AITC-AIT 2006 International Conference on Tribology 20-22 September 2006, Parma, Italy

THE EFFECT OF SURFACE TEXTURING IN SOFT ELASTOHYDRODYNAMIC LUBRICATION

A. SHINKARENKO, Y. KLIGERMAN, I. ETSION Faculty of Mechanical Engineering, Technion-Israel Institute of Technology, Technion City, Haifa, 32000, Israel
alexay@tx.technion.ac.il, mermdyk@technion.ac.il, etsion@technion.ac.il

ABSTRACT A theoretical model is developed to study the potential use of laser surface texturing (LST) in the form of spherical micro-dimples for Soft Elasto-Hydrodynamic Lubrication (SEHL). The model consists of mutual smooth elastomeric and LST rigid surfaces moving relative to each other in the presence of viscous lubricant. The main goal of LST is to improve the tribological performance of mechanical components. For this purpose three different criteria of LST effectiveness are proposed according to the type of application. These are: minimum viscous friction force, minimum lubricant leakage and maximum load carrying capacity. The main applications of this model are several types of elastomeric seals, such as Rotary Lip Seal, Elastomeric Rectangular Seal and others. KEYWORDS Elasto-Hydrodynamic Lubrication, Elastomeric Seals, Laser Surface Texturing.

INTRODUCTION

In the last 80 years the SEHL was used in several mechanical components like rotary lip seals [1-2], elastomeric rectangular seals [3-5], metering size press [6] etc. Until the last decade most studies of SEHL were experimental because of the complexity of the problem. The first significant analytical models appeared in the literature after the 1995s thanks to the rapid development of computers and commercial software. Shi and Salant [1] developed a deterministic mixed lubrication model, governing the interface between a moving perfectly smooth rigid surface and stationary rough perfectly elastic surface. The asperity pattern on the lip surface (roughness) is modeled by a two-dimensional sinusoid. The model was applied to rotary lip seal. The authors divided the domain between the surfaces into three regions: the lubrication region, the cavitation region and the contact region. In a following study of Shi and Salant [2], the authors expanded their model to a more realistic condition of a quasi-random sealing surface. The results showed that interasperity cavitation appears at extremely low shaft speeds, and the flattening of asperities is significant throughout the entire range of operation. Furthermore, the shear deformation of asperities plays an important role in preventing leakage.

Rectangular elastomeric seals that are used in reciprocating hydraulic systems are yet another application of SEHL. Nikas [3, 4] developed a numerical model to study the sealing performance of rectangular elastomeric seals for reciprocating piston rods used in linear hydraulic actuators. The model is used to calculate the contact pressures and film thickness maps as well as the leakage rates and friction for the dynamic or static contact between a seal and a reciprocating piston rod, aiming at the minimization of both the leakage and the wear of the seals. The models [3, 4] assumed that the elastomer obeys the Hookes law. This assumption was checked in a following study of Nikas and Sayles [5]. The authors used a non-linear constitutive law (Mooney-Rivlin model) instead of the classic Hookean model of linear elasticity. It was shown that the difference in the results of linear and non-liner models is usually between 0-5% but it can be as high as 15% depending on operating conditions. The main criteria of well designed seal are minimum friction force and leakage. LST is known as an effective way for significant improvement of load capacity, wear resistance and friction reduction in mechanical components such as: mechanical seals [7-9]; piston rings [1012]; bearings [13]. An extensive review of LST can be found in Ref. [14]. The present study investigates the effect of LST on the effectiveness criteria (load carrying capacity, viscous friction force and leakage) in SEHL. An intensive parametric analysis reveals that the only parameters of LST affecting the criteria proposed above are dimple aspect ratio and area density. The elastomer physical properties and the viscosity of lubricant under given operating conditions (temperature, sliding velocity and pressure gradient) also affect the effectiveness of LST. The optimum parameters of surface texturing (dimple depth, diameter and area density), for the best tribological performance, are evaluated.

