New reynolds equation for line contact based on the carreau model modification by bair

This paper presents a new form of the one-dimensional Reynolds equation for lubricants whose rheological behaviour follows a modified Carreau rheological model proposed by Bair. The results of the shear stress and flow rate obtained through a new Reynolds–Carreau equation are shown and compared with the results obtained by other researchers.

Axial wedge effect in tilted hydrodynamic journal bearings

Hydrodynamic journal bearings are susceptible to static angular misalignment, resulting from improper assemblage, elastic and thermal distortion of the shaft and bearing housing, and also manufacturing errors. Several previous works on the theme, both theoretical and experimental, focused on the determination of the static properties of angular misaligned bearings. Although some reports show agreement between theoretical and experimental results, the increasingly severe operating conditions of hydrodynamic bearings (heavy loads and high rotational speeds) require more reliable theoretical formulations for the evaluation of the journal performance during the design process. The consideration of the angular misalignment in the derivation of the Reynolds equation is presented here in detail, showing that properly conducted geometric and magnitude-order analyses lead to the inclusion of an axial wedge effect term that influences the velocity and pressure fields in the lubricant film. Numerical results evidence that this axial wedge effect more significantly affects the hydrodynamic forces and static operational properties of tilted short journal bearings.

A review of drainage and spontaneous rupture in free standing thin films with tangentially immobile interfaces

A review of spontaneous rupture in thin films with tangentially immobile interfaces is presented that emphasizes the theoretical developments of film drainage and corrugation growth through the linearization of lubrication theory in a cylindrical geometry. Spontaneous rupture occurs when corrugations from adjacent interfaces become unstable and grow to a critical thickness. A corrugated interface is composed of a number of waveforms and each waveform becomes unstable at a unique transition thickness. The onset of instability occurs at the maximum transition thickness, and it is shown that only upper and lower bounds of this thickness can be predicted from linear stability analysis. The upper bound is equivalent to the Freakel criterion and is obtained from the zeroth order approximation of the H-3 term in the evolution equation. This criterion is determined solely by the film radius, interfacial tension and Hamaker constant. The lower bound is obtained from the first order approximation of the H-3 term in the evolution equation and is dependent on the film thinning velocity A semi-empirical equation, referred to as the MTR equation, is obtained by combining the drainage theory of Manev et al. [J. Dispersion Sci. Technol., 18 (1997) 769] and the experimental measurements of Radoev et al. [J. Colloid Interface Sci. 95 (1983) 254] and is shown to provide accurate predictions of film thinning velocity near the critical thickness of rupture. The MTR equation permits the prediction of the lower bound of the maximum transition thickness based entirely on film radius, Plateau border radius, interfacial tension, temperature and Hamaker constant. The MTR equation extrapolates to Reynolds equation under conditions when the Plateau border pressure is small, which provides a lower bound for the maximum transition thickness that is equivalent to the criterion of Gumerman and Homsy [Chem. Eng. Commun. 2 (1975) 27]. The relative accuracy of either bound is thought to be dependent on the amplitude of the hydrodynamic corrugations, and a semiempirical correlation is also obtained that permits the amplitude to be calculated as a function of the upper and lower bound of the maximum transition thickness. The relationship between the evolving theoretical developments is demonstrated by three film thickness master curves, which reduce to simple analytical expressions under limiting conditions when the drainage pressure drop is controlled by either the Plateau border capillary pressure or the van der Waals disjoining pressure. The master curves simplify solution of the various theoretical predictions enormously over the entire range of the linear approximation. Finally, it is shown that when the Frenkel criterion is used to assess film stability, recent studies reach conclusions that are contrary to the relevance of spontaneous rupture as a cell-opening mechanism in foams. (C) 2003 Elsevier Science B.V. All rights reserved.

