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Research Papers: Contact Mechanics

J. Tribol. 2019;141(6):061401-061401-9. doi:10.1115/1.4043281.

The contact condition between the wheel and the rail is paramount to the lifespan, safety, and smooth operation of any rail network. The wheel/rail contact condition has been estimated, calculated, and simulated successfully for years, but accurate dynamic measurement has still not been achieved. Methods using pressure-sensitive films and controlled air flow have been employed, but both are limited. The work described in this paper has enabled, for the first time, the measurement of a dynamic wheel/rail contact patch using an array of 64 ultrasonic elements mounted in the rail. Previous work has successfully proved the effectiveness of ultrasonic reflectometry for static wheel/rail contact determination. The dynamic real-time measurement is based on previous work, but now each element of an array is individually pulsed in sequence to build up a linear measurement of the interface. These cross-sectional, line measurements are then processed and collated resulting in a two-dimensional contact patch. This approach is able to provide not only a contact patch, but more importantly, a detailed and relatively high-resolution pressure distribution plot of the contact. Predictions using finite element methods (FEM) have also been carried out for validation. Work is now underway to increase the speed of the measurement.

Topics: Pressure , Rails , Wheels , Stress
Commentary by Dr. Valentin Fuster

Research Papers: Elastohydrodynamic Lubrication

J. Tribol. 2019;141(6):061501-061501-10. doi:10.1115/1.4043180.

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.

Commentary by Dr. Valentin Fuster
J. Tribol. 2019;141(6):061502-061502-11. doi:10.1115/1.4043182.

This research aims to evaluate the tribological performance of chromium molybdenum (CrMo) coatings under point and line-contact mixed elastohydrodynamic lubrication. This article studies the coatings made from two different methods and treated in an electrifying process of different durations, which produced microchannels and micropockets in the surfaces. The resulting surface topographies had varying impacts on lubricant film thickness, friction, and wear. Root-mean-square roughness (Sq) and porosity are used to characterize the surfaces and their performances in terms of film thickness, friction, and wear. The results suggest that the coated surfaces with a lower Sq and porosity density tended to yield higher film thickness. However, their influence on friction is complicated; lower roughness and porosity are preferred for lower wear, but certain levels of small roughness and surface pores may help to reduce boundary lubrication friction when compared with the frictional behaviors of porosity-free surfaces and those with higher roughness and higher porosity.

Commentary by Dr. Valentin Fuster

Research Papers: Hydrodynamic Lubrication

J. Tribol. 2019;141(6):061701-061701-11. doi:10.1115/1.4043238.

Squeeze film dampers (SFDs) aid to both reduce rotor dynamic displacements and to increase system stability. Dampers sealed with piston rings (PR), common in aircraft engines, are proven to boost damping generation, reduce lubricant flow demand, and prevent air ingestion. This paper presents the estimation of force coefficients in a short length SFD, PR sealed, and supplied with a light lubricant at two feed pressures, Pin-1 ∼ 0.69 barg and Pin-2 ∼ 2.76 barg, i.e., low and high. Two pairs of PRs are installed in the test SFD, one set has flow conductance CS1 = 0.56 LPM/bar, whereas the other pair has CS2 = 0.89 LPM/bar. The second set leaks more as it has a larger slit gap. Dynamic load tests show that both dampers, having seal flow conductances differing by 60%, produce damping and added mass coefficients of similar magnitude, differing by at most 20%. Other experiments quantify the effect of lubricant supply pressure, Pin-1 and Pin-2, on the dynamic film pressure and force coefficients of the PR-SFD. The damper configuration with CS1 and operating with the high Pin-2 shows ∼20% more damping and added mass coefficients compared with test results for the damper supplied with Pin-1. Film pressure measurements show that the air ingestion and oil vapor cavitation coexist for operation at the low Pin-1. Computational predictions accounting for the feed holes in the physical model agree with the experimental coefficients. On the other hand, predictions from classical formulas for an idealized damper geometry, fully sealed at its ends, largely overpredict the measured force coefficients.

Commentary by Dr. Valentin Fuster
J. Tribol. 2019;141(6):061702-061702-21. doi:10.1115/1.4043349.

This paper presents the first simulation model of a tilting pad journal bearing (TPJB) using three-dimensional (3D) computational fluid dynamics (CFD), including multiphase flow, thermal-fluid, transitional turbulence, and thermal deformation of the shaft and pads employing two-way fluid–structure interaction (FSI). Part I presents a modeling method for the static performance. The model includes flow between pads BP, which eliminates the use of an uncertain, mixing coefficient (MC) in Reynold's equation approaches. The CFD model is benchmarked with Reynold's model with a 3D thermal-film, when the CFD model boundary conditions are consistent with the Reynolds boundary conditions. The Reynolds model employs an oversimplified MC representation of the three-dimensional mixing effect of the BP flow and heat transfer, and it also employs simplifying assumptions for the flow and heat transfer within the thin film between the journal and bearing. This manufactured comparison shows good agreement between the CFD and Reynold's equation models. The CFD model is generalized by removing these fictitious boundary conditions on pad inlets and outlets and instead models the flow and temperature between pads. The results show that Reynold's model MC approach can lead to significant differences with the CFD model including detailed flow and thermal modeling between pads. Thus, the CFD approach provides increased reliability of predictions. The paper provides an instructive methodology including detailed steps for properly applying CFD to tilt pad bearing modeling. Parts I and II focus on predicting static and dynamic response characteristic responses, respectively.

