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Article
Publication date: 12 January 2024

Kai Xu, Ying Xiao and Xudong Cheng

The purpose of this study is to investigate the effects of nanoadditive lubricants on the vibration and noise characteristics of helical gears compared with conventional…

Abstract

Purpose

The purpose of this study is to investigate the effects of nanoadditive lubricants on the vibration and noise characteristics of helical gears compared with conventional lubricants. The experiment aims to analyze whether nanoadditive lubricants can effectively reduce gear vibration and noise under different speeds and loads. It also analyzes the sensitivity of the vibration reduction to load and speed changes. In addition, it compares the axial and radial vibration reduction effects. The goal is to explore the application of nanolubricants for vibration damping and noise reduction in gear transmissions. The results provide a basis for further research on nanolubricant effects under high-speed conditions.

Design/methodology/approach

Helical gears of 20CrMnTi were lubricated with conventional oil and nanoadditive oils. An open helical gearbox with spray lubrication was tested under different speeds (200–500 rpm) and loads (20–100 N·m). Gear noise was measured by a sound level meter. Axial and radial vibrations were detected using an M+P VibRunner system and fast Fourier transform analysis. Vibration spectrums under conventional and nanolubrication were compared. Gear tooth surfaces were observed after testing. The experiment aimed to analyze the noise and vibration reduction effects of nanoadditive lubricants on helical gears and the sensitivity to load and speed.

Findings

The key findings are that nanoadditive lubricants significantly reduce the axial and radial vibrations of helical gears under low-speed conditions compared with conventional lubricants, with a more pronounced effect on axial vibrations. The vibration reduction is more sensitive to rotational speed than load. At the same load and speed, nanolubrication reduces noise by 2%–5% versus conventional lubrication. Nanoparticles change the friction from sliding to rolling and compensate for meshing errors, leading to smoother vibrations. The nanolubricants alter the gear tooth surfaces and optimize the microtopography. The results provide a basis for exploring nanolubricant effects under high speeds.

Originality/value

The originality and value of this work is the experimental analysis of the effects of nanoadditive lubricants on the vibration and noise characteristics of hard tooth surface helical gears, which has rarely been studied before. The comparative results under different speeds and loads provide new insights into the vibration damping capabilities of nanolubricants in gear transmissions. The findings reveal the higher sensitivity to rotational speed versus load and the differences in axial and radial vibration reduction. The exploration of nanolubricant effects on gear tribological performance and surface interactions provides a valuable reference for further research, especially under higher speed conditions closer to real applications.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2023-0220/

Details

Industrial Lubrication and Tribology, vol. 76 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 29 August 2023

Jian Sun, Xin Fang, Jinmei Yao, Zhe Zhang, Renyun Guan and Guangxiang Zhang

The study aims to the distribution rule of lubricating oil film of full ceramic ball bearing and improve its performance and life.

Abstract

Purpose

The study aims to the distribution rule of lubricating oil film of full ceramic ball bearing and improve its performance and life.

Design/methodology/approach

The paper established an analysis model based on the fluid–solid conjugate heat transfer theory for full ceramic ball bearings. The distribution of flow, temperature and pressure field of bearings under variable working conditions is analyzed. Meanwhile, the mathematical model of elastohydrodynamic lubrication (EHL) of full ceramic ball bearings is established. The numerical analysis is used to study the influence of variable working conditions on the lubricant film thickness and pressure distribution of bearings. The temperature rise test of full ceramic ball bearing under oil lubrication was carried out to verify the correctness of simulation results.

Findings

As the speed increased, the oil volume fraction in full ceramic ball bearing decreased and the surface pressure of rolling element increased. The temperature rise of full ceramic ball bearings increases with increasing speed and load. The lubricant film thickness of full ceramic ball bearing is positively correlated with speed and negatively correlated with load. The pressure of lubricating film is positively correlated with speed and load. The test shows that the higher inner ring speed and radial load, the higher the steady-state temperature rise of full ceramic ball bearing. The test results are in high agreement with simulation results.