A Mass-Conserving Algorithm for Dynamical Lubrication Problems With Cavitation

A numerical algorithm for fully dynamical lubrication problems based on the Elrod-Adams formulation of the Reynolds equation with mass-conserving boundary conditions is described. A simple but effective relaxation scheme is used to update the solution maintaining the complementarity conditions on the variables that represent the pressure and fluid fraction. The equations of motion are discretized in time using Newmark`s scheme, and the dynamical variables are updated within the same relaxation process just mentioned. The good behavior of the proposed algorithm is illustrated in two examples: an oscillatory squeeze flow (for which the exact solution is available) and a dynamically loaded journal bearing. This article is accompanied by the ready-to-compile source code with the implementation of the proposed algorithm. [DOI: 10.1115/1.3142903]

Analytical investigation of squeeze film dampers

Squeeze film damping effects naturally occur if structures are subjected to loading situations such that a very thin film of fluid is trapped within structural joints, interfaces, etc. An accurate estimate of squeeze film effects is important to predict the performance of dynamic structures. Starting from linear Reynolds equation which governs the fluid behavior coupled with structure domain which is modeled by Kirchhoff plate equation, the effects of nondimensional parameters on the damped natural frequencies are presented using boundary characteristic orthogonal functions. For this purpose, the nondimensional coupled partial differential equations are obtained using Rayleigh-Ritz method and the weak formulation, are solved using polynomial and sinusoidal boundary characteristic orthogonal functions for structure and fluid domain respectively. In order to implement present approach to the complex geometries, a two dimensional isoparametric coupled finite element is developed based on Reissner-Mindlin plate theory and linearized Reynolds equation. The coupling between fluid and structure is handled by considering the pressure forces and structural surface velocities on the boundaries. The effects of the driving parameters on the frequency response functions are investigated. As the next logical step, an analytical method for solution of squeeze film damping based upon Green’s function to the nonlinear Reynolds equation considering elastic plate is studied. This allows calculating modal damping and stiffness force rapidly for various boundary conditions. The nonlinear Reynolds equation is divided into multiple linear non-homogeneous Helmholtz equations, which then can be solvable using the presented approach. Approximate mode shapes of a rectangular elastic plate are used, enabling calculation of damping ratio and frequency shift as well as complex resistant pressure. Moreover, the theoretical results are correlated and compared with experimental results both in the literature and in-house experimental procedures including comparison against viscoelastic dampers.

Approximate Analytical Model for the Squeeze-Film Lubrication of the Human Ankle Joint with Synovial Fluid Filtrated by Articular Cartilage

The aim of this article is to propose an analytical approximate squeeze-film lubrication model of the human ankle joint for a quick assessment of the synovial pressure field and the load carrying due to the squeeze motion. The model starts from the theory of boosted lubrication for the human articular joints lubrication (Walker et al., Rheum Dis 27:512–520, 1968; Maroudas, Lubrication and wear in joints. Sector, London, 1969) and takes into account the fluid transport across the articular cartilage using Darcy’s equation to depict the synovial fluid motion through a porous cartilage matrix. The human ankle joint is assumed to be cylindrical enabling motion in the sagittal plane only. The proposed model is based on a modified Reynolds equation; its integration allows to obtain a quick assessment on the synovial pressure field showing a good agreement with those obtained numerically (Hlavacek, J Biomech 33:1415–1422, 2000). The analytical integration allows the closed form description of the synovial fluid film force and the calculation of the unsteady gap thickness.

Análisis de la influencia de los diferentes parámetros de diseño en la aparición de fatiga superficial en contactos mecánicos

