Tribological Performance of Different Concentrations of Al_(2)O_(3)Nanofluids on Minimum Quantity Lubrication Milling

Nanofluid minimum quantity lubrication(NMQL)is a green processing technology.Cottonseed oil is suitable as base oil because of excellent lubrication performance,low freezing temperature,and high yield.Al_(2)O_(3)nanoparticles improve not only the heat transfer capacity but also the lubrication performance.The physical and chemical proper-ties of nanofluid change when Al_(2)O_(3)nanoparticles are added.However,the effects of the concentration of nanofluid on lubrication performance remain unknown.Furthermore,the mechanisms of interaction between Al_(2)O_(3)nanoparti-cles and cottonseed oil are unclear.In this research,nanofluid is prepared by adding different mass concentrations of Al_(2)O_(3)nanoparticles(0,0.2%,0.5%,1%,1.5%,and 2%wt)to cottonseed oil during minimum quantity lubrication(MQL)milling 45 steel.The tribological properties of nanofluid with different concentrations at the tool/workpiece interface are studied through macro-evaluation parameters(milling force,specific energy)and micro-evaluation parameters(surface roughness,micro morphology,contact angle).The result show that the specific energy is at the minimum(114 J/mm^(3)),and the roughness value is the lowest(1.63μm)when the concentration is 0.5 wt%.The surfaces of the chip and workpiece are the smoothest,and the contact angle is the lowest,indicating that the tribological proper-ties are the best under 0.5 wt%.This research investigates the intercoupling mechanisms of Al_(2)O_(3)nanoparticles and cottonseed base oil,and acquires the optimal Al_(2)O_(3)nanofluid concentration to receive satisfactory tribological properties.

Tribological Mechanism of Graphene and Ionic Liquid Mixed Fluid on Grinding Interface under Nanofluid Minimum Quantity Lubrication

Graphene has superhigh thermal conductivity up to 5000 W/(m·K),extremely thin thickness,superhigh mechanical strength and nano-lamellar structure with low interlayer shear strength,making it possess great potential in mini-mum quantity lubrication(MQL)grinding.Meanwhile,ionic liquids(ILs)have higher thermal conductivity and better thermal stability than vegetable oils,which are frequently used as MQL grinding fluids.And ILs have extremely low vapor pressure,thereby avoiding film boiling in grinding.These excellent properties make ILs also have immense potential in MQL grinding.However,the grinding performance of graphene and ionic liquid mixed fluid under nano-fluid minimum quantity lubrication(NMQL),and its tribological mechanism on abrasive grain/workpiece grinding interface,are still unclear.This research firstly evaluates the grinding performance of graphene and ionic liquid mixed nanofluids(graphene/IL nanofluids)under NMQL experimentally.The evaluation shows that graphene/IL nanofluids can further strengthen both the cooling and lubricating performances compared with MQL grinding using ILs only.The specific grinding energy and grinding force ratio can be reduced by over 40%at grinding depth of 10μm.Work-piece machined surface roughness can be decreased by over 10%,and grinding temperature can be lowered over 50℃at grinding depth of 30μm.Aiming at the unclear tribological mechanism of graphene/IL nanofluids,molecular dynamics simulations for abrasive grain/workpiece grinding interface are performed to explore the formation mechanism of physical adsorption film.The simulations show that the grinding interface is in a boundary lubrication state.IL molecules absorb in groove-like fractures on grain wear flat face to form boundary lubrication film,and graphene nanosheets can enter into the grinding interface to further decrease the contact area between abrasive grain and workpiece.Compared with MQL grinding,the average tangential grinding force of graphene/IL nanofluids can decrease up to 10.8%.The interlayer shear effect and low interlayer shear strength of graphene nanosheets are the principal causes of enhanced lubricating performance on the grinding interface.EDS and XPS analyses are further carried out to explore the formation mechanism of chemical reaction film.The analyses show that IL base fluid happens chemical reactions with workpiece material,producing FeF_(2),CrF_(3),and BN.The fresh machined surface of workpiece is oxidized by air,producing NiO,Cr_(2)O_(3) and Fe_(2)O_(3).The chemical reaction film is constituted by fluorides,nitrides and oxides together.The combined action of physical adsorption film and chemical reaction film make graphene/IL nano-fluids obtain excellent grinding performance.

