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Purpose: This study aims to propose an optimization framework using deep neural networks (DNN) coupled with nondominated sorting genetic algorithm II and technique for order preference by similarity to an ideal solution method to improve the tribological properties of camshaft bearing pairs of internal combustion engine. Design/methodology/approach: A lubrication model based on the theory of elastohydrodynamic lubrication and flexible multibody dynamics was developed for a V6 diesel engine. Setting DNN model as fitness function, the multi-objective optimization genetic algorithm and decision-making method were used to optimize the bearing pair structure with the goal of minimizing the total friction loss and the difference of the average values of minimum oil film thickness. Findings: The results show that the lubrication state corresponding to the optimized bearing pair structure is elastohydrodynamic lubrication. Compared with the original structure, the optimized structure significantly reduces the total friction loss. Originality/value: The optimized performance and corresponding structural parameters are obtained, and the optimization results were verified through multibody dynamics simulation. Peer review: The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2023-0417/ [ABSTRACT FROM AUTHOR]

Purpose: This study aims to enhance the lubrication performance of thrust bearings. The influence of columnar convex–concave compound microtexture on bearing performance is investigated Design/methodology/approach: Based on the compound microtexture model of thrust bearings, considering surface roughness and turbulent effect, the variation of lubrication characteristics with the change in the compound microtexture parameters is studied. Findings: The results indicate that, compared with circular microtexture, the maximum pressure of compound microtexture of thrust bearings increases by 7.42%. Optimal bearing performance is achieved when the internal microtexture depth is 0.02 mm. Turbulent flow states and surface roughness lead to a reduction in the optimal depth. The maximum pressure and load-carrying capacity of the bearing decrease as the initial angle increases, whereas the friction coefficient increases with the increase in the initial angle. The lubrication performance is best for bearings with a circumferential parallel arrangement of microtexture. Originality/value: The novel composite microtexture with columnar convex-concave is proposed, and the computational model of thrust bearings is set. The influence of surface roughness and turbulent flow on the bearing performance should be considered for better conforming with engineering practice. The effect of microtexture depth, arrangement method and distribution position on the lubrication performance of the compound microtexture thrust bearing is investigated, which is of great significance for improving tribology, thrust bearings and surface microtexture theory. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this study is to investigate the application of non-destructive testing methods in measuring bearing oil film thickness to ensure that bearings are in a normal lubrication state. The oil film thickness is a crucial parameter reflecting the lubrication status of bearings, directly influencing the operational state of bearing transmission systems. However, it is challenging to accurately measure the oil film thickness under traditional disassembly conditions due to factors such as bearing structure and working conditions. Therefore, there is an urgent need for a nondestructive testing method to measure the oil film thickness and its status. Design/methodology/approach: This paper introduces methods for optically, electrically and acoustically measuring the oil film thickness and status of bearings. It discusses the adaptability and measurement accuracy of different bearing oil film measurement methods and the impact of varying measurement conditions on accuracy. In addition, it compares the application scenarios of other techniques and the influence of the environment on detection results. Findings: Ultrasonic measurement stands out due to its widespread adaptability, making it suitable for oil film thickness detection in various states and monitoring continuous changes in oil film thickness. Different methods can be selected depending on the measurement environment to compensate for measurement accuracy and enhance detection effectiveness. Originality/value: This paper reviews the basic principles and latest applications of optical, electrical and acoustic measurement of oil film thickness and status. It analyzes applicable measurement methods for oil film under different conditions. It discusses the future trends of detection methods, providing possible solutions for bearing oil film thickness detection in complex engineering environments. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this study is to design and process the optimal V-shaped microstructure for 7075 aluminum alloy and reveal its wear resistance mechanism and performance. Design/methodology/approach: The hydrodynamic pressure lubrication models of the nontextured, V-shaped, circular and square microtextures are established. The corresponding oil film pressure distributions are explored. The friction and wear experiments are conducted on a rotating device. The effects of the microstructure shapes and sizes on the wear mechanisms are investigated via the friction coefficients and surface morphologies. Findings: In comparison, the V-shaped microtexture has the largest oil film carrying capacity and the lowest friction coefficient. The wear mechanism of the V-shaped microtexture is dominated by abrasive and adhesive wear. The V-shaped microtexture has excellent wear resistance under a side length of 300 µm, an interval of 300 µm and a depth of 20 µm. Originality/value: This study is conductive to the design of wear-resistant surfaces for friction components. [ABSTRACT FROM AUTHOR]

Purpose: This paper aims to focus on the high-speed rotary lip seal in aircraft engines, combining its service parameters, its own structure and application conditions, to study the influence of different eccentric forms, eccentricity, rotational speed and other factors on the performance of the rotary lip seal. Design/methodology/approach: A numerical simulation model for high-speed eccentric rotary lip seals has been developed based on the theory of elastic hydrodynamic lubrication. This model comprehensively considers the coupling of multiple physical fields, including interface hydrodynamics, macroscopic solid mechanics and surface microscopic contact mechanics, under the operating conditions of rotary lip seals. The model takes into account eccentricity and uses the hazardous cross-sectional method to quantitatively predict sealing performance parameters, such as leakage rate and friction force. Findings: Eccentricity has a large impact on lip seal performance; lips are more susceptible to wear failure under static eccentricity and to leakage failure under dynamic eccentricity. Originality/value: This study provides a new idea for the design of rotary lip seal considering eccentricity, which is of guiding significance for the engineering application of rotary lip seal. [ABSTRACT FROM AUTHOR]

