TRIBOLOGY EME 452

NAME : NAZIRUL ASYRAFF BIN RASIDI

MATRIX NO. :128961

SCHOOL : SCHOOL OF MECHANICAL

ENGINEERING
EXPERIMENT : FOUR BALL TESTER

LECTURER : DR. RAMDZIAH BINTI MD. NASIR

DR. NURUL FARHANA BINTI
MOHD YUSOF
1) Introduction:
The Four Ball Tester is an excellent development and quality check instrument for
developers and users of lubricating oils and greases. The unique sample configuration
of three stationary balls and one top ball makes a very stable and a repeatable contact
in-turn, allowing test results to be very repeatable.

The Four Ball Tester can be used to determine Wear Preventive properties (WP),
Extreme Pressure properties (EP) and friction behaviour of lubricants (both oils and
greases). The wide acceptance of four ball testing makes it an excellent choice to
benchmark products.

The point contact interface is obtained by rotating a steel ball under load against
three stationary steels balls that secured and placed in triangular pattern within a bath
of lubricant. The torque transferred between the rotating and the stationary balls.
Measurements are taken at the rotating speed, temperature and normal load as specified
by published standard. The normal load, friction force, and temperature can be
monitored using Windows-based Data Acquisition Software. Loads applied for the
wear test producing s circular wear scar on each ball, and the average wear scar diameter
is determined for comparison.

The wear scar diameter on the steel balls are measured using an image acquisition
system to evaluate the relationship between scar diameter and applied load. The size of
the scar shows the ability of the lubricant to prevent wear. A larger diameter indicates
poor wear preventive property while a smaller indicates superior wear preventive
property.

In Extreme Pressure (EP) tests the lubricant is subjected to load that is increased in
specified steps after every run. This increase in loading is continued till a load is reached
where the lubricant fails. The failure of lubricant is indicated by welding of the bottom
three balls to the top ball. The load at which welding occurs is the index of extreme
pressure property of the lubricant. This testing method can used for specification
purposes such as differentiate between lubricating fluids which is having low, medium,
and high level of extreme pressure properties.

Figure 1(a): ASTM D2266

Figure 1(b): Arrangement of ball bearing
Specifications and Characteristics:
a. Test ball bearing diameter: 12.7mm

Table 1(a): Properties of Ball Bearing

b. SKF Bearing Grease (LGMT 2.0)

Table 1(b): Properties of Grease

 ASTM D2266
Load (kg) Duration (sec) Temperature (℃) Speed (rpm)
40 3600 75 1200
Table 1(c): Experiment Condition
Application:
a) Determine extreme pressure (EP), wear preventive (WP), friction, shear
stability and fatigue properties of lubricants.
b) Effect of lubricant in rolling contact fatigue life.
c) Testing and verifying the quality of oil that you’ve either produced yourself or
purchased from wholesalers.
d) Test whether nanoparticles coatings have useful wear-preventive properties.
e) Compare lubricant performance at a range of different loads and temperatures,
across a variety of different compositions and manufactures. By comparing new
and used oils, you can see how lubrication properties deteriorate over time – or
you might want to compare the lubrication properties of bio-degradable or
vegetable oils compared to synthetic oils, or those derived from hydro carbonate
cracking.
f) Test polymeric viscosity modifier to achieve better shear stability and minimize
the viscosity loss.
2) Procedure:

A view of the standard testing machine equipped with the data acquisition
system is presented in Figure 2(a). The electrical motor and the belt transmission rotate
the shaft. At the end of the shaft there is a tapered chuck with the clamped upper rotating
ball. The testing device contains the three stationary lower balls placed in a pot and
completely covered by lubricant, in order to assure a lubrication film between the upper
ball and the lower ones. The three ball was locked into based fixture of test machine.
The upper ball which is the fourth ball was locked into drive shaft. Then, grease was
used as a lubricant was poured into based fixture until it covered the whole ball bearing
and was placed on machine as shown in Figure 2(b). The test was started with the test
load of 40kg. The temperature of test grease has been controlled at 75℃ and recorded
by using the control unit and monitor. The test was carried out at constant speed of 1200
rpm. The data such as torque and other necessary data according to the ASTM standard
was controlled and recorded. The running time of the test is 60 minutes. The test
lubricant cup was assembly and chuck were removed. Then, the ball bearing was
discarded. The ball bearing was removed and cleaned with solvent, then wipe with dry
cloth. Finally, the dimension of all the ball bearing scar was measured by using
microscope of image acquisition system as shown in Figure 2(c).