ANALITICAL MODEL
Lx U c Pa x3 Elastic layer Rigid slider Pa hp x1 Fluid Film

Ly

x2

Rigid foundation

Figure 1: Schematic illustration of the problem

A schematic illustration of the problem is given in Figure 1. A rigid LST slider moves with a constant velocity, U, above an elastic layer. The slider has a length, Lx, in the x1 direction and is infinitely long in the x3 direction. The elastic layer has a thickness, Ly, in the x2 direction and is infinitely long in the two other directions (x1 and x3). The elastic layer is attached to a rigid foundation and is separated from the slider by a thin layer of fluid lubricant (c is the nominal clearance between the slider and the elastic layer). A more detailed description of LST is presented in Figure 2. The dimples are uniformly distributed within the slider surface (see Figure 2(a)) with an area density Sp. Each dimple is modeled by an axisymmetric spherical

segment having a base radius rp and maximum depth hp located in the center of an imaginary square cell of sides 2 r1 2 r1 (see Figure 2(b)) where: rp r1 = Sp (1) 2

x3

U (a) (b)

2r1

x1

2rp

2r1 2r1 p(x1,x3=r1) x1 p(x1,x3=-r1) (c) 2r1

x3 2r1

Figure 2: A geometrical model of a laser textured surface: (a) dimples distribution; (b) individual cell with a single dimple; (c) one dimple column

As a result of LST (see Ref. [9-14]) a hydrodynamic pressure is generated in the narrow gap between the mating surfaces. This hydrodynamic pressure field leads to deformation of the elastomeric layer. Thus, the problem includes two different domains: Hydrodynamic lubrication and Deformation of elastomers.
Hydrodynamic Lubrication Generally fluid flow problems are described by the Navier-Stocks equations, however for thin fluid films these equations could be reduced to the Reynolds equation. The twodimensional, time independent form of the Reynolds equation for an incompressible Newtonian fluid in laminar flow is given by: h 3 p 3 p (2) h x + x h x = 6U x x1 1 3 3 1 2.1

where xi are the Cartesian coordinates; p is the local pressure; h is the local film thickness; is the dynamic viscosity of the fluid; U is the slider velocity. The local film thickness is given as: (3) h( x1 , x3 ) = c + h0 ( x1 , x3 ) + ( x1 , x3 )

where (x1,x3) is the deformation of the surface of the elastic layer; c is the nominal initial clearance (see Figure 1); h0(x1,x3) is the local depth of the dimple (see [10, 13]). Because of the periodicity of the surface texturing in the x3 direction (see Figure 2), and the symmetry in each axial dimple column of width 2r1 (Figure 2(c)) about its longitudinal axis, it is sufficient to consider the pressure distribution within just one half of one dimple column. Thus, the boundary conditions for the Reynolds equation (2) are as follows:

symmetry in the x3 direction (see Figure 2(c)): p (4a) (x1 , x 3 = 0 ) = p (x1 , x 3 = r1 ) = 0 x3 x3 ambient pressure at the the inlet and outlet of the slider (see Figure 1): (4b) p ( x1 = 0 , x 3 ) = p ( x1 = L x , x 3 ) = Pa The boundary conditions (4) should be completed by the condition at boundaries of cavitation regions. In the present paper Reynolds boundary condition (also known as SwiftSteiber) was applied. The Reynolds equation (2) with its boundary conditions (4) was solved by a finite difference method. This method leads to a set of linear algebraic equations for the nodal value of the pressure. These were solved using S.O.R. iterative method.
2.2 Deformable elastomer model Calculation of the deformations in the elastic layer is based on the following assumptions: 1. Elastomer is isotropic and homogeneous ; 2. Deformations of elastomer are small (geometric linearity); 3. Elastomer obeys Hookes law (physical linearity); 4. Elastomer is almost incompressible (Poissons ratio 0.49<<0.5). The time independent equilibrium equations (when body forces are neglected), linear straindisplacement relation and linear constitutive law (Hookes law) are given by: (5) ij , j = 0

ij =

1 ui , j + u j ,i ; 2

ui , j =

ui x j

(6)

