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Preface xvii
Introduction xix
PART I LUBRICATION THEORY 1
1 Properties of Lubricants 3
1.1 Lubrication States 3
1.2 Density of Lubricant 6
1.3 Viscosity of Lubricant 7
1.3.1 Dynamic Viscosity and Kinematic Viscosity 7
1.3.2 Relationship between Viscosity and Temperature 9
1.3.3 Relationship between Viscosity and Pressure 11
1.3.4 Relationships between Viscosity, Temperature and Pressure 12
1.4 Non-Newtonian Behaviors 12
1.4.1 Ree-Eyring Constitutive Equation 13
1.4.2 Visco-Plastic Constitutive Equation 13
1.4.3 Circular Constitutive Equation 14
1.4.4 Temperature-Dependent Constitutive Equation 14
1.4.5 Visco-Elastic Constitutive Equation 14
1.4.6 Nonlinear Visco-Elastic Constitutive Equation 15
1.4.7 A Simple Visco-Elastic Constitutive Equation 16
1.5 Wettability of Lubricants 17
1.5.1 Wetting and Contact Angle 17
1.5.2 Surface Tension 18
1.6 Measurement and Conversion of Viscosity 19
1.6.1 Rotary Viscometer 19
1.6.2 Off-Body Viscometer 20
1.6.3 Capillary Viscometer 20
References 22
2 Basic Theories of Hydrodynamic Lubrication 23
2.1 Reynolds Equation 24
2.1.1 Basic Assumptions 24
2.1.2 Derivation of Reynolds Equation 24
2.2 Hydrodynamic Lubrication 27
2.2.1 Mechanism of Hydrodynamic Lubrication 27
2.2.2 Boundary Conditions and Initial Conditions of Reynolds Equation 28
2.2.3 Calculation of Hydrodynamic Lubrication 29
2.3 Elastic Contact Problems 30
2.3.1 Line Contact 30
2.3.2 Point Contact 33
2.4 Entrance Analysis of EHL 36
2.4.1 Elastic Deformation of Line Contacts 36
2.4.2 Reynolds Equation Considering the Effect of Pressure-Viscocity 37
2.4.3 Discussion 37
2.4.4 Grubin Film Thickness Formula 39
2.5 Grease Lubrication 40
References 42
3 Numerical Methods of Lubrication Calculation 43
3.1 Numerical Methods of Lubrication 44
3.1.1 Finite Difference Method 44
3.1.2 Finite Element Method and Boundary Element Method 50
3.1.3 Numerical Techniques 53
3.2 Numerical Solution of the Energy Equation 57
3.2.1 Conduction and Convection of Heat 57
3.2.2 Energy Equation 59
3.2.3 Numerical Solution of Energy Equation 61
3.3 The Numerical Solution of Elastohydrodynamic Lubrication 62
3.3.1 EHL Numerical Solution of Line Contacts 62
3.3.2 EHL Numerical Solution of Point Contacts 67
3.4 Multi-Grid Method for Solving EHL Problems 70
3.4.1 Basic Principles of Multi-Grid Method 70
3.4.2 Nonlinear Full Approximation Scheme of Multi-Grid Method 72
3.4.3 V and W Iterations 74
3.4.4 Multi-Grid Solution of EHL Problems 74
3.4.5 Multi-Grid Integration Method 76
References 79
4 Lubrication Design of Typical Mechanical Elements 81
4.1 Slider and Thrust Bearing 81
4.1.1 Basic Equations 81
4.1.2 Solutions of Slider Lubrication 82
4.2 Journal Bearing 85
4.2.1 Axis Position and Clearance Shape 85
4.2.2 Infinitely Narrow Bearing 86
4.2.3 Infinitely Wide Bearing 88
4.3 Hydrostatic Bearing 92
4.3.1 Hydrostatic Thrust Plate 93
4.3.2 Hydrostatic Journal Bearings 94
4.3.3 Bearing Stiffness and Throttle 94
4.4 Squeeze Bearing 96
4.4.1 Rectangular Plate Squeeze 97
4.4.2 Disc Squeeze 98
4.4.3 Journal Bearing Squeeze 99
4.5 Dynamic Bearing 100
4.5.1 Reynolds Equation of Dynamic Journal Bearings 101
4.5.2 Simple Dynamic Bearing Calculation 103
4.5.3 General Dynamic Bearings 104
4.6 Gas Lubrication Bearings 107
4.6.1 Basic Equations of Gas Lubrication 107
4.6.2 Types of Gas Lubrication Bearings 108
4.7 Rolling Contact Bearing 111
4.7.1 Equivalent Radius R 111
4.7.2 Average Velocity U 112
4.7.3 Carrying Load Per Width W/b 112
4.8 Gear Lubrication 113
4.8.1 Involute Gear Transmission 113
4.8.2 Arc Gear Transmission EHL 117
4.9 Cam Lubrication 119
