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Research Papers: Elastohydrodynamic Lubrication

Micropitting Fatigue Wear Simulation in Conformal-Contact Under Mixed Elastohydrodynamic Lubrication

[+] Author and Article Information
Hang Jia

State Key Laboratory of Mechanical Transmissions,
Chongqing University,
Chongqing 40044, China
e-mail: 1317304955@qq.com

Junyang Li

State Key Laboratory of Mechanical Transmissions,
Chongqing University,
Chongqing 40044, China
e-mail: lijunyang1982@sina.com

Jiaxu Wang

State Key Laboratory of Mechanical Transmissions,
Chongqing University,
Chongqing 40044, China
e-mail: jxwang@cqu.edu.cn

Guo Xiang

State Key Laboratory of Mechanical Transmissions,
Chongqing University,
Chongqing 40044, China
e-mail: 2437512843@qq.com

Ke Xiao

State Key Laboratory of Mechanical Transmissions,
Chongqing University,
Chongqing 40044, China
e-mail: 490452934@qq.com

Yanfeng Han

State Key Laboratory of Mechanical Transmissions,
Chongqing University,
Chongqing 40044, China
e-mail: fyh-0220@163.com

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the Journal of Tribology. Manuscript received September 25, 2018; final manuscript received January 28, 2019; published online April 5, 2019. Assoc. Editor: Longqiu Li.

J. Tribol 141(6), 061501 (Apr 05, 2019) (10 pages) Paper No: TRIB-18-1400; doi: 10.1115/1.4043180 History: Received September 25, 2018; Accepted January 28, 2019

In this study, a physics-based fatigue wear model is proposed to evaluate the reliability and to predict the life of cumulative micropitting wear for lubricated conformal contacts on rough surfaces. The surface normal load, mean film thickness, and frictional shear traction are simulated by a mixed elastohydrodynamic lubrication (EHL) model for a stress prediction model to calculate the average maximum Hertzian pressure of contact asperities and unit with the statistical contact model and dynamic contact model to obtain the asperity stress cycle number. The wear formula is established through combining a micropitting life prediction model of surface asperities and a mean micropitting damage constant of asperities. The four dominant aspects affecting wear behaviors of the surface contact pairs, working conditions, structure and surface topographies, material properties and lubrication conditions are all taken into account in the model. It is a high-fidelity and comprehensive model that can be used to analyze and optimize the tribological design of rolling–sliding pairs in machinery. The micropitting fatigue wear modeling scheme is validated by comparison of theoretical calculations and available experimental wear data.

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Figures

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Fig. 1

Flowchart of the micropitting wear modeling methodology

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Fig. 2

Simplified conformal contact of transmission mechanism

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Fig. 3

The Greenwood and Tripp model of rough surfaces in contact

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Fig. 4

Equivalent statistical contact topography model

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Fig. 5

Dynamic contact model of the rolling–sliding face-contact pair

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Fig. 6

Equivalent transformation of static contact through roughening and ordering

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Fig. 7

Hertz contact elastic deformation of the asperity

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Fig. 8

Stress distributions of the asperity: (a), (b), and (c) are the von Mises stress distribution in the x–z plane for μc = 0, μc = 0.15, and μc = 0.3, respectively; (d) the maximum tensile stress distribution in the x–z plane for μc = 0.15

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Fig. 9

Micropitting crack propagation model

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Fig. 10

The pin-on-disk contact lubricated numerical solution for surfaces with σ′ = 0.9 μm by means of the mixed EHL model: (a) elastic deformation, (b) gap, (c) contact (asperity) pressure, and (d) fluid (lubricant) pressure

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Fig. 11

Comparison of the experimental and calculative wear loss versus sliding velocity and load. Result A is calculated with the wear model constructed in this article. Result B is calculated with the Bhushan wear model.

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Fig. 12

The relationships of micropitting fatigue wear rate and velocity, load, and slide-to-roll ratio

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Fig. 13

The effect of friction coefficient on model prediction accuracy

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