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This paper aims to investigate the lubrication performance of cam/tappet contact during start up. Especially, the thermal insulation effects of coating on the lubrication performance during cold start up process and warm start up process are studied.

A numerical model for the analysis of thermal elastohydrodynamic lubrication of coated cam/tappet contact is presented. In this model, the Reynolds equation and the energy equations are discretized by the finite difference method and solved jointly.

During start up, the contact force at cam nose-to-tappet contact decreases with increasing time, while the absolute entrainment velocity has the upward trend. The minimum film thickness, maximum average temperature and friction power loss increase with increasing time, while the coefficient of friction decreases during start up. Because of the thermal insulation effect, the coating can significantly increase the degree of temperature rise. Compared with the uncoated case, the coated cam/tappet results in a lower friction power loss. Generally, the friction power loss in the cold start up process is much higher than that in the warm start up process.

By this study, the lubrication performance and the kinematics and the dynamics of the cam/tappet during start up process are investigated. Meanwhile, the thermal insulation effect of coating is also illustrated. The difference of lubrication performance between cold start up process and warm start up process is analyzed. The results and thermal elastohydrodynamic lubrication method presented in this study can be a guidance in the design of the coated cam/tappet.

This paper aims to present the model and method involving multi-body system dynamic analysis, finite element quasi-statics contact analysis and numerical calculation of elastohydrodynamic lubrication (EHL), according to the cam wear prediction using Archard’s model. Cam–follower kinematic pairs always work under wear because of concentrated contacts. Given that a cam and follower contact often operates in the mixed or boundary lubrication regime, simulation of cam wear is a multidisciplinary problem including kinematic considerations, dynamic load and stress calculations and elastohydrodynamic film thickness evaluations.

Multi-body system dynamic analysis, finite element quasi-statics contact analysis and numerical calculation of EHL are applied to obtain the dynamic loads, the time histories of contact pressure and the oil film thicknesses in cam–follower conjunctions to predict cam wear quantitatively.

The wear depth of the cam in the valve train of a heavy-load diesel engine is calculated, which is in good agreement with the measured value in the practical test. The results show that the cam–tappet pair operates under a mixed lubrication or boundary lubrication, and the wear depths on both sides of the cam nose are extremely great. The wear of these points can be decreased significantly by modifying the local cam profile to enlarge the radii of curvature.

The main value of this work lies in the model and method involving multi-body system dynamic analysis, finite element quasi-statics contact analysis and numerical calculation of EHL, which can give good prediction for the wear of cam.

The influence of the cam angular speed on the pressure, film thickness and temperature profiles at some selected angular positions together with the oil characteristics are investigated.

A high-order polynomial cam is used, and thermal elastohydrodynamic lubrication (EHL) calculations are carried out by the multi-grid method and line-line scanning technique.

It is found that the film thickness decreases with a decrease in angular speed. The depth of the dimple that occurred in the reverse motion is also reduced because of the recession in the “temperature–viscosity wedge” effect.

It is revealed that the reduction in the cam angular speed makes the classical big surface dimple evolve into a small centralized dimple during the opposite sliding motion.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-08-2019-0327

There is a continuous drive in automotive sector to shift from conventional lubricants to environmental friendly ones without adversely affecting critical tribological performance parameters. Because of their favorable tribological properties, chemically modified vegetable oils such as palm trimethylolpropane ester (TMP) are one of the potential candidates for the said role. To prove the suitability of TMP for applications involving boundary-lubrication regime such as cam/tappet interface of direct acting valve train system, a logical step forward is to investigate their compatibility with conventional lubricant additives.

In this study, extreme pressure and tribological characteristics of TMP, formulated with glycerol mono-oleate (GMO), molybdenum dithiocarbamate (MoDTC) and zinc dialkyldithiophosphate (ZDDP), has been investigated using four-ball wear tester and valve train test rig. For comparison, additive-free and formulated versions of polyalphaolefin (PAO) were used as reference. Moreover, various surface characterization techniques were deployed to investigate mechanisms responsible for a particular tribological behavior.

In additive-free form, TMP demonstrated better extreme pressure characteristics compared to PAO and lubricant additives which are actually optimized for conventional base-oils such as PAO, are also proved to be compatible with TMP to some extent, especially ZDDP. During cylinder head tests, additive-free TMP proved to be more effective compared to PAO in reducing friction of cam/tappet interface, but opposite behavior was seen when formulated lubricants were used. Therefore, there is a need to synthesize specialized friction modifiers, anti-wear and extreme pressure additives for TMP before using it as engine lubricant base-oil.

In this study, additive-free and formulated versions of bio-lubricant are tested for cam/tappet interface of direct acting valve train system of commercial passenger car diesel engine for the very test time. Another important aspect of this research was comparison of important tribological performance parameters (friction torque, wear, rotational speed of tappet) of TMP-based lubricants with conventional lubricant base oil, that is, PAO and its formulated version.

The purpose of this paper is to study the engineering application of diamond like carbon (DLC) coatings on the surfaces of piston pins and bucket tappets for a 2.0 L supercharged gasoline engine. The friction loss and durability of DLC-coated components were investigated.

The tribological characteristics were examined under oil-lubricated conditions in a CETR UMT reciprocating tribometer. In a motored engine test rig, friction loss torque test was performed to estimate the improvement in fuel economy. Fired engine durability bench tests of typical duration of 450 h were completed to access the durability and wear resistance of DLC coating. Before and after durability tests, coated and uncoated components were measured on the sliding surface by a profilometer technique.

