Abstract
For multilayered or coated substrates in elastohydrodynamic-lubricated (EHL) contacts, the subsurface stress distributions under a normal load combined with shear traction have been analyzed in this article through computer simulations. The Papkovich-Neuber potentials and Fourier transform are adopted to deduce the pressure–displacement, pressure–stress, and shear traction–stress response functions in frequency domain for the coated substrates, and to calculate distributions of pressure and subsurface stress. The results from the analysis of EHL contacts on coated substrates are compared with those from dry contact model in which shear traction is assumed to obey Coulomb’s law. Effects of the Young’s modulus of coatings, the properties of lubricants, and the magnitude of traction are discussed. Similar to the results in dry contacts, hard coatings in lubricated cases tend to increase the von Mises stress, whereas soft coatings decrease the stress. Shear traction makes the max von Mises stress increasing and moving closer to surface. However, the changes in subsurface stress due to shear traction are less obvious in lubricated contacts. Comparison between EHL and dry contact models reveals that lubrication can reduce the von Mises stress in the coating layer due to smaller shear traction. The analyses show that pressure, film thickness, and subsurface stress distributions are influenced by surface coatings, sliding velocity, rheological models, and pressure–viscosity behaviors.
Similar content being viewed by others
Abbreviations
- a :
-
Hertzian contact radius (mm)
- \( \tilde{C}_{p}^{{u_{z}^{\left( 1 \right)} }} \) :
-
The frequency response function of pressure–displacement in frequency domain
- \( \tilde{C}_{p}^{{{\varvec{\upsigma}}^{\left( k \right)} }} \) :
-
The frequency response functions of pressure–stress in frequency domain
- \( \tilde{C}_{q}^{{{\varvec{\upsigma}}^{\left( k \right)} }} \) :
-
The frequency response functions of shear traction–stress in frequency domain
- E 1 :
-
Young’s modulus for the coating (GPa)
- E 2 :
-
Young’s modulus for the substrate (GPa)
- G 1 :
-
Shear modulus for the coating (GPa)
- G 2 :
-
Shear modulus for the substrate (GPa)
- h :
-
Coating thickness (mm)
- h f :
-
Oil film thickness (mm)
- h 0 :
-
Body separation between two surfaces (mm)
- h s :
-
Original geometry of contacting bodies (mm)
- J 2 :
-
The second invariant of the deviatoric stress tensor (MPa)
- \( \sqrt {J_{2} } \) :
-
The von Mises stress (MPa)
- m, n:
-
Frequency domain correspond to x, y, respectively
- p :
-
Pressure (MPa)
- q :
-
Shear traction (MPa)
- p h :
-
Maximum Hertzian pressure (MPa)
- R :
-
Ball radius (mm)
- u x , u y , u z :
-
Displacements of three directions (mm)
- U :
-
Surface velocity (mm/s)
- V :
-
Surface deformation (mm)
- w :
-
Applied load (N)
- x, y, z:
-
Space coordinates (mm)
- α:
-
Pressure–viscosity coefficient (GPa−1)
- γS :
-
Pressure coefficient corresponding to the friction coefficient in boundary lubrication
- \( \dot{\gamma } \) :
-
Shear strain rate of lubricant film (s−1)
- γL :
-
The pressure coefficient
- δ1, δ2 :
-
The roughness amplitudes of surface 1 and 2, respectively (mm)
- δ ij :
-
Kronecker delta
- η:
-
Viscosity (Pa s)
- η0 :
-
Viscosity at normal temperature and pressure (Pa s)
- ν1 :
-
Poisson’s ratio of the coating
- ν2 :
-
Poisson’s ratio of the substrate
- ρ:
-
Lubricant’s density (kg/m3)
- ρ0 :
-
Lubricant’s density at normal temperature and pressure (kg/m3)