Commentary by Dr. Valentin Fuster
J. Tribol. 2019;141(6):061703-061703-16. doi:10.1115/1.4043350.

Part II presents a novel approach for predicting dynamic coefficients for a tilting pad journal bearing (TPJB) using computational fluid dynamics (CFD) and finite element method (FEM), including fully coupled elastic deflection, heat transfer, and fluid dynamics. Part I presented a similarly novel, high fidelity approach for TPJB static response prediction which is a prerequisite for the dynamic characteristic determination. The static response establishes the equilibrium operating point values for eccentricity, attitude angle, deflections, temperatures, pressures, etc. The stiffness and damping coefficients are obtained by perturbing the pad and journal motions about this operating point to determine changes in forces and moments. The stiffness and damping coefficients are presented in “synchronously reduced form” as required by American Petroleum Institute (API) vibration standards. Similar to Part I, an advanced three-dimensional thermal—Reynolds equation code validates the CFD code for the special case when flow Between Pad (BP) regions is ignored, and the CFD and Reynolds pad boundary conditions are made identical. The results show excellent agreement for this validation case. Similar to the static response case, the dynamic characteristics from the Reynolds model show large discrepancies compared with the CFD results, depending on the Reynolds mixing coefficient (MC). The discrepancies are a concern given the key role that stiffness and damping coefficients serve instability and response predictions in rotordynamics software. The uncertainty of the MC and its significant influence on static and dynamic response predictions emphasizes a need to utilize the CFD approach for TPJB simulation in critical machines.

Commentary by Dr. Valentin Fuster

Research Papers: Mixed and Boundary Lubrication

J. Tribol. 2019;141(6):062101-062101-8. doi:10.1115/1.4043181.

The tribological properties of some novel single component perfluoropolyether (PFPE) boundary lubricants with chemically integrated mixture end groups are investigated. Chemically integrated mixture end groups composed of hydroxyl- and anisole-terminated PFPE boundary lubricant films on the –(CF2CF2CF2O)– main chain are reported. These PFPE-based boundary lubricants explore a new method by which single component PFPE lubricants with mixture end groups might be used to tailor boundary film properties instead of using physical mixtures of two or more PFPEs with different end groups. Lubricant transfer to the low-flying read/write head, head wear, and siloxane adsorption as a function of PFPE film thickness and of type are compared. Normalization of the data to the monolayer fraction instead of film thickness allows direct comparison between anisole- and hydroxyl-terminated PFPEs. Lubricant transfer to the head and head wear are independent of the functional end groups. Siloxane adsorption decreases with increasing anisole substitution of the hydroxyl groups. One-component PFPEs with mixed end groups provide a methodology by which boundary film properties could be adjusted.

Commentary by Dr. Valentin Fuster

Research Papers: Other (Seals, Manufacturing)

J. Tribol. 2019;141(6):062201-062201-11. doi:10.1115/1.4043123.

Leakage susceptibility is significant for the functionalization of engineering products, and surface topography plays a crucial role in forming the leakage channel in static sealing interface. This paper proposes a surface connectivity-based approach to predict the leakage channel in static sealing interface. The proposed approach consists of three modules including contact surface generation, leakage parameters definition, and leakage channel prediction. A high-definition metrology (HDM) instrument is adopted to measure the three-dimensional (3D) surface. The contact surface that can be considered as the sealing interface is generated by assembling the virtual gasket surface and waviness surface. Considering the spatial connectivity, two kinds of leakage parameters including connectivity parameters and correlation parameters are proposed to describe the characteristics of the contact surface. Meantime, a novel prediction algorithm is developed to directly indicate the potential leakage channel of the surface. Experimental results demonstrate that the proposed approach is valid to be accurate and effective, which can provide valuable information for surface topography and static sealing performance.

Commentary by Dr. Valentin Fuster

Technical Brief

J. Tribol. 2019;141(6):064501-064501-4. doi:10.1115/1.4043348.

The local viscoelastic properties of soft polishing pads with different usage durations are measured by a micro-scale mechanical analysis testing platform. The testing reveals stimulus-adaptive local viscoelasticity of soft pads under the activation of asperity contact. This phenomenon suggests asperity-dependent local modulus. Such an increase of local modulus induced by higher asperity provides a further enhancement effect to the planarization of surface asperity. Furthermore, the measurement outcomes suggest that the reaction of local micro-scale viscoelastic properties of the soft pad surface to the workpiece asperity will decay with usage time. The current study provides a detailed understanding of the aging effects for the soft pad and explains the performance decay during soft pad polishing from a local micro-scale interfacial perspective.

Commentary by Dr. Valentin Fuster

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