Search Results (13)

With the global shift in energy structure and the advancement of the “double carbon” strategy, methanol has gained attention as a clean low-carbon fuel in the engine sector. However, the corrosion–wear coupling failure caused by acidic byproducts, such as methanoic acid and formaldehyde, generated during combustion severely limits the durability of methanol engines. In this study, we employed a systematic approach combining the construction of a corrosion liquid concentration gradient experiment with a full-load and full-speed bench test to elucidate the synergistic corrosion–wear mechanism of core friction pairs (cylinder liner, piston, and piston ring) in methanol-fueled engines. The experiment employed corrosion-resistant gray cast iron (CRGCI), high chromium cast iron (HCCI), and nodular cast iron (NCI) cylinder liners, along with F38MnVS steel and ZL109 aluminum alloy pistons. Piston rings with DLC, PVD, and CKS coatings were also tested. Corrosion kinetic analysis was conducted in a formaldehyde/methanoic acid gradient corrosion solution, with a concentration range of 0.5–2.5% for formaldehyde and 0.01–0.10% for methanoic acid, simulating the combustion products of methanol. The results showed that the corrosion depth of CRGCI was the lowest in low-concentration corrosion solutions, measuring 0.042 and 0.055 μm. The presence of microalloyed Cr/Sn/Cu within its pearlite matrix, along with the directional distribution of flake graphite, effectively inhibited the micro-cell effect. In high-concentration corrosion solutions (#3), HCCI reduced the corrosion depth by 60.7%, resulting in a measurement of 0.232 μm, attributed to the dynamic reconstruction of the Cr₂O₃-Fe₂O₃ composite passive film. Conversely, galvanic action between spherical graphite and the surrounding matrix caused significant corrosion in NCI, with a depth reaching 1.241 μm. The DLC piston coating obstructed the permeation pathway of formate ions due to its amorphous carbon structure. In corrosion solution #3, the recorded weight loss was 0.982 mg, which accounted for only 11.7% of the weight loss observed with the CKS piston coating. Following a 1500 h bench test, the combination of the HCCI cylinder liner and DLC-coated piston ring significantly reduced the wear depth. The average wear amounts at the top and bottom dead centers were 5.537 and 1.337 μm, respectively, representing a reduction of 67.7% compared with CRGCI, where the wear amounts were 17.152 and 4.244 μm. This research confirmed that the HCCI ferrite–Cr carbide matrix eliminated electrochemical heterogeneity, while the DLC piston coating inhibited abrasive wear. Together, these components reduced the wear amount at the top dead center on the push side by 80.1%. Furthermore, mismatches between the thermal expansion coefficients of the F38MnVS steel piston (12–14 × 10⁻⁶/°C) and gray cast iron (11 × 10⁻⁶/°C) resulted in a tolerance exceeding 0.105 mm in the cylinder fitting gap after 3500 h of testing. Notably, the combination of a HCCI matrix and DLC coating successfully maintained the gap within the required range of 50–95 μm. Full article

During braking, high-power wind turbine disc brake friction pairs experience thermo-mechanical interactions at the interface, which lead to both physical and chemical changes. The friction interface features asperities and embedded hard particles within the substrate. Wear debris from these asperities or dislodged hard particles accumulates at the interface, continuing to participate in the friction process—a phenomenon known as the “endogenous third body”. Throughout braking, the microscopic morphology and contact conditions of the interface evolve dynamically. The stress–strain distribution and vibration behaviour of the friction system, influenced by the endogenous third body, also vary with braking parameters. This study employs the W-M fractal theory to develop a finite element model of a rough friction interface containing hard-particle endogenous third bodies. The model is validated through experimental testing. Based on the performance test parameters of high-power wind turbine disc brakes, a simulation is conducted to analyse the contact friction process involving the endogenous third body at the rough interface between the brake disc and brake pad. The simulation reproduces the formation process of the endogenous third body and reveals its evolutionary stages, including “ploughing”, “gap-filling”, and “aggregation”. Additionally, the study examines changes in the internal stress–strain and vibration states of the friction system under varying braking speeds (5 m/s to 35 m/s) and braking loads (3 MPa to 6 MPa). The findings demonstrate how different braking parameters influence the friction system containing the endogenous third body. The results showed that when the braking speeds were 5 m/s, 15 m/s, 25 m/s, and 35 m/s, and the braking load was 6 MPa, the average amplitude of the brake pads was the smallest, at 0.017 mm, 0.021 mm, 0.025 mm, and 0.020 mm, respectively. This research provides valuable insights into the three-body contact friction mechanism at the micro-braking interface, the formation of composite material third bodies, and the role of wear-stage third bodies in affecting the friction interface. Full article

