Elastohydrodynamic Lubrication Fundamentals

Wind Turbine Tribology Seminar November 15-17, 2011

Vern Wedeven
Wedeven Associates, Inc. 5072 West Chester Pike Edgmont, PA 19028-0646 610-356-7161 www.wedeven.com

National Renewable Energy Laboratory Argonne National Laboratory U.S. Department of Energy Renaissance Bolder Flatiron Hotel Broomfield, CO, USA 1

Elastohydrodynamic Lubrication Fundamentals

Focus on Concentrated Contacts

Hertzian Contact Geometry
Hertzian pressure

Hertzian region 2

How Do Gear/Bearing Surfaces Fail?

Wear
Polishing Adhesive Abrasive Oxidative Corrosive

Mechanistic processes Scuffing

Micro-scuffing Macro-scuffing

Fatigue
Micro-pitting Spalling

Contact Structural Elements

Functions and technologies to prevent wear scuffing and fatigue processes

Separates surfaces

Elastohydrodynamic Film
Prevents adhesion (boundary lubr.)

Surface Film Near-Surface Subsurface

Supports asperity stress

Supports Hertzian stress

Boundary lubrication creates & maintains integrity of surfaces to promote EHD mechanisms

EHD - The Miracle Mechanism

High stress rolling/sliding motion

Surface film h R F N

R Sliding velocity

EHD film generation

EHD - The Miracle Mechanism

Elastohydrodynamic Lubrication
The physics behind the mechanism

The MIRACLE Mechanism

Seven features create the miracle of EHD Lubrication

M I R A C L E
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Viscous Flow Between Parallel Surfaces

Fluid molecules

Force(F) (F) U

Viscous flow between parallel surfaces Shear stress F/A Viscosity () = Shear rate u/h
N sec m2

(poise)

Flow between parallel surfaces

Adsorbed Films

Adsorbed film
Oxide

Metal
Judith A. Harrison
United States Naval Academy

Original surface features

M = Molecular attraction
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Viscous Flow Between Non-Parallel Surfaces

Force U U U
Flow in cannot be greater than flow out

Viscous flow between nonparallel surfaces

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Hydrodynamic Pressure Generation

Pressure

Fluid velocity

Force U
Hydrodynamic pressure generation

Viscous flow between parallel surfaces

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Requirements for Pressure Generation

Pressure

1. Converging geometry
Fluid velocity Force
Hydrodynamic pressure generation

2. Viscous fluid media 3. Surface motion

Viscous flow between parallel surfaces

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Pressure Generation in a Journal Bearing

Bearing Fluid
Load

Journal

Oil film pressure Journal bearing

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Film Thickness Equation (general form)

Load, W

R1 u2 u1 ho

ho R

= 4.896 Ue 0 W

0 = viscosity W = load

Ue = surf vel., 1/2 (u1+u2)

R = radius of curvature
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Conformal and Non-conformal Contacts

Outer ring

Inner ring

Rollers

Roller Bearing Components

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Hertzian Contact
Load (W) 1/2
R

a=

12 11 ____ ____ + E2 E1
2

4 WR _____ L

2W Pmax = La E = elastic modulus = Poissons ratio L = length of roller

Pmax

Hertzian pressure

Hertzian region

(2 a)

Hertzian condition for dry contact

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Fluid flow in Convergent Inlet Region

U1 h U2
INLET REGION
Inlet region Hertzian region

Flow distribution within the convergent inlet region

I = In-flight refueling
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Effect of Pressure on Viscosity

= 0 e p
Viscosity, cp

= pressure-viscosity coef.
Effect of pressure on viscosity (synthetic oil at 38 oC)

= viscosity o = viscosity at p = 0 p = pressure

0
Psi

N/m2

Pressure, p

R = Radical increase of viscosity with pressure

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Fluid Flow and Pressure in Inlet Region

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Perspective of Lubricated Contact

Hertzian pressure

u2 u1
Hertzian region

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Three Functional Regions of an EHD Contact

Hertzian pressure

Pressure
Inlet region PUMPS FILM UP Hertzian region RIDES IT

hm Outlet region
DISCHARGES IT

Elastohydrodynamic pressure and shape

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EHD Film Thickness Equation

Pressure

(oUe)0.71 0.57 R0.40

hm = 3.07
-----------------------------------------

E0.03 w0.11

Inlet

Hertz region

Exit

EHD pressure and film generation

hm = min. film thickness o = viscosity at atm press Ue = entraining velocity, (u 1 + u2 ) = pressure-viscosity coef. R = combined radius of curvature E = combined elastic modulus w = applied load

A = Accommodation of stress
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Contact with Optical Configuration

Air bearing

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Interference Colors from EHD Oil Film

Optical interference colors showing thickness of EHD oil film

Inlet

Hertzian region Exit region

Rolling motion Center film thickness 0.4 m (16x10-6 inch)

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Micro-EHD Lubrication

C = Cushioning of asperities

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Traction (Friction)
Tangential Shear of Pseudo-Solid Film

Hertzian pressure U2

EHD pressure

U1

Inlet region Hertzian region HERTZIAN REGION Outlet region

Traction

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Traction Coefficient Measurement

Entraining Velocity = 30 m/s
0.05
EE Oil #1
Lube: EE Oil #1 Ball: M50, Ra<1 inch, 1.125 inch dia. Disc: M50 Polished Ra<1 inches Stress: 2 GPa (702 N) Data collected from -30%->+30% slip and averaged