Purpose: Gears are prone to instantaneous failure when operating under extreme conditions, affecting the machinery's service life. With numerous types of gear meshing and complex operating conditions, this study focuses on the gear–rack mechanism. This study aims to analyze the effects and optimization of biomimetic texture parameters on the line contact tribological behavior of gear–rack mechanisms under starvation lubrication conditions. Design/methodology/approach: Inspired by the microstructure of shark skin surface, a diamond-shaped biomimetic texture was designed to improve the tribological performance of gear–rack mechanism under starved lubrication conditions. The line contact meshing process of gear–rack mechanisms under lubrication-deficient conditions was simulated by using a block-on-ring test. Using the response surface method, this paper analyzed the effects of bionic texture parameters (width, depth and spacing) on the tribological performance (friction coefficient and wear amount) of tested samples under line contact and starved lubrication conditions. Findings: The experimental results show an optimal proportional relationship between the texture parameters, which made the tribological performance of the tested samples the best. The texture parameters were optimized by using the main objective function method, and the preferred combination of parameters was a width of 69 µm, depth of 24 µm and spacing of 1,162 µm. Originality/value: The research results have practical guiding significance for designing line contact motion pairs surface texture and provide a theoretical basis for optimizing line contact motion pairs tribological performance under extreme working conditions. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this study is to investigate the influence of surface texture on the subsurface characteristics of contact interfaces under elastohydrodynamic lubrication condition. As a typical contact form of gears and bearings, the optimization of friction characteristics at the elastohydrodynamic lubrication (EHL) interface has attracted the attention of scholars. Laser surface texturing is a feasible optimization solution, but there have been concerns about whether the surface texture of high-pair parts will affect their fatigue life. Design/methodology/approach: To examine the impact of texture preparation on the subsurface characteristics of high-pair interfaces under EHL conditions, a point contact EHL model is developed that takes into account the effect of textured surface topography. The pressure and thickness of the oil film are calculated as input parameters under different loads and entrainment velocities. The finite element method is used to simulate the impact of textures with varying diameters, densities and depths on the subsurface characteristics of the elastohydrodynamic interface. According to ISO 25178, analyze the relationship between 3D topography parameters and subsurface characteristics and study the trend of friction characteristics and subsurface characteristics based on the results of the ball on disc friction tests. Findings: The outcomes suggest that under different rotational velocity and load conditions, the textured surfaces exhibit improved friction reduction effects; however, the creation of textures can result in significant subsurface plastic deformation and local peeling. The existence of texture makes the larger stress zone in the subsurface layer closer to the surface, leading to fatigue failure near the surface. Reasonable design parameters can help enhance the attributes of the subsurface. A smaller Sa and a Str greater than 0.5 can achieve ideal subsurface properties on the textured surface. Originality/value: This paper investigates the influence of surface texture on the friction and subsurface characteristics of EHL interfaces and analyzes the impact of surface texture on interface contact performance while achieving lubrication improvement functional characteristics. The results provide theoretical support for the optimization design and functional regulation of surface texture in EHL interfaces. Peer review: The peer review history for this article is https://publons.com/publon/10.1108/ILT-10-2023-0324/ [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this research is to study the dynamic behavior of hydrostatic squeeze film dampers made of four hydrostatic pads, fed through four capillary restrictors with micropolar lubricant. Design/methodology/approach: The modified version of Reynolds equation is solved numerically by the finite differences and the Gauss–Seidel methods to determine the pressure field generated on the hydrostatic bearing flat pads. In the first step, the effects of the pad dimension ratios on the stiffness and damping coefficients are investigated. In the second step, the damping factor is evaluated with respect to the micropolar properties. Findings: The analysis revealed that the hydrostatic squeeze film dampers lubricated with micropolar lubricants produces the maximum damping factor for characteristic length of micropolar lubricant less than 5, while the same bearing operating with Newtonian lubricants reaches its maximum damping factor at eccentricity ratios larger than 0.4. Originality/value: The results obtained show that the effects of micropolar lubricants on the dynamic performances are predominantly affected by the pad geometry and eccentricity ratio. [ABSTRACT FROM AUTHOR]

Purpose: Hydro-viscous drive (HVD) clutches are widely used in equipment requiring soft start, such as fans and pumps, to transmit torque and adjust speed by changing the gap distance between friction pairs. This paper aims to propose a novel two-parameter evaluation method for HVD during the mixed lubrication stage. The objective is to develop an effective model that establishes the relationship between these parameters and the actual surface topography. Design/methodology/approach: In the presented methods, the fractal features of the real manufacturing surface are calculated based on the power spectrum function by the ultra-depth three-dimensional microscope. After that, the hybrid friction model of the friction plate is established based on mixed elasto-hydrodynamic lubrication theory, boundary friction model and fractal theory. Then the torque and load bearing characteristics of the clutch are obtained, and the influences of the surface fractal features are investigated and discussed. Finally, the Weierstrass–Mandelbrot function is adopted for the surface topography characterization and evaluation. Findings: The results indicate that the proposed method exhibits good accuracy, while the speed difference between the friction pair exceeds 2,500 rpm. It is concluded that this paper proposed a way to evaluate the torque and loading capacity of HVD considering the real manufacturing surface topography and is helpful for surface optimization. Originality/value: The originality and value of this study lie in its development of a novel torque and load bearing capacity evaluation method for HVD in mixed lubrication stage, considering manufacturing surface topography and describing the real manufacturing surface. [ABSTRACT FROM AUTHOR]

Purpose: Harmonic gears always work under different operating conditions and may usually break down due to lubrication failures, while its lubrication mechanism is still not clearly understood. This paper aims to present a lubrication model comprehensively considering the influence of contact geometry, lubrication properties and three-dimensional (3D) real surface roughness to analyze the lubrication performance under different conditions. Design/methodology/approach: Based on the discrete convolution-fast Fourier transformation with duplicated padding and quasi-system numerical methods, the lubrication model for harmonic gears is developed, which is verified by comparing results with available lubrication data. Findings: The effects of meshing process, working conditions and 3D roughness on the lubrication characteristics are discussed. From the calculated cases, the increase in rotational speed and decrease of applied torque may increase the film thickness, enhancing the lubrication performance of harmonic gears. It is also observed that proper surface roughness can be used for lubrication design. Originality/value: The research results can provide theoretical guidance for improving lubrication performance and reducing friction/wear of the harmonic gear interfaces. This study can be promoted to various engineering scenarios of harmonic gears, such as industrial robots, space-driven agencies and precision measuring instruments. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this study is to investigate the use of micro-pits technology to the problem of tribological performance in a sliding motion. Design/methodology/approach: Vegetable oil is a sustainable and economically viable alternative to both mineral and synthetic oils, offering significant savings in both the cost of research and manufacturing. To solve the depriving issue and boost lubrication film thickness, the micro-pits on the surface may function as reservoirs that provide the oil to the contact inlet area. In this research, an aluminium block is used as the workpiece material in an evaluation of a through pin-on-disc tribotester. Lubricating oil in the form of super olein (SO) was used in the experiment. Findings: The results show that the friction performance during a rubbing process between a hemispherical pin and an aluminium block lubricated with SO using aluminium alloy materials, AA5083, was significantly improved. Originality/value: In this study, a material that breaks down called SO, which is derived from the fractionation of palm olein, was used to use a modified aluminium micro-pit sample that will serve as a lubricant reservoir in pin-on-disc tribotester. Peer review: The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2023-0200/ [ABSTRACT FROM AUTHOR]

Purpose: This paper aims to study the impact of transient velocity changes on sealing performance during reciprocating sealing processes. Design/methodology/approach: Establish a model of transient mixed lubrication, solve the transient Reynolds equation, consider the effect of temperature rise at the seal interfaces, and determine the behavior of the seal interfaces, such as film thickness and fluid pressure. Evaluation with friction and leakage rate, calculate the variation of sealing performance with reciprocating velocity under different working conditions, and verify it through bench experiments. Findings: Within a reciprocating stroke, the frictional force decreases with increasing velocity, and the frictional force of the outstroke is greater than that of the instroke; at the time of the stroke transition, the fluid pressure is smallest and the rough peak contact pressure is greatest. At present, the dynamic pressure effect of fluids is the largest, and the friction force also increases, which increases the risk of material wear and failure. Friction and leakage increase with increasing pressure and root mean square roughness. As temperature increases, friction increases and leakage decreases. In studying the performance variations of seal components through a reciprocating sealing experiment, it was found that the friction force decreases with increasing velocity, which is consistent with the calculated results and more similar to the calculated results considering the temperature rise. Originality/value: This study provides a reference for the study of transient sealing performance. [ABSTRACT FROM AUTHOR]

Purpose: This study aims to use a machine learning (ML) model for the prediction of traction coefficient and asperity load ratio for different surface topographies of non-conformal rough contacts. Design/methodology/approach: The input data set for the ML model is generated using a mixed-lubrication model. Surface topography parameters (skewness, kurtosis and pattern ratio), rolling speed and hardness are used as input features in the multi-layer perceptron (MLP) model. The hyperparameter tuning and fivefold cross-validation are also performed to minimize the overfitting. Findings: From the results, it is shown that the MLP model shows excellent accuracy (R2 > 90%) on the test data set for making the prediction of mixed lubrication parameters. It is also observed that engineered rough surfaces with high negative skewness, low kurtosis and isotropic surface patterns exhibit a significant low traction coefficient. It is also concluded that the MLP model gives better accuracy in comparison to the random forest regression model based on the training and testing data sets. Originality/value: Mixed lubrication parameters are predicted by developing a regression-based MLP model. The machine learning model is trained using several topography parameters, which are vital in the mixed-EHL regime because of the lack of regression-fit expressions in previous works. The accuracy of MLP with random forest models is also compared. [ABSTRACT FROM AUTHOR]

