Tribology Course Overview
Tribology Course Overview
➢ Objectives
Master the basic concepts of tribology.
Study of friction, lubrication and wear.
Modeling and resolution of tribological
problems.
➢ Assessment method
A final exam grade of 60%
A continuous assessment grade of 40%
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5. Wear Mechanisms Tribological knowledge helps improve the lifespan, safety, and
reliability of interacting machine components, and it brings
substantial economic benefits.
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3. Economic Considerations
➢ Surface fatigue is caused by the
repeated passing of a localized
4. Need for Tribology as a
contact. This type of wear mainly
Subject
affects bearings and gears.
5. Wear Mechanisms
➢ Abrasive wear occurs when metal is removed from a softer surface due to
the passage of hard particles. Two types of abrasion are distinguished: two-
body abrasion and three-body abrasion. The first type occurs when the
abrasive material slides along the surface, while the second occurs when
the abrasive gets trapped between the two wear surfaces.
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All industrial sectors are affected by wear, with some of the most
impacted being: mining, steel production, metal forming (foundry,
shaping, machining, etc.), pulp and paper, chemical processes,
Chapiter 1:
Introduction to the tribology
shipbuilding, energy, oil and gas industry, hydraulics, railways,
and more.
1. Historic of the tribology
Tribological knowledge helps to extend the lifespan, safety, and
2. Tribology in industry
reliability of machine components in interaction, and provides
substantial economic benefits → Failures can often be prevented
3. Economic Considerations through tribological understanding.
Here are a few examples where tribological knowledge is essential:
4. Need for Tribology as a
Subject
➢ Bearings: To reduce friction and wear, ensuring smooth rotational
5. Wear Mechanisms
motion.
➢ Gear systems: To manage wear from surface contact and high
loads.
➢ Seals: Preventing leaks and ensuring effective operation in various
machinery.
➢ Brakes: Managing friction for effective stopping power without
excessive wear.
Academic year: 2024/2025 Teacher : Pr. I. ZIDANE
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Chapiter 1:
➢The carbon graphite seal, as illustrated in the figure, is used to prevent
Introduction to the tribology steam leaks in the paper industry.
➢The failure of this component is primarily caused by adhesive wear, which
leads to an uneven surface, reducing the mechanical contact area.
1. Historic of the tribology
➢With the same applied load, this reduction in mechanical contact increases
the stress level, thereby raising the risk of failure.
2. Tribology in industry
3. Economic Considerations
5. Wear Mechanisms
Example 2 – Cams
➢ Cams are used to convert rotary motion into reciprocating motion.
➢ These components are subjected to impacts on the sliding surface, leading to the formation of pits on
the cam surface.
Chapiter 1: ➢ The creation of these cavities on the cam surface increases noise pollution and reduces mechanical
Introduction to the tribology performance.
➢ Understanding the mechanism behind pit formation helps estimate the component's lifespan and
develop methods to reduce these failures.
1. Historic of the tribology
2. Tribology in industry
3. Economic Considerations
5. Wear Mechanisms
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Chapiter 1: ➢ For example, this phenomenon occurs between the cylinder and the piston of a combustion engine
Introduction to the tribology due to a lack of lubrication. The oil film is destroyed, often locally, due to high temperatures or excess
fuel → which leads to rapid seizure, causing severe surface deterioration. The same issue arises
when the lubricating film between the piston and the cylinder is insufficient due to low oil levels.
1. Historic of the tribology
➢ This failure in the tribological system often leads to the need for costly repairs.
2. Tribology in industry
3. Economic Considerations
5. Wear Mechanisms
2. Tribology in industry
➢ The frictional force between the
brake pads and the disc generates
3. Economic Considerations a braking torque but also heat,
which must be dissipated quickly
4. Need for Tribology as a to prevent deformation or even
Subject destruction of the disc.
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2. Tribology in industry
5. Wear Mechanisms
The fundamental knowledge gained from a tribology course is highly
beneficial for industries like energy, steelmaking, cement
production, and the oil industry. For this reason, tribology courses
are often referred to as "Industrial Tribology" or "Applied
Tribology".
1. Historic of the tribology → The application of tribological knowledge offers both economic
and environmental benefits reducing energy losses due to
2. Tribology in industry
friction, losses due to breakdowns and reducing machine
3. Economic Considerations depreciation.
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Chapiter 1:
Introduction to the tribology
2. Tribology in industry
3. Economic Considerations
5. Wear Mechanisms
[4] K. Holmberg, P. Andersson, and A. Erdemir, “Global energy consumption due to friction in passenger cars,” Tribol. Int.,
vol. 47, pp. 221–234, 2012, doi: https://doi.org/10.1016/j.triboint.2011.11.022.
Chapiter 1: ➢ By implementing tribological guidelines to reduce the spacing between the head
Introduction to the tribology sensor and the magnetic surface, surface density increases, allowing for larger data
storage in a relatively smaller space. This precise control of the gap, achieved through
advancements in surface engineering and lubrication techniques, improves both the
1. Historic of the tribology
performance and reliability of the hard drive.
