Lubricants, Volume 9, Issue 7 (July 2021) – 7 articles

Recently, cycloidal drives have been increasingly used due to their beneficial features, such as the implementation of a large transmission, efficiency, and high performance density. Production accuracy is inevitable in order to ensure the dynamically proper and smooth operation of the drive. Smaller backlash and minimal transmission fluctuations can only be achieved by improving the production accuracy, reducing the number of production failures, and shrinking the tolerance zone. This research primarily focuses on the investigation of the tolerable production accuracy of small-series and individually manufactured drives. The analysis of load distribution was calculated on the cogs of a planetary gear made with a wire EDM machine. On the other hand, we investigate how production failures affect transmission fluctuations and the backlash of a drive. The novelty of this research is based on the determined analytical equations, which can help engineers to find the right tolerances to a given gear ratio fluctuation. Full article

The cutting fluids applied to the machining processes by the MQL process aim to reduce the machining temperatures and tool wear as well as improve the surface and dimensional finishing of the parts. To increase the efficiency of these fluids, graphene lubricating platelets are added. This work investigated the performance of three different cutting fluids with graphene sheets added and applied via MQL, considering the tool life, wear, and wear mechanisms acting on TiAlN-coated cemented carbide cutting tools in the end milling of AISI 1045 steel. We evaluated two vegetable- (MQL15 and LB1000) and one mineral-based (MQL14) neat oils and the same fluids with the addition of 0.05 and 0.1%wt graphene nanoplatelets. Dry cuts were also performed and investigated for comparison. The experiments were conducted under fixed cutting conditions (v_c = 250 m/min, f_z = 0.14 mm/tooth, a_p = 1 mm, and a_e = 20 mm). The end-of-tool-life criterion followed the guidelines of ISO 8688-1 (1989). To analyze the results, ANOVA and Tukey’s test were applied. The addition of graphene sheets in the vegetable-based cutting fluids effectively increased the lubricating properties, partially reducing the wear mechanisms acting on the tools. In addition, there was a predominance of thermal fatigue cracks and mechanical cracks as well as adhesive and abrasive wear mechanisms on the tools used in the cutting with the MQL15 and MQL14 fluids, indicating greater cyclical fluctuations in temperature and surface stresses. Full article

Surface Force Balance (SFB) experiments have been performed in a dry atmosphere and across an ionic liquid, combining the analysis of surface interactions and deformations, and illustrate that the mechanical deformations of the surfaces have important consequences for the force measurements. First, we find that the variation of the contact radius with the force across the ionic liquid is well described only by the Derjaguin–Muller–Toporov (DMT) model, in contrast with the usual consideration that SFB experiments are always in the Johnson–Kendall–Roberts (JKR) regime. Secondly, we observe that mica does not only bend but can also experience a compression, of order $1\mathrm{nm}$ with $7\mathsf{\mu }\mathrm{m}$ mica. We present a modified procedure to calibrate the mica thickness in a dry atmosphere, and we show that the structural forces measured across the ionic liquid cannot be described by the usual exponentially decaying harmonic oscillation, but should be considered as a convolution of the surface forces across the liquid and the mechanical response of the confining solids. The measured structural force profile is fitted with a heuristic formulation supposing that mica compression is dominant over liquid compression, and a scaling criterion is proposed to distinguish situations where the solid deformation is negligible or dominant. Full article

This article presents a test stand with a model high-speed spindle equipped with a system of active control of the preload of the bearings. This preload was changed by means of three piezo actuators. The work presents the results of tests during which the commercial Abacus measuring equipment from Data Physics was used. Its application has shown that the spindle system with angular contact ball bearings is responsive to changes in the preload value of these bearings. The change preload resulted in a change in the value of the resonant frequency of the system and its amplitude. This article presents the dependence between the variable value of the preload of the bearings and the corresponding values of the resonance frequency and amplitude of the spindle system. The use of the Abacus measuring equipment for testing allowed for the preparation of a model showing the dynamic behavior of the spindle. The system was forced by a signal with known parameters, and the response to this excitation was recorded at eleven points located on the surface of the entire spindle. Full article

In the context of targeted improvements in energy efficiency, secondary rolling bearing contacts are gaining relevance. As such, the elastohydrodynamically lubricated (EHL) roller face/rib contact of tapered roller bearings significantly affects power losses. Consequently, this contribution aimed at numerical optimization of the pairing’s macro-geometric parameters. The latter were sampled by a statistical design of experiments (DoE) and the tribological behavior was predicted by means of EHL contact simulations. For each of the geometric pairings considered, a database was generated. Key target variables such as pressure, lubricant gap and friction were approximated by a meta-model of optimal prognosis (MOP) and optimization was carried out using an evolutionary algorithm (EA). It was shown that the tribological behavior was mainly determined by the basic geometric pairing and the radii while eccentricity was of subordinate role. Furthermore, there was a trade-off between high load carrying capacity and low frictional losses. Thereby, spherical or toroidal geometries on the roller end face featuring a large radius paired with a tapered rib geometry were found to be advantageous in terms of low friction. For larger lubricant film heights and load carrying capacity, spherical or toroidal roller on toroidal rib geometries with medium radii were favorable. Full article

The motivations for the move to electrified vehicles are discussed with reference to their improved energy efficiency, their potential for lower CO₂ emissions (if the electricity system is decarbonized), their lower (or zero) NO_x/particulate matter (PM) tailpipe emissions, and the lower overall costs for owners. Some of the assumptions made in life-cycle CO₂ emissions calculations are discussed and the effect of these assumptions on the CO₂ benefits of electric vehicles are made clear. A number of new tribological challenges have emerged, particularly for hybrid vehicles that have both a conventional internal combustion engine and a battery, such as the need to protect against the much greater number of stop-starts that the engine will have during its lifetime. In addition, new lubricants are required for electric vehicle transmissions systems. Although full battery electric vehicles (BEVs) will not require engine oils (as there is no engine), they will require a system to cool the batteries—alternative cooling systems are discussed, and where these are fluid-based, the specific fluid requirements are outlined. Full article

Many researches are focused on the tribological performances of pure vegetable oil in order to replace the conventional mineral engine oils. This work investigates the influence of local moringa oil (noted VO) on the performances of lubricants formed from a blend of dodecane and graphite particles at ambient temperature. In a first part, a reduction of about 50% of friction properties of dodecane is observed when adding small amounts of moringa oil (VO), which is intended to be used as a bio-base performance additive in lubricant formulations. The friction properties of their blends with graphite, generally employed as solid lubricant additive, showed an adsorption effect of fatty acid molecules. The more promising results were obtained for the blend containing 2 w% of VO. Physicochemical characterizations of the tribofilms evidence the good antiwear properties of the lubricant. Full article