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Lubricants
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Advances in Wear Predictive Models
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Advances in Wear Predictive Models

A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: closed (31 July 2023) | Viewed by 21388

Special Issue Editors

Dr. Francesca Di Puccio

E-Mail Website
Guest Editor
Department of Civil and Industrial Engineering, Università di Pisa, Largo Lucio Lazzarino 2, 56122 Pisa, Italy
Interests: biomechanics; tribology; human movement analysis; computational mechanics
Special Issues, Collections and Topics in MDPI journals
Dr. Lorenza Mattei

E-Mail Website
Guest Editor
Department of Civil and Industrial Engineering, University of Pisa, Largo Lucio Lazzarino 2, 56126 Pisa, Italy
Interests: biotribology; computational biomechanics; motion analysis; vibration analysis
Special Issues, Collections and Topics in MDPI journals
Dr. Cristina Curreli

E-Mail Website
Guest Editor
Medical Technology Lab, IRCCS Istituto Ortopedico Rizzoli, 0039 051 Bologna, Italy
Interests: biotribology; biomechanics; numerical modelling; in silico medicine
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

We would like to invite you to contribute to the Special Issue of Lubricants entitled “Advances in Wear Predictive Models”. As you know, the development of effective advanced wear models is gaining interest in many different fields, from automotive to biomedical applications. Predictive models could help to assess the reliability of a product in its actual life-cycle conditions, estimate the on-going damage process, and improve the product design with respect to wear failures. Thus, wear simulations can be a powerful tool, but they still have limits, due to their computational cost and due to the reliability of the wear law, with respect to the real phenomenon, which is typically very complex. We would like to include, in this Special Issue, a cutting-edge collection of papers in this research field, covering a wide range of wear models for different applications, materials and working conditions.

We appreciate your consideration and sincerely hope that you will accept our invitation to contribute to this Special Issue.

We look forward to hearing from you soon.

Prof. Dr. Francesca Di Puccio
Dr. Lorenza Mattei
Dr. Cristina Curreli
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Lubricants is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • tribology
  • wear mechanisms
  • wear law
  • wear prediction
  • finite element model
  • wear simulation

Published Papers (12 papers)

