Journal Home > Volume 12 , Issue 6
Friction 2024, 12(6): 1214-1234 https://doi.org/10.1007/s40544-023-0802-2
Research Article | Open Access | Issue | Published: 20 December 2023

Scuffing failure analysis based on a multiphysics coupling model and experimental verification

Show Author's Information Bugao LYU,  Xianghui MENG( ),  Jiabao YIN,  Yi CUI,  Chengen WANG
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Keywords:
boundary lubrication, tribofilm, scuffing failure, multiphysics coupling effects
Cite this article:
LYU B, MENG X, YIN J, et al. Scuffing failure analysis based on a multiphysics coupling model and experimental verification. Friction, 2024, 12(6): 1214-1234. https://doi.org/10.1007/s40544-023-0802-2
Download citation
EndNote(RIS)
BibTeX

18

Views

6

Downloads

Citations

0

Crossref

0

WoS

0

Scopus

0

CSCD

Abstract Full text About this article

General reductions in lubricant viscosities and increasing loads in machine components highlight the role of tribofilms in providing surface protection against scuffing. However, the relationship between the scuffing process and the growth and removal of tribofilm is not well understood. In this study, a multiphysics coupling model, which includes hydrodynamic lubrication, asperity contact, thermal effect, tribochemistry reaction, friction, and surface wear, was developed to capture the initiation of surface scuffing. Simulations and experiments for a piston ring and cylinder liner contact were conducted following a step-load sequence under different temperature conditions. The results show that high temperature and extreme load could induce the lubricant film collapse, which in turn triggers the breakdown of the tribofilm due to the significantly increased removal process. The failures of both lubricant film and tribofilm progress instantaneously in a coupling way, which finally leads to severe scuffing.


menu
Abstract
Full text
Outline
About this article

Scuffing failure analysis based on a multiphysics coupling model and experimental verification

Show Author's information Bugao LYU, Xianghui MENG( ), Jiabao YIN, Yi CUI, Chengen WANG
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China

Abstract

General reductions in lubricant viscosities and increasing loads in machine components highlight the role of tribofilms in providing surface protection against scuffing. However, the relationship between the scuffing process and the growth and removal of tribofilm is not well understood. In this study, a multiphysics coupling model, which includes hydrodynamic lubrication, asperity contact, thermal effect, tribochemistry reaction, friction, and surface wear, was developed to capture the initiation of surface scuffing. Simulations and experiments for a piston ring and cylinder liner contact were conducted following a step-load sequence under different temperature conditions. The results show that high temperature and extreme load could induce the lubricant film collapse, which in turn triggers the breakdown of the tribofilm due to the significantly increased removal process. The failures of both lubricant film and tribofilm progress instantaneously in a coupling way, which finally leads to severe scuffing.

Keywords: boundary lubrication, tribofilm, scuffing failure, multiphysics coupling effects

References(68)

