Michael Leighton

Combined numerical and experimental investigation of the micro-hydrodynamics of chevron-based textured patterns influencing conjunctional friction of sliding contacts

Reciprocating and low-speed sliding contacts can experience increased friction because of solid boundary interactions. Use of surface texturing has been shown to mitigate undue boundary friction and improve energy efficiency. A combined numerical and experimental investigation is presented to ascertain the beneficial effect of pressure perturbation caused by micro-hydrodynamics of entrapped reservoirs of lubricant in cavities of textured forms as well as improved micro-wedge flow. The results show good agreement between numerical predictions and experimental measurements using a precision sliding rig with a floating bed-plate. Results show that the texture pattern and distribution can be optimised for given conditions, dependent on the intended application under laboratory conditions. The translation of the same into practical in-field applications must be carried out in conjunction with the cost of fabrication and perceived economic gain. This means that near optimal conditions may suffice for most application areas and in practice lesser benefits may accrue than that obtained under ideal laboratory conditions.

Surface-specific flow factors for prediction of friction of cross-hatched surfaces

The paper presents a combined numerical and experimental study of generated sliding friction at low sliding speeds and high load intensity, typical of the top compression ring–cylinder liner conjunction at top dead centre in the compression stroke of high performance race engines. Frictional losses in the transition from compression to power stroke represent a significant portion of cyclic cylinder losses. The cylinder liner is cross-hatch honed with non-Gaussian topography, including larger groove features and a fairly smooth plateau roughness. Surface-specific flow factors are derived to closely represent the actual real rough conjunction. The predictions closely agree with the representative reported precision tribometric study of measured friction.

Combined lubricant-surface system perspective: multi-scale numerical-experimental investigation

Frictional losses are one of the main causes of reduced energy efficiency in all machines and mechanisms. In particular, there is mounting pressure upon manufacturers of all forms of vehicle to comply with increasingly stringent legislation and directives with regard to harmful emissions. Therefore, reduction of friction has become an imperative issue. The traditional approach of dealing with surface material and lubricant formulation in isolation has been replaced by a lubricant–surface system approach. This paper presents multi-scale experimentation from nano/meso-scale lateral force microscopy of ultra-thin surface adsorbed films through to micro-scale precision sliding tribometry to investigate lubricant–surface friction optimisation within the mixed regime of lubrication, using lubricants with different organic and inorganic friction modifying species. These affect the parameters of the system, commonly used as input to models for mixed and boundary regimes of lubrication. Therefore, the precise measurement of these parameters at different physical scales is important. The study also makes use of detailed numerical predictions at micro-scale through combined solution of the average Reynolds equation as well as interaction of wetted asperities in mixed and boundary regimes of lubrication. Good agreement is found between the predictions and measurements at micro-scale tribometric interactions. Furthermore, the same trends are observed in testing across the physical scales.

Multiscale Friction in Lubricant-Surface Systems for High-Performance Transmissions Under Mild Wear

The lubricant-surface system is complex in nature and can significantly affect the frictional performance of high-performance transmission systems. The complexity stems from the coupled mechanical and chemical phenomena that occur at the interfacial tooth conjunctions. A combined analytical and precision experimental approach is presented to analyse the salient parameters of the lubricant-surface system. A multiscale procedure comprising topographical measurement, pin-on-disc tribometry, atomic force microscopy in lateral force mode, X-ray photo-electron spectroscopy and continuum contact mechanics analysis under mixed non-Newtonian thermo-elastohydrodynamics is used to describe the formation of a tribo-film, as well as wear and frictional characteristics of the lubricant-surface system. The contribution of chemisorbed and physisorbed bonded tribo-film on the boundary coefficient of friction is ascertained at different physical scales. Therefore, the paper presents a novel multiscale analysis, promoting improved understanding of the complex interactions between mechanisms of friction, wear and surface chemistry.

Efficiency of disengaged wet brake packs

Key objectives in off-highway vehicular powertrain development are fuel efficiency and environmental protection. As a result, palliative measures are made to reduce parasitic frictional losses while sustaining machine operational performance and reliability. A potential key contributor to the overall power loss is the rotation of disengaged wet multi-plate pack brake friction. Despite the numerous advantages of wet brake pack design, during high-speed manoeuvre in highway travel or at start-up conditions, significant frictional power losses occur. The addition of recessed grooves on the brake friction lining is used to dissipate heat during engagement. These complicate the prediction of performance of the system, particularly when disengaged. To characterise the losses produced by these components, a combined numerical and experimental approach is required. This paper presents a Reynolds-based numerical model including the effect of fluid inertia and squeeze film transience for prediction of performance of wet brake systems. Model predictions are compared with very detailed combined Navier–Stokes and Rayleigh-Plesset fluid dynamics analysis to ascertain its degree of conformity to representative physical operating conditions, as well the use of a developed experimental rig. The combined numerical and experimental approach is used to predict significant losses produced during various operating conditions. It is shown that cavitation becomes significant at low temperatures due to micro-hydrodynamic action, enhanced by high fluid viscosity. The magnitude of the losses for these components under various operating conditions is presented. The combined numerical-experimental study of wet multi-plate brakes of off-highway vehicles with cavitation flow dynamics has not hitherto been reported in the literature.

Atomic force microscopic measurement of a used cylinder liner for prediction of boundary friction

Accurate simulation performs a crucial role in the design and development of new modern internal combustion engines. In the case of piston rings, simulations are used to effectively predict generated friction and power loss of proposed designs. These are consequences of viscous shear of a thin lubricant film, likewise boundary friction caused by direct interaction of piston rings with the cylinder liner/bore surface. The most commonly used model for determining boundary friction is that of Greenwood and Tripp. The model requires the pressure coefficient of boundary shear strength of asperities from the softer of the contacting surfaces as an input. This parameter needs to be measured. The paper describes the process of measurement using an Atomic Force Microscope (AFM), both for a dry surface and that wetted by the presence of a lubricant layer. For realistic results, the investigated specimen is a used, tested engine cylinder liner where boundary active lubricant additives are bonded to its surface as well as combustion products. This approach is as opposed to the previously reported works using new flat surfaces with base oil or partially formulated lubricants and has not been previously reported in the literature. The results show that for used cylinder liners, the measured boundary shear strength of asperities varies according to location along the stroke. Results are reported for the top dead centre, mid-stroke and bottom dead centre locations. The measurements are subsequently used with two-dimensional Reynolds solution for a top compression ring-liner contact, where it is found that accurate localised predictions of generated friction and power loss can be made instead of the usual average value approach reported in the literature.

Effect of surface topography upon micro-impact dynamics

Often the effect of interactions at nano-scale determines the tribological performance of load bearing contacts. This is particularly the case for lightly loaded conjunctions where a plethora of short range kinetic interactions occur. It is also true of larger load bearing conjunctions where boundary interactions become dominant. At the diminutive scale of fairly smooth surface topography the cumulative discrete interactions give rise to the dominance of boundary effects rather than the bulk micro-scale phenomena, based on continuum mechanics. The integration of the manifold localized discrete interactions into a continuum is the pre-requisite to the understanding of characteristic boundary effects, which transcend the physical length scales and affect the key observed system attributes. These are energy efficiency and vibration refinement. This paper strives to present such an approach. It is shown that boundary and near boundary interactions can be adequately described by surface topographical measures, as well the thermodynamic conditions.