Originality/value

Based on the fluid–solid conjugate heat transfer theory and combined with Reynolds equation, lubricating oil film thickness formula, viscosity temperature and viscosity pressure formula. The thermal analysis model and EHL mathematical model of ceramic ball bearings are established. The flow field, temperature field and pressure field distribution of the full ceramic ball bearing are determined. And the thickness and pressure distribution of lubricating oil film in the contact area of full ceramic ball bearing were determined.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0126/

Details

Industrial Lubrication and Tribology, vol. 75 no. 8
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 7 February 2024

Rajesh Shah, Blerim Gashi, Vikram Mittal, Andreas Rosenkranz and Shuoran Du

Tribological research is complex and multidisciplinary, with many parameters to consider. As traditional experimentation is time-consuming and expensive due to the complexity of…

Abstract

Purpose

Tribological research is complex and multidisciplinary, with many parameters to consider. As traditional experimentation is time-consuming and expensive due to the complexity of tribological systems, researchers tend to use quantitative and qualitative analysis to monitor critical parameters and material characterization to explain observed dependencies. In this regard, numerical modeling and simulation offers a cost-effective alternative to physical experimentation but must be validated with limited testing. This paper aims to highlight advances in numerical modeling as they relate to the field of tribology.

Design/methodology/approach

This study performed an in-depth literature review for the field of modeling and simulation as it relates to tribology. The authors initially looked at the application of foundational studies (e.g. Stribeck) to understand the gaps in the current knowledge set. The authors then evaluated a number of modern developments related to contact mechanics, surface roughness, tribofilm formation and fluid-film layers. In particular, it looked at key fields driving tribology models including nanoparticle research and prosthetics. The study then sought out to understand the future trends in this research field.

Findings

The field of tribology, numerical modeling has shown to be a powerful tool, which is both time- and cost-effective when compared to standard bench testing. The characterization of tribological systems of interest fundamentally stems from the lubrication regimes designated in the Stribeck curve. The prediction of tribofilm formation, film thickness variation, fluid properties, asperity contact and surface deformation as well as the continuously changing interactions between such parameters is an essential challenge for proper modeling.

Originality/value

This paper highlights the major numerical modeling achievements in various disciplines and discusses their efficacy, assumptions and limitations in tribology research.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2023-0076/

Details

Industrial Lubrication and Tribology, vol. 76 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 24 October 2023

Alireza Khodabandeh and Mohammad Mahdi Abootorabi

First, the effect of magnetic field intensity and nano-ferrofluid concentrations on surface roughness was evaluated in magnetic minimum quantity lubrication (MMQL). Then, the…

Abstract

Purpose

First, the effect of magnetic field intensity and nano-ferrofluid concentrations on surface roughness was evaluated in magnetic minimum quantity lubrication (MMQL). Then, the effect of lubricant flow rate and nozzle position on surface roughness was investigated in MQL, MMQL, electrostatic MQL (EMQL) and electromagnetic MQL (EMMQL).

Design/methodology/approach

This study examined the performance of MQL under magnetic and electric fields in turning AISI 304 stainless steel in terms of surface roughness and compared the results with those obtained from wet cutting and MQL turning operations. To prepare the nano-ferrofluid used in different states of MQL, Fe3O4 nanoparticles were added to the base fluid.

Findings

The results showed that the surface roughness under the EMMQL technique decreased by 36% and 49.4% on average compared with wet and MQL techniques, respectively. The lubrication technique affected the surface roughness by 90.2%, whereas it was 8.3% for the lubricant flow rate. EMQL and EMMQL techniques had no significant difference in their effects on surface roughness. In the innovative MMQL technique, the nano-ferrofluid concentration of 6% and magnetic field intensity of 93 G resulted in lower surface roughness of the workpiece relative to other counterparts.

Originality/value

Examining previously published studies showed that using nano-ferrofluids under a magnetic field for cooling purposes in machining processes have less considered by researchers. This study applies an innovative method of lubrication under the concurrent effect of magnetic and electric fields, called EMMQL, to improve the efficiency of MQL in machining hard-to-cut materials. For comprehensively inspecting the newly presented method, the effects of several parameters, including the nano-ferrofluid concentration, magnetic field intensity, lubricant flow rate and position of lubricant spray nozzle, on the surface roughness of workpiece in turning of AISI 304 stainless steel are investigated.

Details

Industrial Lubrication and Tribology, vol. 75 no. 10
Type: Research Article
ISSN: 0036-8792

Keywords

Open Access
Article
Publication date: 22 September 2023

Nengsheng Bao, Yuchen Fan, Chaoping Li and Alessandro Simeone

Lubricating oil leakage is a common issue in thermal power plant operation sites, requiring prompt equipment maintenance. The real-time detection of leakage occurrences could…

Abstract

Purpose

Lubricating oil leakage is a common issue in thermal power plant operation sites, requiring prompt equipment maintenance. The real-time detection of leakage occurrences could avoid disruptive consequences caused by the lack of timely maintenance. Currently, inspection operations are mostly carried out manually, resulting in time-consuming processes prone to health and safety hazards. To overcome such issues, this paper proposes a machine vision-based inspection system aimed at automating the oil leakage detection for improving the maintenance procedures.