2. Tribology in industry
3. Economic Considerations
5. Wear Mechanisms
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1. Historic of the tribology ➢ With over 700 million vehicles worldwide and an average engine power of around
30 BHP (brake horsepower), tribological advancements can increase efficiency by 2
to 5%. Assuming a modest 2% improvement in BHP due to tribological
2. Tribology in industry
optimizations, this could result in savings of approximately 420 million BHP, leading
to significant energy conservation and performance improvements globally.
3. Economic Considerations
5. Wear Mechanisms
Example 3 – Bearings
➢ Industries allocate significant costs to the maintenance and replacement of
Chapiter 1:
bearings. An approximate estimate shows that bearing lifespan can be greatly
Introduction to the tribology extended by using better lubricants, applying appropriate lubricant additives,
and ensuring the proper installation of bearings. Implementing tribological
knowledge in these areas leads to improved performance and increased
1. Historic of the tribology efficiency, ultimately reducing maintenance costs and enhancing productivity
across industries.
2. Tribology in industry
3. Economic Considerations
5. Wear Mechanisms
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There are several common wear mechanisms, each leading to the degradation of
surfaces in different ways. Here are the key types:
➢ Abrasive Wear: Involves processes like polishing, scratching, … This occurs when
harder particles or surfaces wear away softer materials.
Chapiter 1: ➢ Adhesive Wear: happens when materials transfer between surfaces in contact, often
Introduction to the tribology due to inadequate lubrication or high local pressure.
➢ Cavitation Wear: Occurs due to
1. Historic of the tribology fluid interaction, where vapor
bubbles form and collapse near
the surface, causing damage.
2. Tribology in industry
➢ Corrosive Wear: Related to
chemical reactions, leading to
3. Economic Considerations the degradation of a surface
when it interacts with its
4. Need for Tribology as a environment.
Subject ➢ Erosive Wear: Caused by
particles or fluid impinging on a
5. Wear Mechanisms surface, gradually wearing it
away.
➢ Fatigue Wear: Involves
delamination due to repeated
loading, often affecting surfaces
like bearings or gears.
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➢ At the beginning of the friction action and in a short time, it is possible that the
surfaces are rough which increases the failure rate of the asperities of the two
surfaces.
Chapiter 2:
Surfaces and Interfaces ➢ Subsequently, the failure rate becomes low or even constant since the roughness
decreases after the first phase.
1. Definition ➢ At the end of life, there is a significant increase in the failure rate since the surfaces
become rough due to surface fatigue and the tearing of particles and the creation of
2. Surface Finish/Roughness microcavities during the long period of the second phase.
3. Material Hardness
Roughness Indication
4. Friction and Surface The indications Rm or Rp must be entered, but Ra can be omitted. In
Deformation the case where Ra must not be less than a certain value, two
superimposed limit values are indicated.
5. Solutions for Surface Defects
0,1
0,04
0,04 < Ra < 0,10
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When the probe is guided over the surface by the feed device, the
shape of the surface irregularities is “faithfully” recognized by the tip
of the probe, thus the profile y=f(x) of the surface is established.
1. Definition
2. Surface Finish/Roughness
3. Material Hardness
➢ or from the envelope of the measured profile
4. Friction and Surface
Deformation
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Roughness parameters
Rp : Maximum peak
Chapiter 2: observed over the analyzed
Surfaces and Interfaces length.
Rp= ymax.
1. Definition
Rc : Maximum trough
2. Surface Finish/Roughness observed over the analyzed
length.
3. Material Hardness Rc= |ymin|
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1. Definition
2. Surface Finish/Roughness
3. Material Hardness
z is the difference
4. Friction and Surface between the depth
Deformation before load and that
after load F.
5. Solutions for Surface Defects
s = 0.002 for
volumetric part
measurements and
HRC=100- 0.001 for surface
(z)/(s) measurements.
HRB=130-(z)/(s)
1. Definition Due to positive deviations (roughness above the nominal surface), the
contact between the solids is limited to a very small fraction of the
2. Surface Finish/Roughness
nominal surface (δA) and, therefore, the estimated contact stresses
3. Material Hardness
on the rough surface = F/δA are much larger compared to the nominal
stresses as expressed by the following equation for stress on a
4. Friction and Surface smooth surface: 𝐹
Deformation 𝜏=
𝐴
5. Solutions for Surface Defects
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3. Material Hardness
➢ If Λ ≤ 1, the lubrication mechanism is known as boundary lubrication. To
study this lubrication mechanism, knowledge of materials science, solid
4. Friction and Surface
Deformation mechanics, and chemistry is required.
➢ If 1< Λ ≤ 3, the lubrication mechanism is called mixed lubrication. To study
5. Solutions for Surface Defects this lubrication mechanism, knowledge of all four disciplines (materials
science, solid mechanics, chemistry, and fluid mechanics) is required.
➢ If 3< Λ ≤ 5, the lubrication mechanism is called elastohydrodynamic
lubrication. For this lubrication mechanism, knowledge of both solid and
fluid mechanics is required.
➢ If Λ > 5, the lubrication mechanism is called hydrodynamic lubrication for
which knowledge in fluid mechanics is required.