1, if i = j (7) kk ij ; ij = ij + 0, if i j 1 2 where ij,j is the divergence of the stress tensor ij; ij is a deformation tensor and ui is the displacement vector; E is Youngs modulus and is Poissons ratio. The boundary conditions assumed for the elastomer model are: the bottom surface of the elastomer is attached to a rigid foundation (see Figure 1), thus all displacements are zero: (8a) u i ( x1 , x 2 = L y , x3 ) = 0 E ij = 1 +

the effect of the viscous shear stresses in the fluid film on the upper surface of the elastomer is neglected compared to that of the fluid film pressure. Thus, in the region 0 x1 Lx (see Figure1):

22 ( x1 , x 2 = 0, x3 ) = ( p ( x1 , x3 ) Pa ) 22 ( x1 , x 2 = 0, x3 ) = 0

(8b)

and in the region x1 0 or x1 Lx : symmetry in the fluid pressure distribution leads to similar symmetrical deformation in the elastic layer about the planes x 3 = 0 and x3 = r1 . This leads to the following boundary conditions for the displacement u3 and the x3 derivatives of the displacements u1 and u2 (see Figures 1 and 2):

u 3 ( x1 , x2 , x3 = 0) = u 3 ( x1 , x 2 , x3 = r1 ) = 0; u1 u ( x1 , x2 , x3 = 0) = 1 ( x1 , x2 , x3 = r1 ) = 0; x3 x3
(8c)

u 2 u ( x1 , x 2 , x3 = 0) = 2 ( x1 , x 2 , x3 = r1 ) = 0; x3 x3 Substituting of eq. (6) into eq. (7) and then into eq. (5) and eqs. (8b-8c) leads to the deformable elastomer model formulation in terms of the displacement components only. This problem is solved in the present work using the Finite Element Method.
The Soft Elasto-Hydrodynamic Lubrication Due to the mutual effect of the fluid film pressure and the elastomer deformation on each other a simultaneous iterative solution of eq. (2) and eqs. (5) to (7) is required. An initial approximation for the geometry of the gap and the fluid film pressure distribution is used to solve eq. (2) and obtain the next pressure distribution. This pressure field leads to deformation of the elastomeric layer that is now evaluated by using the theory of linear elasticity eqs. (5-7). These deformations change the film thickness, eq. (3). The modified film thickness profile is returned to the Reynolds equation, etc. The iterative process is repeated until a desired convergence is achieved. Following such convergence the tribological performance can be calculated The load carrying capacity above one half of one dimples column, Wlc, is obtained by integrating the pressure over the area: (9) Wlc = ( p ( x1 , x3 ) Pa )dx1 dx3 2.3

where A=r1Lx is the area of half of one dimple column. The friction force, Ff, due to shear stresses (assuming negligible pressure gradient effect) in the fluid film, acting on one half of one dimples column area is given by:

F f = U
The leakage, q x1 , is:

dx 1 dx 3 h
dx 3

(10)

h 3 p h q x1 = 12 x + 2 U 1
3 RESULTS

(11)

As was pointed out a good measure of the effectiveness of LST is the friction force and load carrying capacity. Hence, a parametric analysis was performed to study the effect of the following parameters on the friction force and load carrying capacity: 1. Parameters of LST: dimple diameter, 2rp; dimple depth, hp; dimple area density, Sp. 2. Parameters of operating conditions and elastomer properties: lubricant viscosity and slider velocity, U; nominal clearance, c; length of slider (or length of lubricated region), Lx; thickness of the elastic layer, Ly; its Youngs modulus, E, and Poissons ratio, . The main goal of the parametric analysis is to optimize the parameters of LST for a given elastomer and operating conditions. In addition, the effects of elastomer properties and operating conditions on the friction losses and load carrying capacity were investigated. The