Figure 2(b): Balls Setup

Figure 2(a): ASTM D2266

Figure 2(c): Image Acquisition System

3) Results and Discussion:
Experimental Results:
Bearing Scar Diameter Scar Line

Table 3(a): Scar Line and Diameter

Experimental Data:
Rotation per minute = 1200 rpm (refer to the ASTM D2266)
Applied Normal Diameter Diameter Diameter Average Scar
Load Load Bearing 1 Bearing 2 Bearing 3 Diameter
(kg) (N) (mm) (mm) (mm) (mm)
40 392.4 0.53329 0.50810 0.51230 0.51790
Table 3(b): Scar Diameter (ASTM D2266)
Applied Normal Line Line Line
Average Scar
Load Load Bearing 1 Bearing 2 Bearing 3
Line (mm)
(kg) (N) (mm) (mm) (mm)
40 392.4 0.52070 0.51230 0.51230 0.51510
Table 3(c): Scar Line (ASTM D2266)
 2
Z2

1 1

Figure 3(a): Spheres in Elastic Contact

Base on the Figure 3(a), the two elastic spheres 1 and 2 have radii R1 and R2 will press
into contact with force P. Then, the resultant circular contact area has

3 3𝑃𝑅
𝑅𝑎𝑑𝑖𝑢𝑠, 𝑎 = √( )
4𝐸 ∗

Figure 3(b): Resulting Semi-elliptical Pressure Distribution

According to the Hertzian Contact, after supply a load, the surface contact will
compress as shown in Figure 3(b). The maximum pressure or Hertz pressure P0 will
occur on the axis of symmetry. This will make the centers of the two spheres move
together by the interference, δ.

𝑎2 3 9𝑃2
𝛿= = √ 2
𝑅 16𝑅𝐸 ∗

Where
a = Sphere Radius
R = Effective Radius
P = Applied Load
E* = Elastic Modulus
Effective Young’s Modulus
𝟏 𝟏 − 𝒗𝟏 𝟐 𝟏 − 𝒗𝟐 𝟐
= ( + )
𝑬∗ 𝑬𝟏 𝑬𝟐

1 1 − 0.2852 1 − 0.2852
=( + )
𝐸∗ 200 × 109 200 × 109
1
= 9.18775 × 10−12
𝐸∗
𝐸 ∗ = 𝟏. 𝟎𝟖𝟖𝟒𝟎𝟓𝟕𝟓𝟖 × 𝟏𝟎𝟏𝟏 𝑷𝒂

Effective Radius of Curvature

𝟏 𝟏 𝟏
= +
𝑹 𝑹 𝟏 𝑹𝟐
1 1 1
= −3
+
𝑅 12.7 × 10 12.7 × 10−3
1
= 157.480315
𝑅
𝑅 = 𝟔. 𝟑𝟓 × 𝟏𝟎−𝟑 𝒎

Interference
𝟏
𝒂𝟐 𝟗𝑷𝟐 𝟑
𝜹= =( 𝟐)
𝑹 𝟏𝟔𝑹𝑬∗
𝑎2 (2.579829783 × 10−4 )2
𝛿= =
𝑅 6.35 × 10−3
𝛿 = 𝟏. 𝟎𝟒𝟖𝟏𝟏𝟑𝟔𝟓𝟓 × 𝟏𝟎−𝟓 𝒎

