Tribology Days

-vik
6-8 Nov 2012

Andreas Almqvist, Lule University of Technology andreas.almqvist@ltu.se

 Why is modelling & simulation important?
The Lule mixed lubrication model
Surface Topography
Computing Flow factors
Component simulation
Current activities
Future work

2
 3

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Understanding 1
= +
2

Testing new ideas ?

Optimisation
Ranking 1 , 2 , 3

3
 A complement to:
Full-
scale

Component

Model

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 Few commercially available packages

Excite
AVL Piston&Rings
Lubrication Shell
COMSOL
Ricardo Suite Multiphysics

MIT Consortium

5
 2010
6 PhDs 60+ publications Award
2004- 40+ Tribology
5 Lics
20+ Mathematics

Delveloped by: The division of at LTU

I Topography IIFlow Factor computations III Component Simulation

representation Flow between asperities Utilizing the Flow Factors
Asperity deformation All regimes considered
u Coarse grid = fast
Pressure
Load
Friction

u+1
u

Leakage

y2
y1 u
 Local scale; describing the Surface Topography
Global scale; describing Geometry
- Incorporating the effects of roughness through homogenization

Local

Global

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 1. Representative roughness
# of realizations / measurements
Resampling, interpolation
Filtering, mirroring p minV *
0 p
u
2. Flow factors
u
Contact mechanics
Material model - Linear Elastic Perfectly Plastic

u+1

u
# Loads (=> separations)
Local problems y2
y u
Core of the homogenization 1

# Separations

3. Component simulation
Interpolate ffs onto global domain and
solve for homogenized pressure

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 I

Artificial surfaces measured AFM VSI

with AFM and VSI
Anomalies created from
measurement technique
observed
Effect on tribological
parameters investigated
Sa (m) Sk (m) Spk (m) Svk (m)
AFM 39.0 10.9 45.1 101.0
VSI 91.6 64.3 220.0 521.0

Large differences in
roughness parameters
for artificial surfaces
Far smaller
differences for real
surfaces
However, care must
be taken with extreme
surfaces, i.e. laser
textured
9Paper by Andrew Spencer et al. - Trib. Int. Vol. 57
 Mirroring => Perfect periodicity

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11
 Resampling

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Matlab GUI by Dr. Fredrik Sahlin
 II

Revamped!
Was Matlab 2007 + COMSOL Multiphysics 3.5a
Is MATLAB code only!

Mini-courses / tutorial sessions on the usage of

the code will be given.

(http://www.python.org/ code under construction)

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 II

Contact mechanics Local problems

BEM model Homogenization

How to achieve a physically acceptable result?

Representative contact mechanics model
Clearance measure defining direct contact
Full film computation over the non-contact area only

In contact
Rigid
point

Topography rep.

14 Contact spot
 ---> Incorrect modelling of the so called micro-bearing problems

Patir and Cheng Homogenization

15 Paper by Almqvist et al. ASME Journal of Tribology, Vol. 133

 We want to: u
- Include inter-asperity coupling p
- Have a deterministic representation of the
surface

[ m ]

[mm]

[mm]

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 Contact pressure (-)

Average interfacial separation ()

17 Almqvist and Persson et al. Journal of the Mechanics and Physics of Solids, Vol 59.
 II

Cavitation VR

Asperity collision SSF

Wear modelling VR, SSF, Sauer-Danfoss

Piston ring - Cylinder liner lubrication SSF, Scania

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 II

Universal equation (Non-linear)

= ,
Elrod Incompressible HL
1, 1
Vijayaraghavan Compressible =
0, <1

Linear Complementarity Problem

Dini - Incompressible + 1 = ,
Almqvist & Wall - Compressible 1 =0

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 II

Friction contribution to deformation included

FFT accelerated solution procedure
Frictionless N Friction included N
F f= N

20 PhD Student - Joel Furustig

 II

After the first component scale simulation, new flow

factors can be computed and then incorporated to
compensate for possible plastic deformations

21 PhD Students - Joel Furustig & Andrew Spencer

 II

80 m 3
80 m 3
Thermoelasto-plastic, time dependent
simulations in LS DYNA

60m
60m
Interference:
4 4
4 4

2 2
2 2 Mesh convergence studies
&
Y Optimisation of geometries
Y
X 1
X 1 have been conducted to verify the
accuracy of the model.
22 PhD Student - Shaojie Kang
 II

Interference Friction Velocity

Stress Plastic strain Temperature

23 PhD Student - Shaojie Kang

 II

A B

C D
Stress grows from zero to the maximum value, then decreases to
the residual stress after collision.
The distorted stress profile is due to the existence of friction.
Maximum stress is observed near the surface and large plastic
deformation are observed.
24 PhD Student - Shaojie Kang
 II

A B

C D

Maximum plastic strain is found close to the surface

Wear model could be established -> plastic strain is larger
than a critical value means seizure.

25 PhD Student - Shaojie Kang

 II

A B

C D

Maximum temperature is found at the smaller(top) asperity

Max temp rise 40

26 PhD Student - Shaojie Kang

 II III

27 PhD Student - Andrew Spencer

 II III

28 PhD Student - Andrew Spencer

 II

Cavitation VR

Asperity collision SSF

Wear modelling VR, SSF, Sauer-Danfoss

Piston ring - Cylinder liner lubrication SSF, Scania

III

Piston ring - Cylinder liner lubrication Energimyndigheten,

Scania, Volvo

Power losses in hydraulic motors VR, Hgglunds Drives

Lubrication of cam roller systems Scania, Bosch, HD

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30
 III

Volvo Powertrain AB
Energy agency
Scania
- Out of roundness
- Ring twist & dynamics
- Effect of laser texture

- Floating liner test rig

31 PhD Student - Markus Sderfjll

 III

Bosch Rexroth
(Hgglunds drives AB)

More than 50% reduction of power losses

32 PhD Student - Patrik Isaksson
 III

Hgglunds drives AB (Bosch Rexroth), Sweden

Robert Bosch GmbH, Germany

Scania AB, Sweden

Aim
A fast and reliable tool for
prediction of slippage in cam - roller contacts

33 PhD Student - Mohammad Shirzadegan

 III

Conformal contact
Global
Non-conformal contact

Local

Are the scales separable?

Reaction forces?

34 PhD Student - Mohammad Shirzadegan

 System Lumped model Free body
diagram
Follower

Spring

Roller
, ,
() ()

Cam

The dynamic behaviour can be predicted if the physics can

represented by a mathematical model:
=
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 Inter-asperity cavitation
Micro-EHL
Non-Newtonian Rheology

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 Tribology Days
-vik
6-8 Nov 2012

Questions?

Andreas Almqvist, Lule University of Technology andreas.almqvist@ltu.se