Lubrication Fundamentals

Friction, Lubrication and Wear

Tribology

 Greek:
„tribos“ = friction
 Subject of Tribology
 Friction
 Wear
 Lubrication
 Wide range from theoretical fundamentals
to practical issues
 Triboresearch
 Tribophysics
 Tribochemistry
 Tribotechnics
The tribological System („Tribosystem“)

Friction
F  Generates a resistance
 This slows down the movement
 Acts where
 Contact area of solid body to
S S body
 Within fluids and gases too
 Friction can be a problem
 Decrease of efficiency factor
 Leads to increased wear
FR  Can also be a feature
   Brakes
FN  Couplings
Type of Friction

 Determined by geometric shapes and kinematic characteristics

 Sliding friction, kinematic (dynamic) friction

 Friction (journal) bearing
 Piston - cylinder

 Rolling (wheel) friction

 Grooved ball bearing
 Wheel – street

 Combined friction
 Rolling and Sliding friction
 Gears

State of friction: Lubrication Condition

1. 2. 3.

 Dry friction, interfacial friction (1)

 direct contact of Metallic surfaces (surface reaction layer)
 Fluid friction, viscous friction (2)
 no direct contact between the metallic surfaces
 Lubrication film stable and thicker than the surface irregularities of the
friction parts
 Mixed friction, partial lubrication (3)
 Lubricating film exists, but film not stable or thinner than the surface
irregularities of the friction parts
 local contact areas of asperity peaks
Interfacial friction

 „ Dry friction“ or „boundary lubrication“

 Direct contact of metallic surfaces
 surface reaction layers
 High friction level
 High wear level
 To be avoided: Short life time or risk of damage!

Fluid friction

 Fluid lubricating film separates the metallic surfaces completely

 Lubrication film stable and thicker than the surface irregularities of the
friction parts
 No direct contact between the metallic surfaces
 Nearly no wear (apart from contaminations, erosion, cavitation)
 Ideal case to minimize friction and wear
Mixed Friction

 „Partial lubrication“
 Lubricating film exists, but film not stable or thinner than the surface
irregularities of the friction parts
 Load to heavy or dynamic with strong peaks
 Low or oscillating speed
 Local contact areas of asperity peaks
 Extrem-Pressure/Anti-Wear properties required

Hydrodynamic Lubrication

 Effect comparable with

 Water skiing
 Aquaplaning
 Minimum speed required
 Waterski driver is carried by water flow
 Friction bearing
 Shaft is carried by oil flow
 Effect depends on speed
  Stribeck Graph
Hydrostatic Lubrication

 Known from hydraulic systems

 Static pressure to the hydraulic piston
 Cylinder moves in or out
 Static pressure to the surface of the shaft
 Shaft moves apart from the bearing surface
 Realization very expensive
 In large friction bearings only F
F
 Sliding bearings of turbines in S
start-up and stop procedures
S

Stribeck Graph
Wear

 Normal phenomena
 Wear particles present
everytime
 Typa, number and size
 Specific for application
 Depends on
 Built-in machine elements
 Working principle
 Load
 Design
 Enviroment

Wear
 Definition:
 Proceeding lost of material
 From the surface of a solid
body
 Caused by mechanical stress:
 contact and relative
movement of a solid, fluid or
gaseous counterbody
 From our point of view (oil
analysis) enhancement is needed
 Caused by mechanical or
chemical stress
 E.g. corrosion
Mechanism and Type of Wear
 Wear Mechanism
 Physical and chemical processes
during wear process
 Abrasiv wear
 Adhesive wear
 Fatigue
 Tribochemical reaction
 Type of Wear
 Depends on type and severity of stress
and on the structure of the tribosystem
 Shaped from one or more wear
mechanism

Abrasive Wear

 Scarifying, Grooving
 „Micro lathe tool “
 „Sandpapering“
 Possible reason:
 Dust, dirt
 Wear Particles
 Combination of hard and soft material
interacting each other
 Result
 Cutting wear
Adhesive Wear
 Classic wear due to „bad lubrication“
 Lubricating film is not stable
 Locally direct contact of the metallic
surfaces under high pressure
 Melting and welding of the asperity
peaks
 Welded point have to be disrupted
 Possible reason
 Poor Lubrication (quantity, viscosity)
 Overload
 Slow or oscillating speed
 Result
 Scuffing wear

Fatigue Wear
 Break-up of the material structure near
to the surface due to cyclical stress
under combined rolling and sliding
contact
 Typical for
 Gear tooth
 Roller bearings
 Possible reason
 Low viscosity
 Overload
 Poor additive package
 Result
 Crack initiation
 Break-out of material (e.g. pittings)
Tribochemical Reaction
 High energy level due to oscillating stress
 Increasing energy level starts chemical
reactions
 Especially when machine parts stand still
and vibrations occure
 Poor cooling property of the lubricant
due to poor oil flow
 Possible reason
 Besign
 Operation conditions, e.g. vibrations
 Poor additive package against this
phenomena
 Result
 Tribocorrosion (chemical)
 Fretting wear (mechanical)