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Research

18 pages, 4739 KiB  
Article
Evaluation of Wear Models for the Wear Calculation of Journal Bearings for Planetary Gears in Wind Turbines
by Benjamin Lehmann, Philipp Trompetter, Francisco Gutiérrez Guzmán and Georg Jacobs
Lubricants 2023, 11(9), 364; https://doi.org/10.3390/lubricants11090364 - 29 Aug 2023
Cited by 2 | Viewed by 1475
Abstract
To increase the power density of the electromechanical drive train of wind turbines, journal bearings can be used as planetary gear bearings instead of rolling bearings. This technological change presents new challenges. For example, wind turbine drive systems are subject to dynamic and [...] Read more.
To increase the power density of the electromechanical drive train of wind turbines, journal bearings can be used as planetary gear bearings instead of rolling bearings. This technological change presents new challenges. For example, wind turbine drive systems are subject to dynamic and low-speed operating conditions, which can lead to accelerated abrasive wear of the journal bearings. In addition, oil supply failure or peak loads due to wind gusts and grid and power converter faults could potentially result in catastrophic failure due to adhesive wear in a very short time. Such operating characteristics are, therefore, critical regarding the journal bearing wear lifetime and must be considered in the design. The successful implementation of journal bearings in wind turbines depends on a reliable estimation of adhesive and abrasive wear. In this paper, five different models for the wear calculation of journal bearings are evaluated regarding their suitability for the wear calculation of planetary gear bearings in wind turbines. For this purpose, the following evaluation criteria were defined: parameter uncertainty, parametrization effort, in particular number of parameters, parameterization method, load case dependency of parameters and calculation effort. In order to be able to evaluate the wear models, the wear models are numerically implemented, and the wear of a test journal bearing is exemplarily calculated under load conditions, which are comparable to load conditions in a wind turbine. Relevant influences from the wind turbine system, such as lubricant, material and manufacturing-dependent surface influences, such as roughness and hardness, are considered. The wear models are evaluated with respect to their fulfillment of the defined criteria. The resulting evaluation allows the selection of a wear model that can be used to calculate the wear of planetary gear journal bearings in wind turbines, considering the available input variables. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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28 pages, 9061 KiB  
Article
Dynamics and Wear Prediction of Mechanisms Considering Multiple Clearances and Coatings
by Qian Jing and Hongzhao Liu
Lubricants 2023, 11(7), 310; https://doi.org/10.3390/lubricants11070310 - 22 Jul 2023
Viewed by 786
Abstract
The increase in joint clearance and system vibration caused by joint wear are important factors that may lead to the failure of the mechanism and a decrease in the motion accuracy of the actuator. In this paper, to investigate the impact of different [...] Read more.
The increase in joint clearance and system vibration caused by joint wear are important factors that may lead to the failure of the mechanism and a decrease in the motion accuracy of the actuator. In this paper, to investigate the impact of different numbers of spherical joint clearances on the dynamics performance of the mechanism and explore effective measures to reduce the vibration of the mechanism caused by multiple joint clearances, on the basis of the previous research on the mechanism dynamics when there is clearance in a single spherical joint, an improved contact force model is used to study the effects of coating, no coating, and different clearance quantities on the dynamics of a mechanism containing multiple spherical joint clearances. Moreover, the joint reaction forces and contact-impact forces under different working conditions are calculated. In order to reduce the difficulty of calculating the joint wear, an approximate calculation method for contact area is proposed, and an improved Archard wear model is employed to calculate and analyze the changes in wear amount under the influence of both spherical joint clearance and coating. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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22 pages, 3230 KiB  
Article
Wear and Subsurface Stress Evolution in a Half-Space under Cyclic Flat-Punch Indentation
by Javier M. Juliá and Luis Rodríguez-Tembleque
Lubricants 2023, 11(6), 265; https://doi.org/10.3390/lubricants11060265 - 17 Jun 2023
Cited by 1 | Viewed by 1131
Abstract
Wear is a tremendously important phenomenon, which takes place on the surfaces of two solids in contact under cyclic loads and constitutes one of the most-significant ways of failure for mechanical elements. However, it is not the only source of failure in contacting [...] Read more.
Wear is a tremendously important phenomenon, which takes place on the surfaces of two solids in contact under cyclic loads and constitutes one of the most-significant ways of failure for mechanical elements. However, it is not the only source of failure in contacting solids. The subsurface stresses should also be considered, due to the fatigue and crack initiation problems. Nevertheless, these stresses (i.e., their maximum values and distributions) evolve with the solids’ surface wear (i.e., with the load cycles) and also depend on the friction intensity. Therefore, their evolution should be properly computed to predict failures in mechanical elements under wear conditions. This work focused on the study of the evolution of the surface wear and the subsurface stress distributions generated—in an elastic half-space—by a cylindrical flat-ended punch, under cyclic indentation loading (i.e., radial fretting wear conditions). Based on a numerical scheme recently presented by the authors, this is the first time that, for this contact problem, the surface wear and subsurface stress distribution (i.e., maximum value and its location)—and its evolution—were simultaneously analyzed when orthotropic friction and fretting wear conditions were considered. The studies presented in this work were developed for purely elastic contact assumptions. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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12 pages, 3185 KiB  