La fatiga superficial es uno de los principales problemas en las transmisiones mecánicas y es uno de los focos de atención de las investigaciones de los últimos anos en Tribología. La disminución de viscosidad de los lubricantes para la mejora de la eficiencia, el aumento de las potencias a transmitir, el aumento de la vida de los componentes o la mejora de su fiabilidad han supuesto que los fenómenos de fatiga superficial hayan cobrado especial relevancia, especialmente los fenómenos de pitting y micropitting en cajas multiplicadoras/reductoras de grandes potencias de aplicación, por ejemplo, en el sector eólico. Como todo fenómeno de fatiga, el pitting y micropitting son debidos a la aplicación de cargas ciclicas. Su aparición depende de las presiones y tensiones cortantes en el contacto entre dos superficies que al encontrarse en rodadura y deslizamiento varian con el tiempo. La principal consecuencia de la fatiga superficial es la aparición de hoyuelos de diferente magnitud segun la escala del fenómeno (pitting o micropitting) en la superficie del material. La aparición de estos hoyuelos provoca la perdida de material, induce vibraciones y sobrecargas en el elemento que finalmente acaba fallando. Debido a la influencia de la presión y tensión cortante en el contacto, la aparición de fatiga depende fuertemente del lubricante que se encuentre entre las dos superficies y de las condiciones de funcionamiento en las cuales este trabajando. Cuando el contacto trabaja en condiciones de lubricacion mixta-elastohidrodinamica tiende a aparecer micropitting debido a las altas tensiones localizadas en las proximidades de las asperezas, mientras que si el régimen es de lubricación completa el tipo de fatiga superficial suele ser pitting debido a las tensiones mas suavizadas y menos concentradas. En esta Tesis Doctoral se han analizado todos estos factores de influencia que controlan el pitting y el micropitting prestando especial atención al efecto del lubricante. Para ello, se ha dado un enfoque conjunto a ambos fenómenos resolviendo las ecuaciones involucradas en el contacto elastohidrodinamico no-Newtoniano (la ecuación de Reynolds, la deformación elástica de los sólidos y la reologia del lubricante) para conocer la presión y la tensión cortante en el contacto. Conocidas estas, se resuelve el campo de tensiones en el interior del material y, finalmente, se aplican criterios de fatiga multiaxial (Crossland, Dang Van y Liu-Mahadevan) para conocer si el material falla o no falla. Con la metodología desarrollada se ha analizado el efecto sobre las tensiones y la aparición de la fatiga superficial del coeficiente viscosidad-presion, de la compresibilidad, del espesor especifico de película y de la fricción así como de la influencia de las propiedades a fatiga del material y de las condiciones de funcionamiento (radios de contacto, velocidad, deslizamiento, carga y temperatura). Para la validación de los resultados se han utilizado resultados teóricos y experimentales de otros autores junto con normas internacionales de amplia utilización en el mundo industrial, entre otras, para el diseño y calculo de engranajes. A parte del trabajo realizado por simulación y cálculo de los diferentes modelos desarrollados, se ha realizado un importante trabajo experimental que ha servido no solo para validar la herramienta desarrollada sino que además ha permitido incorporar al estudio factores no considerados en los modelos, como los aditivos del lubricante. Se han realizado ensayos de medida del coeficiente de fricción en una maquina de ensayo puntual con la que se ha validado el cálculo del coeficiente de fricción y se ha desarrollado un proceso de mejora del coeficiente de fricción mediante texturizado superficial en contactos puntuales elastohidrodinamicos mediante fotolitografia y ataque quimico. Junto con los ensayos de medida de fricción en contacto puntual se han realizado ensayos de fricción y fatiga superficial en contacto lineal mediante una maquina de discos que ha permitido evaluar la influencia de diferentes aditivos (modificadores de fricción, antidesgaste y extrema-presion) en la aparición de fatiga superficial (pitting y micropitting) y la fricción en el contacto. Abstract Surface fatigue is one of the most important problems of mechanical transmissions and therefore has been one of the main research topics on Tribology during the last years. On the one hand, industrial demand on fuel economy has led to reduce lubricant viscosity in order to improve efficiency. On the other hand, the requirements of power and life of machine elements are continuously increasing, together with the improvements in reliability. As a consequence, surface fatigue phenomena have become critical in machinery, in particular pitting and micropitting in high power gearboxes of every kind of machines, e.g., wind turbines or cranes. In line with every fatigue phenomena, pitting and micropitting are caused by cyclic loads. Their appearance depends on the evolution of pressures and shear stresses with time, throughout the contact between surfaces under rolling and sliding conditions. The main consequence of surface fatigue is the appearance of pits on the surface. The size of the pits is related to the scale of the fatigue: pitting or micropitting. These pits cause material loss, vibrations and overloads until the final failure is reached. Due to the great influence of the pressures and shear stresses in surface fatigue, the appearance of pits depends directly on the lubricant and the operating conditions. When the contact works under mixed regime (or under elastohydrodynamic but close to mixed regime) the main fatigue failure is micropitting because of the high pressures located near the asperities. In contrast, when the contact works under elastohydrodynamic fully flooded conditions the typical fatigue failure is pitting. In this Ph.D. Thesis, the main factors with influence on pitting and micropitting phenomena are analyzed, with special attention to the effect of the lubricant. For this purpose, pitting and micropitting are studied together by solving the equations involved in the non-Newtonian elastohydrodynamic contact. Thus, pressure and shear stress distributions are found by taking into account Reynolds equation, elastic deflection of the solids and lubricant rheology. Subsequently, the stress field inside the material can be calculated and different multiaxial fatigue criteria (Crossland, Dang Van and Liu- Mahadevan) can be applied to predict whether fatigue failure is reached. The influences of the main parameters on pressure and surface fatigue have been studied, taking into account the lubricant compressibility and its viscosity-pressure coefficient, the specific film thickness, the friction coefficient and the fatigue properties of the contacting materials, together with the operating conditions (contact radius, mean velocity, sliding velocity, load and temperature). Several theoretical and experimental studies of different authors have been used to validate all the results obtained, together with international standards used worldwide in gear design industry. Moreover, an experimental stage has been carried out in order to validate the calculation methods and introduce additional influences not included previously, e.g., lubricant additives. The experimentation includes different friction tests in point contacts performed with a tribological equipment in order to validate the results given by the calculations. Furthermore, the reduction and optimization of the friction coefficient is analyzed by means of textured surfaces, obtained combining photolithography and chemical etching techniques. Besides the friction tests with point contact, friction and surface fatigue tests have also been performed with line contact in a tribological test rig. This equipment is also used to study the influence of different types of additives (friction modifiers, anti-wear and extreme-pressure additives) on surface fatigue (pitting and micropitting).