Chapiter 2:
Surfaces et Interfaces
1. Definition
2. Surface Finish/Roughness
3. Material Hardness
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2. Static and Kinetic Friction Friction is part of everyday life. It is essential for us to walk on the ground.
However, in most operating machines, friction is undesirable (energy loss,
3. Possible Causes of Friction wear of vital parts, performance degradation due to heat generation).
4. Theories of Friction Various attempts have been made to reduce friction, such as:
5. Mechanical Tests ❖ Placing rolling elements between the contact surfaces, thus creating rolling
bearings,
6. Selection of Friction Materials ❖ Use of low-friction materials,
❖ Lubricating surfaces with oil or grease,
❖ Modifying the design to reduce sliding, etc.
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4. Theories of Friction
5. Mechanical Tests
Chapiter 3: Friction There is static equilibrium between the applied force and the friction force.
When a load of 50 N is applied, the block begins to slide.
1. Introduction
At this point, the friction force remains equal to 50 N, but the resistance to
friction subsequently decreases to 40 N. In other words, static friction is
2. Static and Kinetic Friction
greater than kinetic friction.
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1. Introduction ❖ Dry dynamic or sliding friction, which occurs when there is relative motion
between the two contact surfaces.
2. Static and Kinetic Friction
These two types of friction obey Coulomb's laws.
3. Possible Causes of Friction
4. Theories of Friction While statics studies bodies at rest or in equilibrium moving at a constant
speed, dynamics focuses on the accelerated movement of a body under the
5. Mechanical Tests influence of forces. Time plays an important role in dynamics. Dynamics
considers both the forces acting on a body and the resulting motion of the
6. Selection of Friction Materials body.
1. Introduction The goal of dynamics is to calculate the stresses and loads on components
and systems to size them properly.
2. Static and Kinetic Friction
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Dry friction is also called solid-body friction and means that there is no
coherent film of liquid or gas lubricant between the two contacting surfaces.
Chapiter 3: Friction
Four theories given by Leonardo da Vinci, Amonton, Coulomb, and Tomlinson
for dry friction are explained in this presentation:
1. Introduction
Coulomb clearly distinguished between static and kinetic friction.
Friction is due to the interlocking of rough surfaces
2. Static and Kinetic Friction
➢ Contact occurs at discrete points μstatic ≥ μdynamic (kinetic).
3. Possible Causes of Friction
➢ The force of friction does not depend on the surface area F ≠ function (A).
➢ The force of friction does not depend on the relative tangential velocity
4. Theories of Friction
F ≠ Function (v).
5. Mechanical Tests
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5. Mechanical Tests These values were calculated based on the following material parameters:
6. Selection of Friction Materials
Clean steel E ≈ 30 Mpsi, G ≈ 12 Mpsi
Aluminum E ≈ 10 Mpsi, G ≈ 3,6 Mpsi
Titanium E ≈ 15,5 Mpsi G ≈ 6,5 Mpsi
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4. Theories of Friction
5. Mechanical Tests
[5] F. P. Bowden and D. Tabor, “The Friction and Lubrication of Solids,” New York Oxford
Univ. Press, p. 337, 1950, [Online]. Available:
https://books.google.de/books?id=OQ7FCKNixK0C.
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This theory is unable to estimate different μ values for steel on indium versus
steel on lead alloy. A theory based on deformation (abrasion) must be
explored.
𝑊 ≃ 𝑛 0.5 × 𝜋𝑟 2 𝐻 F 𝑛 𝑟ℎ 𝐻 2ℎ 2 1
൞ 𝐴 ≃ 𝑛 0.5 × 𝜋𝑟 2 𝜇𝑑 = ≃ ≃ ≃
W 𝑛 0.5 × 𝜋𝑟 2 𝐻 𝜋 𝑟 𝜋 tan 𝜃
𝐹 ≃ 𝑛 𝑟ℎ 𝐻
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Chapiter 3: Friction
θ 5 10 20 30 40 50 60 70 80 85
μd 7.271 3.608 1.748 1.102 0.758 0.534 0.367 0.231 0.112 0.055
In practice, the slopes of real surfaces are less than 10° (i.e., θ > 80°), so µd =
1. Introduction 0.1. Adding this value (µd = 0.1) means that the total μ should not exceed 0.3.
The total μ represents the contribution of both plowing (deformation) and
2. Static and Kinetic Friction adhesion.
Summary
𝐹𝑎 𝜏
Adhesion : 𝜇𝑎 = =
𝑊 𝐻
Chapiter 3: Friction
ℎ
Deformation by conical asperities: 𝜇𝑑 ≃ 0,64
𝑟
1. Introduction
ℎ
Deformation by spherical asperities: 𝜇𝑑 ≃ 0,6
2. Static and Kinetic Friction 𝑟
Three friction theories were discussed:
3. Possible Causes of Friction ➢ The first expression shows that friction depends on the lower shear
resistance of the two contact surfaces. Reducing shear strength and
4. Theories of Friction increasing the hardness of the soft surface reduces the coefficient of
friction.
5. Mechanical Tests ➢ The second expression shows the dependence of the friction coefficient on
the conical asperity angle.
6. Selection of Friction Materials ➢ The third expression indicates a lower sensitivity of the friction coefficient
to spherical asperities compared to conical ones.