parameters of LST, elastomer properties and operating conditions were varied over a wide range as shown in Table 1. Parameter Dimple Area Density [%], Sp Dimple Depth [m], hp Dimple Diameter [m], 2rp Bearing Number [Paxm], 6U Nominal Clarence [m], c Length of Slider [mm], Lx Youngs Modulus [MPa], E Poissons Ratio, Thickness of Elastic Layer [mm], Ly Minimum Value 5 0 80 0.1 0.5 0.5 5 0.499 0 Reference Value 10 10 100 0.6 1.5 1.5 10 0.499 0.5 Maximum Value 20 20 120 1.2 3 3 20 0.499 2

Table 1: Range of the dimensionless parameters variation

Figure 3 presents the friction force per unit area as a function of the elastomer thickness, Ly, for two values of the Youngs modulus, E. As can be seen the friction decreases from 0.063MPa for Ly=0 to about 0.043 MPa with increase of the elastomer thickness reaching an asymptotic behavior above Ly=0.8 mm. This behavior of friction reduction is expected since an increase of the elastomer thickness, Ly, leads to larger surface displacements, namely, larger local clearance, h, and hence, smaller friction force which is inversely proportional to the clearance. As evident from Refs. [7-14], the dimple depth, hp, plays a major role in affecting tribological performance of LST components. The effect of this parameter on the friction force per unit area is presented in Figure 4 for various Youngs moduli, E, and slider lengths, Lx.
0.065 0.060 Ff /A [MPa ] 0.055 0.050 E =20 MPa 0.045 0.040 0 0.2 0.4 L y [mm ]
Figure 3: Friction force per unit area, Ff/A , vs. elastomer width, Ly, for different Youngs moduli, E.

S p = 10% , h p = 10m , r p = 50m , 6U= 0.6Pa*m , c= 1.5m, L x =1.4mm , =0.499

E =10 MPa

0.6

0.8

As follows from Figure 4 the friction force at a given Lx value decreases with decreasing Youngs modulus. This is because a lower Youngs modulus, E, leads to increase of the surface displacements (increase of the local clearance) and hence, decrease of the friction force. An optimum value between 7-10 m of the dimple depth for minimum friction is shown in the figure. This optimum is almost independent of E. The minimum friction corresponding to optimum depth of dimples is about 20% lower than for 2 m depth and can be much lower compared to untextured slider (zero dimple depth). It can be also seen from Figure 4 that for small values of the dimple depth the friction is not affected by E. This is because shallow dimples generate low pressure and result in negligible displacements of the elastomer surface regardless of E. Reducing the slider length, Lx, increases the friction force per unit area but the optimum dimple depth is hardly affected by Lx and remains about (hp)opt9 m.

0.055 0.053

S p = 10% , h p = 10m , r p = 50m , 6U= 0.6Pa*m , c= 1.5m, =0.499, L y =0.5 mm E= 10 MPa, L x = 0.5mm

Ff /A [MPa ]

0.051 0.049 0.047 0.045 0 5 10 h p [m ]

E= 20 MPa, L x = 1.4mm

E= 10 MPa, L x = 1.4mm 15 20

Figure 4: Friction force per unit area, Ff/A , vs. dimple depth, hp, for different values of Youngs modulus, E, and slider lenhth, Lx.

CONCLUSION

A theoretical model was developed to analyze the potential of LST in Soft ElastoHydrodynamic Lubrication. Significant friction reduction of over 20% can be achieved with optimum LST slider in comparison with a non-textured slider The optimum value of dimple depth was evaluated from an intensive parameter analysis. This value is almost independent of all the other parameters and varies in a small range of 7-10 m. The friction is smaller for lower modulus of elasticity, thicker elastomer layer, and longer slider. The current model is very important for understanding the effect of LST on tribological performance of SEHL. In the future this model can be applied to mechanical components such as elastomeric seals for hydraulic actuators or rotary lip seal.

References
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