Microtextured surfaces in higher loaded rolling-sliding EHL line-contacts

Abstract Due to scarce resources coupled with increasing mobility requirements, resource-efficient machine and motor elements are vital. Therefore, surfaces in lubricated tribological contacts can be microtextured, enabling improved lubricating conditions and friction behavior. While this has already been shown for lower loaded contacts, the effects for higher loaded, application-oriented EHL contacts are topic of basic research. Therefore, geometrically defined microtextures are adapted to the tribological system of the tappet/camshaft contact in the valve train of combustion engines as a demonstrator. The tribological performance in respect to lubricating conditions, friction and wear behavior is analyzed on single cam/tappet component test-rigs. EHL simulation is used as ‘numerical zoom’ into a section of the contact area contributing to better understanding of effects and observed phenomena.

[1]  Francesco P. Mezzapesa,et al.  Friction Properties of Lubricated Laser-MicroTextured-Surfaces: An Experimental Study from Boundary- to Hydrodynamic-Lubrication , 2012, Tribology Letters.

[2]  Kamlakar P Rajurkar,et al.  Micro and Nano Machining by Electro-Physical and Chemical Processes , 2006 .

[3]  A. Gosman,et al.  Entrainment and Inlet Suction: Two Mechanisms of Hydrodynamic Lubrication in Textured Bearings , 2007 .

[4]  Sergei Glavatskih,et al.  Computational fluid dynamics analysis of a journal bearing with surface texturing , 2008 .

[5]  Izhak Etsion,et al.  Experimental Investigation of Laser Surface Textured Parallel Thrust Bearings , 2004 .

[6]  Antonius Lubrecht,et al.  Transient increase of film thickness in micro-textured EHL contacts , 2005 .

[7]  R. P. Glovnea,et al.  Electrical Methods for the Evaluation of Lubrication in Elastohydrodynamic Contacts , 2012 .

[8]  Carlos Hidrovo,et al.  Emission reabsorption laser induced fluorescence (ERLIF) film thickness measurement , 2001 .

[9]  M. Fillon,et al.  Optimizing surface texture for hydrodynamic lubricated contacts using a mass-conserving numerical approach , 2010 .

[10]  P. Pawlus,et al.  Tribological behaviours of textured surfaces under conformal and non-conformal starved lubricated contact conditions , 2015 .

[11]  C. Venner Multilevel solution of the EHL line and point contact problems , 1991 .

[12]  Jürgen Buck,et al.  Konstruktive Wege zum reibungsarmen Ventiltrieb , 1998 .

[13]  Johannes Schneider,et al.  Efficiency of laser surface texturing in the reduction of friction under mixed lubrication , 2014 .

[14]  R. S. Dwyer-Joyce,et al.  The measurement of lubricant–film thickness using ultrasound , 2003, Proceedings of the Royal Society of London. Series A: Mathematical, Physical and Engineering Sciences.

[15]  J.-P. Stemplinger,et al.  Engineering Software Solution for Thermal Elastohydrodynamic Lubrication Using Multiphysics Software , 2016 .

[16]  D. Dowson,et al.  A Numerical Solution to the Elasto-Hydrodynamic Problem , 1959 .

[17]  M. Kaneta,et al.  Effects of Surface Roughness on Point Contact EHL , 1993 .

[18]  Hugh Spikes,et al.  The Influence of Longitudinal Roughness in Thin-Film, Mixed Elastohydrodynamic Lubrication , 2006 .

[19]  J. Tripp,et al.  Effects of Surface Micro-Geometry On the Lift-Off Speed of an EHL Contact , 2002 .

[20]  Fritz Klocke,et al.  Development of an incremental rolling process for the production of defined riblet surface structures , 2007, Prod. Eng..

[21]  Hugh Spikes,et al.  The Development of a Spacer Layer Imaging Method (SLIM) for Mapping Elastohydrodynamic Contacts , 1996 .

[22]  Claus Daniel,et al.  Laser Interference Metallurgy – using interference as a tool for micro/nano structuring , 2006 .

[23]  Jürgen Fleischer,et al.  The manufacturing of micro molds by conventional and energy-assisted processes , 2007 .

[24]  D. Dini,et al.  Experimental Validation of a Mixed-Lubrication Regime Model for Textured Piston-Ring-Liner Contacts , 2017 .

[25]  J. Tripp,et al.  Effects of Surface Micro-Geometry on the Pressures and Internal Stresses of Pure Rolling EHL Contacts , 2003 .

