Martin N. Webster

Grease Degradation in R0F Bearing Tests

This paper is the second in a series that examines grease lubrication mechanisms and failure in rolling element bearings. The aim of the work was to understand the grease condition changes during use and the relationship to lubrication performance and failure. R0F bearing tests were carried out with two lithium hydroxystearate greases and the effects of the temperature, the speed, and the additive package on lubrication life was studied. Post-test, one pair of bearings (fail and non-fail) was dismantled and grease distribution and condition assessed. IR spectroscopy was then used to determine the lubricant composition and the oxidation level of the grease remaining on the shields, the inner raceway, and the cage pockets. The additive package increased the grease life by 100-700% depending on the test condition. Most of the grease remaining in the bearing was found on the shields, with only trace amounts in the cage pockets or close to the rolling track. The IR analysis showed that the composition of the shield sample was similar to the fresh grease although the base oil oxidation was evident and this increased with the running time. The cage pocket and inner raceway films contained a number of chemical species; these included the base oil and the thickener and their oxidation products. The study concludes that after an initial running-in period the “active” lubricant is heavily degraded grease, which contains oxidized species from the base oil and the thickener. Different failure mechanisms are identified depending on the test condition. High-speed tests that fail relatively quickly are due to poor boundary lubrication performance or cage failure rather than the lubricant reaching its “oxidation” limit. Long-term tests at slower speeds suffer considerable base oil oxidation. Under these conditions, failure is due to a reduction in the amount and/or mobility of the raceway lubricant.

Grease Degradation in Rolling Element Bearings

Grease is degraded during use in rolling element bearings and as a result the lubrication performance can deteriorate. Under severe conditions this can result in lubrication failure and, thus, the grease life will effectively limit the bearing life. At present there is a lack of detailed information regarding the changes that occur in the grease and the way in which this degradation affects lubrication performance and failure. This paper reports an initial study into grease degradation in bearings. The aim of the work was to characterize the changes that occur to the chemical and physical properties during use. A series of bearing tests using the modified DIN 51 806 test designated R2F(M) have been carried out using two greases: additized and non-additized. The tests have been run for different temperature and speed conditions for up to 300 hours. The aim was to examine the grease during normal running rather than after failure. At the end of the tests the bearings were dismantled and grease taken from different parts of the bearing for infrared spectroscopic analysis. This technique can characterize the degree of oxidation or degradation of the grease both in the bulk sample and from thin grease layers remaining on the bearing surfaces. The analysis has shown that the condition of the grease varies depending on the distribution within the bearing. The lubricant remaining in the cage pocket region was heavily degraded and contained very little thickener. The grease on the seals contained different amounts of thickener depending on the seal position. The lubricant remaining on the inner raceway surface was predominately base oil although there was some thickener present. These results are discussed in the light of proposed bearing lubrication mechanisms. Presented at the 56th Annual Meeting Orlando, Florida May 20–24, 2001

Effects of Friction on the Contact and Deformation Behavior in Sliding Asperity Contacts

Finite-element analyses are carried out to study the effects of friction on the contact and deformation behavior of sliding asperity contacts. In the analysis, on elastic-perfectly-plastic asperity is brought in contact with a rigid flat at a given normal approach. Two critical values of the normal approach are used to describe the asperity deformation. One is the approach corresponding to the point of initial plastic yielding, and the other at the point of full plastic flow. Additional variables used to characterize the deformation behavior include the shape and size of the plastic zone and the asperity contact size, pressure, and load capacity. Results from the finite-element analysis show that the two values of critical normal approach decrease significantly as the friction in the contact increases, particularly the approach that causes plastic flow of the asperity. The size of the plastically deformed zone is reduced by the friction when the contact becomes fully plastic. The reduction is very considerable with a high friction coefficient, and the plastic deformation is largely confined to a small thin surface layer. For a low friction coefficient, the contact size, pressure and load capacity of the asperity are not very sensitive to the friction coefficient. For a moderate friction coefficient, the contact pressure is reduced and the junction size increased; the load capacity of the asperity is not significantly affected due to the compensating effects of the pressure reduction and the junction growth. For a high friction coefficient, the pressure-junction compensation is not longer sufficient and the asperity load capacity is reduced. The degree of the friction effects on these contact variables depends on the applied force or the normal approach. Although the analyses are conducted using a line-contact model, the authors believe that the effects of friction in sliding asperity contacts of three-dimensional geometry are essentially the same and the same conclusions would have been reached. These results may provide some guidance to the modeling of rough surfaces in boundary lubrication, in which the asperity friction coefficient can be high and vary significantly both in time and from one micro-contact to another. Presented at the 57th Annual Meeting in Houston, Texas May 19–23, 2002

Atomic Force Microscopy and Raman Spectroscopy Investigation of Additive Interactions Responsible for Anti-Wear Film Formation in a Lubricated Contact