The friction pair gap affects not only the temperature increase of the multi-disc wet clutch, but also the efficiency of the helicopter transmission system. Consequently, a rotational–axial engagement and disengagement-coupled kinetic model of a wet multi-disc clutch considering asperity contact, hydrodynamic lubrication, spline resistance, and a separating spring model are developed in this paper. The effects of operating conditions on the dynamic characteristics of the wet clutch are investigated. Further, the gap deviation coefficient is proposed to characterize the dynamic behavior of the friction pair gap. As the control oil pressure increases from 1.3 MPa to 1.7 MPa, the gap deviation coefficient increases by 8.6%. Moreover, as the rotation speed increases from 888 rpm to 2488 rpm and the lubricant oil temperature increases from 25 °C to 85 °C, the gap deviation coefficient decreases by 1.1% and 4.44%, respectively. Therefore, an appropriate increase in lubricant oil temperature and rotation speed can facilitate the friction pair gap to be more uniform. These results are useful for the development of optimal control strategies for aviation wet clutch systems. Full article

Pavement texture and skid resistance are pivotal surface features of roadway to traffic safety, especially under wet weather. Engineering interventions should be scheduled periodically to restore these features as they deteriorate over time under traffic polishing. While many studies have investigated the effects of traffic polishing on pavement texture and skid resistance through laboratory experiments, the absence of real-world traffic and environmental factors in these studies may limit the generalization of their findings. This study addresses this research gap by conducting a comprehensive field study of pavement texture and skid resistance under traffic polishing in the real world. A total of thirty pairs of pavement texture and friction data were systematically collected from three distinct locations with different levels of traffic polishing (middle, right wheel path, and edge) along an asphalt pavement in Oklahoma, USA. Data acquisition utilized a laser imaging device to reconstruct 0.01 mm 3D images to characterize pavement texture and a Dynamic Friction Tester to evaluate pavement friction at different speeds. Twenty 3D areal parameters were calculated on whole images, macrotexture images, and microtexture images to investigate the effects of traffic polishing on pavement texture from different perspectives. Then, texture parameters and testing speeds were combined to develop friction prediction models via linear and nonlinear methodologies. The results indicate that Random Forest models with identified inputs achieved excellent performance for non-contact friction evaluation. Last, the friction decrease rate was discussed to estimate the timing of future maintenance to restore skid resistance. This study provides more insights into how engineers should plan maintenance to restore pavement texture and friction considering real-world traffic polishing. Full article

The clearance of a kinematic pair will lead to the contact collision between the joints of the mechanism, which will have a great influence on the dynamic characteristics of a mechanical system with clearance. In order to study the influence of a rotating motion pair with clearance on the dynamic characteristics of a tool changing robot, a contact wear dynamics model of a modular tool changing robot was established based on the three-state model of “free-contact-collision”. Different from analysis of a light linkage structure, this paper takes a solid structure with large mass as the analysis object. Based on the impact contact force model and the improved Coulomb friction model, the effects of clearance size, rotational speed and friction coefficient on the dynamic characteristics of the tool changing robot were analyzed. The Archard wear model was used to predict the wear between the motion pairs with clearance. The analysis results show that, with the increase of clearance size and actuating speed, the fluctuation range of velocity and acceleration increases, and the fluctuation frequency decreases. Under the action of friction, the contact force between components will be reduced due to energy loss so that the kinematic reliability of the mechanism is improved. The wear of the moving pair with clearance is non-uniform. Through the research of this paper, the motion characteristics of the tool-changing robot at low speed and heavy load are clarified. The results show that the established method can realize the dynamic characteristics analysis of low-speed heavy-duty mechanisms with joint gaps, which can be used to guide the design of tool-changing robots, and also has important reference significance for the design of mechanisms containing joint gaps in general. Full article

This article reviews the state of the knowledge and technology in the field of friction-loss measurements in internal combustion piston engines. The dependencies that describe the loss of energy in combustion engines and injection apparatus are presented. Currently, very little can be found in the literature on the study of frictional forces in injection apparatus, but mainly in the piston–cylinder group, so this work significantly fills that gap. The aim of this article is to construct a device and to develop a method for assessing the technical state of injector nozzles to minimize friction losses in internal combustion engines at the stages of evaluation, design, production and operation. This article presents a stand for determining the maximum friction forces due to gravity loading by water-jet control. This article also presents test results on the maximum friction force between a needle and a body of injector nozzles in piston combustion engines on a designed and purpose-built stand outside of the combustion engine. Various designs and injector nozzles are made from various types of alloy steel for marine and automotive piston internal combustion engines fueled with distillation or residual fuels, and are tested. The research concerned conventional elements for the injection apparatus as well as electronically controlled subsystems. Precision pairs of injection equipment are selected for the tests: new ones are employed after the storage period and operated in natural conditions. The elements dismantled from the internal combustion engines are tested in the presence of fuel or calibration oil of similar properties. The maximum static frictional forces under the hydrostatic loading are measured, alongside the parameters for the dynamic movement of the nozzle needles from bodies of the injector nozzle as time, speed, acceleration and dynamic force. The influence of the angular position of the needle in relation to the bodies of the precision pairs conventional internal combustion engines, the diametral clearance between the nozzle body and needle, and the surface conditions on the values of the maximum friction force are also presented. Errors in shape and position result in the uniqueness of the friction force at the mutual angular position of the needle in relation to the nozzle body, and the decrease in diametral clearance and deterioration of the surface state increase the friction losses. A model was elaborated of the influence of various factors on the value of the maximum friction force. Full article