References 121
5 Special Fluid Medium Lubrication 123
5.1 Magnetic Hydrodynamic Lubrication 123
5.1.1 Composition and Classification of Magnetic Fluids 123
5.1.2 Properties of Magnetic Fluids 124
5.1.3 Basic Equations of Magnetic Hydrodynamic Lubrication 126
5.1.4 Influence Factors on the Magnetic EHL 129
5.2 Micro-polar Hydrodynamic Lubrication 129
5.2.1 Basic Equations of Micro-polar Fluid Lubrication 130
5.2.2 Influence Factors on Micro-polar Fluid Lubrication 133
5.3 Liquid Crystal Lubrication 135
5.3.1 Types of Liquid Crystal 136
5.3.2 Deformation Analysis of Liquid Crystal Lubrication 138
5.3.3 Friction Mechanism of Liquid Crystal as a Lubricant Additive 142
5.4 Electric Double Layer Effect in Water Lubrication 143
5.4.1 Electric Double Layer Hydrodynamic Lubrication Theory 144
5.4.2 Influence of Electric Double Layer on Lubrication Properties 148
References 151
6 Lubrication Transformation and Nanoscale Thin Film Lubrication 153
6.1 Transformations of Lubrication States 153
6.1.1 Thickness-Roughness Ratio 153
6.1.2 Transformation from Hydrodynamic Lubrication to EHL 154
6.1.3 Transformation from EHL to Thin Film Lubrication 155
6.2 Thin Film Lubrication 159
6.2.1 Phenomena of Thin Film Lubrication 159
6.2.2 Time Effect of Thin Film Lubrication 161
6.2.3 Shear Strain Rate Effect on Thin Film Lubrication 163
6.3 Analysis of Thin Film Lubrication 165
6.3.1 Difficulties in Numerical Analysis of Thin Film Lubrication 165
6.3.2 Tichy's Thin Film Lubrication Models 166
6.4 Nano-Gas Film Lubrication 168
6.4.1 Rarefied Gas Effect 168
6.4.2 Bounardy Slip 169
6.4.3 Reynolds Equation Considering the Rarefied Gas Effect 172
6.4.4 Calculation of Magnetic Head/Disk of Ultra Thin Gas Lubrication 173
References 176
7 Boundary Lubrication and Additives 177
7.1 Types of Boundary Lubrication 177
7.1.1 Stribeck Curve 177
7.1.2 Adsorption Films and their Lubrication Mechanisms 178
7.1.3 Chemical Reaction Film and its Lubrication Mechanism 183
7.1.4 Other Boundary Films and their Lubrication Mechanisms 185
7.2 Theory of Boundary Lubrication 186
7.2.1 Boundary Lubrication Model 186
7.2.2 Factors Influencing Performances of Boundary Film 187
7.2.3 Strength of Boundary Film 190
7.3 Lubricant Additives 191
7.3.1 Oily Additives 191
7.3.2 Tackifier 192
7.3.3 Extreme Pressure Additives (EP Additives) 193
7.3.4 Anti-Wear Additives (AWAdditives) 193
7.3.5 Other Additives 194
References 195
8 Lubrication Failure and Mixed Lubrication 197
8.1 Roughness and Viscoelastic Material Effects on Lubrication 197
8.1.1 Modifications of micro-EHL 197
8.1.2 Viscoelastic Model 198
8.1.3 Lubricated Wear 199
8.2 Influence of Limit Shear Stress on Lubrication Failure 202
8.2.1 Visco-Plastic Constitutive Equation 203
8.2.2 Slip of Fluid-Solid Interface 203
8.2.3 Influence of Slip on Lubrication Properties 204
8.3 Influences of Temperature on Lubrication Failure 207
8.3.1 Mechanism of Lubrication Failure Caused by Temperature 208
8.3.2 Thermal Fluid Constitutive Equation 208
8.3.3 Analysis of Lubrication Failure 209
8.4 Mixed Lubrication 210
References 215
PART II FRICTION AND WEAR 217
9 Surface Topography and Contact 219
9.1 Parameters of Surface Topography 219
9.1.1 Arithmetic Mean Deviation Ra 219
9.1.2 Root-Mean-Square Deviation (RMS) s or Rq 219
9.1.3 Maximum Height Rmax 220
9.1.4 Load-carrying Area Curve 220
9.1.5 Arithmetic Mean Interception Length of Centerline Sma 220 219
9.2 Statistical Parameters of Surface Topography 222
9.2.1 Height Distribution Function 222
9.2.2 Deviation of Distribution 224
9.2.3 Autocorrelation Function of Surface Profile 225
9.3 Structures and Properties of Surface 226