Article
Further Validation of a Simple Mathematical Description of Wear and Contact Pressure Evolution in Sliding Contacts
by Francesca Di Puccio and Lorenza Mattei
Lubricants 2023, 11(5), 230; https://doi.org/10.3390/lubricants11050230 - 21 May 2023
Viewed by 1043
Abstract
The present study proposes the further validation of a simple mathematical procedure recently proposed by the authors to describe contact and wear evolution in line and point contacts. The procedure assumed that the maximum contact pressure could be determined using Hertz equations and [...] Read more.
The present study proposes the further validation of a simple mathematical procedure recently proposed by the authors to describe contact and wear evolution in line and point contacts. The procedure assumed that the maximum contact pressure could be determined using Hertz equations and a parabolic pressure profile. The contact half-width was obtained using the equilibrium equation and the Archard wear law. Several cases were selected from the literature, reporting experimental data or Finite Element simulations, and the results were compared to those obtained with the proposed approach. This paper confirms the reliability and potentialities of the proposed analytical procedure, which is capable of providing accurate solutions in case of frictional contacts and at the borders of the contact area, where the main discrepancies were found in the previous study. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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21 pages, 8188 KiB  
Article
Method for On-Line Remaining Useful Life and Wear Prediction for Adjustable Journal Bearings Utilizing a Combination of Physics-Based and Data-Driven Models: A Numerical Investigation
by Denis Shutin, Maxim Bondarenko, Roman Polyakov, Ivan Stebakov and Leonid Savin
Lubricants 2023, 11(1), 33; https://doi.org/10.3390/lubricants11010033 - 15 Jan 2023
Cited by 8 | Viewed by 2160
Abstract
RUL (remaining useful life) estimation is one of the main functions of the predictive analytics systems for rotary machines. Data-driven models based on large amounts of multisensory measurements data are usually utilized for this purpose. The use of adjustable bearings, on the one [...] Read more.
RUL (remaining useful life) estimation is one of the main functions of the predictive analytics systems for rotary machines. Data-driven models based on large amounts of multisensory measurements data are usually utilized for this purpose. The use of adjustable bearings, on the one hand, improves a machine’s performance. On the other hand, it requires considering the additional variability in the bearing parameters in order to obtain adequate RUL estimates. The present study proposes a hybrid approach to such prediction models involving the joint use of physics-based models of adjustable bearings and data-driven models for fast on-line prediction of their parameters. The approach provides a rather simple way of considering the variability of the properties caused by the control systems. It has been tested on highly loaded locomotive traction motor axle bearings for consideration and prediction of their wear and RUL. The proposed adjustable design of the bearings includes temperature control, resulting in an increase in their expected service life. The initial study of the system was implemented with a physics-based model using Archard’s law and Reynolds equation and considering load and thermal factors for wear rate calculation. The dataset generated by this model is used to train an ANN for high-speed on-line bearing RUL and wear prediction. The results show good qualitative and quantitative agreement with the statistics of operation of traction motor axle bearings. A number of recommendations for further improving the quality of predicting the parameters of active bearings are also made as a summary of the work. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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21 pages, 9651 KiB  
Article
Modelling Approaches of Wear-Based Surface Development and Their Experimental Validation
by Michael Maier, Michael Pusterhofer and Florian Grün
Lubricants 2022, 10(12), 335; https://doi.org/10.3390/lubricants10120335 - 26 Nov 2022
Cited by 1 | Viewed by 1586
Abstract
Surface topography has a significant influence on the friction behaviour in lubricated contacts. During running-in, the surface topography is continuously changed. The surface structure influences the contact stiffness (asperity contact pressure) as well as the microhydrodynamics (flow factors). In this study, different models [...] Read more.