The clutch temperature rise characteristics in successive shifting conditions are crucial to its thermal stability and thermal safety. In the present paper, a comprehensive numerical model is proposed to investigate the temperature change of separator discs during successive shifting with the consideration of convection heat transfer in disengaged friction pair gaps, which is validated by repeated shifting experiments on the SAE#2 test bench. Since the second separator disc near the piston has the widest disengaged gaps and double-sided heat input, its temperature rise and temperature drop are the highest. The temperature rise gradually equals the temperature drop with the increasing working cycle, then the maximum clutch temperature no longer increases. The longer the shifting interval, the better the heat dissipation is, thus the lower the accumulated temperature rise. Moreover, the increasing lubrication oil temperature reduces the convection heat transfer and increases the temperature rise in an engaging process, but the accumulated temperature rise does not increase due to the widened friction pair gaps. This paper can obtain the temperature rise characteristics of a wet multi-disc clutch concerning its disengaged gaps during successive shifting, which is a promising candidate for investigating its overall performance. Full article

Clutch disengaging dynamic characteristics, including the disengaging duration and the variations of friction pair gaps and friction torque, are crucial to the shifting control of an automatic transmission. In the present paper, the influence of lubrication oil (ATF) temperature on disengaging dynamic characteristics is investigated through a comprehensive numerical model for the clutch disengaging process, which considers the hydrodynamic lubrication, the asperity contact, the heat transfer, the spline resistance, and the impact between the piston and clutch hub. Moreover, the non-uniformity coefficient (NUC) is proposed to characterize the disengaging uniformity of friction pairs. As the ATF temperature increases from 60 °C to 140 °C, the clutch disengaging duration shortens remarkably (shortened by 55.1%); besides, the NUC sees a decreasing trend before a slight increase. When the ATF temperature is 80 °C, the distribution of friction pair gaps is most uniform. During the disengaging process, the increase of ATF temperature not only accelerates the change of the lubrication status between friction pairs but also contributes to the decrease of contact torque and hydrodynamic torque. This research demonstrates for the first time, evidence for clutch disengaging dynamic characteristics with the consideration of ATF temperature. Full article

In this work, the lubrication mechanism and friction-wear characteristics of the friction pair between carbon-fiber-reinforced polyether ether ketone (CF/PPEK) and 316L stainless steel with a micro-hemispherical pit textured surface at different sliding speeds under seawater lubrication were studied through numerical simulation and experimental investigation. The study results indicate that the seawater moves following the sliding direction of the upper specimen, forms a vortex ring flow in the hemispherical pit of the bottom specimen, uses the convergent gap to generate a hydrodynamic effect, produces the bearing capacity, and realizes fluid lubrication. The hemispherical pit diminishes the abrasive wear during the friction process by storing the wear debris, and the main wear forms of the hemispherical-pit surface friction pair are oxidative wear and adhesive wear. The friction coefficient of the hemispherical-pit surface friction pair is 0.018–0.027, the specimen contact temperature is 40.2–55.1 °C, and it is always in the hydrodynamic lubrication state in a rotation speed ranging from 1000 r/min to 1750 r/min. As the sliding speed increases, the specimen contact temperature climbs, and the oxidation reaction gradually becomes full. Oxidative wear and adhesive wear alternately play a dominant role in the friction, and the wear rate first decreases and then increases sharply. Full article

In the context of targeted improvements in energy efficiency, secondary rolling bearing contacts are gaining relevance. As such, the elastohydrodynamically lubricated (EHL) roller face/rib contact of tapered roller bearings significantly affects power losses. Consequently, this contribution aimed at numerical optimization of the pairing’s macro-geometric parameters. The latter were sampled by a statistical design of experiments (DoE) and the tribological behavior was predicted by means of EHL contact simulations. For each of the geometric pairings considered, a database was generated. Key target variables such as pressure, lubricant gap and friction were approximated by a meta-model of optimal prognosis (MOP) and optimization was carried out using an evolutionary algorithm (EA). It was shown that the tribological behavior was mainly determined by the basic geometric pairing and the radii while eccentricity was of subordinate role. Furthermore, there was a trade-off between high load carrying capacity and low frictional losses. Thereby, spherical or toroidal geometries on the roller end face featuring a large radius paired with a tapered rib geometry were found to be advantageous in terms of low friction. For larger lubricant film heights and load carrying capacity, spherical or toroidal roller on toroidal rib geometries with medium radii were favorable. Full article