[26]  Eric Willis,et al.  Surface finish in relation to cylinder liners , 1986 .

[27]  Izhak Etsion,et al.  Improving Tribological Performance of Mechanical Components by Laser Surface Texturing , 2004 .

[28]  Ling Wang Use of structured surfaces for friction and wear control on bearing surfaces , 2014 .

[29]  T. Hughes,et al.  The Galerkin/least-squares method for advective-diffusive equations , 1988 .

[30]  O. C. Zienkiewicz,et al.  The Finite Element Method for Fluid Dynamics , 2005 .

[31]  Harald Meerkamm,et al.  Auswirkungen von laserstrukturierten Substratoberflächen auf die tribologischen Eigenschaften beschichteter Gleitpaarungen , 2006 .

[32]  J. A. Findlay Cavitation in mechanical face seals. , 1968 .

[33]  Si-Geun Choi,et al.  The effect of multi-scale laser textured surface on lubrication regime , 2013 .

[34]  F. Klocke,et al.  The effects of powder suspended dielectrics on the thermal influenced zone by electrodischarge machining with small discharge energies , 2004 .

[35]  S. M. Hsu,et al.  A critical assessment of surface texturing for friction and wear improvement , 2017 .

[36]  Izhak Etsion,et al.  Experimental Investigation of Laser Surface Texturing for Reciprocating Automotive Components , 2002 .

[37]  J. A. Walowit,et al.  A Theory of Lubrication by Microirregularities , 1966 .

[38]  Carsten Gachot,et al.  Correlation between solid–solid contact ratios and lubrication regimes measured by a refined electrical resistivity circuit , 2014 .

[39]  A. Gherca,et al.  Influence of Surface Geometry on the Hydrodynamic Performances of Parallel Bearings in Transient Flow Conditions , 2013 .

[40]  P. McNally,et al.  A comparative study of Pd/Sn/Au, Au/Ge/Au/Ni/Au, Au-Ge/Ni and Ni/Au-Ge/Ni ohmic contacts to n-GaAs , 1998 .

[41]  R. Bosma,et al.  Multigrid, An Alternative Method for Calculating Film Thickness and Pressure Profiles in Elastohydrodynamically Lubricated Line Contacts , 1986 .

[42]  M. Fillon,et al.  An experimental analysis of the hydrodynamic contribution of textured thrust bearings during steady-state operation: A comparison with the untextured parallel surface configuration , 2015 .

[43]  G. Jacobs,et al.  Improved Wear Behavior of Cylindrical Roller Thrust Bearings by Three‐Beam Laser Interference   , 2016 .

[44]  Gustavo C. Buscaglia,et al.  Texture-induced cavitation bubbles and friction reduction in the Elrod–Adams model , 2015 .

[45]  Izhak Etsion,et al.  The Effect of Laser Texturing of Steel Surfaces and Speed-Load Parameters on the Transition of Lubrication Regime from Boundary to Hydrodynamic , 2004 .

[46]  Peder Klit,et al.  Observations on the effects of grooved surfaces on the interfacial torque in highly loaded rolling and sliding tests , 2015 .

[47]  G. Stachowiak,et al.  Evaluation of discretization and integration methods for the analysis of finite hydrodynamic bearings with surface texturing , 2015 .

[48]  S. Wartzack,et al.  Efficiency improvement in automobile bucket tappet/camshaft contacts by DLC coatings – Influence of engine oil, temperature and camshaft speed , 2016 .

[49]  Martin Berzins,et al.  Adaptive high-order finite element solution of transient elastohydrodynamic lubrication problems , 2006 .

[50]  Oliver Kreil,et al.  Einfluss der Oberflächenstruktur auf Druckverteilung und Schmierfilmdicke im EHD-Kontakt , 2009 .

[51]  S. Stroj,et al.  Sub-Micro Laser Modifications of Tribological Surfaces , 2017 .

[52]  O. Reynolds IV. On the theory of lubrication and its application to Mr. Beauchamp tower’s experiments, including an experimental determination of the viscosity of olive oil , 1886, Philosophical Transactions of the Royal Society of London.

[53]  D. G. McWatt,et al.  The Effect of Novel Surface Textures on Tappet Shims on Valvetrain Friction and Wear , 2008 .

[54]  I. Etsion State of the art in Laser Surface Texturing , 2004 .

[55]  Hugh Spikes,et al.  The influence of transverse roughness in thin film, mixed elastohydrodynamic lubrication , 2007 .

[56]  Marie-Laure Dumont,et al.  Surface Feature Effects in Starved Circular EHL Contacts , 2002 .