0.05

0.04

40 40CC

0.04

Traction Coefficient

0.03

0.03

100 100 C
0.02

C
0.02

150CC 150
0.01

200 C 200 C

0.01

0.00 0 5 10 15 % Slip
Typical thrust bearing slip range

0.00 20 25 30

Traction Coefficient

L = Limiting shear strength

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Oil/Air Separation at Divergent Exit Region

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Oil/Air Separation at Divergent Exit Region

Schematic representation of cavitated region

Transparent disc

Steel ball

Ribs of oil

Cavitation fingers

Transparent disc

Ball track

Waves of oil

Ribs of oil

E = Exit without trauma

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EHD - the MIRACLE Mechanism

Pressure

U1

hm
Hertz region Exit

U2

Inlet

EHD pressure and film generation

M Molecular attachment I Inlet refueling R Radical viscosity increase with pressure A Accommodation of stress C Cushioning of asperities L Limiting shear stress (traction) 30 E Exit without trauma

Contact Structural Elements

Functions and technologies to prevent failures

Wear
Separates surfaces

Scuffing
Surface Film Near-Surface Subsurface

Elastohydrodynamic Film
Prevents adhesion (boundary lubr.)

Fatigue

Supports asperity stress

Supports Hertzian stress

Boundary lubrication creates & maintains integrity of surfaces to promote EHD mechanisms

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Contact Structural Elements

Functions and technologies to prevent wear scuffing and fatigue processes

Separates surfaces

Elastohydrodynamic Film
Prevents adhesion (boundary lubr.)

Surface Film Near-Surface Subsurface

Supports asperity stress

Supports Hertzian stress

Boundary lubrication creates & maintains integrity of surfaces to promote EHD mechanisms

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Five Parameters Control Wear, Scuffing and Fatigue

u1 u2
Surface filmR h R Sliding velocity F N

Entraining velocity, Ue = (U 1 + U2)

1 2

Degree of asperity penetration (h/) Sliding velocity, Us = (U1 - U2) Contact temp (Tc = Tbulk + Tflash)

Us

Contact Stress (asperity stress)

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Wedeven Assoc. Machine (WAM)

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Wear and Scuffing Tests Gear Simulation

Us

Ue

Test Protocol Angle Z = 75 Ue = 5.72 m/sec Us = 8.8 m/sec

Ue = Entraining vel. vector Us = Sliding vel. vector

Test method simulates gear tooth mesh where scuffing is initiated.

AISI 9310 ball, roughness = 11 in (0.28 m), Ra AISI 9310 disc, roughness = 6 in (0.15 m), Ra

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Wear and Micro-Scuffing

220 0.14 0.12
Test: NA1368,NA1369,NA1370,NA1371
Lube: TEL-0004 MIL-PRF 7808 Grade 4 Ball: 9310, Ra=10 in Disc: 9-24b, 9310, Ra=6 in. Entraining Velocity: 225 in/sec. Sliding Velocity: 346 in/sec. Temperature: Ambient Velocity Vector Angle (Z): 75

200

Traction Coefficient

0.10 0.08 0.06 0.04 0.02 0.00 -0.02 0

Ref. Oil TEL-0004 MIL-PRF-7808 Grade 4 cSt Oil A 4

Micro-scuff failure
Ball Temperature
NA1370 NA1369

160 140 120 100 80 60 40

Traction Coefficient

NA1371

NA1368

Disc Temperature

Vertical Load

20 0

150

300

450

600

750

900

1050 1200 1350 1500 1650 1800

Run Time (seconds)

36

Load (lbs.), Temperature ( C)

180

Wear and Scuffing

Average TC for each load stage
0.14 0.12
Test: NA1323,NA1324,NA1325,NA1326
Lube: MIL-PRF-7808, Grade 4 (TEL-0001/3) Ball: 9310, Ra=10 in. Disc: 9-26b, 9310, Ra=6 in. Entraining Velocity: 225 in/sec. Sliding Velocity: 346 in/sec. Temperature: Ambient Velocity Vector Angle (Z): 75 NA1325 NA1323

220 200

Traction Coefficient

0.10 0.08

160 140
NA1326 NA1324

TEL-0003 4MIL-PRF-7808 cSt Oil B Grade 4

Traction Coefficient

120 100 80

0.06 0.04 0.02 0.00

Vertical Load Ball Temperature

Disc Temperature

60 40 20 0

-0.02 0 150 300 450 600 750 900

1050 1200 1350 1500 1650 1800

Run Time (seconds)

<consulting/sae/Tel-0001.jnb>

Load (lbs.), Temperature ( C)

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Macro-scuff failure

180

Wear and Scuffing Tests Gear Simulation

WAM High Speed Load Capacity Test Method
0.10
Failure criteria (avg. of all tests)

0.09 Anti-wear 0.08

behavior

Good AW additive

Traction Coefficient

0.07 0.06 0.05 0.04 0.03 0.02 0.01 0.00 0 2 4 6

= combined roughness Good AW Mild EP Good EP, Good AW

Test suspended

Base stock

Good EP, Poor AW

EP behavior

Lower bound reference, polished surfaces, STD oil

10

12

14

16

18

20

22

24

26

28

30

32

Load Stage

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Dither Motion and Fretting

u1 u2
Surface filmR h R Sliding velocity F N

1 2

Us
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Thank you, Questions?

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