
Faculty of Engineering Technology,
University of Twente,
P.O. Box 217,
Enschede 7500 AE, The Netherlands

Mark van Drogen

Central Laboratory Metals,
DAF Trucks N.V.,
P.O. Box 90065,
Eindhoven 5600 PT, The Netherlands

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received February 12, 2018; final manuscript received July 23, 2018; published online August 24, 2018. Assoc. Editor: Longqiu Li.

J. Tribol 141(1), 011503 (Aug 24, 2018) (15 pages) Paper No: TRIB-18-1067; doi: 10.1115/1.4040979 History: Received February 12, 2018; Revised July 23, 2018

In this work, a mixed lubrication model, applicable to cam-roller contacts, is presented. The model takes into account non-Newtonian, thermal effects, and variable roller angular velocity. Mixed lubrication is analyzed using the load sharing concept, using measured surface roughness. Using the model, a quasi-static analysis for a heavily loaded cam-roller follower contact is carried out. The results show that when the lubrication conditions in the roller-pin contact are satisfactory, i.e., low friction levels, then the nearly “pure rolling” condition at the cam-roller contact is maintained and lubrication performance is also satisfactory. Moreover, non-Newtonian and thermal effects are then negligible. Furthermore, the influence of roller-pin friction coefficient on the overall tribological behavior of the cam-roller contact is investigated. In this part, a parametric study is carried out in which the friction coefficient in the roller-pin contact is varied from values corresponding to full film lubrication to values corresponding to boundary lubrication. Main findings are that at increasing friction levels in the roller-pin contact, there is a sudden increase in the slide-to-roll ratio (SRR) in the cam-roller contact. The value of the roller-pin friction coefficient at which this sudden increase in SRR is noticed depends on the contact force, the non-Newtonian characteristics, and viscosity–pressure dependence. For roller-pin friction coefficient values higher than this critical value, inclusion of non-Newtonian and thermal effects becomes highly important. Furthermore, after this critical level of roller-pin friction, the lubrication regime rapidly shifts from full film to mixed lubrication. Based on the findings in this work, the importance of ensuring adequate lubrication in the roller-pin contact is highlighted as this appears to be the critical contact in the cam-follower unit.

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Fig. 1

Cam-roller follower configuration showing the frictional forces acting at the cam-roller and roller-pin contact

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Fig. 2

Equivalent geometry for EHL analysis of the infinite line contact problem. The dimensions are exaggerated for the sake of clarity.

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Fig. 3

Schematic view of the surfaces which are in contact. z(x, y) represents the surface roughness heights, hs the separating distance and the deflection u(x, y) = z(x, y) – hs (x, y).

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Fig. 4

Relationship between the mean contact pressure p¯a and film thickness h

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Fig. 5

Computational domain for the thermal model

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Fig. 6

Numerical solution scheme for the cam-roller lubrication model

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Fig. 7

Surface roughness influence curve “h−p¯a curve” calculated from the work of Gelinck [53]

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Fig. 8

Comparison model predictions and experiments [52,53] for (a) Stribeck curves and (b) traction curves

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Fig. 9

Variation of the lift, reduced radius of curvature Rx, cam surface speed uc, and contact force F as a function of cam angle θ

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Fig. 10

Measured surface roughness for (a) base circle, (b) nose center, and (c) roller

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Fig. 11

(a) Surface roughness influence curves “h−p¯a curves” and (b) interpolation function g for the mapping of “h−p¯a curves” against cam angle

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Fig. 12

Evolution of crucial design variables such as (a) film thicknesses hcent and hmin, (b) asperity load ratio Fa/F and SRR, (c) maximum total pressure pmax, and (d) maximum contact temperature Tmax, as a function of the cam angle θ

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Fig. 13

Snapshot of the asperity P¯a, hydrodynamic Ph and total pressure P distributions, together with the dimensionless film thickness distribution H at 63.5 deg cam angle

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Fig. 14

Variation of crucial design variables such as (a) the SRR, (b) central film thickness hcent, (c) asperity load ratio Fa/F, and (d) maximum contact temperature Tmax, as a function of the roller-pin friction coefficient fr–p. Results are presented for 0 deg cam angle.

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Fig. 15

Variation of crucial design variables such as (a) the SRR, (b) central film thickness hcent, (c) asperity load ratio Fa/F, and (d) maximum contact temperature Tmax, as a function of the roller-in friction coefficient fr–p. Results are presented for 63.5 deg cam angle.



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