Friction and wear test results show that DLC coating has low friction coefficient and reduces the wear rates by almost ten times compared to those of uncoated surfaces. Friction loss measurements indicate that DLC-coated tappets can reduce valve train friction loss by 29 per cent, and DLC-coated piston pins can reduce piston group friction by 11 per cent. Based on fired engine durability bench tests, it is evidenced that none of the coated tappets and pins show any noticeable peeling or delamination. Wear profiles analysis results indicate that DLC-coated engine components give rise to a substantial reduction in wear.

DLC coating applied onto the working surface of piston pin and bucket tappet can effectively reduce the friction loss of gasoline engine. DLC coating exhibits sufficient durability and improves friction and wear performance.

This paper aims to study the influence of three-column groove shell radius, ball radius, lubricating oil viscosity and elastic modulus on the thermal elastohydrodynamic lubrication (TEHL) characteristics and optimisation of the ball-type tripod universal joint.

The point contact TEHL model of the joint was developed, and the multi-grid method was used to solve it. The influence of three-column groove shell radius, ball radius, lubricating oil viscosity and elastic modulus on the lubrication characteristics was analysed. Further, the optimisation of the joint TEHL performance was carried out by the Kriging approximation model combined with the multi-objective particle swarm optimisation (MOPSO) algorithm.

The research results show that increasing groove shell radius and ball radius can effectively increase the oil film thickness, and decrease the oil film pressure, as well as the temperature rise. Decreasing elastic modulus can reduce the oil film temperature rise and pressure, and increasing viscosity can effectively increase the oil film thickness. The optimised minimum oil film thickness increases by 33.23% and the optimised maximum oil film pressure and maximum temperature rise decrease by 11.92% and 28.87%, respectively. Furthermore, the relative error of each response output is less than 10%.

This study applies TEHL theory to the tribological research of the ball-type tripod universal joint, and the joint’s lubrication performance is improved greatly by the Kriging model and MOPSO algorithm, which provides an effective measure to raise the joint’s working efficiency.

This study aims to present the discrepancy in oil film distribution in reciprocating motion experimentally with zero entraining velocity (ZEV) on a conventional ball-disk test rig with oil lubrication.

Driven independently by two individual servomotors, a steel ball and a sapphire disc move at equal speed but in opposite directions in a triangle wave. The oil film images between the ball and the disc were recorded by a camera. After the experiments, the mid-section film thickness was evaluated by using a dichromatic interference intensity modulation approach.

The dimpled oil film in transient condition is shallower than that at steady state with the same load and velocities, and the transient dimple depth decreases with the decrease of time. The increase of the applied load offers a beneficial effect on lubrication. Boundary slippage happens in ZEV reciprocating motion. The slippage at the interface is related to the transient effect and applied load.

This study reveals the significant difference of the oil film variation in ZEV reciprocating motion, especially the complex boundary slippage at the interface of the oil and the sapphire disc.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2020-0021

The purpose of this paper is to understand the effect of engine operating conditions and lubricant friction modifier on direct acting tappet rotation. In this research work, novel method of measuring engine tappet rotation speed has been developed. The technique is so novel. It allows the measurement on real production engine with no modification to the engine tappet bore. Also, In this paper, the effect of engine operating conditions and the effectiveness of friction modifier on tappet rotation is reported.

For the very first time, for the purpose of measuring follower rotation in a real production engine, a 4 × 6 mm2 electronic chip called Gradiometer is mounted outside the tappet housing, allowing the monitoring of tappet rotation speed without the need to machine a hole in the tappet bore. This novel technique is adopted on Mercedes Benz OM464 engine to study the effect of engine conditions and lubricant chemistry on tappet performance.

The main outcome of this research work is the development of novel method of measuring tappet rotation. Also, during the experiments, it was revealed that although friction modifiers help in reducing friction at the cam/tappet interface, they can also adversely affect the tappet rotation speed.

The novel technique developed in the research work is one of the most cost effective and simple to use. Researches can adopt the technique to study the tribological performance of direct acting tappet on real production engine. Researches acknowledge the effectiveness of friction modifiers in valve train but its effect on rotation which plays a key role in the component durability has not been the focus of most of the researches mainly due to lack of effective techniques.

THE Hobson “Master” Carburettor, manufactured by H. M. Hobson Components, Ltd., of Acton, incorporating Automatic Boost and Mixture controls, has done more to relieve the pilot of responsibility with regard to his engine during flight than any other invention of recent years.

Microtextured surfaces can reduce friction in tribological systems under certain contact conditions. Because it is very time-consuming to determine suitable texture patterns experimentally, numerical approaches to the design of microtextures are increasingly gaining acceptance. The purpose of this paper is to investigate to what extent the selected modeling approach affects optimized texturing.

Using the cam/tappet contact as an application-oriented example, a simplified 2D and a full 3D model are developed for determining the best possible texturing via a design study. The study explores elongated Gaussian-shaped texture elements for this purpose. The optima of the simplified 2D simulation model and the full 3D model are compared with each other to draw conclusions about the influence of the modeling strategy. The target value here is the solid body friction in contact.

For the elongated texture elements used, both the simplified 2D model and the full model result in very similar optimal texture patterns. In the selected application, the simplified simulation model can significantly reduce the computational effort without affecting the optimization result.

Depending on the selected use case, the simulation effort required for microtexture optimization can be significantly reduced by comparing different models first. Therefore, an exact physical replica of the real contact is not necessarily the primary goal when it comes to texture selection based on numerical simulations.