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Rolling Friction
Rolling friction is much smaller, often 100 to 1000 times less than sliding
friction. Rolling friction is defined according to the model in Figure opposite.
Chapiter 3: Friction
To prevent the spherical or cylindrical
wheel from stopping, its speed v must
be kept constant to overcome friction.
1. Introduction This can be done by applying a torque
parallel 𝐶Ԧ to the axis of rotation.
2. Static and Kinetic Friction
5. Mechanical Tests
𝐶 = 𝑑. 𝑁
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4. Theories of Friction
❖ Cast irons
➢ Gray iron: Offers good wear resistance and machinability.
➢ Ductile iron: Has higher strength and ductility compared to gray iron.
5. Mechanical Tests
❖ Specific Materials and Their Applications
6. Selection of Friction Materials ➢ Hadfield steel: Used for highly abrasive applications due to its work-
hardening properties.
➢ The TGV (high-speed train) brakes feature 28 CrMoV5-08 chrome-
molybdenum-vanadium steel discs and Cerametal G35 metal matrix
composite linings. This pair produces a third body in the form of "flat
plates" that allow speed accommodation by a shear mechanism.
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Babbitt metals
6. Selection of Friction Materials These soft, tin-based alloys are used as bearing materials in many applications due
to their ability to embed abrasive particles.
➢ Tin-based Babbitt: Offers good conformability and embeddability of
abrasive particles.
➢ Lead-based Babbitt: Has lower melting point and is often used for
applications where a softer material is desired.
Academic year: 2024/2025 Teacher : Pr. I. ZIDANE
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4. Theories of Friction
5. Mechanical Tests
4. Theories of Friction
5. Mechanical Tests
Example: Front and rear axles of a vehicle equipped with Glycodur A bushings – The
Glycodur A bushings (Federal Mogul) consist of three layers of composite materials fixed
to a steel backing, including sintered bronze and acetal resins. Pockets retain the grease,
providing a low coefficient of friction and preventing stick-slip. Lubrication is
maintenance-free for life. Applications: axle.
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2. Static and Kinetic Friction ❖ Composition: A combination of binders, fibers, and fillers.
❖ Applications: Brakes, clutches, and other friction-based systems.
3. Possible Causes of Friction
❖ Performance: Key factors include coefficient of friction, wear resistance, noise,
4. Theories of Friction and thermal stability.
5. Mechanical Tests ❖ Materials: Asbestos has been replaced by synthetic fibers, metals, and
minerals.
6. Selection of Friction Materials
General example Applications
❖ Automotive: Engine bearings, gears, brake pads, clutch plates
❖ Industrial machinery: Bearings, gears, seals, wear rings
Chapiter 3: Friction The selection of friction materials is a complex process that requires a thorough
understanding of the material properties, operating conditions, and the desired
performance outcomes. The text provides a valuable overview of the key factors to
consider, including mechanical, physico-chemical, and environmental properties, as
1. Introduction
well as the range of available materials. By carefully evaluating these factors,
engineers can choose the most appropriate friction material for a specific
2. Static and Kinetic Friction application. The selection process depends on considerations such as:
5. Mechanical Tests ❖ Hardness: While hardness is important, it's not the only factor. Too hard a
material can be brittle.
6. Selection of Friction Materials
❖ Compatibility: The chosen material must be compatible with the mating material
and operating conditions.
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➢ Nitriding: implantation of
2. Surface Treatments
nitrogen atoms into steel;
3. Coatings
➢ Carburizing: implantation
of carbon atoms into
steel;
➢ Hardening (surface or
through hardening):
modification of the steel’s
crystalline structure
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2. Surface Treatments
3. Coatings
2. Surface Treatments ➢ Soft Coating (softer than the substrate): reduces surface energy,
forms a sacrificial layer, or provides solid lubrication.
3. Coatings
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2. Surface Treatments
3. Coatings
3. Hertzian Contacts
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1. Introduction
2. Surface contacts
3. Hertzian Contacts
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Mixed Lubrication
This lubrication can be considered a transition between boundary
lubrication and hydrodynamic lubrication.
Chapiter 5: Lubrication Due to surface roughness, there are convergent areas in the fluid film
where hydrodynamic pressure can be generated. Thus, part of the
load is supported by fluid areas, and another part by areas in
1. Introduction
boundary lubrication.
2. Surface contacts
This type of lubrication continues
3. Hertzian Contacts until the surface speed is sufficient
for the lubricating film to fully
4. Reynolds equation for separate the surfaces due to
hydrodynamic contacts
hydrodynamic effect.
5. Elementary Case of Bearing
Capacity The piston ring-cylinder contact at
top dead center and bottom dead
center in internal combustion
engines corresponds to this type of
lubrication.
Hydrodynamic Lubrication
The viscous lubricant is drawn into the contact, forming a converging
space where hydrodynamic pressure develops. This pressure fully
Chapiter 5: Lubrication separates the contact surfaces and balances the load.
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Hydrostatic Lubrication
When reliable operation is essential or if reducing friction is desired,
the surfaces can be completely separated by injecting pressurized
Chapiter 5: Lubrication fluid into the contact. This type of lubrication, represented by the
dashed curve in Stribeck curve, is hydrostatic lubrication.