Effect of Surface Roughness on Lubrication Performance of Bump-Type Gas Foil Bearings

Taking bump-type gas foil bearings as the research object,a deformation model of bump foil and a thin-plate finite element model of top foil were proposed.By solving Reynolds equation and energy equation,the pressure distribution and the temperature distribution of gas films in foil bearings were obtained.Further,a numerical method for calculating the lubrication performance of gas foil bearings with considering the surface roughness was proposed.With a specific example,effects of the surface roughness on the bearing lubrication performance were parametrically studied.The results indicate that rougher journal surface can lead to larger fluctuation of the lubrication performance,while surface roughness of top foil has few effects on the fluctuation.Moreover,the mean values of performance parameters almost remain constant at different values of surface roughness.

Assessment of Lubrication Property and Machining Performance of Nanofluid Composite Electrostatic Spraying(NCES)Using Different Types of Vegetable Oils as Base Fluids of External Fluid

The current study of minimum quantity lubrication(MQL)concentrates on its performance improvement.By contrast with nanofluid MQL and electrostatic atomization(EA),the proposed nanofluid composite electrostatic spraying(NCES)can enhance the performance of MQL more comprehensively.However,it is largely influenced by the base fluid of external fluid.In this paper,the lubrication property and machining performance of NCES with different types of vegetable oils(castor,palm,soybean,rapeseed,and LB2000 oil)as the base fluids of external fluid were compared and evaluated by friction and milling tests under different flow ratios of external and internal fluids.The spraying current and electrowetting angle were tested to analyze the influence of vegetable oil type as the base fluid of external fluid on NCES performances.The friction test results show that relative to NCES with other vegetable oils as the base fluids of external fluid,NCES with LB2000 as the base fluid of external fluid reduced the friction coefficient and wear loss by 9.4%-27.7%and 7.6%-26.5%,respectively.The milling test results display that the milling force and milling temperature for NCES with LB2000 as the base fluid of external fluid were 1.4%-13.2%and 3.6%-11.2%lower than those for NCES with other vegetable oils as the base fluids of external fluid,respectively.When LB2000/multi-walled carbon nanotube(MWCNT)water-based nanofluid was used as the external/internal fluid and the flow ratio of external and internal fluids was 2:1,NCES showed the best milling performance.This study provides theoretical and technical support for the selection of the base fluid of NCES external fluid.

Simulation analysis of wear characteristics of connecting rod bearing bush based on improved mixed lubrication model

The failure rate of crankpin bearing bush of diesel engine under complex working conditions such as high temperature,dynamic load and variable speed is high.After serious wear,it is easy to deteriorate the stress state of connecting rod body and connecting rod bolt,resulting in serious accidents such as connecting rod fracture and body damage.Based on the mixed lubrication characteristics of connecting rod big endbearing shell of diesel engine under high explosion pressure impact load,an improved mixed lubrication mechanism model is established,which considers the influence of viscoelastic micro deformation of bearing bush material,integrates the full film lubrication model and dry friction model,couples dynamic equation of connecting rod.Then the actual lubrication state of big end bearing shell is simulated numerically.Further,the correctness of the theoretical research results is verified by fault simulation experiments.The results show that the high-frequency impact signal with fixed angle domain characteristics will be generated after the serious wear of bearing bush and the deterioration of lubrication state.The fault feature capture and alarm can be realized through the condition monitoring system,which can be applied to the fault monitoring of connecting rod bearing bush of diesel engine in the future.

Achieving oxidation protection effect for strips hot rolling via Al_(2)O_(3) nanofluid lubrication

It was discovered the application of Al_(2)O_(3) nanofluid as lubricant for steel hot rolling could synchronously achieve oxidation protection of strips surface.The underlying mechanism was investigated through hot rolling tests and molecular dynamics (MD) simulations.The employment of Al_(2)O_(3) nanoparticles contributed to significant enhancement in the lubrication performance of lubricant.The rolled strip exhibited the best surface topography that the roughness reached lowest with the sparsest surface defects.Besides,the oxide scale generated on steel surface was also thinner,and the ratio of Fe_(2)O_(3) among various iron oxides became lower.It was revealed the above oxidation protection effect of Al_(2)O_(3) nanofluid was attributed to the deposition of nanoparticles on metal surface during hot rolling.A protective layer in the thickness of about 193 nm was formed to prevent the direct contact between steel matrix and atmosphere,which was mainly composed of Al_(2)O_(3) and sintered organic molecules.MD simulations confirmed the diffusion of O_(2) and H_(2)O could be blocked by the Al_(2)O_(3) layer through physical absorption and penetration barrier effect.