Purpose: Due to high speeds, heavy loads, large slide-to-roll ratios (SRR) and other variable operating conditions, some rolling bearings that have been working in harsh conditions may experience flash temperatures in the contact area, which may result in early damage like smearing and then affect service life. This study aims to investigate the flash temperature phenomenon of rolling bearings through theoretical and experimental analysis. Design/methodology/approach: A technology for measuring temperature distribution in rolling ball on disk contact under lubrication was developed. The test-rig can simulate the ball bearing contact. The effects of working conditions such as entrainment speed, load, SRR and lubricating oil viscosity on the flash temperature were investigated. Findings: The results of the theoretical calculation and experiments indicate that the parameters promoting the reduction of film thickness in elastohydrodynamic lubrication are always related with the number of flash points, even film thickness reduced to mixed lubrication. The flash temperature is easier to happen in conditions of high SRR, heavy load, slow entrainment speed and low viscosity oil. Originality/value: This work conducts an experimental study on the flash temperature phenomenon, providing a test technology for bearing lubrication and failure investigation. Peer review: This author has opted into Transparent Peer Review available at: https://publons.com/publon/10.1108/ILT-04-2023-0104 [ABSTRACT FROM AUTHOR]

Purpose: Tantalum is a kind of metal material with moderate hardness, high ductility, small thermal expansion coefficient, excellent corrosion resistance and outstanding biocompatibility. The purpose of this study is that its tribological performance could be tested and analyzed so as to use it in different fields. Design/methodology/approach: The friction resistance of a-Ta under dry friction conditions was tested at different roads. The relationships between load and friction coefficient, wear rate and two-dimensional shape of wear scars were studied. Findings: The stable Ta2O5 film with lubrication effect was generated in the process of friction. And, the larger the test load, the more Ta2O5 would be generated. Originality/value: This work lays a theoretical foundation for tantalum as an excellent wear-resistant material. Peer review: The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-02-2023-0047/ [ABSTRACT FROM AUTHOR]

Purpose: The study aims to the distribution rule of lubricating oil film of full ceramic ball bearing and improve its performance and life. Design/methodology/approach: The paper established an analysis model based on the fluid–solid conjugate heat transfer theory for full ceramic ball bearings. The distribution of flow, temperature and pressure field of bearings under variable working conditions is analyzed. Meanwhile, the mathematical model of elastohydrodynamic lubrication (EHL) of full ceramic ball bearings is established. The numerical analysis is used to study the influence of variable working conditions on the lubricant film thickness and pressure distribution of bearings. The temperature rise test of full ceramic ball bearing under oil lubrication was carried out to verify the correctness of simulation results. Findings: As the speed increased, the oil volume fraction in full ceramic ball bearing decreased and the surface pressure of rolling element increased. The temperature rise of full ceramic ball bearings increases with increasing speed and load. The lubricant film thickness of full ceramic ball bearing is positively correlated with speed and negatively correlated with load. The pressure of lubricating film is positively correlated with speed and load. The test shows that the higher inner ring speed and radial load, the higher the steady-state temperature rise of full ceramic ball bearing. The test results are in high agreement with simulation results. Originality/value: Based on the fluid–solid conjugate heat transfer theory and combined with Reynolds equation, lubricating oil film thickness formula, viscosity temperature and viscosity pressure formula. The thermal analysis model and EHL mathematical model of ceramic ball bearings are established. The flow field, temperature field and pressure field distribution of the full ceramic ball bearing are determined. And the thickness and pressure distribution of lubricating oil film in the contact area of full ceramic ball bearing were determined. Peer review: The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0126/ [ABSTRACT FROM AUTHOR]

Purpose: This study aims to present a numerical solution for the analysis of the influence of surface roughness as presented by a sinusoidal ripple of different amplitude and wavelength on the performance of transient elastohydrodynamic lubrication at motion start-up under different operational parameters of entraining speed and load as well as different acceleration rates. Design/methodology/approach: A statistical asperity micro-contact model represented by a sinusoidal ripple expressed by two parameters (wavelength and undeformed amplitude) is considered. The ball equation of motion is used to calculate the force on the ball as it starts to move. The time-dependent Reynolds equation is solved together with surface deformation and statistical asperity models using the Newton–Raphson technique with the Gauss–Seidel iteration method. Findings: The behaviour of the film thickness was found to be strongly influenced by the acceleration rate for different ripple amplitude and wavelength parameters. The effect of increasing the final entraining speed will eventually lead to rapid film thickness build-up and increase the film thickness jump at the moment of motion start-up. The effect of increasing applied load is to reduce the deviation of the minimum film thickness jump at the start-up of motion, making its value approximately equal to the steady-state value over the entire run-time period. Originality/value: Influence of surface roughness for various wavelength and undeformed amplitude on the performance of transient elastohydrodynamic lubrication at motion start-up is presented at different acceleration rates as well as for different operating parameters of entraining speed and load. Ball equation of motion is used to calculate the force on the ball as it starts to move. [ABSTRACT FROM AUTHOR]

Purpose: Internal gearings are commonly used in transmissions due to their advantages like high-power density. To ensure high efficiency, load-carrying capacity and good noise behavior, a profound knowledge of the local gear mesh is essential. The tooth contact of internal gears relates to a convex and concave surface that form a conformal contact. This is in contrast to external gears, where two convex surfaces form a contraformal contact. This paper aims at a better understanding of conformal contacts under elastohydrodynamic lubrication (EHL) to improve the design of internal gearings. Design/methodology/approach: An existing numerical EHL model is used for studying the characteristic properties of a hard conformal EHL line contact. A hard contraformal EHL line contact is studied as reference. Non-Newtonian fluid behavior and thermal effects are considered. By taking into account the local contact conformity and kinematics, the effects and relevance of the curvature of the lubricant gap and micro-slip are analyzed. In a parameter study, scale effects of the contact radii on film thickness, temperature rise and friction are examined. Findings: The curvature of the lubricant gap and effects of micro-slip are small in hard conformal EHL line contacts. For high micro-slip, it can be neglected. Hence, the modeling of conformal contacts using an equivalent geometry of the contact problem is reasonable. The parameter study shows beneficial tribological aspects of the conformal contact compared to the contraformal contact. Higher film thickness and lower fluid coefficient of friction are observed for conformal contacts, which can be attributed to lower pressures for the case of the same external normal force, or to a higher contact temperature rise for the case of equivalent contact pressure. Originality/value: Despite its widespread existence, the local geometry and kinematics in hard conformal EHL line contacts like in internal gearings have been rarely studied. The findings help for a better understanding of local contact characteristics and its relevance. The quantified scale effects help to improve the efficiency and load-carrying capacity of machine elements with hard conformal EHL contacts, like internal gearings. Peer review: The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2022-0366/ [ABSTRACT FROM AUTHOR]