1. Introduction
In a hydrostatic system, friction primarily depends on surface
movement and is almost independent of the load applied to the
2. Surface contacts
mechanism; thus, when surfaces are stationary, friction is zero.
3. Hertzian Contacts
Chapiter 5: Lubrication In this type of contact, the pressure generated in the film is high
enough to elastically deform the surfaces, and calculating contact
characteristics requires simultaneously solving Reynolds' equation
1. Introduction
and elasticity equations.
2. Surface contacts
Furthermore, fluid viscosity varies significantly with pressure. The
3. Hertzian Contacts loads applied to the contact are not necessarily very large, but the
contact area is very small, resulting in very high pressures, which can
4. Reynolds equation for exceed 3 gigapascals.
hydrodynamic contacts
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Extreme-Pressure Lubrication
In extreme-pressure lubrication, surfaces are separated by a reactive
film formed by a chemical reaction between extreme-pressure
Chapiter 5: Lubrication additives in the lubricant. Current lubricants for gears and ball
bearings in automotive gearboxes contain extreme-pressure additives
that prevent seizure.
1. Introduction
Mixed Lubrication
2. Surface contacts
As with surface contacts, this is a transition zone. For high-pressure
3. Hertzian Contacts contacts, this transition occurs between extreme-pressure lubrication
and elastohydrodynamic lubrication.
4. Reynolds equation for
hydrodynamic contacts
Elastohydrodynamic Lubrication (EHD)
In elastohydrodynamic lubrication, the lubricant fully separates the
5. Elementary Case of Bearing
Capacity contact surfaces. Determining the characteristics of the mechanism
requires simultaneously solving the Reynolds equation within the film
and the elasticity equations in the materials forming the contact, while
considering the rheological behavior of the lubricant.
Is to calculate:
1. Introduction
➢ the load W which the contact can carry,
➢ the frictional force F or the frictional torque C,
2. Surface contacts
➢ the flow rate Q of the fluid in the mechanism,
3. Hertzian Contacts ➢ the dissipated power P in the contact.
the pressure field and the velocity field in the fluid
4. Reynolds equation for
hydrodynamic contacts
Pressure can be generated by a pump external to the contact, known
5. Elementary Case of Bearing
as hydrostatics; this is the case for certain bearings and the slides of
Capacity some machine tools.
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Chapiter 5: Lubrication
1. Introduction
2. Surface contacts
Cartesian coordinate system applied
3. Hertzian Contacts to a general lubricated contact.
Velocity field
Determination of the velocity component u(y) in x-direction:
Chapiter 5: Lubrication
𝜕 2 𝑢 𝜕𝑝
𝜂 =
C1 and C2 ? 𝜕𝑦 2 𝜕𝑥
1 𝜕𝑝 2
⇒𝑢 𝑦 = 𝑦 + 𝐶1 𝑦 + 𝐶2
1. Introduction
Boundary conditions: 2𝜂 𝜕𝑥
Bottom wall: u(0)=U1 ⇒ 𝐶2 = 𝑈1
2. Surface contacts
Upper wall: u(h)=U2 1 𝜕𝑝 𝑈1 − 𝑈2
3. Hertzian Contacts ⇒ 𝐶1 = − ℎ−
2𝜂 𝜕𝑥 ℎ
4. Reynolds equation for After identifying the constants:
hydrodynamic contacts
1 𝜕𝑝 2 ℎ 𝜕𝑝 𝑈1 − 𝑈2
𝑢 𝑦 = 𝑦 − 𝑦− 𝑦 + 𝑈1
5. Elementary Case of Bearing 2𝜂 𝜕𝑥 2𝜂 𝜕𝑥 ℎ
Capacity
With the same method of calculating the component u(y), we
determine the component of w(y) in z-direction :