Rational formulation of lubricants requires an understanding of additive interactions that impact antiwear film qualities such as thickness, topography, and friction. In an effort to understand the complex additive interactions responsible for formation of anti-wear and friction-reducing films, atomic force microscopy (AFM) in conjunction with Raman microscopy has been used to conduct a nanoscale investigation of the wear tracks formed by a high-frequency reciprocating rig (HFRR) in the presence of various commercial lubricant additives combinations. Of the additives examined, zinc dithiophosphate (ZnDTP)-based additives are found to be solely responsible for the formation of a thick (hundreds of nm) film that exhibits a pitted topography. Addition of a molybdenum-based friction modifier to the lubricant blend reduces the film thickness considerably and reacts to produce MoS 2 on the surface, suggesting an interaction with the zinc dithiophosphate–based additive that prevents antiwear film formation. Formation of MoS 2 , found only in the wear track, is consistent with a dramatic reduction of friction coefficient measured in the HFRR. Subsequent addition of borated dispersants to the lubricant reveals a further reduction in friction coefficient and a modest return of anti-wear film. However, addition of detergents to the formulation increases the friction coefficient and also promotes the formation of an anti-wear film. Nanoindentation measurements on the bulk properties of the anti-wear films determined that all of the anti-wear films had similar modulus and hardness measurements which were lower than that of the parent steel material, but did not correlate with the friction measurements obtained from the HFRR. This indicates that nanoscale measurements on material properties of the film are necessary to elucidate friction properties of the interface, and that these properties cannot be determined from macroscale measurements on the bulk film. Presented at the STLE Annual Meeting, in Toronto, Ontario, Canada. May 17–20, 2004 Review led by Bob Kauffman

On the Mechanisms of the Reduction in EHL Traction at Low Temperature

Various experiments have revealed a dramatic traction reduction in elastohydrodynamic lubrication (EHL) contacts under subambient temperatures or with fluids of high viscosity and high pressure-viscosity coefficients. This paper conducts a systematic theoretical analysis to identify and analyze the mechanisms of this reduction. A thermal EHL model is used for the analysis that is capable of capturing many possible effects, including a thermally induced cross-film shear localization within the EHL film. The analysis is carried out for a wide range of ambient viscosity and pressure-viscosity coefficients. The results and analysis suggest that the thermal effects are responsible for the dramatic reduction of the EHL traction. Two thermal effects become particularly pronounced with high viscosity and high pressure-viscosity coefficients. One is the lubricant re-circulation induced inlet shear that generates and accumulates heat in a prolonged inlet region and significantly increases the film temperature in the region of high pressure. The other is the thermally induced cross-film shear localization that generates high temperature in a small central layer of the EHL film. Presented at the STLE Annual Meeting in Houston, Texas May 19-23, 2002 Review led by Greg Kostrzewsky

The Effect of Lubricant Viscosity-Temperature Characteristics on the Performance of Plain Journal Bearings

Experimental and analytical results of bearing friction loss, operating temperature, and oil gap thickness are presented comparing performance characteristics of bearings operating with the different lubricants. The lubricants were blended using a variety of mineral and synthetic base stocks to achieve a range of viscosity-temperature characteristics. The results show that the test bearings running with higher viscosity index (VI) lubricants generated slightly lower bearing surface temperatures than those generated using a low VI lubricant. The high VI lubricant also reduced the total power losses by up to 10%. These gains are achieved with little or no change in the minimum oil film thickness.Copyright

Effect of EHL Contact Conditions on the Behavior of Traction Fluids

New infinitely variable transmission (IVT) systems are under development for the automotive industry as a means to achieving significant fuel economy benefits. These systems rely on the lubricating fluid to transmit the drive train loads across the interface of the transmission components. This requires the development of new fluids that exhibit high traction properties under elastohydrodynamic lubrication (EHL) conditions. However, it has been reported recently that the traction performance of some fluids can reduce dramatically as temperature is reduced. This may place severe operational limits on IVT systems and suggests that the low-temperature traction properties of fluids for these systems should be studied in order to understand the mechanism for the observed reduction in traction. The work reported here is an experimental study aimed at identifying whether low temperature traction reduction is related to a fundamental change in rheological behavior specific to the fluids tested or to more generic changes in the EHL contact conditions. A series of model experiments were performed using a mini traction machine (MTM) on three high-viscosity polybutene samples. The results have been mapped against previously reported non-dimensional parameters used to identify different EHL regimes. The results show that dramatic reductions in traction occur when the contact transitions from the rigid piezo-viscous (RP) toward the rigid iso-viscous (RI) region. Similar results were also found for two other high-viscosity fluids of different molecular structure and lower traction properties. The results support the hypothesis that the reduction in traction observed at low temperature is due to a change in EHL contact conditions rather than being solely due to a change in the rheological performance of the test fluids.

An experimental/theoretical approach to modelling the viscous behaviour of liquid lubricants in elastohydrodynamic lubrication contacts:

Abstract This paper presents an experimental/theoretical approach to modelling the viscous behaviour of liquid lubricants under elastohydrodynamic lubrication (EHL) conditions. The main feature of the approach is that the rheological variables at a single point in the EHL contact are used rather than their global averages. The local rheological variables are calculated using first-principle theories in conjunction with experimental traction data. They are then curve fitted into an Eyring-based rheological model, and the model parameters are determined by minimizing the error vector associated with the curve-fitting procedures. The modelling approach is evaluated both theoretically and experimentally. The theoretical evaluation suggests that the method of modelling is meaningful for median to high-loading conditions of a Hertz peak pressure above 0.8 GPa. The experimental evaluation demonstrates that the approach may be used to study the rheological behaviour of synthetic lubricants with various molecular structures.