Purpose: Microtextured surfaces can reduce friction in tribological systems under certain contact conditions. Because it is very time-consuming to determine suitable texture patterns experimentally, numerical approaches to the design of microtextures are increasingly gaining acceptance. The purpose of this paper is to investigate to what extent the selected modeling approach affects optimized texturing. Design/methodology/approach: Using the cam/tappet contact as an application-oriented example, a simplified 2D and a full 3D model are developed for determining the best possible texturing via a design study. The study explores elongated Gaussian-shaped texture elements for this purpose. The optima of the simplified 2D simulation model and the full 3D model are compared with each other to draw conclusions about the influence of the modeling strategy. The target value here is the solid body friction in contact. Findings: For the elongated texture elements used, both the simplified 2D model and the full model result in very similar optimal texture patterns. In the selected application, the simplified simulation model can significantly reduce the computational effort without affecting the optimization result. Originality/value: Depending on the selected use case, the simulation effort required for microtexture optimization can be significantly reduced by comparing different models first. Therefore, an exact physical replica of the real contact is not necessarily the primary goal when it comes to texture selection based on numerical simulations. [ABSTRACT FROM AUTHOR]

Purpose: This study aims to investigate mixed lubrication performances of stern bearing in a misaligned state considering turbulence and bearing deformation impacts. Design/methodology/approach: A mixed lubrication model of stern bearing is established. The generalized average Reynolds equation governing the turbulent flow of lubricant is analyzed by considering the interaction of bearing elastic deformation, asperity contact pressure and film pressure. The bearing behaviors including minimum film thickness, hydrodynamic pressure, asperity friction force and frictional coefficient are studied under different models. The correctness of this model is verified by comparing it with that of the published data. Findings: Numerical results indicate that elastic deformation noticeably decreases the maximum film pressure, the asperity contact force and the friction coefficient in the mixed lubrication stage. The effect of elastic deformation and turbulence reduces the transition speed from mixed to liquid lubrication. Originality/value: This model includes both turbulence and bearing deformation impacts on journal bearing performances. It is expected that the numerical results can provide useful information to establish a stern bearing exposed to mixed lubrication conditions. Peer review: The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-11-2022-0352/ [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this study is to prepare ZnFe2O4 nanospheres, sheet MoS2 and three ZnFe2O4@MoS2 core-shell composites with various shell thicknesses, and add them to the base oil for friction and wear tests to simulate the wear conditions of hybrid bearings. Design/methodology/approach: Through the characterization and analysis of the morphology of wear scars and the elemental composition of friction films, the tribological behavior and wear mechanism of sample materials as lubricant additives were investigated and the effects of shell thickness and sample concentration on the tribological properties of core–shell composite lubricant additives were discussed. Findings: The findings demonstrate that each of the five sample materials can, to varying degrees, enhance the lubricating qualities of the base oil and that the core–shell nanocomposite sample lubricant additive has superior lubricating properties to those of ZnFe2O4 and MoS2 alone, among them ZnFe2O4@MoS2-2 core–shell composites with moderate shell thickness performed most ideally. In addition, the optimal concentration of the ZnFe2O4@MoS2 lubricant additive was 0.5 Wt.%, and a concentration that was too high led to particle deposition and affected the friction effect. Originality/value: In this work, ZnFe2O4@MoS2 core–shell composites were synthesized for the first time using ZnFe2O4 as the carrier and the lubrication mechanism of core–shell composites and single materials were compared and studied, which illustrated the advantages of core–shell composite lubricant additives. At the same time, the influence of different shell thicknesses on the lubricant additives of core–shell composites was studied. Peer review: The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2022-0367/ [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this paper is to investigate the performance of an ultra-thin film lubricated conjunction through the elastohydrodynamic lubrication of point contacts for various ridge shapes and sizes located within the contact zone including flat-top, triangle and cosine wave profiles, considering the influence of surface forces of solvation and Van der Waals' in addition to the hydrodynamic effect to predict an optimum geometric characteristics for surface texture for lubricated conjunctions. Design/methodology/approach: Surface features are simulated in a variety of sizes and shapes including flat-top, triangle and cosine wave profiles. While estimating the elastic deformation of the contacting surfaces, surface forces of solvation and Van der Waals' are taken into account. The Reynolds equation is solved using the Newton–Raphson method to get the pressure profile and film thickness including the elastic deformation, and surface feature. Findings: The geometrical characteristics of the ridge, its placement in relation to the contact zone and its height all have a significant impact on the performance of ultra-thin film lubricated conjunction. When the triangular-shaped ridge is present in contact, it forecasts even sharper peaks in film thickness and pressure. More friction, wear and eventually contact fatigue are brought on by this more acute pressure and film thickness peaks. The flat-top ridge shape shows a better performance for lubricated conjunction where, the minimum film thickness value is comparable to that obtained for the case of a smooth contact surface. This behavior is attributed to the effect of intermolecular force of solvation. An increase in the size of the ridge results in a step increase in the film thickness for different ridge shapes, particularly for the flat-topped ridge pattern. Originality/value: Evaluation of the performance of elastohydrodynamic lubricated ultra-thin film conjunction related to film thickness and pressure profile for various ridge surface features of different amplitudes, shapes and sizes located through the contact zone considering the influence of surface forces of solvation and Van der Waals' in addition to the hydrodynamic effect. Peer review: The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2023-0062/ [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this study is to develop a 3D wheel-rail adhesion model under wet condition, which considers the generated surface roughness topography and the traditional braking procedure for high-speed trains. Design/methodology/approach: Wheel-rail adhesion has an important effect on the braking ability of railway vehicle. Based on the deterministic mixed lubrication approach, the model was solved to get the adhesion characteristics of the train during braking. The elastic deformation was calculated with the discrete convolution and fast Fourier transform method. The simulation results of adhesion coefficient were compared with the experimental values. The wheel-rail adhesion characteristics of train braking at several different initial speeds were investigated. The effects of the time-step length and roughness orientation on the contact load ratio were also discussed. Findings: The results show that the adhesion coefficient of the numerical model is in good agreement with the experimental results. At the instant of braking, the adhesion coefficient drops to a lower adhesion level, the value of adhesion coefficient is lower than 0.06, especially at a higher speed (200, 300 and 400 km/h). Originality/value: It can provide a better understanding of the low adhesion phenomenon of train braking under wet condition. Peer review: The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-02-2023-0040/ [ABSTRACT FROM AUTHOR]

Purpose: Bearing friction moments are important factors that affect the vibrations of rotor systems. The bearing friction moments are related to the dimension parameters, lubrication conditions and manufacturing errors of support bearings. This work studies the effects of the bearing friction moments on the vibrations of rotor systems. Design/methodology/approach: The rotor is separated into several shaft elements for formulating a flexible rotor. The time-varying friction moment (TFM) is affected by the time-varying contact loads. The vibrations of FRS from the TFM and Palmgren's friction moment (PFM) calculation methods are compared. Moreover, the effects of the rotor offset and radial clearance on the frequency-amplitude characteristics of FRS are studied. Findings: The TFM method is more consistent with the actual operation mechanisms. The rotor offset and radial clearance can significantly affect the nonlinear vibrations of FRS. This work provides a new reference and research method for the vibration analysis of rotor systems considering the friction effects. Originality/value: The elastohydrodynamic lubrication (EHL), elastic hysteresis and differential sliding are considered. A flexible rotor system (FRS) dynamic model considering the TFM is proposed. The vibrations of FRS from the TFM calculation method and empirical calculation formula are compared. The effects of the rotor offset and radial clearance on the frequency–amplitude characteristics of FRS are studied. [ABSTRACT FROM AUTHOR]