[57]  Sandro Wartzack,et al.  Simulation of Microtextured Surfaces in Starved EHL Contacts Using Commercial FE Software , 2017 .

[58]  B. Karpuschewski,et al.  Analysis of the Textured Surface of Tangential Turn-Milling , 2017 .

[59]  D. Dowson,et al.  Isothermal Elastohydrodynamic Lubrication of Point Contacts: Part III—Fully Flooded Results , 1976 .

[60]  Izhak Etsion,et al.  Friction-Reducing Surface-Texturing in Reciprocating Automotive Components , 2001 .

[61]  Diego Marchetto,et al.  Tribological effects of surface texturing on nitriding steel for high-performance engine applications , 2008 .

[62]  W. 0. Winer,et al.  Correlational Aspects of the Viscosity-Temperature-Pressure Relationship of Lubricating Oils(Dr In dissertation at Technical University of Delft, 1966) , 1966 .

[63]  J. N. Anno,et al.  Load Support and Leakage from Microasperity-Lubricated Face Seals , 1969 .

[64]  Ian Graham Pegg,et al.  The effects of surface texture in reciprocating contacts - An experimental study , 2015 .

[65]  Miroslav Plančak,et al.  Coining process as a means of controlling surface microgeometry , 1998 .

[66]  F. Mücklich,et al.  Friction reduction under mixed and full film EHL induced by hot micro-coined surface patterns , 2016 .

[67]  I. Křupka,et al.  Experimental Study of Microtextured Surfaces Operating Under Thin-Film EHD Lubrication Conditions , 2007 .

[68]  A. Erdemir,et al.  Tribology of diamond-like carbon films : fundamentals and applications , 2008 .

[69]  Ian M. Hutchings,et al.  Hydrodynamic lubrication of textured steel surfaces under reciprocating sliding conditions , 2007 .

[70]  Michael R. Hoeprich,et al.  Torque of Tapered Roller Bearings , 1991 .

[71]  Oyelayo O. Ajayi,et al.  Friction and wear behavior of laser textured surface under lubricated initial point contact , 2011 .

[72]  I. Etsion,et al.  Tribological Behavior of Oil-Lubricated Laser Textured Steel Surfaces in Conformal Flat and Non-Conformal Contacts , 2017 .

[73]  D. Dowson,et al.  Elasto-hydrodynamic lubrication : the fundamentals of roller and gear lubrication , 1966 .

[74]  Siyoul Jang,et al.  Effect of surface texturing on elastohydrodynamically lubricated contact under transient speed conditions , 2011 .

[75]  H. Bosse,et al.  Online-Messung des Schmierungszustandes mit Hilfe des Übergangswiderstandes , 2004 .

[76]  Philippe Vergne,et al.  A finite element approach of thin film lubrication in circular EHD contacts , 2007 .

[77]  Gonzalo Brito Gadeschi,et al.  Numerical Analysis of Laser-Textured Piston-Rings in the Hydrodynamic Lubrication Regime , 2012 .

[78]  Michael M. Khonsari,et al.  An Experimental Investigation of Dimple Effect on the Stribeck Curve of Journal Bearings , 2007 .

[79]  Jing Wang,et al.  Influence of Surface Waviness on the Thermal Elastohydrodynamic Lubrication of an Eccentric-Tappet Pair , 2013 .

[80]  Wassim Habchi,et al.  A full-system finite element approach to elastohydrodynamic lubrication problems , 2008 .

[81]  Izhak Etsion,et al.  Analytical and Experimental Investigation of Laser-Textured Mechanical Seal Faces , 1999 .

[82]  I. Etsion,et al.  The Effect of Elastomer Surface Texturing in Soft Elasto-Hydrodynamic Lubrication , 2009 .

[83]  A. Lubrecht,et al.  Numerical Simulation of a Transverse Ridge in a Circular EHL Contact Under Rolling/Sliding , 1994 .

[84]  B. Podgornik,et al.  Design and Tribological Performance of Textured Surfaces , 2017 .

[85]  Karsten Stahl,et al.  Friction reduction of highly-loaded rolling-sliding contacts by surface modifications under elasto-hydrodynamic lubrication , 2015 .

[86]  Roland Larsson,et al.  Two-Dimensional CFD-Analysis of Micro-Patterned Surfaces in Hydrodynamic Lubrication , 2005 .

[87]  Marion Merklein,et al.  Investigation of Production Limits in Manufacturing Microstructured Surfaces Using Micro Coining , 2017, Micromachines.