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To decrease wear and friction, zinc dialkyldithiophosphate (ZDDP) has been used in engine oil for several decades, but the mechanism of the tribofilm formation is still unclear. The purpose of this study is to characterize the chemical details of the tribofilm by using high-resolution approaching.

An ISO VG 100 mineral oil mixed with ZDDP was used in sliding tests on cylindrical roller bearings. Tribofilm formation was observed after 2 h of the sliding test. X-ray photoelectron spectroscopy (XPS) and atom probe tomography (APT) were used for chemical analysis of the tribofilm.

The results show that the ZDDP tribofilm consists of the common ZDDP elements along with iron oxides. A considerable amount of zinc and a small amount of sulfur were observed. In particular, an oxide interlayer with sulfur enrichment was revealed by APT between the tribofilm and the steel substrate. The depth profile of the chemical composition was obtained, and a tribofilm of approximately 40 nm thickness was identified by XPS.

A sulfur enrichment at the interface is observed by APT, which is beneath an oxygen enrichment. The clear evidence of the S interlayer confirms the hard and soft acids and bases principle.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2020-0035/

This paper aims to investigate the wear behaviour of different materials for cylinder liners and piston rings in a linear reciprocating tribometer with special focus on the wear of the cylinder liner in the boundary lubrication regime.

Conventional nitrided steel, as well as diamond-like carbon and chromium nitride-coated piston rings, were tested against cast iron, AlSi and Fe-coated AlSi cylinder liners. The experiments were carried out with samples produced from original engine parts to have the original surface topography available. Radioactive tracer isotopes were used to measure cylinder liner wear continuously, enabling separation of running-in and steady-state wear.

A ranking of the material pairings with respect to wear behaviour of the cylinder liner was found. Post-test inspection of the cylinder samples by scanning electron microscopy (SEM) revealed differences in the wear mechanisms for the different material combinations. The results show that the running-in and steady-state wear of the liners can be reduced by choosing the appropriate material for the piston ring.

The use of original engine parts in a closely controlled tribometer environment under realistic loading conditions, in conjunction with continuous and highly sensitive wear measurement methods and a detailed SEM analysis of the wear mechanisms, forms an intermediate step between engine testing and laboratory environment testing.

The purpose of this paper is to investigate the effect of round pits arrangement patterns on tribological properties of journal bearing. In this paper, the tribological behaviors of journal bearing with different arrangement patterns under lubrication condition were studied based on M-2000 friction and wear tester.

The friction and wear of journal bearing contact surface were simulated by ANSYS. The wear mechanism of bearing contact surfaces was investigated by the means of energy dispersive spectrum analysis on the surface morphology and friction and wear status of the journal bearing specimens by Scanning Electron Microscopy (SEM) and Energy Dispersive Spectrometer (EDS). Besides, the wearing capacity of the textured bearing was predicted by using the GM (1,1) and Grey–Markov model.

As the loads increase, the friction coefficient of journal bearing specimens decrease first and then increase slowly. The higher rotation speed, the lower friction coefficient and the faster temperature build-up. The main friction method of the bearing sample is three-body friction. The existence of texture can effectively reduce friction and wear. In many arrangement patterns, the best is 4# bearing with round pits cross-arrangement pattern. Its texturing diameters are 60 µm and 125 µm, and the spacing and depth are 200 µm and 25 µm, respectively. In addition, the Grey–Markov model prediction result is more accurate and fit the experimental value better.

The friction and wear mechanism is helpful for scientific research and engineers to understand the tribological behaviors and engineering applications of textured bearing. The wear capacity of textured bearing is predicted by using the Grey–Markov model, which provides technical help and theoretical guidance for the service life and reliability of textured bearing.

This review aims to give a critical view of the wheel/rail high frequency vibration-induced vibration fatigue in railway bogie.

Vibration fatigue of railway bogie arising from the wheel/rail high frequency vibration has become the main concern of railway operators. Previous reviews usually focused on the formation mechanism of wheel/rail high frequency vibration. This paper thus gives a critical review of the vibration fatigue of railway bogie owing to the short-pitch irregularities-induced high frequency vibration, including a brief introduction of short-pitch irregularities, associated high frequency vibration in railway bogie, typical vibration fatigue failure cases of railway bogie and methodologies used for the assessment of vibration fatigue and research gaps.

The results showed that the resulting excitation frequencies of short-pitch irregularity vary substantially due to different track types and formation mechanisms. The axle box-mounted components are much more vulnerable to vibration fatigue compared with other components. The wheel polygonal wear and rail corrugation-induced high frequency vibration is the main driving force of fatigue failure, and the fatigue crack usually initiates from the defect of the weld seam. Vibration spectrum for attachments of railway bogie defined in the standard underestimates the vibration level arising from the short-pitch irregularities. The current investigations on vibration fatigue mainly focus on the methods to improve the accuracy of fatigue damage assessment, and a systematical design method for vibration fatigue remains a huge gap to improve the survival probability when the rail vehicle is subjected to vibration fatigue.

The research can facilitate the development of a new methodology to improve the fatigue life of railway vehicles when subjected to wheel/rail high frequency vibration.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

This study aims to investigate the effect of vibration on ceramic tools under dry cutting conditions and find the optimum cutting condition for the hardened steel machining process in a computer numerical control (CNC) lathe machine.