Purpose: To understand the service performance of full ceramic ball bearings under extreme working conditions and improve their service life, dynamic characteristic tests of full ceramic ball bearings under ultra-low temperature conditions were carried out by a low-temperature bearing life testing machine, and temperature rise and friction were measured under extreme low-temperature environment. Design/methodology/approach: The heat-flow coupling model of bearing was established by CFD software, and the test results were further analyzed. Findings: The results show that the temperature rise of the bearing is not obvious in the liquid nitrogen environment. With the increase of the chamber temperature, the lubrication state of the bearing changes, resulting in the temperature rise of the outer ring of the bearing. As the temperature of the test chamber increases, the friction force on the bearing increases first and then decreases under the action of multifactor coupling. Research limitations/implications: The research results provide test data and theoretical basis for the application of all-ceramic ball bearings in aerospace and other fields and have important significance for improving the service life of high-end equipment under extreme working conditions. Practical implications: The research results provide test data and theoretical basis for the application of full ceramic ball bearings in aerospace and other fields and have important significance for improving the service life of high-end equipment under extreme working conditions. Social implications: The research results provide test data and theoretical basis for the application of full ceramic ball bearings in aerospace and other fields and have important significance for improving the service life of high-end equipment under extreme working conditions. Originality/value: The research results provide test data and theoretical basis for the application of full ceramic ball bearings in aerospace and other fields and have important significance for improving the service life of high-end equipment under extreme working conditions. [ABSTRACT FROM AUTHOR]

Purpose: This study aims to investigate the effect of compound pit textures on the tribological properties of thrust cylindrical roller bearings (TCRBs) using several parameters, such as compound type, pit diameter, pit depth and pit area density. Design/methodology/approach: The surface texture parameters of the shaft washer (WS) raceway include pit diameter (D; 100, 300 and 500 µm), pit depth (H; 10 and 20 µm) and pit area density (S; 10%, 13% and 18%). Pits were produced on the WS of the TCRBs using laser marking equipment. The friction and wear performances of compound pit-textured TCRBs under starved lubrication conditions are studied using a friction and wear test rig. The influence mechanisms of the compound pit texture on the friction and wear properties of TCRBs are discussed through real tests and discussions. Findings: Compared with nontextured bearings, the average coefficient of friction (ACOFs) and wear loss of TCRBs with single/compound pit textures are reduced when rotating under starved lubrication. D has the greatest effect on the COFs curve. When D = 300 µm, H = 10 µm and S = 10%, the ACOF and wear loss are the lowest, that is, 0.0207 and 3.38 mg, respectively. Under the same lubrication conditions, compared with the nontextured bearing group, the COF and wear loss are reduced by 41.4 and 59.6%, respectively. Originality/value: This study provides a useful reference for the raceways of textured TCRBs. [ABSTRACT FROM AUTHOR]

Purpose: This paper aims to investigate the effects of inertia of the lubricant on the performance parameters of journal bearings textured with spherical-shaped textures. Design/methodology/approach: The lubricant is assumed to be Newtonian, and the flow is considered laminar. Considering the lubricant inertia effects, the modified Reynolds equation is discretized using the finite difference method and solved with the Gauss–Seidel successive over-relaxation scheme using the progressive mesh densification method. Findings: The results from this numerical study indicate that the lubricant inertia improves textured journal bearing performance characteristics significantly. The improvement is more significant in the case of heavily loaded bearings. Furthermore, it is observed that protruded texturing in journal bearings shows better results compared to dimple textured journal bearings. Originality/value: Understanding the effect of lubricant inertia is essential for efficiently designing textured journal bearings. Thus, the results shown here would be helpful for the researchers and the bearing designers. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this study is to describe and observe the influence of boundary slip associated with an arbitrary entrainment angle on the contact lubrication properties of ellipses. Design/methodology/approach: Based on the modified Reynolds equation, the boundary slip of any angle is considered in the elliptic contact, and numerical simulation is carried out. In the above calculation, the progressive mesh densification method is used, which greatly reduces the computation time. Findings: The results indicate that the variation of film thickness corresponding to different entrainment angles is distinct from those without considering boundary slip. In addition, boundary slip reduces the central film thickness and minimum film thickness, which makes the hydrodynamic pressure distribution smoother. Originality/value: The present study focuses on the specific condition with the arbitrary direction of rolling and sliding velocity found in hypoid gears and worm, and some other components. The influence of boundary slip associated with arbitrary entrainment angle on the lubrication film thickness in elliptical contacts is first revealed, which improves a good understanding of elastohydrodynamic lubrication characteristics. [ABSTRACT FROM AUTHOR]

Purpose: This study aims to investigate the combined effects of roughness and ferrofluid lubricant on finite journal bearing load capacity and squeeze time. Design/methodology/approach: The stochastic theory of Christensen is applied to study the surface roughness effect. The Shliomis model is used to take into account the effects of the rotational viscosity of ferromagnetic particles and their magnetic moment. A finite wire located in the center of the shaft produces the applied magnetic field. A developed computing code allows predicting the effect of the surface roughness on the performance of the considered journal bearing. The good agreement with the results of the literature validates the used approach. Findings: This study shows that unlike longitudinal roughness, the presence of transverse roughness makes the use of ferrofluid more beneficial in terms of increasing the performance of finite journal bearings. This increase is more significant for large relative eccentricities, which present an ideal confinement. Originality/value: This study shows the effect of two surface roughness patterns on the squeezing performance of a finite journal bearing lubricated by a ferrofluid. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this paper is to investigate the thermal elastohydrodynamic lubrication (TEHL) flash temperature of the helical gear pairs considering profile modification. Design/methodology/approach: A flash temperature model of the helical gear pair considering the profile modification is proposed based on the TEHL and meshing theories. In doing so, the slicing, fast Fourier transform and chase-after methods are applied to accurately and rapidly obtain the flash temperature of the gear pair. Then, the effects of the modification, input torque and rotation speed on the flash temperature are studied. Findings: With the increment of the tip relief amount, the flash temperature of the helical gear pair with the axial modification decreases first and then increases, and the meshing position of the maximum flash temperature moves toward the pitch point. Moreover, reducing the input torque or increasing the rotation speed can efficiently reduce the TEHL flash temperature. Originality/value: This work is a valuable reference for the profile design and optimization of the helical gears to avoid the excessive flash temperature. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this paper is to study the influence of dimple textures on the friction and wear properties of tapered roller bearings (TRBs) with many pattern parameters, e.g. diameter, depth and area density under starved lubrication. Design/methodology/approach: The pattern parameters include the dimple diameter (D; 60, 100 and 200 µm), dimple depth (H; 5, 10 and 20 µm) and area density (S; 6%, 12% and 24%). Dimples were fabricated on the outer ring (OR) of TRBs using a laser marking machine. The tribological properties of dimple-textured TRBs under starved lubrication were studied on a vertical universal friction wear tester with special friction pairs. The effect mechanisms of dimple textures on the tribological properties of TRBs are presented and summarized through experiments and discussions. Findings: When dimple-textured TRBs revolve under starved lubrication, the average coefficients of friction (ACOF) and wear losses are markedly lower than those of non-textured bearings. S has the greatest influence on the COF curve. When D is 100 µm and S is 24%, the ACOF and wear losses are both lowest, i.e. 0.00426 and 0.51 mg, respectively. Under the same test conditions, compared with the non-textured group, its COF and wear loss decreased by 35.6% and 62.5%, respectively. Originality/value: This work provides a useful reference for the research on the raceways of textured TRBs. [ABSTRACT FROM AUTHOR]