1 𝜕𝑝 2 ℎ 𝜕𝑝 𝑊1 − 𝑊2
𝑤 𝑦 = 𝑦 − 𝑦− 𝑦 + 𝑊1
2𝜂 𝜕𝑧 2𝜂 𝜕𝑧 ℎ
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Velocity field
Concerning the component v(y), concerning the component :
𝑦 = 0 ⇒ 𝑣(0) = 𝑉1 = 0
ቊ
Chapiter 5: Lubrication 𝑦 = ℎ ⇒ 𝑣(ℎ) = 𝑉2
1 𝜕𝑝 2 ℎ 𝜕𝑝 𝑈1 − 𝑈2 𝑦
1. Introduction 𝑢 𝑦 = 𝑦 − 𝑦− + 𝑈1
2𝜂 𝜕𝑥 2𝜂 𝜕𝑥 ℎ
2. Surface contacts 1 𝜕𝑝 2 ℎ 𝜕𝑝 𝑊1 − 𝑊2 𝑦
𝑤 𝑦 = 𝑦 − 𝑦− + 𝑊1
2𝜂 𝜕𝑧 2𝜂 𝜕𝑧 ℎ
3. Hertzian Contacts 𝑣(0) = 𝑉1 = 0, 𝑣(ℎ) = 𝑉2
4. Reynolds equation for Reynolds equation
hydrodynamic contacts
Reynolds' equation is derived from the continuity equation:
𝜕𝜌 𝜕 𝜕 𝜕
5. Elementary Case of Bearing + 𝜌𝑢 + 𝜌𝑣 + 𝜌𝑤 = 0
Capacity 𝜕𝑡 𝜕𝑥 𝜕𝑦 𝜕𝑧
ℎ
Reynolds equation 𝜕 ℎ
Integration is done term by term: න 𝜌𝑣 𝑑𝑦 = 𝜌𝑣 0 = 𝜌𝑉2
𝜕𝑦
0
Chapiter 5: Lubrication ℎ
𝜕𝜌 𝜕𝜌
As ρ does not depend on y, we can write: න 𝑑𝑦 = .ℎ
𝜕𝑡 𝜕𝑡
0
1. Introduction
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Reynolds equation ℎ
Example: 𝜕 ℎ 𝜕 1 𝜕𝑝 2 ℎ 𝜕𝑝 𝑈1 − 𝑈2
න 𝜌𝑢 𝑑𝑦 = 𝜌 𝑦 − 𝑦− 𝑦 + 𝑈1 𝑑𝑦
𝜕𝑥 𝜕𝑥 2𝜂 𝜕𝑥 2𝜂 𝜕𝑥 ℎ
Chapiter 5: Lubrication 0
0
ℎ
𝜕 𝜕 𝜌 𝜕𝑝 3 𝜌 𝑈1 + 𝑈2 ℎ
⇒ න 𝜌𝑢 𝑑𝑦 = − ℎ +
1. Introduction 𝜕𝑥 𝜕𝑥 12𝜂 𝜕𝑥 2
0
2. Surface contacts
By grouping all the terms, we obtain:
3. Hertzian Contacts
𝜕 𝜌ℎ3 𝜕𝑝 𝜕 𝜌ℎ3 𝜕𝑝 𝜕 𝜌 𝑈1 + 𝑈2 ℎ
+ =
4. Reynolds equation for 𝜕𝑥 12𝜂 𝜕𝑥 𝜕𝑧 12𝜂 𝜕𝑧 𝜕𝑥 2
hydrodynamic contacts 𝜕ℎ 𝜕 𝜌 𝑊1 + 𝑊2 ℎ 𝜕ℎ 𝜕𝜌
−𝜌𝑈2 + − 𝜌𝑊2 + 𝜌𝑉2 + ℎ
5. Elementary Case of Bearing
𝜕𝑥 𝜕𝑧 2 𝜕𝑧 𝜕𝑡
Capacity
The shear stresses in the fluid film:
𝜕𝑢 𝜕𝑝 ℎ 𝜕𝑝 𝜂 𝑈1 − 𝑈2
𝜏𝑥𝑦 = 𝜂 = 𝑦− −
𝜕𝑦 𝜕𝑥 2 𝜕𝑥 ℎ
𝜕𝑤 𝜕𝑝 ℎ 𝜕𝑝 𝜂 𝑊1 − 𝑊2
𝜏𝑧𝑦 = 𝜂 = 𝑦− −
𝜕𝑦 𝜕𝑧 2 𝜕𝑧 ℎ
Academic year: 2024/2025 Teacher : Pr. I. ZIDANE
79
3. Hertzian Contacts 2.The medium is continuous, and the Reynolds equation does not
apply in areas where there is a film rupture.
4. Reynolds equation for
hydrodynamic contacts 3.The fluid is Newtonian: there is a proportional relationship between
the shear rate and the shear stress within the film.
5. Elementary Case of Bearing
Capacity 4.The flow is laminar; in non-laminar conditions, a different model
would be required.
5.One of the contact surfaces is perfectly flat and has no roughness,
allowing the coordinate system origin to be set on this surface, thus
neglecting the film’s overall curvature.
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2. Surface contacts 9. The fluid’s viscosity and density do not vary across the film
thickness.
3. Hertzian Contacts
10. This implies that the temperature does not vary across the film
4. Reynolds equation for thickness.
hydrodynamic contacts
The Reynolds equation is quite general and applies to various
5. Elementary Case of Bearing lubricants and types of contact. We can distinguish:
Capacity
➢ Compressible and incompressible fluids: In the latter case,
density is absent from the Reynolds equation.
➢ Variable-viscosity and constant-viscosity fluids: Note that for a
variable-viscosity fluid, the viscosity does not vary across the film
thickness.
Academic year: 2024/2025 Teacher : Pr. I. ZIDANE
81
𝜕 𝜌ℎ3 𝜕𝑝 𝜕 𝜌ℎ3 𝜕𝑝
+ =0
𝜕𝑥 12𝜂 𝜕𝑥 𝜕𝑧 12𝜂 𝜕𝑧
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Organization of Calculations
Calculating the characteristics of a hydrodynamic contact is carried
out in the following steps:
Chapiter 5: Lubrication 1. Selection of a coordinate system that considers any symmetries.
2. Determination of surface velocities in the chosen coordinate
system.