On the development of advanced techniques for mixed-elastohydrodynamic lubrification modelling of journal and sliding bearing systems.

The present thesis is focused on the development of a thorough mathematical modelling and computational solution framework aimed at the numerical simulation of journal and sliding bearing systems operating under a wide range of lubrication regimes (mixed, elastohydrodynamic and full film lubrication regimes) and working conditions (static, quasi-static and transient conditions). The fluid flow effects have been considered in terms of the Isothermal Generalized Equation of the Mechanics of the Viscous Thin Films (Reynolds equation), along with the massconserving p-Ø Elrod-Adams cavitation model that accordingly ensures the so-called JFO complementary boundary conditions for fluid film rupture. The variation of the lubricant rheological properties due to the viscous-pressure (Barus and Roelands equations), viscous-shear-thinning (Eyring and Carreau-Yasuda equations) and density-pressure (Dowson-Higginson equation) relationships have also been taken into account in the overall modelling. Generic models have been derived for the aforementioned bearing components in order to enable their applications in general multibody dynamic systems (MDS), and by including the effects of angular misalignments, superficial geometric defects (form/waviness deviations, EHL deformations, etc.) and axial motion. The bearing exibility (conformal EHL) has been incorporated by means of FEM model reduction (or condensation) techniques. The macroscopic in fluence of the mixedlubrication phenomena have been included into the modelling by the stochastic Patir and Cheng average ow model and the Greenwood-Williamson/Greenwood-Tripp formulations for rough contacts. Furthermore, a deterministic mixed-lubrication model with inter-asperity cavitation has also been proposed for full-scale simulations in the microscopic (roughness) level. According to the extensive mathematical modelling background established, three significant contributions have been accomplished. Firstly, a general numerical solution for the Reynolds lubrication equation with the mass-conserving p - Ø cavitation model has been developed based on the hybridtype Element-Based Finite Volume Method (EbFVM). This new solution scheme allows solving lubrication problems with complex geometries to be discretized by unstructured grids. The numerical method was validated in agreement with several example cases from the literature, and further used in numerical experiments to explore its exibility in coping with irregular meshes for reducing the number of nodes required in the solution of textured sliding bearings. Secondly, novel robust partitioned techniques, namely: Fixed Point Gauss-Seidel Method (PGMF), Point Gauss-Seidel Method with Aitken Acceleration (PGMA) and Interface Quasi-Newton Method with Inverse Jacobian from Least-Squares approximation (IQN-ILS), commonly adopted for solving uid-structure interaction problems have been introduced in the context of tribological simulations, particularly for the coupled calculation of dynamic conformal EHL contacts. The performance of such partitioned methods was evaluated according to simulations of dynamically loaded connecting-rod big-end bearings of both heavy-duty and high-speed engines. Finally, the proposed deterministic mixed-lubrication modelling was applied to investigate the in fluence of the cylinder liner wear after a 100h dynamometer engine test on the hydrodynamic pressure generation and friction of Twin-Land Oil Control Rings.