Purpose: The rotor system supported by the cylindrical roller bearings is widely used in various fields such as aviation, space and machinery due to its importance. In the study of the dynamic characteristics of the cylindrical roller bearings, it is important to accurately calculate the stiffness of the cylindrical roller bearings. The stiffness of the cylindrical roller bearings is very important in the analysis of the vibration characteristics of the rotor system. Therefore, in this paper, the method of creating a comprehensive stiffness model of the cylindrical roller bearing is mentioned. The purpose of this study is to improve the dynamic stability of the rotor system supported by the cylindrical roller bearing by accurately establishing the comprehensive stiffness calculation model of the cylindrical roller bearings. Design/methodology/approach: In consideration of the radial clearance of the cylindrical roller bearing, the radial load acting on the cylindrical roller bearing was derived, and based on this, a model for calculating the Hertz contact stiffness of the cylindrical roller bearing was created. Based on the load considering the radial clearance, an oil film stiffness model of the cylindrical roller bearing was created under the elastohydrodynamic lubrication (EHL) theory. Then, the comprehensive stiffness was calculated by combining Hertz contact stiffness and the oil film stiffness of the cylindrical roller bearing, and the dynamic parameters are calculated by using the MATLAB program. Findings: When the radial clearance of the cylindrical roller bearing is considered, the comprehensive stiffness is larger than when the radial clearance is not taken into account, and the radial clearance of the cylindrical roller bearing is an important factor that directly affects the comprehensive stiffness of the cylindrical roller bearing. Originality/value: In this paper, based on Hertz contact theory and the EHL theory, the authors investigated the method of creating a comprehensive stiffness model of the cylindrical roller bearing considering the radial clearance. These results will contribute to the theoretical basis for studying the mechanics of cylindrical roller bearings and optimizing their structures, and they will provide an important theoretical basis for analyzing the dynamic characteristics of the rotor system supported by the cylindrical roller bearing. [ABSTRACT FROM AUTHOR]

Purpose: Friction and wear are very important factors in predicting the performance of journal bearings, particularly under heavy load in start-up processes. However, there are few relevant studies on the numerical model. This study aims to establish a transient-mixed lubrication model to predict the performance of journal bearings, focusing on the friction and wear behavior under heavy load during start-up. Design/methodology/approach: The average Reynold equation, three-dimensional energy equation, shear stress model for friction and Archard model for wear are coupled in the transient model by finite difference method. The linear wear simulation method is bought out to reduce the update times and the calculation time. Findings: The different start-up accelerations and linear wear times set are compared and discussed, which indicates a reasonable start-up acceleration is necessary for journal bearings under heavy load during start-up, and setting linear wear times is an effective method to reduce the simulation time significantly. Furthermore, the wear profile in the start-up process spreads in both the clearance and circumferential directions, but mainly in the clearance direction, which increases the minimum film thickness and affects the friction performance. Originality/value: This study is of great significance for the numerical prediction of the transient performance of journal bearings during start-up considering friction and wear. [ABSTRACT FROM AUTHOR]

Purpose: To solve the problem of oil film thinning when hydrostatic thrust bearings are overloaded or rotating at high speed, the dynamic pressure formed by tiny oil wedges is used to compensate, and the optimum height of oil wedges is determined by the compensation rate to improve the bearing capacity of hydrostatic thrust bearings. Design/methodology/approach: This research method is aimed at the new type of double rectangular cavity static bearing with microbevel surface of q1-205. The wedge parameters of oil film were defined. The oil film lubrication performance of the bearing with the wedge parameters of 0, 0.02, 0.04, 0.06, 0.08 and 0.10 mm was simulated by the finite volume method, the comprehensive influence law of the wedge-shaped parameters on the vorticity and flow rate of the oil cavity pressure fluid was revealed. Finally, the oil cavity pressure changes of oil films with different wedge parameters under certain load and speed were tested by design experiments, and the theoretical analysis and simulation were verified. Findings: This study found that the oil film wedge shape can well compensate the static pressure loss caused by the high-speed or heavy-duty operation of the bearing, but the dynamic pressure effect of the wedge shape does not always increase with the increase of the wedge height. The oil film exhibits superior lubrication performance in the range of 0.06–0.08 mm. Originality/value: The original hydrostatic oil pad was designed as a microinclined plane, and the dynamic pressure caused by the microwedge of the oil pad was used to compensate the static pressure loss of the bearing. The lubrication performance of the oil film under the condition of varying viscosity was obtained by using the simulation method. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this paper is to put forward the lubrication model of oil bearing and enrich the design theory under the condition of mixed lubrication. Design/methodology/approach: A mixed lubrication model of bilayer porous bearing is established. The effects of the working conditions on the lubrication performance and seepage behavior were analyzed. Findings: Results show that the oil film pressure mainly occurs in the bearing convergence zone and contact pressure mainly occurs near the minimum film thickness. The oil infiltrates into the porous matrix in the contact area and precipitates out to the friction surface at the inlet of the contact area. The oil seepage velocity and dynamic pressure effect at the friction interface can be improved by reasonably matching the load and speed. With the decrease of the external load or increase of the rotating speed, the lubrication performance becomes well. Originality/value: This study provides a reference for the design and application of oil bearing under harsh working conditions. [ABSTRACT FROM AUTHOR]

Purpose: This study aims to investigate the performance improvement of journal bearing by applying the arc-shaped textures on various regions of bearing expressly full, second half and pressure increasing regions operating with and without nanoparticles in the lubricant. Design/methodology/approach: The Reynolds equation is solved numerically by using the finite element method to obtain static performance parameters such as load-carrying capacity (LCC) and coefficient of friction (COF), which are then compared with untextured bearing at eccentricity ratios of 0.2 to 0.8. Aluminum oxide (Al2O3) and copper oxide (CuO) nanoparticles additives are used, and viscosity variation due to the addition of additives in the base lubricant is computed for considering the range of temperatures 50 to 90°C at a weight fraction of 0.1 to 0.5% by using an experimentally validated regression model. Findings: The results indicate that the maximum LCC and the lower COF are found in the pressure-increasing region. A maximum increase of 34.42% is observed in the pressure-increasing region without nanoparticles, and furthermore, with the addition of Al2O3 and CuO nanoparticles in lubricants in the same region, the LCC increased to 21 and 24%, respectively. Originality/value: Designers should use optimal parameters from the present work to achieve high bearing performance. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this paper is to report the tribological behavior of dimples textured rolling element bearings (REBs) under variable load and starved lubrication. Design/methodology/approach: The pattern parameters include line-diameter of dimples (200 µm, 250 µm, 300 µm), depth of dimples (10 µm, 20 µm, 30 µm). Dimple patterns were prepared on the raceways of the shaft washers of cylindrical roller thrust bearings (CRTBs). A vertical wear test rig was used to obtain their coefficients of friction (COFs) under stepped load (1200–6000 N, with a manually increase of 1200 N every 3600 s) and starved lubrication. The wear losses and worn surfaces were characterized. The tribological performance between stepped load and fixed load (4000 N) was compared. The influence mechanism of dimples on the friction and wear properties of CRTBs under stepped load and starved lubrication was also discussed. Findings: Compared with the data of smooth ones, the average COFs of the dimples textured bearings are almost all reduced under stepped load and starved lubrication, while their mass losses almost all get higher. The depth−diameter ratio and the effective volume coefficient of dimples are the important factors. In this work, compared with the smooth group, when the line-diameter of dimple is 250 µm and the depth is 20 µm, i.e. the depth−diameter ratio is 0.08, its average COF is reduced by 46.8% and its mass loss is reduced by about 7%, showing wonderful friction-reducing effect and good wear resistance. Originality/value: This work can provide a reference for the raceway design of REBs. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this paper is to compare the spherical protruded and dimple textured journal bearings performance characteristics with the untextured bearing. Design/methodology/approach: The governing Reynolds equation considering the mass conserving (JFO) boundary conditions is solved using the computationally efficient progressive mesh densification (PMD) method. The central difference scheme is used for the discretization of the governing Reynolds equation. The numerical code developed is validated with the experimental results available in the literature. Findings: From this numerical study, it has been observed that the protruded textured journal bearing gives better performance compared to the dimple textured and untextured journal bearing for friction variable, whereas dimple textured journal bearing provides better performance compared to the protruded textured and untextured journal bearing for load carrying capacity and flow coefficient. For better performance, dimple and protruded textured bearings must be textured in second-half textured region configuration. Practical implications: The results shown here would be quite useful for the researchers generally and the bearing designers particularly. Originality/value: The load carrying capacity should be maximum whereas, the friction coefficient should be minimum and also the adequate flow of lubricant is necessary to maintain hydrodynamic lubrication and to remove the heat generated within the bearing due to friction, which impacts the bearing performance and life. Thus, this study would be significant in effective bearing design aspect. [ABSTRACT FROM AUTHOR]