[1]
Wang Y, Yao C, Barber G C, Zhou B, Zou Q. Scuffing resistance of coated piston skirts Run against cylinder bores. Wear 259(7–12): 1041–1047 (2005)
DOI Google Scholar
[2]
Ferreira R, Carvalho Ó, Sobral L, Carvalho S, Silva F. Laser texturing of piston ring for tribological performance improvement. Friction 11(10): 1895–1905 (2023)
DOI Google Scholar
[3]
Lyu B G, Meng X H, Zhang R, Wen C W. A deterministic contact evolution and scuffing failure analysis considering lubrication deterioration due to temperature rise under heavy loads. Eng Fail Anal 123: 105276 (2021)
DOI Google Scholar
[4]
Li H J, Tian P Y, Lu H Y, Jia W P, Du H D, Zhang X J, Li Q Y, Tian Y. State-of-the-art of extreme pressure lubrication realized with the high thermal diffusivity of liquid metal. ACS Appl Mater Interfaces 9(6): 5638–5644 (2017)
DOI Google Scholar
[5]
Blok H. Surface temperature measurements on gear teeth under extreme pressure lubricating condition. Proc Inst Mech Eng 2:14–20 (1937)
Google Scholar
[6]
Dyson A. The failure of elastohydrodynamic lubrication of circumferentially ground discs. Proc Inst Mech Eng 190(1): 699–711 (1976)
DOI Google Scholar
[7]
Hershberger J, Ajayi O O, Zhang J, Yoon H, Fenske G R. Evidence of scuffing initiation by adiabatic shear instability. Wear 258(10): 1471–1478 (2005)
DOI Google Scholar
[8]
Ajayi O O, Lorenzo-Martin C, Erck R A, Fenske G R. Analytical predictive modeling of scuffing initiation in metallic materials in sliding contact. Wear 301(1–2): 57–61 (2013)
DOI Google Scholar
[9]
Saeidi F, Taylor A A, Meylan B, Hoffmann P, Wasmer K. Origin of scuffing in grey cast iron-steel tribo-system. Mater Des 116: 622–630 (2017)
DOI Google Scholar
[10]
Kamps T J, Walker J C, Wood R J, Lee P M, Plint A G. Scuffing mechanisms of EN-GJS 400-15 spheroidal graphite cast iron against a 52100 bearing steel in a PAO lubricated reciprocating contact. Wear 376–377: 1542–1551 (2017)
DOI Google Scholar
[11]
Lee B, Yu Y H, Cho Y J. A scuffing model considering additive depletion in boundary lubrication. Ind Lubr Tribol 72(3): 267–272 (2019)
DOI Google Scholar
[12]
Zhang C W, Zhai H, Sun D, Zheng D Z, Zhao X L, Gu L, Wang L Q. Thermal shock of subsurface material with plastic flow during scuffing. Friction 11(1): 64–75 (2023)
DOI Google Scholar
[13]
Hsu S M, Shen M C, Klaus E E, Cheng H S, Lacey P I. Mechano-chemical model: Reaction temperatures in a concentrated contact. Wear 175(1–2): 209–218 (1994)
DOI Google Scholar
[14]
Li S, Kahraman A, Anderson N, Wedeven L D. A model to predict scuffing failures of a ball-on-disk contact. Tribol Int 60: 233–245 (2013)
DOI Google Scholar
[15]
Castro J, Seabra J. Scuffing and lubricant film breakdown in FZG gears Part I. Analytical and experimental approach. Wear 215(1–2): 104–113 (1998)
DOI Google Scholar
[16]
Chen Y, Renner P, Liang H. A review of current understanding in tribochemical reactions involving lubricant additives. Friction 11(4): 489–512 (2023)
DOI Google Scholar
[17]
Ma Z Y, Huang R X, Yuan X S, Shen Y, Xu J J. Tribological performance and scuffing behaviors of several automobile piston rings mating with chrome-plated cylinder liner. Friction 10(8): 1245–1257 (2022)
DOI Google Scholar
[18]
Spikes H. The history and mechanisms of ZDDP. Tribol Lett 17(3): 469–489 (2004)
DOI Google Scholar
[19]
Buyanovskii I A, Samusenko V D, Strelnikova S S, Shcherbakov Y I. Boundary lubrication by a chemically modified layer. J Mach Manuf Reliab 51(6): 532–539 (2022)
DOI Google Scholar
[20]
Barnes A M, Bartle K D, Thibon V R A. A review of zinc dialkyldithiophosphates (ZDDPS): Characterisation and role in the lubricating oil. Tribol Int 34(6): 389–395 (2001)
DOI Google Scholar
[21]
Lei X, Zhang Y J, Zhang S M, Yang G B, Zhang C L, Zhang P Y. Study on the mechanism of rapid formation of ultra-thick tribofilm by CeO2 nano additive and ZDDP. Friction 11(1): 48–63 (2023)
DOI Google Scholar
[22]
Zhang J, Spikes H. On the mechanism of ZDDP antiwear film formation. Tribol Lett 63(2): 1–15 (2016)
DOI Google Scholar
[23]
Čoga L, Akbari S, Kovač J, Kalin M. Differences in nano-topography and tribochemistry of ZDDP tribofilms from variations in contact configuration with steel and DLC surfaces. Friction 10(2): 296–315 (2022)
DOI Google Scholar
[24]
Liu K, Kang J J, Zhang G G, Lu Z B, Yue W. Effect of temperature and mating pair on tribological properties of DLC and GLC coatings under high pressure lubricated by MoDTC and ZDDP. Friction 9(6): 1390–1405 (2021)