Surface topography has a significant influence on the friction behaviour in lubricated contacts. During running-in, the surface topography is continuously changed. The surface structure influences the contact stiffness (asperity contact pressure) as well as the microhydrodynamics (flow factors). In this study, different models for wear simulation of real rough surfaces were created in Matlab© (MathWorks, Natick, MA) and Abaqus© (ABAQUS Inc., Palo Alto, CA, USA) using the Usersubroutine Umeshmotion. The arithmetic mean height Sa(wh), the maximum height Sz(wh), as well as the asperity contact pressure pasp(h,wh) as a function of the wear height (wh) are used to characterise the surface for the respective wear state. The surface characteristics obtained from the simulations are validated with parameters from experiments. The aim of this study was to create a simulation methodology for mapping surface development during the running-in process. The results show, that the qualitative course of the surface parameters can be reproduced with the applied simulation methodology. Compared to the experiments, the rough surfaces are flattened faster. By adapting the simulation results in postprocessing, good agreements with the experiments can be achieved. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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19 pages, 5603 KiB  
Article
Numerical Wear Modeling in the Mixed and Boundary Lubrication Regime
by Andreas Winkler, Marcel Bartz and Sandro Wartzack
Lubricants 2022, 10(12), 334; https://doi.org/10.3390/lubricants10120334 - 26 Nov 2022
Cited by 5 | Viewed by 2053
Abstract
The increasing use of low-viscosity lubricants in order to reduce the friction in machine elements such as rolling bearings is leading to increased operation in the mixed or boundary lubrication regime. The associated wear can lead to an earlier failure of tribological systems. [...] Read more.
The increasing use of low-viscosity lubricants in order to reduce the friction in machine elements such as rolling bearings is leading to increased operation in the mixed or boundary lubrication regime. The associated wear can lead to an earlier failure of tribological systems. In this context, a detailed wear simulation offers great potential with regard to the design of machine elements as well as the calculation of lifetimes. This contribution presents an approach for the numerical wear simulation of lubricated rolling/sliding-contacts. Therefore, a finite element method-based simulation model was developed which is able to deal with non-Gaussian surfaces and contacts subject to boundary and mixed lubrication. Using the example of an axial cylindrical roller bearing considering realistic geometry, locally varying velocities, and two load cases, the wear modeling results of the mixed and the boundary lubrication regime were illustrated. The wear coefficient required for Archard’s wear model was determined experimentally by means of a two-disc tribometer. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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22 pages, 10875 KiB  
Article
Micro-Wear Simulation of Braking Interface Based on Particle Discrete Element Modeling
by Zhihua Sha, Qiang Hao, Jian Yin, Fujian Ma, Yu Liu and Shengfang Zhang
Lubricants 2022, 10(7), 136; https://doi.org/10.3390/lubricants10070136 - 26 Jun 2022
Cited by 1 | Viewed by 1472
Abstract
For material fracture and severe wear in braking conditions, the discrete element method (DEM) is used to simulate the wear process of the braking interface explicitly. Based on the central difference method, particle motion equations are established considering the influence of elemental damping [...] Read more.
For material fracture and severe wear in braking conditions, the discrete element method (DEM) is used to simulate the wear process of the braking interface explicitly. Based on the central difference method, particle motion equations are established considering the influence of elemental damping on particle contact. Combined with the Particle Flow Code (PFC) software, a DEM wear model of the braking interface is established using the parallel bond modeling method. The braking wear process is simulated, and the material damage process is investigated. The simulation results demonstrate that with the increase of the initial braking load and the initial braking speed, the wear depth increased by 24.75% and 16.22%, respectively. The increase in the number of detached particles leads to an increasing trend of fracture force chains, which increases the thickness of the flowing particle layer, revealing the micro-wear mechanism of the braking interface. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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19 pages, 3511 KiB  
Article
A Closer Look at the Contact Conditions of a Block-on-Flat Wear Experiment
by André Rudnytskyj, Roland Larsson and Carsten Gachot
Lubricants 2022, 10(7), 131; https://doi.org/10.3390/lubricants10070131 - 21 Jun 2022
Cited by 2 | Viewed by 1967
Abstract
Specific wear rates of tribosystems always rely on the data obtained from wear experiments. Nonetheless, the events taking place during an experiment may often lead to wide variations and low repeatability of the results. In this work, the authors attempt to take a [...] Read more.
Specific wear rates of tribosystems always rely on the data obtained from wear experiments. Nonetheless, the events taking place during an experiment may often lead to wide variations and low repeatability of the results. In this work, the authors attempt to take a closer look into the dynamic contact conditions of a dry linearly reciprocating block-on-flat wear experiment. The finite element method and Archard’s wear model are used through COMSOL Multiphysics® 5.2a and LiveLink™ for MATLAB® software to model the wear and study the influence of different conditions of the block surface and alignment of the sample. Changes of the geometry of the block and the contact pressure are quantified for several back and forth motions, using an extrapolation scheme in the wear modelling methodology. The tracking of such changes allow a dynamic overview of how the block contact area and the contact pressure distribution change throughout time. The results show how the assumption of a constant contact area and use of a nominal contact pressure in calculating the wear rate in such experiments can be inappropriate, especially in the presence of roughness and misalignments of the block. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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18 pages, 5687 KiB  