Design/methodology/approach

The approach aims at developing a novel modular-structured automatic inspection system. The image acquisition module collects digital images along a predefined inspection path using a dual-light (i.e. ultraviolet and blue light) illumination system, deploying the fluorescence of the lubricating oil while suppressing unwanted background noise. The image processing module is designed to detect the oil leakage within the digital images minimizing detection errors. A case study is reported to validate the industrial suitability of the proposed inspection system.

Findings

On-site experimental results demonstrate the capabilities to complete the automatic inspection procedures of the tested industrial equipment by achieving an oil leakage detection accuracy up to 99.13%.

Practical implications

The proposed inspection system can be adopted in industrial context to detect lubricant leakage ensuring the equipment and the operators safety.

Originality/value

The proposed inspection system adopts a computer vision approach, which deploys the combination of two separate sources of light, to boost the detection capabilities, enabling the application for a variety of particularly hard-to-inspect industrial contexts.

Details

Journal of Quality in Maintenance Engineering, vol. 29 no. 5
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 28 November 2023

Aboubakeur Benariba, Ahmed Bouzidane, Hicham Aboshighiba and Mark Thomas

The purpose of this research is to study the dynamic behavior of hydrostatic squeeze film dampers made of four hydrostatic pads, fed through four capillary restrictors with…

Abstract

Purpose

The purpose of this research is to study the dynamic behavior of hydrostatic squeeze film dampers made of four hydrostatic pads, fed through four capillary restrictors with micropolar lubricant.

Design/methodology/approach

The modified version of Reynolds equation is solved numerically by the finite differences and the Gauss–Seidel methods to determine the pressure field generated on the hydrostatic bearing flat pads. In the first step, the effects of the pad dimension ratios on the stiffness and damping coefficients are investigated. In the second step, the damping factor is evaluated with respect to the micropolar properties.

Findings

The analysis revealed that the hydrostatic squeeze film dampers lubricated with micropolar lubricants produces the maximum damping factor for characteristic length of micropolar lubricant less than 5, while the same bearing operating with Newtonian lubricants reaches its maximum damping factor at eccentricity ratios larger than 0.4.

Originality/value

The results obtained show that the effects of micropolar lubricants on the dynamic performances are predominantly affected by the pad geometry and eccentricity ratio.

Details

Industrial Lubrication and Tribology, vol. 76 no. 1
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 7 February 2024

Burcu Küçükoğlu Doğan, Abdurrahim Dal, Görkem Ağören and Tuncay Karaçay

In industry applications, polymer hybrid bearings have become widespread in recent years owing to the lack of lubricant requirements, particularly in areas requiring hygiene. The…

Abstract

Purpose

In industry applications, polymer hybrid bearings have become widespread in recent years owing to the lack of lubricant requirements, particularly in areas requiring hygiene. The additive manufacturing method gives significant advantages to have complex machinery parts, and it has become popular in the industry in recent years. However, it has some inherent disadvantages caused by layered deposition/addition of the materials, and the probability of the localized defect is much higher than in the conventional manufacturing methods. This study aims to investigate the effect of the outer race defect on the characteristics of vibration and service lifetime of hybrid polymer ball bearings produced with the stereolithography (SLA) additive manufacturing method.

Design/methodology/approach

In this study, polymer bearings’ races were produced with the additive manufacturing SLA method, and the outer race defect was analyzed with measured vibrations.

Findings

The results show that the additive manufacturing method suggests a practical solution for producing a polymer hybrid ball bearing. On the other hand, the hybrid three-dimensional-printed bearing, which has an outer race defect, worked for approximately 8 h without any problems under a 1 kg load and a shaft speed of around 1,000 rpm. In addition, when there is a defect in the outer and/or inner race of the ball bearing, the crest factor and kurtosis of the vibration are higher than faultless ball bearing, as expected.

Originality/value

This paper provides valuable information on the lifetime and vibration characteristics of polymer hybrid ball bearing produced by means of additive manufacturing.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2023-0183/

Details

Industrial Lubrication and Tribology, vol. 76 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 28 June 2023

David S.F.T. Mendes, Helena V.G. Navas and Fernando M.B. Charrua-Santos

The purpose of this study was to develop and implement a new model to improve maintenance management and the production system through the concepts: maintenance, lean philosophy…

Abstract

Purpose

The purpose of this study was to develop and implement a new model to improve maintenance management and the production system through the concepts: maintenance, lean philosophy and Industry 4.0.

