Experimental and numerical study of the mixed lubrication under the action of magnetic ionic liquid additives

In this paper, the tribological characteristics of an oil-soluble magnetic fluid additive under mixed lubrication are studied by experiments and numerical simulation. [bmim][FeCl4] is dissolved in CF10W-40 lubricating oil as a magnetic liquid additive, and its friction coefficient is tested by a point contact friction tester at different temperatures, rotational speeds and magnetic field intensities. The transition condition of lubrication state is obtained through analyzing the Stribeck curves based on the experiments, and the strength model of boundary film is established accordingly. A mixed lubrication model is established by substituting the boundary film strength model and the surface roughness model into the hydrodynamic lubrication model based on Reynolds equation. The results show that the magnetic solution as an additive can obviously reduce friction and wear, and the effect is more obvious under the condition of magnetic field. The boundary film strength model can accurately reflect the transition characteristics of lubrication state in the presence of boundary film, and the mixed lubrication model based on boundary film strength model can more precisely reflect the tribological characteristics of friction pairs, so this study provides a new theoretical method for the related research on the influence of boundary film on lubrication characteristics.

Experimental and Numerical Study of Micropitting Initiation in Real Rough Surfaces in a Micro-elastohydrodynamic Lubrication Regime

Micropitting is a form of surface fatigue damage that happens at the surface roughness scale in lubricated contacts in commonly used machine elements, such as gears and bearings. It occurs where the specific film thickness (ratio of smooth surface film thickness to composite surface roughness) is sufficiently low for the contacts to operate in the mixed lubrication regime, where the load is in part carried by direct asperity contacts. Micropitting is currently seen as a greater issue for gear designers than is regular pitting fatigue failure as the latter can be avoided by control of steel cleanliness. This paper describes the results of both theoretical and experimental studies of the onset of micropitting in test disks operated in the mixed lubrication regime. A series of twin disk mixed-lubrication experiments were performed in order to examine the evolution of micropitting damage during repeated cyclic loading of surface roughness asperities as they pass through the contact. Representative measurements of the surfaces used in the experimental work were then evaluated using a numerical model which combines a transient line contact micro-elastohydrodynamic lubrication (micro-EHL) simulation with a calculation of elastic sub-surface stresses. This model generated time-history of stresses within a block of material as it passes through the contact, based on the instantaneous surface contact pressure and traction at each point in the computing mesh at each timestep. This stress time-history was then used within a shear-strain-based fatigue model to calculate the cumulative damage experienced by the surface due to the loading sequence experienced during the experiments. The proposed micro-EHL model results and the experimental study were shown to agree well in terms of predicting the number of loading cycles that are required for the initial micropitting to occur.