Purpose: This paper aims to present a numerical model to examine the finite magneto-hydrodynamic (MHD) journal bearings performances including both non-Newtonian couple stress and bearing deformation impacts. Design/methodology/approach: Based upon the MHD and Stokes theories, a novel expression of modified Reynolds equation including bearing deformation is obtained. The bearing elastic deformation impact is predicted by means of the Winkler model. Using the numerical differentiation approach, the film pressure is iteratively solved. Different bearing characteristics are then numerically calculated. The validity of the proposed model was verified by comparing with some particular cases from literature. Findings: From the numerical presented results, it is demonstrated that the conducting couple stress lubricant with an applied radial magnetic field results in an induced electric current density and thus significantly improves the performances of elastic journal bearings. Particularly, the load-carrying capacity is increased, whereas a reduction in friction factor is observed. Originality/value: This numerical model is original, which combines both non-Newtonian couple stress and bearing deformation impacts on finite MHD journal bearings performances. It provides useful information in designing MHD journal bearings, given the lack of experimental studies. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this paper is to study the lubrication characteristics of double involute gear (DIG), compare its lubrication differences under quasi-static and tribo-dynamic conditions and study the influence of different factors on its lubrication characteristics under the tribo-dynamic condition. Design/methodology/approach: According to the meshing characteristics of DIG and elastohydrodynamic lubrication (EHL) theory, a tribo-dynamic model of DIG is established based on the "subsection method." The Runge-Kutta method and the multigrid method are integrated to solve the model, and the dynamic analytical model of lubricating oil is established in the iterative solution. Findings: The load and the transmission error fluctuate obviously under the tribo-dynamic condition, which is not conducive to the lubrication of DIG. The influence of rotational speeds and torque on the lubrication properties of DIG has obvious differences under tribo-dynamic and quasi-static conditions. Originality/value: This research can provide a theoretical basis for improving the lubrication performance, reducing the loss of mechanical efficiency and improving the bearing capacity and service life of DIG. [ABSTRACT FROM AUTHOR]

Purpose: Researchers have not reached an agreement on which biomimetic shape has the best lubrication performance. This paper aims to study the influence of microtexture size, shape and direction on bearing capacity, end leakage, friction coefficient and wear of oil film. Design/methodology/approach: Different oil film thickness equations considering the microtexture of bearing surface are gained. The two-dimensional finite difference equation and the calculation equation of wear are established. Findings: The theoretical research shows that the wear value and the wear ratio when long side is perpendicular to the axial direction of the bearing are generally lower than when the long axis is parallel to the axial direction of bearing. The theoretical and experimental results show that the appropriate microtexture shape, such as circular dimple, crescent-shaped dimple, triangular dimple and fish-shaped dimple can improve effectively the lubrication performance of journal bearing and reduce the friction coefficient. Originality/value: The research has great significance to reduce friction and improve the wear resistance of equipment. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this study is to investigate the combined effect of surface force, solvation and Van der Waals forces and surface topography parameters of amplitude and wavelength on the formation of ultrathin films for elastohydrodynamic lubrication of point contact problems. Design/methodology/approach: The Newton–Raphson technique is used to simultaneously solve the Reynolds' film thickness including surface roughness and elastic deformation, surface force of solvation and Van der Waals forces and load balance equations. Different values of surface amplitude and wavelength were simulated in addition to the load variation. Findings: The simulation results revealed that roughness effects are important as the film thickness decreases. The oscillation in the pressure and film thickness is due to the combined action of the solvation force and surface topography parameters. The limiting values of the surface topography parameters of the amplitude and wavelength varied and depended on the load. For different values of wavelength and load, amplitude values up to 0.25 nm have no effect on ultrathin film formation. Originality/value: The combined effect of the surface force and surface roughness on the formation of ultrathin films was evaluated for elastohydrodynamic lubrication of point contact problems under different operating conditions of load and surface topography parameters of amplitude and wavelength. The limited surface topography parameters of the amplitude and wavelength are shown and analyzed. [ABSTRACT FROM AUTHOR]

Purpose: The paper is devoted to presenting a systematic investigation on the mechanical model and nonlinear dynamic characteristics of spur gear system with and without input shaft crack. Design/methodology/approach: Considering the backlash, load-distribution, time-varying meshing stiffness and sliding friction, the modelling of a 5DOF gear system is proposed. Likewise, stiffness and damping models under elastohydrodynamic lubrication are developed, and sliding friction between gear pair is also outlined. In particular, a cracked input shaft which affects the support stiffness is presented, and breathing crack in keyway is adopted. On this basis, the dynamic responses of a gear system with and without input shaft crack are examined using numerical method, and some classical response diagrams are given, illustrating the effect of the important parameters on the gear system. Findings: Dynamic simulation demonstrates that there exist periodic, quasi-periodic and chaotic motions in the gear system, and rational speed of the gear pair has noteworthy effects on vibration characteristic. Besides, comparison between healthy and cracked condition of input shaft indicates that occurring of crack convert periodic motion to quasi-periodic or chaotic motion. Originality/value: The results give an understanding of the operating conditions under which undesirable dynamic behavior occurs, and provide some useful information to design and diagnose such gear system with crack fault. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this paper is to reveal the transient thermo-elasto-hydrodynamic lubrication mechanism of a bidirectional thrust bearing in a pumped-storage unit, and to propose the transient simulation method of two-way fluid-solid-thermal interaction of thrust bearing. Design/methodology/approach: The transient fluid-solid-thermal interaction method is used to simulate the three-dimensional lubrication of the thrust bearing, during the start-up and shutdown process of a pumped storage unit. A pad including an oil hole is modelled to analyze the temporal variation of lubrication characteristics, such as the film pressure, thickness and temperature, during the transient operation process. Findings: The injection of the high-pressure oil sufficiently affects the lubrication characteristics on film, in which the hysteresis phenomena were found between the start-up and shutdown possess. Originality/value: This paper reveals the transient lubrication mechanism of tilting pad in a thrust bearing, by means of transient fluid-solid-thermal interaction method. Lubrication characteristics are simulated without assuming the temperature relationship between the oil film inlet and the outlet and the heat transfer on the pad free surface. This paper provides a theoretical basis for the safe design and stable operation of thrust bearings. [ABSTRACT FROM AUTHOR]

