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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 paper aims to provide thermal elastohydrodynamic lubrication (TEHL) contact model to study all balls’ lubrication performance of the ball screw when the multidirectional load is applied.

A new TEHL contact model combining the multidirectional load and the roughness surface texture is established to describe fatigue life of the ball screw. Meanwhile, the authors use the Reynolds equation to study the lubrication performance of the ball screw.

When the multidirectional load is applied, contact load, slide-roll ratio and entrainment velocity of all balls have a periodic shape. The TEHL performance values at the ball-screw contact points including contact stress, shear stress, minimum film thickness and temperature rise are higher than that at the ball-nut contact points. The TEHL performance values increase with the increase of root mean square (RMS) except for the film thickness. In addition, the radial load of the ball screw has a significant effect on the fatigue life.

The results of the studies demonstrate the new TEHL contact model that provides the instructive significance to analyze the fatigue life of the ball screw under the multidirectional load.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2020-0097/

The purpose of this study is to investigate the thermal elastohydrodynamic lubrication (TEHL) analysis of a deep groove ball bearing.

The TEHL model for the groove ball is first established, into which the elastic deformation is incorporated. In doing so, the elastic deformation is solved with the fast Fourier transform (FFT). And the bearing temperature rise is solved by the point heat source integration method. Then, effects of the applied load, relative velocity and the slide-roll ratio on the TEHL of the bearing are analyzed.

There exist the large pressure peaks at two edges of the raceway along its width direction and the increment in the relative velocity between the roller and the raceway, or one in the slide-roll ratio arguments the temperature rise.

This study conducts a detailed discussion of the TEHL analysis of deep groove ball bearing and gives a beneficial reference to the design and application of this kind of bearings.

This paper aims to improve the grease thermal elastohydrodynamic lubrication (TEHL) properties of the tripod sliding universal coupling (TSUC) under automotive practical conditions. For this purpose, the effect of effective radius was theoretically investigated.

Based on the simplified geometric model, the effect of effective radius on the pressure distribution, film thickness and temperature distribution of the TSUC was theoretically investigated using the multigrid and stepping methods. The TEHL properties were compared with the results obtained using the isothermal calculation method.

The results show that the thermal effect has a great impact on the film thickness and the pressure distribution of grease lubrication properties. Moreover, larger effective radius results in a wider but lower pressure distribution, a wider and thicker lubricating film and a lower temperature distribution.

The TSUC can be widely used in the front drive automotive transmission because it can transmit larger torque than before. The effect of effective radius on the thermal grease lubrication properties under automotive practical conditions provides a new direction for designing it.

This paper aims to address the influence of diamond-like carbon (DLC) coatings on the frictional power loss of spur gears. It shows potentials for friction and bulk temperature reduction in industrial use. From a scientific point of view, the thermal insulation effect on fluid friction is addressed, which lowers viscosity in the gear contact due to increasing contact temperature.

Thermal insulation effect is analyzed in detail by means of the heat balance and micro thermal network of thermal elastohydrodynamic lubrication contacts. Preliminary results at a twin-disk test rig are summarized to categorize friction and bulk temperature reduction by DLC coatings. Based on experiments at a gear efficiency test rig, the frictional power losses and bulk temperatures of DLC-coated gears are investigated, whereby load, speed, oil temperature and coatings are varied.

Experimental investigations at the gear efficiency test rig showed friction and bulk temperature reduction for all operating conditions of DLC-coated gears compared to uncoated gears. This effect was most pronounced for high load and high speed. A reduction of the mean gear coefficient of friction on average 25% and maximum 55% was found. A maximum reduction of bulk temperature of 15% was observed.

DLC-coated gears show a high potential for reducing friction and improving load-carrying capacity. However, the industrial implementation is restrained by the limited durability of coatings on gear flanks. Therefore, a further and overall consideration of key durability factors such as substrate material, pretreatment, coating parameters and gear geometry is necessary.

Thermal insulation effect of DLC coatings was shown by theoretical analyses and experimental investigations at model test rigs. Although trial tests on gears were conducted in literature, this study proves the friction reduction by DLC-coated gears for the first time systematically in terms of various operating conditions and coatings.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2020-0257/

The purpose of this paper is to investigate the thermal elastohydrodynamic lubrication (TEHL) flash temperature of the helical gear pairs considering profile modification.

A flash temperature model of the helical gear pair considering the profile modification is proposed based on the TEHL and meshing theories. In doing so, the slicing, fast Fourier transform and chase-after methods are applied to accurately and rapidly obtain the flash temperature of the gear pair. Then, the effects of the modification, input torque and rotation speed on the flash temperature are studied.

With the increment of the tip relief amount, the flash temperature of the helical gear pair with the axial modification decreases first and then increases, and the meshing position of the maximum flash temperature moves toward the pitch point. Moreover, reducing the input torque or increasing the rotation speed can efficiently reduce the TEHL flash temperature.