Article
Research on Contact and Wear Characteristics of the Planetary Roller Screw Mechanism with Screw Misalignments
by Junjie Meng, Xing Du, Xin Zhao, Junwei Zheng, Dingwei Wang and Long Wan
Lubricants 2022, 10(6), 115; https://doi.org/10.3390/lubricants10060115 - 3 Jun 2022
Cited by 6 | Viewed by 1942
Abstract
Misalignments are unavoidable in most applications of the planetary roller screw mechanism (PRSM) due to many potential causes. However, the effect of screw misalignments on the contact characteristics for the PRSM have not been thoroughly investigated. In this paper, a comprehensive analytical procedure [...] Read more.
Misalignments are unavoidable in most applications of the planetary roller screw mechanism (PRSM) due to many potential causes. However, the effect of screw misalignments on the contact characteristics for the PRSM have not been thoroughly investigated. In this paper, a comprehensive analytical procedure for the PRSM performance considering screw misalignments is proposed. First, the contact positions and clearances of the PRSM with screw misalignments are calculated. Next, an improved model is presented for evaluation of the load distribution, in which the variation of axial clearances is taken into consideration. The numerical results are validated by finite element analysis. Then, the precision loss model caused by wear is derived considering the variation of contact forces. The results indicate that the contact positions slightly change due to the misalignment angle of the screw, while the axial clearances and load distribution at the screw-roller interface are significantly affected. At the same time, the contact forces over thread vary periodically. In addition, the screw misalignment aggravates the wear of the PRSM, resulting in accuracy degradation. The theoretical investigations lay the foundation for the engineering application of the PRSM. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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17 pages, 5498 KiB  
Article
Development of Universal Friction Calibration Curve for Ball Ironing Test
by Nuttakorn Sae-eaw, Sutee Olarnrithinun, Varunee Premanond and Yingyot Aue-u-lan
Lubricants 2022, 10(6), 106; https://doi.org/10.3390/lubricants10060106 - 30 May 2022
Viewed by 1560
Abstract
The friction calibration curve (FCC) is normally constructed to indirectly approximate the friction value for any simulative friction test based on sensitive friction indicators (i.e., forming load or final geometry) by finite element modeling (FEM). For calculation, these indicators are highly dependent on [...] Read more.
The friction calibration curve (FCC) is normally constructed to indirectly approximate the friction value for any simulative friction test based on sensitive friction indicators (i.e., forming load or final geometry) by finite element modeling (FEM). For calculation, these indicators are highly dependent on flow stress data and the techniques to extrapolate them. A universal FCC is preferable with the independence of these factors. In this paper, the sensitivity of the material data and our proposed extrapolation techniques for the ball ironing test (BIT) were studied to construct a new universal FCC. A specific load was proposed as a new friction indicator for this universal FCC. It was used to approximate the friction value for different materials and lubricants. This friction value was also validated to determine the maximum load and geometry for pulley forming. The results obtained from the simulation were in good agreement with the experiment. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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20 pages, 7979 KiB  
Article
Accelerated Wear Test Design Based on Dissipation Wear Model Entropy Analysis under Mixed Lubrication
by Hongju Li, Ying Liu, Haoran Liao and Zhurong Liang
Lubricants 2022, 10(4), 71; https://doi.org/10.3390/lubricants10040071 - 16 Apr 2022
Cited by 6 | Viewed by 2262
Abstract
Theoretical life prediction of tribo-pairs such as seals, bearings and gears with the failure form of wear under mixed lubrication depends on quantitative analysis of wear. Correspondingly, the wear life test depends on an accelerated wear test method to save the time and [...] Read more.
Theoretical life prediction of tribo-pairs such as seals, bearings and gears with the failure form of wear under mixed lubrication depends on quantitative analysis of wear. Correspondingly, the wear life test depends on an accelerated wear test method to save the time and financial costs. Therefore, the theoretical basis of accelerated test design is a wear model providing a quantitative relationship between equivalents and accelerated test duration. In this paper, an accelerated wear test design method based on dissipation wear model entropy analysis under mixed lubrication is proposed. Firstly, the dissipation wear model under mixed lubrication is verified by standard experiments as a theoretical basis. Then, an accelerated wear test design method is proposed, taking the entropy increase in the dissipation wear model as an equivalent. The verification test shows that 20 times acceleration could be reached by adjustment of the entropy increase rate. The effect of entropy increase rate gradient of duty parameters is also discussed, revealing the fastest acceleration direction. Finally, the advantages and disadvantages of the proposed method are discussed. The results in this paper are expected to contribute to long life predictions of tribo-pairs. Full article
(This article belongs to the Special Issue Advances in Wear Predictive Models)
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