Purpose: Cold forging operation is one of the widely used techniques in industry production. This paper aims to present a case study in highlighting and modelling the use of different type of palm oil-based [palm stearin (PS), palm kernel oil (PKO) and palm mid olein (PMO)] as a bio-lubricant in cold forging process using experimental and finite element method. Design/methodology/approach: Ring compression test plays a fundamental role in the understanding of materials science and engineering because of the deformation, friction and wear behaviour. Aluminium (A6061) was used in this test to observe the deformation of the ring with different palm oil and its derivatives by comparing with commercial metal forming oil. Findings: The presence of certain type of palm oil-based lubricant has a good performance compared to mineral-based oil in terms of surface roughness but when observed in terms of friction the result shows that palm oil-based lubricant has poor friction performance compared to mineral oil-based lubricant (m = 0.25), where PS has the lowest friction at m = 0.3 compared to PKO (m = 0.35) and PMO (m = 0.38). Research limitations/implications: This research is using palm oil in cold forging test to study the friction, formation and stress at certain levels of stroke. The detail of the test is explained in the manuscript as attached. Social implications: This research is trying to promote the use of biodegradable material to reduce pollution to the surrounding. Originality/value: The originality of this paper has been checked using Turnitin and the result is 13%. [ABSTRACT FROM AUTHOR]

Purpose: This paper aims to study the effect of isosceles triangle micro concave texture with different parameters on the performance of oil seal to obtain a reasonable combination of parameters. Design/methodology/approach: Based on the theory of elastohydrodynamic lubrication, a numerical model is established by coupling the texture parameters of isosceles triangle with concave lip with the two-dimensional average Reynolds equation considering surface roughness. Findings: The results show that there is an optimal combination of parameters to improve the performance of the oil seal. When hp = 5µm-6.5 µm, a = 110°−130°, O = 1.4, C = 1.6 mm-2.2 mm, the oil seal with isosceles triangle micro concave texture can show good lubrication characteristics, friction characteristics and sealing ability. Originality/value: The model provides a new idea for the design of new oil seal products and provides a theoretical support for the application of surface texture technology in the sealing field in the future. [ABSTRACT FROM AUTHOR]

Purpose: This paper aims to investigate the squeeze film lubrication properties of hexagonal patterned surface inspired by the epidermis structure of tree frog's toe pad and numerically explore the working mechanism of hexagonal micropillar during the acquisition process of high adhesive and friction for wet contacts. Design/methodology/approach: A two-dimensional elastohydrodynamic numerical model is employed for the squeezing contacts. The pressure distribution, load carrying capacity and liquid flow rate of the squeeze film are obtained through a simultaneous solution of the two-dimensional Reynolds equation and elasticity deformation equations. Findings: Higher pressure is found to be longitudinally distributed across individual hexagonal pillar, with pressure peak emerging at the center of hexagonal pillar. Expanding the area density and shrinking the channel depth or initial film thickness will improve the magnitude of squeezing pressure. Relatively lower pressure is generated inside interconnected channels, which reduces the load carrying capacity of the squeeze film. Meanwhile, the introduction of microchannel is revealed to downscale the total mass flow rate of squeezing contacts. Originality/value: This paper provides a good proof for the working mechanism of surface microstructures during the acquisition process of high adhesive and friction for wet contacts. [ABSTRACT FROM AUTHOR]

Purpose: The purpose of this paper is to verify the effectiveness of the proposed transient mixed lubrication and wear coupling model [mixed lubrication and wear (MLW) coupling model] under water lubricated conditions by comparing with the experimental results. Design/methodology/approach: Water lubricated bearings are the key parts of the transmission system of an underwater vehicle and some surface ships. In this study, the friction and wear behaviors of rubber, nylon and polyether ether ketone (PEEK) samples with stainless steel underwater lubrication were compared by using ring-block contact structure on multifunctional friction and wear test bench-5000 friction and wear tester. Findings: The results show that the transient wear depth and wear amount of PEEK, nylon and rubber samples under water lubrication are in good agreement with the calculated results of the theoretical model, which verifies the rationality and scientific nature of the MLW coupling model. Thus, the numerical model is applicable for the wear prediction of the journal bearing under water-lubricated conditions. Furthermore, numerical and experimental results reveal that the anti-wear performance among three water-lubricated materials can be ranked by: PEEK > nylon > rubber. Originality/value: It is expected that this study can provide more information for experimental and numerical research of water-lubricated bearings under water-lubricated conditions. [ABSTRACT FROM AUTHOR]

Purpose: This paper aims to revel the leakage characteristics of the bent-axis piston pump considering elastohydrodynamic deformation via a dynamic leakage model. Design/methodology/approach: A dynamic leakage model of bent-axis piston pump based on elastohydrodynamic lubrication theory is proposed, which is used to present the leakage characteristics of bent-axis piston pump. The model is composed of three parts. First, the dynamic gap in the piston ring-cylinder bore interface (PRCB) is described via the elastohydrodynamic lubrication equations. Then, the PRCB leakage is presented based on the dynamic gap. Finally, combined with leakage equation of the valve plate-cylinder block interface (VPCB), the total leakage model is proposed. Through the numerical simulation and experiment, the leakage characteristics of bent-axis piston pump considering elasto-hydrodynamic deformation are studied. Findings: The PRCB leakage is negatively correlated with VPCB leakage under the range of 800–1400 r/min and 1–25 MPa. When the discharge pressure is less than the critical pressure, the PRCB leakage is the main factor affecting the total leakage in bent-axis piston pump. On the contrary, the VPCB leakage is the main factor. The critical pressure increases with increasing speed Originality/value: The effect of operating parameters has a significant effect on the elastic deformation of piston ring without considering wear of friction pairs in bent-axis piston pump. There is a critical phenomenon in the leakage, which is related to the operating parameters, and provides a novel idea for extracting wear information from leakage and evaluating the status of bent-piston pump. [ABSTRACT FROM AUTHOR]

Purpose: The edge of diesel engine crankshaft main bearing is more likely to fail in its real working condition. This paper aims to study the bearing failure mechanism by finding the relationship between bearing lubrication characteristics and its working condition. Design/methodology/approach: This work builds the mixed lubrication model of crankshaft bearing to analyze the cause of bearing abnormal wear, and the finite difference method was used to solving the average Reynolds equation. During the analysis, journal misaligned angle, external load and roughness are considered. Findings: The result shows that the wear of the diesel engine crankshaft bearing happens in engine startup phase and the bottom of the bearing are more prone to be excessively worn. Under the influence of journal misalignment, bearing asperity contact load and speed range of mixed lubrication will increase markedly. The edge of the bearing will be excessively worn. The effect of misalignment on bearing lubrication performance varies under different shaft rotation speed. Originality/value: The former research studies on crankshaft bearing either just focused on its lubrication characteristics or interested in its failure types (wear, adhere, cavitation). This paper studies the relationship between bearing failure mechanism and lubrication performance. [ABSTRACT FROM AUTHOR]