1. Introduction
3. Equation defining the film thickness.
4. Reynolds equation corresponding to the contact under study.
2. Surface contacts
5. Boundary conditions for pressure.
3. Hertzian Contacts 6. Calculation of the pressure within the film (solution to the Reynolds
equation).
4. Reynolds equation for 7. Calculation of the load-bearing capacity by integrating the pressure
hydrodynamic contacts
𝑊 = ඵ𝑝𝑑𝑥𝑑𝑧
5. Elementary Case of Bearing
Capacity
8. Calculation of friction by integrating the shear stresses on the
contact surfaces; integration by parts usually simplifies these
calculations.
𝐹𝑚 = ඵ𝜏𝑥𝑦 𝑦 = 0 𝑑𝑥𝑑𝑧
Organization of Calculations
𝑄𝑥 = ඵ𝑢 𝑦 . 𝑑𝑦𝑑𝑧
Chapiter 5: Lubrication 9. Calculation of flow rate:
𝑄𝑦 = ඵ𝑤 𝑦 . 𝑑𝑦𝑑𝑥
1. Introduction
3. Hertzian Contacts
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𝜕𝑝
So: = 𝑐𝑠𝑡𝑒
𝜕𝑥
Chapiter 5: Lubrication
1.The pressure is identical at both the
𝜕𝑝
inlet and outlet. In this case = 0;
1. Introduction 𝜕𝑥
there is no bearing capacity in the
2. Surface contacts contact, and the velocity distribution
across the film thickness is linear.
3. Hertzian Contacts This is known as Couette flow.
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2. Surface contacts
3. Hertzian Contacts
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2. Surface contacts 𝑑ℎ
avec: 𝑉=
𝑑𝑡
3. Hertzian Contacts
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Reynolds equation ?
2. Surface contacts
𝜕 2 𝑝 6𝜂 𝑑𝑈
=
3. Hertzian Contacts 𝜕𝑥 2 ℎ2 𝑑𝑥
2. Surface contacts
3. Hertzian Contacts
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5. Eco-lubricants
7. Examples of Lubrication
Devices
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
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Mineral Oils
Mineral oils are obtained directly from petroleum distillation. The base
material is relatively viscous and is refined to produce various types
Chapiter 6: Lubricants of oils with differing chemical structures and viscosities. All these oils
are hydrocarbons, composed solely of carbon (C) and hydrogen (H)
atoms.
1. Introduction
Three main families of mineral oils: paraffinic, naphthenic, and
aromatic. They differ in molecular structure and viscosity levels.
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
5. Eco-lubricants
7. Examples of Lubrication
Devices
Synthetic Oils
Mineral oils have limitations, such as high viscosity dependence on
temperature, which led to the development of high-performance
Chapiter 6: Lubricants synthetic oils. Synthetic oils are produced through chemical
processes that are generally more expensive than distillation and
refining. The main families include:
1. Introduction
7. Examples of Lubrication
Devices
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Additives
Additive Role Mechanism of Action
Reduces wear and
Anti-wear/extreme Forms a sacrificial film with lower shear
Chapiter 6: Lubricants friction, prevents
pressure strength than metal surfaces.
seizing
Prevents corrosion of Creates an adsorbed film on surfaces
Anti-corrosion
surfaces or neutralizes corrosive acids.
1. Introduction Forms a coating around particles,
Protects surfaces
Detergent preventing deposits, and neutralizes
from acidic products
2. Composition of Lubricants acids.
Prevents particle Hydrocarbon chains suspend particles
Dispersant
3. Viscosity
agglomeration in the lubricant.
Prevents lubricant Decomposes components (e.g.,
Antioxidant
oxidation hydroperoxides) that lead to oxidation.
4. Standardized Oil Prevents foam
Classification Lowers surface tension to eliminate air
Antifoaming agent formation in the
bubbles.
lubricant
5. Eco-lubricants Alters the coefficient Forms a durable adsorbed film on
Friction modifier
of friction surfaces, reducing friction.
6. Key Selection Criteria Pour Point Facilitates flow at low Prevents crystalline networks that
Depressant temperatures hinder fluid flow.
7. Examples of Lubrication
Minimizes viscosity Associates with lubricant molecules to
Devices Viscosity modifier variation with limit viscosity reduction at high
temperature temperatures.
2. Composition of Lubricants
where 𝜂 is the dynamic viscosity of the fluid. Therefore, the more
3. Viscosity viscous a fluid is, the higher the shear stress will be for the same
value of the velocity gradient. The unit of viscosity is “Pa.s”.
4. Standardized Oil Kinematic viscosity is also used, which is the ratio of dynamic
Classification
viscosity to the fluid's density:
5. Eco-lubricants
𝜂
𝜈=
6. Key Selection Criteria 𝜌
7. Examples of Lubrication
Devices
The unit of Kinematic viscosity is m2/s.
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Oils are generally classified based on their viscosity. There are different
classifications depending on the application. For industrial oils, the ISO
classification is used. Each oil is designated by ISO VG followed by a
Chapiter 6: Lubricants number that indicates its kinematic viscosity at 40°C in mm²/s.