DOI Google Scholar
[25]
Dorgham A, Azam A, Morina A, Neville A. On the transient decomposition and reaction kinetics of zinc dialkyldithiophosphate. ACS Appl Mater Interfaces 10(51): 44803–44814 (2018)
DOI Google Scholar
[26]
Gosvami N N, Bares J A, Mangolini F, Konicek A R, Yablon D G, Carpick R W. Mechanisms of antiwear tribofilm growth revealed in situ by single-asperity sliding contacts. Science 348(6230): 102–106 (2015)
DOI Google Scholar
[27]
Lyu B G, Zhang L M, Meng X H, Wang C G. A boundary lubrication model and experimental study considering ZDDP tribofilms on reciprocating friction pairs. Tribol Lett 70(2): 1–16 (2022)
DOI Google Scholar
[28]
Bayat R, Lehtovaara A. Tribofilm formation of simulated gear contact along the line of action. Tribol Lett 69(4): 1–11 (2021)
DOI Google Scholar
[29]
Westerfield C, Agnew S. IR study of the chemistry of boundary lubrication with high temperature and high pressure shear. Wear 181–183: 805–809 (1995)
DOI Google Scholar
[30]
Nehme G, Mourhatch R, Aswath P B. Effect of contact load and lubricant volume on the properties of tribofilms formed under boundary lubrication in a fully formulated oil under extreme load conditions. Wear 268(9–10): 1129–1147 (2010)
DOI Google Scholar
[31]
Ueda M, Kadiric A, Spikes H. Influence of PMA on the anti-scuffing properties of AW/EP additives. Tribol Int 174: 107756 (2022)
DOI Google Scholar
[32]
Ueda M, Spikes H, Kadiric A. In-situ observation of the effect of the tribofilm growth on scuffing in rolling-sliding contact. Tribol Lett 70(3): 1–21 (2022)
DOI Google Scholar
[33]
Patir N, Cheng H S. An average flow model for determining effects of three-dimensional roughness on partial hydrodynamic lubrication. J Lubr Technol 100(1): 12–17 (1978)
DOI Google Scholar
[34]
Patir N, Cheng H S. Application of average flow model to lubrication between rough sliding surfaces. J Lubr Technol 101(2): 220–229 (1979)
DOI Google Scholar
[35]
Wu C W, Zheng L Q. An average Reynolds equation for partial film lubrication with a contact factor. J Tribol 111(1): 188–191 (1989)
DOI Google Scholar
[36]
Ausas R, Ragot P, Leiva J, Jai M, Bayada G, Buscaglia G C. The impact of the cavitation model in the analysis of microtextured lubricated journal bearings. J Tribol 129(4): 868–875 (2007)
DOI Google Scholar
[37]
Jakobsson B. The finite journal bearing, considering vaporization. Transactions of Chalmers University of Technology 190 (1957)
Google Scholar
[38]
Olsson K. Cavitation in dynamically loaded bearings. Transactions of Chalmers University of Technologie 308 (1965)
Google Scholar
[39]
Qiu Y, Khonsari M M. On the prediction of cavitation in dimples using a mass-conservative algorithm. J Tribol 131(4): 1 (2009)
DOI Google Scholar
[40]
Harigaya Y, Suzuki M, Toda F, Takiguchi M. Analysis of oil film thickness and heat transfer on a piston ring of a diesel engine: Effect of lubricant viscosity. J Eng Gas Turbines Power 128(3): 685–693 (2006)
DOI Google Scholar
[41]
Roelands C J A, Winer W O, Wright W A. Correlational aspects of the viscosity-temperature-pressure relationship of lubricating oils (Dr in dissertation at Technical University of Delft, 1966). J Lubr Technol 93(1): 209–210 (1971)
DOI Google Scholar
[42]
Gu C X, Meng X H, Xie Y B, Fan J Z. A thermal mixed lubrication model to study the textured ring/liner conjunction. Tribol Int 101: 178–193 (2016)
DOI Google Scholar
[43]
Yang P, Wang J, Kaneta M. Thermal and non-newtonian numerical analyses for starved EHL line contacts. J Tribol 128(2): 282–290 (2006)
DOI Google Scholar
[44]
Greenwood J A, Tripp J H. The contact of two nominally flat rough surfaces. Proc Inst Mech Eng 185(1): 625–633 (1970)
DOI Google Scholar
[45]
Pereira G, Munoz-Paniagua D, Lachenwitzer A, Kasrai M, Norton P R, Capehart T W, Perry T A, Cheng Y T. A variable temperature mechanical analysis of ZDDP-derived antiwear films formed on 52100 steel. Wear 262(3–4): 461–470 (2007)
DOI Google Scholar
[46]
Ghanbarzadeh A, Parsaeian P, Morina A, Wilson M C T, Eijk M C P, Nedelcu I, Dowson D, Neville A. A semi-deterministic wear model considering the effect of zinc dialkyl dithiophosphate tribofilm. Tribol Lett 61(1): 1–15 (2015)
DOI Google Scholar
[47]
Zhang J, Ewen J P, Ueda M, Wong J S S, Spikes H A. Mechanochemistry of zinc dialkyldithiophosphate on steel surfaces under elastohydrodynamic lubrication conditions. ACS Appl Mater Interfaces 12(5): 6662–6676 (2020)