The piston-cylinder pair is the key friction pairs in the piston pump. Its performance determines the volume efficiency of piston pump. With the increase of load pressure, the leakage at the clearance of piston-cylinder pair will also increase. In order to reduce leakage, the clearance of the piston-cylinder pair of the ultra-high pressure piston pump is smaller than that of the medium-high pressure piston pump. In order to explore whether the piston will stuck in the narrow gap, it is necessary to study the oil film characteristics of the piston-cylinder pair under the condition of ultra-high pressure, so as to provide a theoretical basis for the optimal design of the piston-cylinder pair of ultra-high pressure axial piston pump. In this paper, an ultra-high pressure axial piston pump is taken as the research object, and its structural characteristics are analyzed. The mathematical model of the oil film thickness of the piston-cylinder pair is established by using the cosine theorem in the cross section of the piston. The finite volume method is used to discretize the Reynolds equation of the oil film of the piston-cylinder pair, and the over relaxation iteration method is used to solve the discrete equations, and the mathematical model of the oil film pressure of the piston-cylinder pair is obtained. The mathematical model of oil film thickness and pressure field of piston-cylinder pair is solved by programming. The dynamic change process of oil film thickness and pressure field of the plunger pair of the ultra-high pressure axial piston pump under the load of 20 MPa and 70 MPa is obtained. Under the two conditions, the thinnest area of the oil film reaches 3 μm and 2 μm dangerous area respectively; the oil film pressure reaches 20 MPa and 70 MPa respectively when the swashplate rotates 10° and continues to increase with the increase of swashplate rotation angle. When the rotation angle reaches 90°, the oil film pressure also reaches the maximum value, but there is no pressure spike phenomenon. The oil film pressure characteristics of ultra-high pressure axial piston pump under conventional and ultra-high pressure conditions were obtained by modification and experimentation. Full article

This work describes the development, design, and parameter identification of a lychee peeling machine. The working principle of the machine combines two rollers with a pressing belt to separate the peel from the fruits. It was designed and its operational parameters identified on the basis of experimental data on the Thieu lychee, which currently covers about 80% of the plantation area in Vietnam. To this end, the first step was to measure the physical characteristics of the fruits, such as size, shape, and density. Moreover, the coefficient of static friction between lychees and rubber rollers, and the critical peeling force, were identified, with a view to optimizing the operational parameters later on. Results showed that a minimum tangential force of 10.5 N is needed to break the peel and separate it from the pulp. Based on the balanced force principle, various optimal machine parameters such as roller rotation speed, roller diameter, roller length, gap size between the two rollers, belt velocity, and minimum pressure of the belt were calibrated. In addition, spiral grooves were created on the roller surface to facilitate the motion of the fruits. The optimal results were roller size 900 × 100 mm (length × diameter), rotation speed 159 RPM, gap size between rollers 4 mm, belt size 850 × 60 mm (length × width), belt pressure 13.5 N, and belt velocity 140 mm/s. Using the design and operational parameters mentioned above, the machine was able to perform regularly at a throughput of 100 kg/h, as demanded by the current market. Moreover, it would be easily feasible to combine multiple pairs of rollers and pressing belts in order to increase throughput. The methodology for the design of this peeling machine and identification of working parameters with respect to experimental data could be applied in many other post-harvesting configurations. Full article

Active magnetic bearing (AMB) systems support rotating shafts without any physical contact, using electromagnetic forces. Each radial AMB uses two pairs of electromagnets at opposite sides of the rotor. This allows the rotor to float in the air gap, and the machine to operate without frictional losses. In active magnetic suspension, displacement sensors are necessary to detect the radial and axial movement of the suspended object. In a high-speed rotating machine equipped with an AMB, the rotor bending modes may be limited to the operating range. The natural frequencies of the rotor can cause instability. Thus, notch filters are a useful circuit for stabilizing the system. In addition, commercial displacement sensors are sometimes not suitable for AMB design, and cannot filter the noise caused by the natural frequencies of rotor. Hence, implementing displacement sensors based on the AMB structure is necessary to eliminate noises caused by natural frequency disturbances. The displacement sensor must be highly sensitive in the desired working range, and also exhibit a low interference noise, high stability, and low cost. In this study, we used the differential inductive sensor head and lock-in amplifier for synchronous demodulation. In addition, an active low-pass filter and a notch filter were used to eliminate disturbances, which caused by natural frequencies. As a consequence, the inductive displacement sensor achieved satisfactory linearity, high sensitivity, and disturbance elimination. This sensor can be easily produced for AMB applications. A prototype of these displacement sensors was built and tested. Full article