9.4 Rough Surface Contact 227
9.4.1 Single Peak Contact 228
9.4.2 Ideal Roughness Contact 229
9.4.3 Random Roughness Contact 230
9.4.4 Plasticity Index 232
References 232
10 Solid Friction and Control 233
10.1 Basic Characteristics of Friction 233
10.1.1 Influence of Stationary Contact Time 234
10.1.2 Jerking Motion 234
10.1.3 Pre-Displacement 235
10.2 Macro-friction Theory 236
10.2.1 Mechanical Engagement Theory 236
10.2.2 Molecular Action Theory 237
10.2.3 Adhesive Friction Theory 238
10.2.4 Plowing Effect 241
10.2.5 Deformation Energy Friction Theory 243
10.2.6 Binomial Friction Theory 245
10.3 Micro-friction Theory 246
10.3.1 ‘‘Cobblestone’’ Model 246
10.3.2 Oscillator Models 248
10.3.3 Phonon Friction Model 251
10.4 Sliding Friction 251
10.4.1 Influence of Load 252
10.4.2 Influence of Sliding Velocity 252
10.4.3 Influence of Temperature 253
10.4.4 Influence of Surface Film 253
10.5 Rolling Friction 254
10.5.1 Rolling Friction Mechanism 256
10.5.2 Resistances of Rolling Friction 256
10.6 Special Friction and Friction Control 257
10.6.1 Special Friction 257
10.6.2 Friction Control 258
References 261
11 Characteristics and Mechanisms of Wear 263
11.1 Classification of Wear 263
11.1.1 Wear Categories 264
11.1.2 Wear Process 264
11.1.3 Conversion of Wear 266
11.2 Abrasive Wear 266
11.2.1 Types of Abrasive Wear 267
11.2.2 Influence Factors on Abrasive Wear 267
11.2.3 Mechanism of Abrasive Wear 271
11.3 Adhesive Wear 272
11.3.1 Types of Adhesive Wear 272
11.3.2 Influence Factors on Adhesive Wear 273
11.3.3 Adhesive Wear Mechanism 275
11.3.4 Criteria of Scuffing 277
11.4 Fatigue Wear 280
11.4.1 Types of Fatigue Wear 280
11.4.2 Influence Factors on Fatigue Wear 281
11.4.3 Criteria of Fatigue Strength and Fatigue Life 285
11.5 Corrosive Wear 289
11.5.1 Oxidation Wear 289
11.5.2 Special Corrosive Wear 291
11.5.3 Fretting 291
11.5.4 Cavitation Erosion 292
References 295
12 Macro-wear Theory 297
12.1 Friction Material 298
12.1.1 Friction Material Properties 298
12.1.2 Wear-Resistant Mechanism 299
12.2 Wear Process Curve 300
12.2.1 Types of Wear Process Curves 300
12.2.2 Running-In 301
12.3 Surface Quality and Wear 304
12.3.1 Influence of Geometric Quality 304
12.3.2 Physical Quality 307
12.4 Theory of Adhesion Wear 308
12.5 Theory of Energy Wear 309
12.6 Delamination Wear Theory and Fatigue Wear Theory 311
12.6.1 Delamination Wear Theory 311
12.6.2 Fatigue Wear Theory 312
12.7 Wear Calculation 313
12.7.1 IBM Wear Calculation Method 313
12.7.2 Calculation Method of Combined Wear 314
References 319
13 Anti-Wear Design and Surface Coating 321
13.1 Selection of Lubricant and Additive 321
13.1.1 Lubricant Selection 322
13.1.2 Grease Selection 324
13.1.3 Solid Lubricants 325
13.1.4 Seal and Filter 326
13.2 Matching Principles of Friction Materials 326
13.2.1 Material Mating for Abrasive Wear 327
13.2.2 Material Mating for Adhesive Wear 328
13.2.3 Material Mating for Contact Fatigue Wear 329
13.2.4 Material Mating for Fretting Wear 330
13.2.5 Material Mating for Corrosion Wear 330
13.2.6 Surface Hardening 330
13.3 Surface Coating 331
13.3.1 Commonly Plating Methods 331
13.3.2 Design of Surface Coating 338
13.4 Coating Performance Testing 339
13.4.1 Appearance and Structure 339
13.4.2 Bond Strength Test 340
13.4.3 Hardness Test 344
13.4.4 Wear Test 345
13.4.5 Tests of Other Performances 345
References 346
14 Tribological Experiments 347
14.1 Tribological Experimental Method and Device 347
14.1.1 Experimental Methods 347
14.1.2 Commonly Used Friction and Wear Testing Machines 349
14.1.3 EHL and Thin Film Lubrication Test 349
14.2 Measurement of Wear Capacity 352