DOI Google Scholar
[48]
Chen Z, Gu C J, Tian T. Modeling of formation and removal of ZDDP tribofilm on rough surfaces. Tribol Lett 69(1): 1–9 (2021)
DOI Google Scholar
[49]
Bowden, F P, Leben, L. The friction of lubricated metals. Phil Trans R Soc Lond A 239(799): 1–27 (1940)
DOI Google Scholar
[50]
Bec S, Tonck A, Georges J M, Coy R C, Bell J C, Roper G W. Relationship between mechanical properties and structures of zinc dithiophosphate anti-wear films. Proc R Soc Lond A 455(1992): 4181–4203 (1999)
DOI Google Scholar
[51]
Aktary M, McDermott M, McAlpine G A. Morphology and nanomechanical properties of ZDDP antiwear films as a function of tribological contact time. Tribol Lett 12: 155–162 (2002)
DOI Google Scholar
[52]
Taylor R I. Tribology and energy efficiency: From molecules to lubricated contacts to complete machines. Faraday Discuss 156: 361 (2012)
DOI Google Scholar
[53]
Demmou K, Bec S, Loubet J L, Martin J M. Temperature effects on mechanical properties of zinc dithiophosphate tribofilms. Tribol Int 39(12): 1558–1563 (2006)
DOI Google Scholar
[54]
Tse J S, Song Y, Liu Z X. Effects of temperature and pressure on ZDDP. Tribol Lett 28(1): 45–49 (2007)
DOI Google Scholar
[55]
Akchurin A, Bosman R. A deterministic stress-activated model for tribo-film growth and wear simulation. Tribol Lett 65(2): 1–9 (2017)
DOI Google Scholar
[56]
Roshan R, Priest M, Neville A, Morina A, Xia X, Warrens C P, Payne M J. Friction modelling in boundary lubrication considering the effect of MoDTC and ZDDP in engine oils. Tribol Online 6(7): 301–310 (2011)
DOI Google Scholar
[57]
Archard J F. Contact and rubbing of flat surfaces. J Appl Phys 24(8): 981–988 (1953)
DOI Google Scholar
[58]
Ueda M, Kadiric A, Spikes H. Influence of steel surface composition on ZDDP tribofilm growth using ion implantation. Tribol Lett 69(2): 1–14 (2021)
DOI Google Scholar
[59]
Marx N, Fernández L, Barceló F, Spikes H. Shear thinning and hydrodynamic friction of viscosity modifier-containing oils. part I: Shear thinning behaviour. Tribol Lett 66(3): 1–14 (2018)
DOI Google Scholar
[60]
Taylor R I, de Kraker B R. Shear rates in engines and implications for lubricant design. Proc Inst Mech Eng Part J J Eng Tribol 231(9): 1106–1116 (2017)
DOI Google Scholar
[61]
Ueda M, Kadiric A, Spikes H. On the crystallinity and durability of ZDDP tribofilm. Tribol Lett 67(4): 1–13 (2019)
DOI Google Scholar
[62]
Azam A, Dorgham A, Parsaeian P, Morina A, Neville A, Wilson M C T. The mutual interaction between tribochemistry and lubrication: Interfacial mechanics of tribofilm. Tribol Int 135: 161–169 (2019)
DOI Google Scholar
[63]
Kamps T J, Walker J C, Wood R J, Lee P M, Plint A G. Reproducing automotive engine scuffing using a lubricated reciprocating contact. Wear 332–333: 1193–1199 (2015)
DOI Google Scholar
[64]
Savolainen M, Lehtovaara A. An experimental investigation of scuffing initiation due to axial displacement in a rolling/sliding contact. Tribol Int 119: 688–697 (2018)
DOI Google Scholar
[65]
Liu Z, Liang F X, Zhai L M, Meng X H. A comprehensive experimental study on tribological performance of piston ring–cylinder liner pair. Proc Inst Mech Eng Part J J Eng Tribol 236(1): 184–204 (2022)
DOI Google Scholar
[66]
Suh A Y, Polycarpou A A, Conry T F. Detailed surface roughness characterization of engineering surfaces undergoing tribological testing leading to scuffing. Wear 255(1–6): 556–568 (2003)
DOI Google Scholar
[67]
Lin Y C, So H. Limitations on use of ZDDP as an antiwear additive in boundary lubrication. Tribol Int 37(1): 25–33 (2004)
DOI Google Scholar
[68]
McCool J I. Relating profile instrument measurements to the functional performance of rough surfaces. J Tribol 109(2): 264–270 (1987)
DOI Google Scholar
Publication history
Copyright
Acknowledgements
Rights and permissions

Publication history

Received: 03 March 2023
Revised: 08 May 2023
Accepted: 07 July 2023
Published: 20 December 2023
Issue date: June 2024

Copyright

© The author(s) 2023.

Acknowledgements

This study was supported by the National Natural Science Foundation of China (52130502, 52171315) and the National Key R&D Program of China (2022YFB4201102).

Rights and permissions

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.

The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.

To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.

Return