Multifunctional Lubricant Additive Improves Lubrication and Antioxidation Properties of Tung Oil

It is of considerable significance to develop efficient and environmentally friendly machinery lubricant additives because of the increasing depletion of petrochemical resources and severe environmental problems.Herein,we proposed a facile strategy to synthesize a multifunctional vegetable oil-based lubricant via the lignin derivative vanillin coupled to amine and diethyl phosphite to produce a lubricating additive with both extreme pressure and antioxidant properties.Compared with pure tung oil,the lubricating and antioxidant performance of tung oil is significantly improved after adding additives.Adding the 1.0 wt%additive to the tung oil reduced the friction wear coefficient and the volume,and the oxidation induction time was much longer than pure tung oil.

Influencing factors on hydrodynamic lubrication failure of upstream pumping mechanical seal

Considering the effect of viscosity-temperature relationship and cavitation of micro-scale film,the influencing factors on hydrodynamic lubrication performance of upstream pumping mechanical seal were investigated based on the theory of hydrodynamic lubrication.N-S equation,energy equation,viscosity-temperature equation and vapor transport equation were solved with the finite volume method by using Fluent software,which was performed to analyze the influence of the viscosity-temperature and cavitation effect on hydrodynamic lubrication failure of the film.The research demonstrates that it will lead to the significant difference of the temperature field by considering the coupling of temperature and viscosity.When the film thickness decreases and the rotating speed rises,cavitation regions and viscous friction heat increases,the opening force of the film is also enhanced.However,the growth rate is restricted to the cavitation regions and viscous friction heat,and the opening force begins to decline to a certain extent,and thereby being insufficient to open the surfaces of the seals and leading to the failure of automatic adjustment function and severe wear,lubrication failure occurrs.Through comprehensive research on the influences of viscosity-temperature and cavitation effect on hydrodynamic lubrication performance,the theories of failure and design of upstream pumping mechanical seal are further developed.

Dynamic Characteristics of High-speed Water-Lubricated Spiral Groove Thrust Bearing Based on Turbulent Cavitating Flow Lubrication Model

The water-lubricated bearings are usually the state of turbulent cavitating flow under high-speed conditions. And the distribution of cavitation bubbles and the interface effect between the two phases have not been included in previous studies on high-speed water-lubricated bearings. In order to study the influence of interface effect and cavitation bubble distribution on the dynamic characteristics of high-speed water-lubricated spiral groove thrust bearings(SGTB).A turbulent cavitating flow lubrication model based on two-phase fluid and population balance equation of bubbles was established in this paper. Stiffness and the damping coefficients of the SGTB were calculated using the perturbation pressure equations. An experimental apparatus was developed to verify the theoretical model. Simulating and experimental results show that the small-sized bubbles tend to generate in the turbulent cavitating flow when at a high rotary speed, and the bubbles mainly locate at the edges of the spiral groove. The simulating results also show that the direct stiffness coefficients are increased due to cavitation effect, and cross stiffness coefficients and damping coefficients are hardly affected by the cavitation effect. Turbulent effect on the dynamic characteristics of SGTB is much stronger than the cavitating effect.

Plastic-elastic Model for Water-based Lubrication Considering Surface Force

Water-based lubrication is an effective method to achieve superlubricity,which implies a friction coefficient in the order of 10−3 or lower.Recent numerical,analytical,and experimental studies confirm that the surface force effect is crucial for realizing water-based superlubricity.To enhance the contribution of the surface force,soft and plastic materials can be utilized as friction pair materials because of their effect in increasing the contact area.A new numerical model of water-based lubrication that considers the surface force between plastic and elastic materials is developed in this study to investigate the effect of plastic flow in water-based lubrication.Considering the complexity of residual stress accumulation in lubrication problems,a simplified plastic model is proposed,which merely calculates the result of the dry contact solution and avoids repeated calculations of the plastic flow.The results of the two models show good agreement.Plastic deformation reduces the local contact pressure and enhances the function of the surface force,thus resulting in a lower friction coefficient.

RESEARCH ON THE EVALUATION METHOD OF FRICTION AND LUBRICATION IN DEEP DRAWING

The deformation characteristic of bland in deep drawing is discussed. It is pointed out that the friction and lubrication conditions in for drawing are different from that in mechanical motion or machine work or other plastic process. The common test methods in laboratories are analyzed. It shows that though all those test methods can test the friction coefficient, the probe test method is most suitable for the research of friction and lubrication and the process in deep drawing, for this method is identical with the actual work condition either from the test principle or deformation status of the blank. Last the successful application in the deep drawing simulator newly developed the the probe method are intro- duced in detail.