14.2.1 Weighing Method 352
14.2.2 Length Measurement Method 352
14.2.3 Profile Method 352
14.2.4 Indentation Method 353
14.2.5 Grooving Method 356
14.2.6 Precipitation Method and Chemical Analysis Method 357
14.2.7 Radioactive Method 357
14.3 Analysis of Friction Surface Morphology 358
14.3.1 Analysis of Surface Topography 358
14.3.2 Atomic Force Microscope (AFM) 358
14.3.3 Surface Structure Analysis 360
14.3.4 Surface Chemical Composition Analysis 362
14.4 Wear State Detection 363
14.4.1 Ferrography Analysis 363
14.4.2 Spectral Analysis 365
14.4.3 Lubricant Composition Analysis 365
14.4.4 Mechanical Vibration and Noise Analysis 365
14.4.5 Lubrication State Analysis 365
14.5 Wear Failure Analysis 365
14.5.1 Site Investigation 365
14.5.2 Lubricant and its Supply System 366
14.5.3 Worn Part Analysis 366
14.5.4 Design and Operation 366
References 367
PART III APPLIED TRIBOLOGY 369
15 Micro-tribology 371
15.1 Micro-friction 371
15.1.1 Macro-friction and Micro-friction 371
15.1.2 Micro-friction and Surface Topography 372
15.1.3 Plowing Effect and Adhesion Effective 375
15.2 Micro-contact and Micro-adhesion 377
15.2.1 Solid Micro-contact 377
15.2.2 Solid Adhesion and Surface Force 378
15.3 Micro-Wear 380
15.3.1 Micro-Wear Experiment 380
15.3.2 Micro-Wear of Magnetic Head and Disk 382
15.4 Molecular Film and Boundary Lubrication 385
15.4.1 Static Shear Property of Molecular Layer 386
15.4.2 Dynamic Shear Property of Monolayer and Stick-Slip Phenomenon 387
15.4.3 Physical State and Phase Change 389
15.4.4 Temperature Effect and Friction Mechanism 390
15.4.5 Rheological Property of Molecular Film 390
15.4.6 Ordered Molecular Film 393
References 395
16 Metal Forming Tribology 397
16.1 Mechanics Basis of Metal Forming 397
16.1.1 Yield Criterion 397
16.1.2 Friction Coefficient and Shear Factor 398
16.1.3 Influence of Friction on Metal Forming 400
16.2 Forging Tribology 401
16.2.1 Upsetting Friction 401
16.2.2 Friction of Open Die Forging 403
16.2.3 Friction of Closed-Die Forging 403
16.2.4 Lubrication and Wear 404
16.3 Drawing Tribology 406
16.3.1 Friction and Temperature 406
16.3.2 Lubrication 407
16.3.3 Wear of Drawing Die 409
16.3.4 Anti-Friction of Ultrasound in Drawing 412
16.4 Rolling Tribology 415
16.4.1 Friction in Rolling 415
16.4.2 Lubrication in Rolling 417
16.4.3 Roller Wear 419
16.4.4 Emulsion Lubricity in Rolling 421
References 421
17 Bio-Tribology 423
17.1 Mechanics Basis for Soft Biological Tissue 423
17.1.1 Rheological Property of Soft Tissue 423
17.1.2 Stress-Strain Curve Analysis 423
17.1.3 Anisotropy Relationship 425
17.2 Characteristics of Joint Lubricating Fluid 426
17.2.1 Joint Lubricating Fluid 426
17.2.2 Lubrication Characteristics of Joint Fluid 427
17.3 Lubrication of Human and Animal Joints 430
17.3.1 Performance of Human Joint 430
17.3.2 Joint Lubricating Fluid 431
17.3.3 Lubrication Mechanism of Joint 432
17.4 Friction and Wear of Artificial Joint 434
17.4.1 Friction and Wear Test 434
17.4.2 Wear of Artificial Joint 435
17.5 Other Bio-Tribological Studies 438
References 438
18 Space Tribology 439
18.1 Features of Space Agency and Space Tribology 439
18.1.1 Working Conditions in Space 439
18.1.2 Features of Space Tribology Problems 441
18.2 Analysis of Performances of Space Tribology 442
18.2.1 Starved Lubrication 442
18.2.2 Parched Lubrication 443
18.2.3 Volatility Analysis 444
18.2.4 Creeping 446
18.3 Space Lubricating Properties 448
18.3.1 EHL Characteristics of Space Lubricant 448
18.3.2 Space Lubrication of Rolling Contact Bearing 449
References 450
Index 453
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