Scaling laws for the critical rupture thickness or common thin films

Despite decades of experimental and theoretical investigation on thin films, considerable uncertainty exists in the prediction of their critical rupture thickness. According to the spontaneous rupture mechanism, common thin films become unstable when capillary waves. at the interfaces begin to grow. In a horizontal film with symmetry at the midplane. unstable waves from adjacent interfaces grow towards the center of the film. As the film drains and becomes thinner, unstable waves osculate and cause the film to rupture, Uncertainty sterns from a number of sources including the theories used to predict film drainage and corrugation growth dynamics. In the early studies, (lie linear stability of small amplitude waves was investigated in the Context of the quasi-static approximation in which the dynamics of wave growth and film thinning are separated. The zeroth order wave growth equation of Vrij predicts faster wave growth rates than the first order equation derived by Sharma and Ruckenstein. It has been demonstrated in an accompanying paper that film drainage rates and times measured by numerous investigations are bounded by the predictions of the Reynolds equation and the more recent theory of Manev, Tsekov, and Radoev. Solutions to combinations of these equations yield simple scaling laws which should bound the critical rupture thickness of foam and emulsion films, In this paper, critical thickness measurements reported in the literature are compared to predictions from the bounding scaling equations and it is shown that the retarded Hamaker constants derived from approximate Lifshitz theory underestimate the critical thickness of foam and emulsion films, The non-retarded Hamaker constant more adequately bounds the critical thickness measurements over the entire range of film radii reported in the literature. This result reinforces observations made by other independent researchers that interfacial interactions in flexible liquid films are not adequately represented by the retarded Hamaker constant obtained from Lifshitz theory and that the interactions become significant at much greater separations than previously thought. (c) 2005 Elsevier B.V. All rights reserved.

Dynamic behaviour of rotary mechanical seals

This thesis covers both experimental and computer investigations into the dynamic behaviour of mechanical seals. The literature survey shows no investigations on the effect of vibration on mechanical seals of the type common in the various process industries. Typical seal designs are discussed. A form of Reynolds' equation has been developed that permits the calculation of stiffnesses and damping coefficients for the fluid film. The dynamics of the mechanical seal floating ring have been investigated using approximate formulae, and it has been shown that the floating ring will behave as a rigid body. Some elements, such as the radial damping due to the fluid film, are small and may be neglected. The equations of motion of the floating ring have been developed utilising the significant elements, and a solution technique described. The stiffness and damping coefficients of nitrile rubber o-rings have been obtained. These show a wide variation, with a constant stiffness up to 60 Hz. The importance of the effect of temperature on the properties is discussed. An unsuccessful test rig is described in the appendices. The dynamic behaviour of a mechanical seal has been investigated experimentally, including the effect of changes of speed, sealed pressure and seal geometry. The results, as expected, show that high vibration levels result in both high leakage and seal temperatures. Computer programs have been developed to solve Reynolds' Equation and the equations of motion. Two solution techniques for this latter program were developed, the unsuccesful technique is described in the appendices. Some stability problems were encountered, but despite these the solution shows good agreement with some of the experimental conditions. Possible reasons for the discrepancies are discussed. Various suggestions for future work in this field are given. These include the combining of the programs and more extensive experimental and computer modelling.