Effect of Die Wall Lubrication on Warm Compaction Powder Metallurgy

Die wall lubrication was applied on warm compaction powder metallurgy in hope to reduce the concentration level of the admixed lubricant since lubricant is harmful to the mechanical property of the sintered materials. Iron-based samples were prepared by die wall lubricated warm compaction at 135 ℃ and 175 ℃, using polytetrafluoroethylene (PTFE) emulsion as die wall lubricant. A compacting pressure of 700 MPa and 550 MPa were used. The admixed lubricant concentration ranging from 0 to 0.6 wt.% was used in this study. Compared with non-die wall lubricated samples, the die wall lubricated samples have higher green densities. Results show that in addition to the decrease in ejection forces, green density of the compacts increased linearly with the decrease in admixed lubricant content. Mechanical property of the sintered compacts increase sharply when the admixed lubricant concentration reduced to 0.125 wt.% or less. Ejection force data indicated that samples with die wall lubrication show lower ejection forces when compared with samples without die wall lubrication. No scoring was observed in all experiments even for samples contain no admixed lubricant. Our results indicated that under experimental condition used in this study, no matter at which compaction pressure, compaction temperature, graphite and lubricant contents in the powder the die wall lubricated warm compaction would give the highest green density and lowest ejection force. It can be concluded that combination of die wall lubrication and warm compaction can provide P/M products with higher density and better quality. It is a feasible way to produce high performance P/M parts if suitable die wall lubrication system was applied.

Synthesis and Lubrication of Phosphorylcholine Derivative

The monomer of phosphorylcholine derivative, O-(5-(2-methacryloxy)-3, 3-dimethyl-3-azapentyl)-O’-(ω-hydroxy-octyl)-phosphatequaternary ammonium salt, was designed and synthesized successfully. It was characterized by the spectra of ~1HNMR and Mass spectra (ESI+), and every signal was assigned. Then the lubricating characteristics of the phosphorylcholinederivative were investigated on the tribological setup of ball-oh-flat. The Ultra-High Molecular Weight Polyethylene(UHMWPE) flat was rotated against a stainless steel ball with 6 mm diameter. The load was 2.3 N, which corresponded to amaximal Hertz contact pressure of 29 MPa. Water, phosphorylcholine derivative, and Acrylic Acid (AA) solution were used aslubricants, respectively. Compared with AA, the phosphorylcholine derivative shows significant lubrication. It can be stronglyhydrated under water due to the charged segment in chemical structure. The thick water layers within the chains serves asboundary lubricants, and this is thought to be the molecular origins of lubricating behavior.

Preparation of nano-copper as lubrication oil additive

Nano-copper used as lubrication oil additive has good tribological property and active self-repairing effect for friction pairs. The reduction in liquid phase for preparing nano-additive is one of the most common method. Nano-copper was prepared by reduction in liquid phase. The different project and routine practice for preparing nano-copper were researched. The dispersion problem of nano-copper was investigated by surface treatment and high dispersion. The particles dimension, the dispersion stability and the purity of nano-copper were characterized by TEM and XRD. The conclusion indicates that the methods of the preparation and dispersion can obtain 20nm copper additive with good dispersion property in lubrication oil.

Electrostatic atomization minimum quantity lubrication machining:from mechanism to application

Metal cutting fluids(MCFs)under flood conditions do not meet the urgent needs of reducing carbon emission.Biolubricant-based minimum quantity lubrication(MQL)is an effective alternative to flood lubrication.However,pneumatic atomization MQL has poor atomization properties,which is detrimental to occupational health.Therefore,electrostatic atomization MQL requires preliminary exploratory studies.However,systematic reviews are lacking in terms of capturing the current research status and development direction of this technology.This study aims to provide a comprehensive review and critical assessment of the existing understanding of electrostatic atomization MQL.This research can be used by scientists to gain insights into the action mechanism,theoretical basis,machining performance,and development direction of this technology.First,the critical equipment,eco-friendly atomization media(biolubricants),and empowering mechanisms of electrostatic atomization MQL are presented.Second,the advanced lubrication and heat transfer mechanisms of biolubricants are revealed by quantitatively comparing MQL with MCF-based wet machining.Third,the distinctive wetting and infiltration mechanisms of electrostatic atomization MQL,combined with its unique empowering mechanism and atomization method,are compared with those of pneumatic atomization MQL.Previous experiments have shown that electrostatic atomization MQL can reduce tool wear by 42.4%in metal cutting and improve the machined surface Ra by 47%compared with pneumatic atomization MQL.Finally,future development directions,including the improvement of the coordination parameters and equipment integration aspects,are proposed.