This work is a valuable reference for the profile design and optimization of the helical gears to avoid the excessive flash temperature.

The purpose of this paper was to construct lubrication model closer to the fact of thrust bearings and to calculate the bearings characteristics of lubrication for understanding how structures influence bearings performances and, importantly, what can be the most beneficial. Large-scale composite thrust bearings with Polytetrafluoroethylene (PTFE)-faced sector pad backed by steel base are used increasingly in equipment. But there are plenty of puzzled problems in design and application.

The authors established a 3D thermal elastohydrodynamic lubrication (TEHL) model. Oil film was formulated by Reynolds equation for pressure, and by energy equation for temperature varying through oil film thickness. Meanwhile, pad temperature was formulated by solid heat transfer equation. Elastic and thermal deformations of pad surface were calculated. Viscosity and density of oil were valued separately under different pressure and temperature. Load balance was considered as well as overturning moment balance. Finite difference method was applied to discrete these equations.

PTFE layer and steel base have either helpful or detrimental impact on contact strength and full film lubrication of thrust bearing depending on their relationship in thickness. Temperature lag between middle layer of steel base and pad surface depends on PTFE layer, but not on the steel base. PTFE layer thickness should be considered when alarming threshold value of the bearings temperature is chosen.

Three-dimensional TEHL model of large-scale composite thrust bearings was established, which included more factors close to the actual. Conclusions were drawn. These proposals are helpful to design the bearings.

The purpose of this paper is to describe an inverse approach to estimate the pressure distribution, temperature distribution, and pressure‐viscosity index (z) in a thermal elastohydrodynamic lubrication (TEHL) line contact.

Once the film thickness is given, the pressure distribution can be calculated using the inverse approach. Subsequently, thermal expansivity and temperature‐viscosity coefficient of lubricant are given, and then the z is guessed initially. The Gauss‐Seidel iteration is employed to calculate the temperature distribution from the rheology, energy, and surface temperature equations. In order to increase the algorithm stability, the least‐squares method must be employed to calculate the optimum value of the z in the computational domain. Furthermore, the pressure‐viscosity index must be updated by the iteration method to calculate accurate temperature distribution and apparent viscosity until convergence.

This approach presents a smooth curve of the pressure and temperature distributions with the measurement error from the resolution in the film thickness measurement and z value. Furthermore, this approach still provides a superior solution in apparent viscosity, whereas the direct method provides a much larger error in apparent viscosity.

The paper describes an inverse approach to estimate the pressure distribution, temperature distribution, and pressure‐viscosity index in a TEHL line contact. This approach overcomes the problems of pressure and temperature rise fluctuations and generates accurate results of pressure and temperature distribution from a small number of measured points of film thickness, which also saves computing time. Furthermore, this approach still provides a superior solution in apparent viscosity.

The purpose of this paper is to determine parameters for an efficient running-in of gears and an improved method for the prediction of the tooth flank load carrying capacity.

In this contribution, a model for the calculation of the pitting life of involute spur gears is introduced, which is based on an extension of the life model according to Ioannides and Harris for rough surfaces. To achieve the most realistic thermal elastohydrodynamic lubrication simulation and stress calculation possible, measured real surfaces and elastic-plastic material properties of the area close to the surface are used. Special attention is paid to the compatibility of the fatigue life calculation for heterogeneous rough surfaces and their consistent consideration in the lifespan calculation.

A non-destructive running-in for twin-disc pairings can be performed using suitable operating parameters, which subsequently can be transferred to tooth flank tests. Using the extended life model according to Ioannides and Harris, an enhanced prediction of the tooth flank load carrying capacity is possible.

The developed extended life model includes a new numerical approach for calculating the tooth flank load carrying capacity. It has the potential to reliably support and hence to accelerate the design process of gears.

This paper aims to investigate the grease isothermal lubrication properties of the tripod sliding universal coupling (TSUC) in automotive transmission shaft and study its impact on a variety of factors to improve its grease lubrication properties.

Based on the simplified geometrical model, the research of grease lubrication properties of the TSUC was analyzed, and compared with oil lubrication in same parameters. Then the effects of effective radius, frequency (vehicle speed) and amplitude (angle between intermediate shaft and input shaft) on grease isothermal lubrication properties are theoretically investigated by using multigrid methods.

The results indicate that the grease isothermal elastohydrodynamic lubrication (EHL) film thickness shape and pressure distribution shape of the TSUC are similar to the oil lubrication, but the film thickness of grease lubrication is less than that of oil lubrication. Higher effective radius results in a wider pressure distribution, a lower center pressure and a thicker lubricating film. Higher frequency (vehicle speed) results in a remarkable second pressure peak and a thicker lubricating film. The effects of amplitude (angle between intermediate shaft and input shaft) and frequency have similar tendencies.

The numerical analysis research on grease lubrication properties of the TSUC is significant because the automotive transmission shaft is widely used. And it provides a new direction in designing TSUCs.