Design/methodology/approach

The methodology employed in this study includes conducting a bibliographic survey of existing models exploring the joint application of the concepts under study, critically analyzing these models, developing a model proposal and subsequently analyzing the results obtained. The model is implemented on a belt conveyor of a feed mill to improve its performance.

Findings

The proposed model contributes to improve maintenance and production system management, proving to be a useful tool to improve real-time decision-making. After its application, it was possible to verify that it increased the performance of the conveyor belt, as well as improved the skills of the operators who operate on it.

Research limitations/implications

Limitation about the distance between the devices that make up the model. The implementation of autonomous maintenance can highlight some challenges within the company. The implementation was only in the belt conveyor, being useful to introduce this in the remaining areas of the factory.

Originality/value

The study presents an innovative, versatile, low-cost and easy-to-apply model to improve maintenance management by combining the three concepts. The model can be easily adapted to monitor condition parameters such as temperature, noise, among others, through the correct choice of devices and proper programming. This work also contributed to help in real-time decision-making for both the maintenance and production departments.

Details

Journal of Quality in Maintenance Engineering, vol. 29 no. 4
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 8 January 2024

Zhi Li, YiYuan Du, Zhiming Xu, Xuqian Qiao and Hong Zhang

The purpose of this study is to investigate the influence of surface texture on the subsurface characteristics of contact interfaces under elastohydrodynamic lubrication…

50

Abstract

Purpose

The purpose of this study is to investigate the influence of surface texture on the subsurface characteristics of contact interfaces under elastohydrodynamic lubrication condition. As a typical contact form of gears and bearings, the optimization of friction characteristics at the elastohydrodynamic lubrication (EHL) interface has attracted the attention of scholars. Laser surface texturing is a feasible optimization solution, but there have been concerns about whether the surface texture of high-pair parts will affect their fatigue life.

Design/methodology/approach

To examine the impact of texture preparation on the subsurface characteristics of high-pair interfaces under EHL conditions, a point contact EHL model is developed that takes into account the effect of textured surface topography. The pressure and thickness of the oil film are calculated as input parameters under different loads and entrainment velocities. The finite element method is used to simulate the impact of textures with varying diameters, densities and depths on the subsurface characteristics of the elastohydrodynamic interface. According to ISO 25178, analyze the relationship between 3D topography parameters and subsurface characteristics and study the trend of friction characteristics and subsurface characteristics based on the results of the ball on disc friction tests.

Findings

The outcomes suggest that under different rotational velocity and load conditions, the textured surfaces exhibit improved friction reduction effects; however, the creation of textures can result in significant subsurface plastic deformation and local peeling. The existence of texture makes the larger stress zone in the subsurface layer closer to the surface, leading to fatigue failure near the surface. Reasonable design parameters can help enhance the attributes of the subsurface. A smaller Sa and a Str greater than 0.5 can achieve ideal subsurface properties on the textured surface.

Originality/value

This paper investigates the influence of surface texture on the friction and subsurface characteristics of EHL interfaces and analyzes the impact of surface texture on interface contact performance while achieving lubrication improvement functional characteristics. The results provide theoretical support for the optimization design and functional regulation of surface texture in EHL interfaces.

Peer review

The peer review history for this article is https://publons.com/publon/10.1108/ILT-10-2023-0324/

Details

Industrial Lubrication and Tribology, vol. 76 no. 1
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 26 March 2024

Cong Ding, Zhizhao Qiao and Zhongyu Piao

The purpose of this study is to design and process the optimal V-shaped microstructure for 7075 aluminum alloy and reveal its wear resistance mechanism and performance.

Abstract

Purpose

The purpose of this study is to design and process the optimal V-shaped microstructure for 7075 aluminum alloy and reveal its wear resistance mechanism and performance.

Design/methodology/approach

The hydrodynamic pressure lubrication models of the nontextured, V-shaped, circular and square microtextures are established. The corresponding oil film pressure distributions are explored. The friction and wear experiments are conducted on a rotating device. The effects of the microstructure shapes and sizes on the wear mechanisms are investigated via the friction coefficients and surface morphologies.

Findings

In comparison, the V-shaped microtexture has the largest oil film carrying capacity and the lowest friction coefficient. The wear mechanism of the V-shaped microtexture is dominated by abrasive and adhesive wear. The V-shaped microtexture has excellent wear resistance under a side length of 300 µm, an interval of 300 µm and a depth of 20 µm.

Originality/value

This study is conductive to the design of wear-resistant surfaces for friction components.

Details

Industrial Lubrication and Tribology, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0036-8792

Keywords

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