Effect of Pressure on Boundary Slip of Thin Film Lubrication Using Atomistic Simulation

Mechanical systems on all length scales may be subjected to nanoscale thin film lubrication(TFL). Molecular dynamics(MD) simulations were conducted to investigate the lubrication mechanism and boundary slip of squalane confined in nanogap at 293 K with two different film thicknesses and a wide range of pressures. The molecular distribution, density and velocity profiles of squalane were analyzed. The results show that the lubricant atoms tend to form layers parallel to the wall, but the lubricant molecules orient randomly throughout the film in the directions both parallel and perpendicular to the wall. Most squalane molecules appear twisted and folded, and extend to several atomic layers so that there are no slips between lubricant layers. The distances between the lubricant layers are irregular rather than broadening far away from the walls. The boundary slip at the interface of bcc Fe(001) and squalane only occurs at high pressure because of the strong nonbond interactions between lubricant atoms and wall atoms. The tendency of boundary slip is more obvious for films with thinner film thickness. According to the simulations, the relationship between the slip length and the pressure is given.

MATHEMATICAL PROGRAMMING ANALYSIS OF BILINEAR RHEOLOGICAL LUBRICATION MECHANICS

Bilinear theological lubrication mechanics provides an important basis for the designs of re-cently developed electrorheological(ER)"smart"journal bearings and those lubricated by mixed fluid-solid lubri-cants.But there is not yet a reliable and efficient numerical method for such a problem of non-Newtonian flu-id mechanics.In the present paper,a finite element method(FEM)together with mat hematical programmingsolution is successfully used to solve such a problem.A reliable and generalized numerical method forthe designs of electrorheological "smart" journal bearings and the bearings lubricated by mixed fluid- solid lubri-cant is presented.

A Micro-layer Model for the Lubrication Effect Near Collisions of Immersed Particles

A micro-layer model is proposed to account for the lubrication effect of liquid layer near collisions of immersed particles at moderate particle Reynolds number.This new model is to allow determination of the pressure profile within the micro-layer including the fluid inertia and viscosity.Then a correction based on the micro-layer model is applied to unsteady 3-D direct simulation of a particle approaching another one.The simulation is based on a modified immersed boundary method with direct force scheme.The quantitative agreement between numerical and experimental results validates the model presented in the study.The simulation results show that the fluid is squeezed prior to contact.When a particle approaches a flat wall or another particle,the lubrication force,obtained by integrating the pressure profile over the particle surface,is increased and prevents the particle from approaching.The model predicts that the velocity of approaching particle starts to decrease when separation distance of particles is less than 0.1dp,where dp is the particle diameter.

Effect of Micro-Dimples on Hydrodynamic Lubrication of Textured Sinusoidal Roughness Surfaces

Surface texturing has been applied to improving the tribological performance of mechanical components for many years. Currently, the researches simulate the film pressure distribution of textured rough surfaces on the basis of the average flow model, and however the influence of roughness on the film pressure distribution could not be precisely expressed. Therefore, in order to study the hydrodynamic lubrication of the rough textured surfaces, sinusoidal waves are employed to characterize untextured surfaces. A deterministic model for hydrodynamic lubrication of microdimple textured rough surfaces is developed to predict the distribution of hydrodynamic pressure. By supplementing with the JFO cavitation boundary, the load carrying capacity of the film produced by micro-dimples and roughness is obtained. And the geometric parameters of textured rough surface are optimized to obtain the maximum hydrodynamic lubrication by specifying an optimization goal of the load carrying capacity. The effect of roughness on the hydrodynamic pressure of surface texture is significant and the load carrying capacity decreases with the increase of the roughness ratio because the roughness greatly suppresses the hydrodynamic effect of dimples. It shows that the roughness ratio of surface may be as small as possible to suppress the effect of hydrodynamic lubrication. Additionally,there are the optimum values of the micro-dimple depth and area density to maximize the load carrying capacity for any given value of the roughness ratio. The proposed approach is capable of accurately reflects the influence of roughness on the hydrodynamic pressure, and developed a deterministic model to investigate the hydrodynamic lubrication of textured surfaces.

Dynamic Characteristics of Lubrication and Wear Prediction of Slipper/Swash-Plate in Axial Piston Pumps

A novel dynamic model describing the slipper posture of the swash plate in axial piston pumps is proposed, taking into account the hydrodynamic and squeezing effects, which involves three degrees of freedom. The variation in the lubricating film thickness and the slipper tilt are accurately calculated. The influence of hydrodynamic effects and charging pressure on the slipper lubrication is discussed. The minimum film thickness, the overturning angle and the azimuth angle are obtained.Then, the trajectory of minimum thickness on the friction surface of the swash plate is predicted, the accuracy of which can be verified with the abrasion distribution of an actual swash plate. Research results can predict the durability and provide theoretical help for the design of the slipper.