In this research, an integrated fuzzy TOPSIS-based Taguchi L9 optimization model has been applied for the multi-objective optimization (MOO) of the hard-turning responses. Additionally, the effect of vibration on the ceramic tool wear was investigated using Analysis of Variance (ANOVA) and Fast Fourier Transform (FFT).

The optimum cutting conditions for the multi-objective responses were obtained at 98 m/min cutting speed, 0.1 mm/rev feed rate and 0.2 mm depth of cut. According to the ANOVA of the input cutting parameters with respect to response variables, feed rate has the most significant impact (53.79%) on the control of response variables. From the vibration analysis, the feed rate, with a contribution of 34.74%, was shown to be the most significant process parameter influencing excessive vibration and consequent tool wear.

The MOO of response parameters at the optimum cutting parameter settings can significantly improve productivity in the dry turning of hardened steel and control over the input process parameters during machining.

Most studies on optimizing responses in dry hard-turning performed in CNC lathe machines are based on single-objective optimization. Additionally, the effect of vibration on the ceramic tool during MOO of hard-turning has not been studied yet.

For many decades, it has been recognized that maintenance activities should be adapted to the specific usage of a system. For that reason, many advanced policies have been developed, such as condition-based and load-based maintenance policies. However, these policies require advanced monitoring techniques and rather detailed understanding of the failure behavior, which requires the support of an OEM or expert, prohibiting application by an operator in many cases. The present work proposes a maintenance policy that relieves the high (technical) demands set by these existing policies and provides a more accurate specification of the required (dynamic) maintenance interval than traditional usage-based maintenance.

The methodology followed starts with a review and critical assessment of existing maintenance policies, which are classified according to six different aspects. Based on the need for a technically less demanding policy that appears from this comparison, a new policy is developed. The consecutive steps required for this functional usage profiles based maintenance policy are then critically discussed: usage profile definition, monitoring, profile severity quantification and the possible extension to the fleet level. After the description of the proposed policy, it is demonstrated in three case studies on real systems.

A maintenance policy based on a simple usage registration procedure appears to be feasible, which enables a significantly more efficient maintenance process than the traditional usage-based policies. This is demonstrated by the policy proposed here.

The proposed maintenance policy based on functional usage profiles offers the operators of fleets of systems the opportunity to increase the efficiency and effectiveness of their maintenance process, without the need for a high investment in advanced monitoring systems and in experts interpreting the results.

The original contribution of this work is the explicit definition of a new maintenance policy, which combines the benefits of considering the effects of usage or environment severity with a limited investment in monitoring technology.

This paper aims to study the influence of the dimension change of bush-pin on the pressure, oil film thickness, temperature rise and traction coefficient in contact zone by using a thermal elastohydrodynamic lubrication (EHL) model for finite line contact. Concretely, the effects of the equivalent curvature radius of the bush and the pin, and the length of the bush are investigated.

In this paper, the contact between the bush and pin is simplified as finite line contact. The lubrication state is studied by numerical simulation using steady-state line contact thermal EHL. A constitutive equation Ree–Eyring fluid is used in the calculations.

It is found that by selecting an optimal equivalent radius of curvature and prolonging the bush length can improve the lubrication state effectively.

Under specific working conditions, there exists an optimal equivalent radius to maximize the minimum oil film thickness in the contact zone. The increase of generatrix length will weaken the stress concentration effect in the rounded corner area at both ends of the bush, which can improve the wear resistance of chain.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2019-0448.

With the help of multi-body dynamics software UM, the paper uses Kik–Piotrowski model to simulate wheel-rail contact and Archard wear model for rail wear.

The CRH5 vehicle-track coupling dynamics model is constructed for the wear study of rails of small radius curves, namely 200 and 350 m in Guangzhou East EMU Depot and those 250 and 300 m radius in Taiyuan South EMU Depot.

Results show that the rail wear at the straight-circle point, the curve center point and the circle-straight point follows the order of center point > the circle-straight point > the straight-circle point. The wear on rail of small radius curves intensifies with the rise of running speed, and the wearing trend tends to fasten as the curve radius declines. The maximum rail wear of the inner rail can reach 2.29 mm, while that of the outer rail, 10.11 mm.

With the increase of the train passing number, the wear range tends to expand. The rail wear decreases with the increase of the curve radius. The dynamic response of vehicle increases with the increase of rail wear, among which the derailment coefficient is affected the most. When the number of passing vehicles reaches 1 million, the derailment coefficient exceeds the limit value, which poses a risk of derailment.

This study aims to focus on the development of an experimental setup for testing tribological pairings under a gas atmosphere at pressures up to 10 bar.

A pressure chamber allowing oscillating movement through an outer shaft was constructed and mounted on an oscillating tribometer. Due to a metal spring bellows system, a methodology for the evaluation of the coefficient of friction values separately from the spring forces was developed.

The selected material concept was qualitatively and quantitatively assessed. An evaluation of the static and the dynamic coefficient of friction was performed, which was crucial for the understanding of the adhesion effects of the tested material pairing. The amount of information that is lost due to averaging the measured friction values is higher than one would expect.

The developed experimental setup is unique and, compared with the existing tribometers for testing under gas ambient pressures, allows testing under contact conditions that are closer to real applications, such as compressors and expanders. An in-depth observation of the adhesion and stick–slip effects of the tested material pairings is possible as well.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2023-0173/