Lubrication I

26-Feb-15
Wear Characterization
Lecture 7 Lubrication I
I.
II.
III.
IV.
Lubrication
Regimes of Lubrication
Other Considerations
Since wear behavior is complex and many different

relationships may be used to describe wear behavior,
characterization is an essential element of a wear analysis.
Characterization of the wear situation is the basis for
selecting appropriate relationships for wear behavior and
identifying relevant databases.
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Manufacturing Processes & Metrology
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Characterization should contain the following elements:
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Example of initial Characterization of Wear
Nominal descriptions of the state of lubrication and the

environment that are contained in the characterization of
the state of lubrication and the environment that are
contained in the characterization are often adequate for
the entire analysis.
Example 1
Example 2
Motion
Reciprocating
Sliding
Unidirectional Sliding, smaller

member separates for return
Stroke
Geometry
Flat against flat
Cylinder on flat, cylinder is

smaller member
Lubrication Thin oil film
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None
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26-Feb-15
Tribology
Wear is damage to a solid surface, generally involving
progressive loss of material, due to the relative motion between
that surface and a contacting substance or substances.
Tribology
Wear is the major cause of material wastage and loss of
mechanical performance and any reduction in wear can result in
considerable savings.
Friction, or friction force, is the resisting force tangential to the

interface between two bodies when, under the action of an
external force, one body moves or tends to move relative to the
other.
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Lubrication
Lubrication
Lubrication is the reduction of frictional resistance and wear
between two load-bearing surfaces by application of a lubricant.
The primary elements of a tribosystem are the materials, contact

geometry, load conditions, motion conditions, and
environmental conditions.
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Lubrication
Lubrication
Lubrication is an essential element of many practical

tribosystems.
To characterize a tribosystem it is necessary to identify whether
or not a lubricant is used.
These layers of material separate contacting solid bodies and are

usually very thin and often difficult to observe.
In general, the thicknesses of these films range from 1 to 100
microns, although thinner and thicker films can also be found.
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26-Feb-15
Lubrication
Lubrication
A gaseous film can be suitable for low contact stress while

solid films are usually applied to slow sliding speed
contacts.
A specialised form of hydrodynamic lubrication involving

physical interaction between the contacting bodies and
the liquid lubricant is termed as elastohydrodynamic
lubrication.
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Lubrication
Lubrication
In the absence of any films, the only reliable means of

ensuring relative movement is to maintain, by external
force fields, a small distance of separation between the
opposite surfaces.
There is evidence that the lubrication of surfaces to reduce

friction and wear dates back about four millenia to
lubricate various linear and rotary moving components.
This, for example, can be achieved by the application of

magnetic forces, which is the operating principle of
magnetic levitation or maglev.
For example, chariot wheels were lubricated with beef

tallow (fat) in 1400 B.C.
Various oils also were used for lubrication in metalworking
processes, beginning in about 600 A.D.
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Lubrication
In manufacturing processes the surfaces of tools, dies, and

workpieces are subjected to;
1. Thick-film lubrication - the surfaces are separated completely by

a film of lubricant and lubricant viscosity is an important factor.
a) force and contact pressure, which ranges from very low

values to multiples of the yield stress of the workpiece
material;
b) relative speed, from very low to very high; and
Such films can develop in some regions of the workpiece in highspeed operations and also can develop from high-viscosity
lubricants that become trapped at die-workpiece interfaces.
c) temperature, which ranges from ambient to melting.
A thick lubricant film results in a dull, grainy surface appearance

on the workpiece after forming operations, with the degree of
roughness varying with grain size.
In addition to selecting appropriate materials and controlling

process parameters to reduce friction and wear, lubricants,
or, more generally, metalworking fluids, are applied widely.
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26-Feb-15
2.
As the load between the die and the workpiece increases

or as the speed and viscosity of the metalworking fluid
decrease, the lubricant film becomes thinner and the
process is known as thin-film lubrication.
This condition raises the friction at the sliding interfaces

and results in slight wear.
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3. In mixed lubrication, a significant portion of the load is
carried by the physical contact between the asperities of
the two contacting surfaces.
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4. In boundary lubrication, the load is supported by
contacting surfaces that are covered with a boundary
film of lubricant (Next Fig. (d))-a thin molecular lubricant
layer.
The film is attracted to the metal surfaces and prevents
direct metal-to-metal contact of the two bodies, thus
reducing wear.
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26-Feb-15
4.
However, boundary films can break down;

(a) as a result of desorption caused by high temperatures
developed at the sliding interfaces or
(b) by being rubbed off during sliding. Deprived of this
protective film, the sliding metal surfaces then begin to
wear and may also score severely.
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Note that the valleys in the surface of the contacting bodies

(see Fig. below) can serve as local reservoirs or pockets for
lubricants, thereby supporting a substantial portion of the
load.
The workpiece, but not the die, should have the rougher
surface; otherwise, the rougher and harder die surface, acting
like a file, may damage the workpiece surface.
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The overall geometry of the interacting bodies is another
important consideration in ensuring proper lubrication.
The movement of the workpiece into the deformation zone, as
occurs during wire drawing, extrusion, and rolling, should
allow a supply of lubricant to be carried into the die-workpiece
interface.
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Lecture 7 Summary
I.
II.
III.
IV.
Lubrication
BIBLIOGRAPHY:
1. Kalpakjian S, Schmid SR. Manufacturing Engineering and Technology,
Sixth ed. Singapore: Prentice Hall; 2010. Copyright 2014 by Pearson
Education South Asia Pte Ltd. All rights reserved. PEARSON
2. Groover, M.P (2010) Fundamentals of Modern Manufacturing, 4th edn.,
USA: John Wiley & Sons, Inc
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26-Feb-15

Since wear behavior is complex and many different

Example of initial Characterization of Wear

Nominal descriptions of the state of lubrication and the

Unidirectional Sliding, smaller

Flat against flat

Cylinder on flat, cylinder is

Lubrication Thin oil film

Friction, or friction force, is the resisting force tangential to the

The primary elements of a tribosystem are the materials, contact

Lubrication is an essential element of many practical

These layers of material separate contacting solid bodies and are

A gaseous film can be suitable for low contact stress while

A specialised form of hydrodynamic lubrication involving

In the absence of any films, the only reliable means of

There is evidence that the lubrication of surfaces to reduce

This, for example, can be achieved by the application of

For example, chariot wheels were lubricated with beef

In manufacturing processes the surfaces of tools, dies, and

1. Thick-film lubrication - the surfaces are separated completely by

a) force and contact pressure, which ranges from very low

c) temperature, which ranges from ambient to melting.

A thick lubricant film results in a dull, grainy surface appearance

In addition to selecting appropriate materials and controlling

As the load between the die and the workpiece increases

This condition raises the friction at the sliding interfaces

However, boundary films can break down;

Note that the valleys in the surface of the contacting bodies

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