Contact Radius
𝟏
𝟑𝑷𝑹 𝟑
𝒂= ( ∗)
𝟒𝑬
1
3(392.4)(6.35 × 10−3 ) 3
𝑎=( )
4(1.088405758 × 1011 )

𝑎 = 2.579829783 × 10−4 𝑚
𝑑 = 𝟓. 𝟏𝟓𝟗𝟔𝟓𝟗𝟓𝟔𝟔 × 𝟏𝟎−𝟒 𝒎
 Based on the results that was obtained, two data will be compared between
experimental and calculation data. The experimental average scar diameter is
0.51790mm. While from the calculation, the average scar diameter 0.5159659566mm.
The percentage of error is. 0.3748 %.

Graph 3: (a) Normal Loads vs Time (b) Friction Torque vs Time

Graph 3(c): Friction Torque vs Time

Based on the Graph 3 (a) shows above, the normal load that was applied is
40kg which is 392.4N. The normal load keeps fluctuated throughout the experiment
between 391-394N which gives inconsistence normal load applied. From the Graph 3
(b), the friction torque increased rapidly at the beginning. After that, the friction torque
decreased until it achieved almost steady state as the time is increasing. The steady state
condition of the friction torque shows that the grease layer between ball bearings was
stable and no breakdown of lubricant film occurred.
 Graph 3(c): Time vs Coefficient of Friction
Based on the Graph 3 (c), a short friction increased at the start of the curve
around 0.070, as is characteristic of frictional process. After that, the curve become
constant with friction coefficient of 0.060 as increasing with time.

Graph 3(d): EP Test

The Graph 3(d) above shows frictional torque against normal load. The
frictional torque increased as the normal load increase. However, in this experiment the
load was fixed at 392.4N but the load keeps fluctuated because of vibration of the
machine. The frictional force should increase as the normal load increase.
4) Conclusion:

Based on the experiment that has been conducted, the experimental average scar
diameter of ball bearings is 0.51790mm. While from the calculation, the average scar
diameter of ball bearings is 0.51597mm with the percentage of error of 0.3748 %.
Then, the interference that was obtained from the calculation is 1.048113655x10-5m.

By referred to Hertz Theory, where:

1
𝑎 ∝ (𝑃)3
1
𝛿 ∝ (𝑃)3

The scar diameter, 𝑎 and interference, 𝛿 is directly proportional to applied

load, 𝑃 . As the applied increased, the scar diameter and interference also increased.

Lubrication is a process introducing lubricant into the contact of loaded rolling/

sliding bodies to control friction and wear. The grease is being used as a lubricant in
this experiment. The primary advantage of grease over oil is that bearings can be pre-
lubricated, eliminating the need for - and the cost of - an external lubrication system.
Besides simplicity, grease lubrication also requires less maintenance and has less
stringent sealing requirements than oil systems. Grease tends to remain in proximity to
bearing components.
The drawbacks of using grease are that it does not conduct heat away from a
bearing as efficiently as oil. Also, grease can increase the initial torque within a bearing
and cause running torque to be slightly higher. The speed limits for greases (expressed
as a ndm value, with ndm being the rpm multiplied by the bearing PCD in mm) are
generally lower than for oils due to the plastic nature of grease that tends to cause
overheating at high speeds.
In certain applications the design of the bearing and the selection of a suitable
grease become very challenging. Current "greased-for-life" bearing technology can
consistently give 30,000+ hours of life at 700,000 ndm.

5) References:

1. https://www.azom.com/article.aspx?ArticleID=15391
2. https://www.skf.com/group/products/lubrication-solutions/lubricants/general-purpose-
industrial-and-automotive-nlgi-2-grease/index.html
3. http://www.astmsteel.com/product/52100-bearing-steel-aisi/
4. http://www.fkm.utm.my/~syahruls/publication/9%20JZUS%20Tiong.pdf
5. http://www.nanovit.co.uk/linked/51350.pdf
6. https://www.industrialtechnology.co.uk/products--the-importance-of-bearing-
lubrication.html