ISO Viscosity kinematic viscosity at 40°C (mm2/s)
grade Min Mean Max
1. Introduction ISO VG 2 1.98 2.2 2.42
ISO VG 3 2.88 3.2 3.52
ISO VG 5 4.14 4.6 5.06
2. Composition of Lubricants
ISO VG 7 6.12 6.8 7.48
ISO VG 10 9 10 11
3. Viscosity ISO VG 15 13.5 15 16.5
ISO VG 22 19.8 22 24.2
4. Standardized Oil ISO VG 32 28.8 32 35.2
Classification ISO VG 46 41.4 46 50.6
ISO VG 68 61.2 68 74.8
5. Eco-lubricants ISO VG 100 90 100 110
ISO VG 150 135 150 165
ISO VG 220 198 220 242
6. Key Selection Criteria
ISO VG 320 288 320 352
ISO VG 460 414 460 506
7. Examples of Lubrication ISO VG 680 612 680 748
Devices
ISO VG 1000 900 1000 1100
ISO VG 1500 1350 1500 1650
Engine oils do not fall under this standard and instead rely on the SAE
(Society of Automotive Engineers) classification. Two types are distinguished:
1. Monograde oils have a single viscosity, for example: 10W.
Chapiter 6: Lubricants 2. Multigrade oils have a range of viscosities, for example:
10W40.
The first number indicates the viscosity in cold conditions. ("W" stands for
Winter) and remains liquid down to -35°C. It flows faster through the
1. Introduction
lubrication system to ensure complete lubrication. The second number
indicates the viscosity in hot conditions (measured at 100°C). It reflects the
2. Composition of Lubricants
oil's resistance and ability to withstand high temperatures. Theoretically, the
lower the first number (down to 0) and the higher the second number (up to
3. Viscosity
60), the better the performance.
4. Standardized Oil
Classification
5. Eco-lubricants
7. Examples of Lubrication
Devices
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5. Eco-lubricants
7. Examples of Lubrication
Devices
Choosing a lubricant is
Chapiter 6: Lubricants complex due to factors like
temperature, which are
often poorly understood
1. Introduction during the design phase.
Manufacturers typically
2. Composition of Lubricants offer products tailored to
specific applications (e.g.,
3. Viscosity
two-stroke or four-stroke
4. Standardized Oil
engines, gear oils,
Classification transmission oils, cutting
oils, etc.). It is crucial to
5. Eco-lubricants ensure compatibility with
other system components.
6. Key Selection Criteria
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Oil Lubrication
In this system, the properties of oil, such as viscosity and lubricity, are
utilized to transport it to the surfaces requiring lubrication. This can be
Chapiter 6: Lubricants
achieved either by the mechanism itself (e.g., gears), as illustrated in
the figure below, which shows a classic lubrication system commonly
known as splash lubrication (Fr: lubrification par barbotage).
1. Introduction
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
5. Eco-lubricants
7. Examples of Lubrication
Devices
Oil Lubrication
In many cases, it is also necessary to cool the lubricant. An example of forced
cooling is shown in Figure 6-7, corresponding to a worm gear reducer of
Chapiter 6: Lubricants 24.5kW for N = 1500 rpm.
1. Introduction
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
5. Eco-lubricants
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Oil Lubrication
The following two examples demonstrate the principle of oil
circulation with recovery mechanisms (Fr: Circulation d’huile avec
Chapiter 6: Lubricants
récupération):
1. Introduction
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
5. Eco-lubricants
7. Examples of Lubrication
Devices
Oil Lubrication
The following example shows us the different technological solutions
used in different systems for this lubrication.
Chapiter 6: Lubricants
1. Introduction
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
5. Eco-lubricants
7. Examples of Lubrication
Devices Lubrication by projection and flow recovery
(Fr: lubrification par projection et ruissellement)
Academic year: 2024/2025 Teacher : Pr. I. ZIDANE
108
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Hassiba
Université
Benbouali
Faculté
Ben Boualiof–Chlef
Hassiba university
Faculty de
Chlef
of Technologie
Technology
Course: TRIBOLOGY AND LUBRICATION
Mechanical
Département
engineering
de Génie Mécanique
department OF MECHANICAL SYSTEMS
Oil Lubrication
Finally, examples below present the principle of oil mist lubrication,
which is often employed in high-speed mechanisms,
Chapiter 6: Lubricants
1. Introduction
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
5. Eco-lubricants
7. Examples of Lubrication
Devices
Grease Lubrication
Grease lubrication simplifies the various mechanisms required to
deliver the lubricant. However, this simplification is only feasible for
Chapiter 6: Lubricants
moderate speeds and limited heat generation.
1. Introduction
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
5. Eco-lubricants
7. Examples of Lubrication
Devices
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Grease Lubrication
Chapiter 6: Lubricants
1. Introduction
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
5. Eco-lubricants
7. Examples of Lubrication
Devices
Grease Lubrication
Chapiter 6: Lubricants
1. Introduction
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
5. Eco-lubricants
7. Examples of Lubrication
Devices
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Grease Lubrication
Chapiter 6: Lubricants
1. Introduction
2. Composition of Lubricants
3. Viscosity
4. Standardized Oil
Classification
5. Eco-lubricants
7. Examples of Lubrication
Devices
57