Computations of the flow past a still sphere at moderate reynolds numbers using an immersed boundary method

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

A Reynolds stress model for turbulent flows of viscoelastic fluids

A second-order closure is developed for predicting turbulent flows of viscoelastic fluids described by a modified generalised Newtonian fluid model incorporating a nonlinear viscosity that depends on a strain-hardening Trouton ratio as a means to handle some of the effects of viscoelasticity upon turbulent flows. Its performance is assessed by comparing its predictions for fully developed turbulent pipe flow with experimental data for four different dilute polymeric solutions and also with two sets of direct numerical simulation data for fluids theoretically described by the finitely extensible nonlinear elastic - Peterlin model. The model is based on a Newtonian Reynolds stress closure to predict Newtonian fluid flows, which incorporates low Reynolds number damping functions to properly deal with wall effects and to provide the capability to handle fluid viscoelasticity more effectively. This new turbulence model was able to capture well the drag reduction of various viscoelastic fluids over a wide range of Reynolds numbers and performed better than previously developed models for the same type of constitutive equation, even if the streamwise and wall-normal turbulence intensities were underpredicted.

An engineering modification of the blade element momentum equation for vertical descent : an autoration case study

An engineering modification of blade element/momentum theory is applied to describe the vertical autorotation of helicopter rotors. A full non-linear aerodynamic model is considered for the airfoils, taking into account the dependence of lift and drag coefficients on both the angle of attack and the Reynolds number. The proposed model, which has been validated in previous work, has allowed the identification of different autorotation modes, which depend on the descent velocity and the twist of the rotor blades. These modes present different radial distributions of driven and driving blade regions, as well as different radial upwash/downwash patterns. The number of blade sections with zero tangential force, the existence of a downwash region in the rotor disk, the stability of the autorotation state, and the overall rotor autorotation efficiency, are all analyzed in terms of the flight velocity and the characteristics of the rotor. It is shown that, in vertical autorotation, larger blade twist leads to smaller values of descent velocity for a given thrust generated by the rotor in the autorotational state.

Shelf-life of a 2.5% sodium hypochlorite solution as determined by arrhenius equation

Accelerated stability tests are indicated to assess, within a short time, the degree of chemical degradation that may affect an active substance, either alone or in a formula, under normal storage conditions. This method is based on increased stress conditions to accelerate the rate of chemical degradation. Based on the equation of the straight line obtained as a function of the reaction order (at 50 and 70 ºC) and using Arrhenius equation, the speed of the reaction was calculated for the temperature of 20 ºC (normal storage conditions). This model of accelerated stability test makes it possible to predict the chemical stability of any active substance at any given moment, as long as the method to quantify the chemical substance is available. As an example of the applicability of Arrhenius equation in accelerated stability tests, a 2.5% sodium hypochlorite solution was analyzed due to its chemical instability. Iodometric titration was used to quantify free residual chlorine in the solutions. Based on data obtained keeping this solution at 50 and 70 ºC, using Arrhenius equation and considering 2.0% of free residual chlorine as the minimum acceptable threshold, the shelf-life was equal to 166 days at 20 ºC. This model, however, makes it possible to calculate shelf-life at any other given temperature.

LOCAL HEAD LOSS OF NON-COAXIAL EMITTERS INSERTED IN POLYETHYLENE PIPE

The design of a lateral line for drip irrigation requires accurate evaluation of head losses in not only the pipe but in the emitters as well. A procedure was developed to determine localized head losses within the emitters by the formulation of a mathematical model that accounts for the obstruction caused by the insertion point. These localized losses can be significant when compared with tire total head losses within the system due to the large number of emitters typically installed along the lateral line. Air experiment was carried out by altering flow characteristics to create Reynolds numbers (R) from 7,480 to 32,597 to provide turbulent flow and a maximum velocity of 2.0 m s(-1). The geometry of the emitter was determined by an optical projector and sensor An equation was formulated to facilitate the localized head loss calculation using the geometric characteristics of the emitter (emitter length, obstruction ratio, and contraction coefficient). The mathematical model was tested using laboratory measurements on four emitters. The local head loss was accurately estimated for the Uniram (difference of +13.6%) and Drip Net (difference of +7.7%) emitters, while appreciable deviations were found for the Twin Plus (-21.8%) and Tiran (+50%) emitters. The head loss estimated by the model was sensitive to the variations in the obstruction area of the emitter However, the variations in the local head loss did not result in significant variations in the maximum length of the lateral lines. In general, for all the analyzed emitters, a 50% increase in the local head loss for the emitters resulted in less than an 8% reduction in the maximum lateral length.