- σ ij :
-
Stress (MPa)
- τc :
-
Shear stress of boundary film (MPa)
- τS0 :
-
Initial shear strength of boundary film (MPa)
- τl :
-
Shear stress of lubricant film (MPa)
- τL :
-
Limiting shear stress of lubricant film (MPa)
- τL0 :
-
Initial limiting shear stress (MPa)
- τmax :
-
Maximum shear stress (MPa)
- ϕ, ψ1, ψ2, ψ3 :
-
Papkovich-Neuber potentials
- Tilde(~) or FT:
-
The Fourier transform
- IFFT:
-
The inverse discrete Fourier transform
- k = 1, 2:
-
Means in the coating and substrate, respectively
References
Burmister, D.M.: The general theory of stresses and displacement in layered system. J. Appl. Phys. 16, 89–94 (1945). doi:10.1063/1.1707558
Hannah, M.: Contact stress and deformation in a thin elastic layer. J. Mech. Appl. Math. 4, 94–105 (1951). doi:10.1093/qjmam/4.1.94
Meijers, P.: The contact problem of a rigid cylinder on an elastic layer. Appl. Sci. Res. 18, 353–382 (1968). doi:10.1007/BF00382359
O’Sullivan, T.C., King, R.B.: Sliding contact stress field due to a spherical indenter on a layered elastic half-space. ASME J. Tribol. 110(2), 235–240 (1988)
Nogi, T., Kato, T.: Influence of a hard surface layer on the limit of elastic contact, Part I: analysis using a real surface model. ASME J. Tribol. 119(3), 493–500 (1997). doi:10.1115/1.2833525
Bhushan, B., Peng, W.: Contact mechanics of multilayered rough surface. Appl. Mech. Rev. 55(5), 435–480 (2002). doi:10.1115/1.1488931
Bennett, A., Higginson, G.R.: Hydrodynamic lubrication of soft solids. J. Mech. Eng. Sci. 12(3), 218–222 (1970). doi:10.1243/JMES_JOUR_1970_012_037_02
Elsharkawy, A.A., Hamrock, B.J.: EHL of coated surfaces, Part I—Newtonian results. ASME J. Tribol. 116(1), 29–36 (1994). doi:10.1115/1.2927041
Elsharkawy, A.A., Hamrock, B.J.: EHL of coated surfaces, Part II—non-Newtonian results. ASME J. Tribol. 116(4), 786–793 (1994). doi:10.1115/1.2927333
Elsharkawy, A.A., Holmes, M.J.A., Evans, H.P., Snidle, R.W.: Microelastohydrodynamic lubrication of coated cylinders using coupled differential deflection method. Proc. Inst. Mech. Eng. Part J: J. Eng. Tribol. 220(1), 29–41 (2006). doi:10.1243/13506501J10005
Bohan, M.F.J., Lim, C.H., Korochkina, T.V., Claypole, T.C., Gethin, D.T., Roylance, B.J.: An investigation of the hydrodynamic and mechanical behaviour of a soft nip rolling contact. Proc. Inst. Mech. Eng. Part J: J. Eng. Tribol. 221(1), 37–49 (1997). doi:10.1243/1350650971542309
Xue, Y.K., Gethin, D.T., Lim, C.H.: Elastohydrodynamic lubrication analysis of layered line contact by the boundary element method. Int. J. Numer. Methods Eng. 39(15), 2531–2554 (1996). doi:10.1002/(SICI)1097-0207(19960815)39:15<2531::AID-NME965>3.0.CO;2-N
Goryacheva, I., Sadeghi, F., Xu, G.: Viscoelastic effects in lubricated contacts. Wear 198, 307–312 (1996). doi:10.1016/0043-1648(96)07206-7
Jin, Z.M.: Elastohydrodynamic lubrication of a circular point contact for a compliant layered surfaces bonded to a rigid substrate, Part 1: theoretical formulation and numerical method. Proc. Inst. Mech. Eng. Part J: J. Eng. Tribol. 214(3), 267–279 (2000). doi:10.1243/1350650001543160
Jin, Z.M.: Elastohydrodynamic lubrication of a circular point contact for a compliant layered surfaces bonded to a rigid substrate, Part 2: numerical results. Proc. Inst. Mech. Eng. Part J: J. Eng. Tribol. 214(3), 281–289 (2000). doi:10.1243/1350650001543179
Harris, T.A.: Rolling Bearing Analysis, 4th edn. Wiley, New York (2001)
Liu, L.C., Chen, W.W., Zhu, D., Liu, S.B., Wang, Q.: An elastohydrodynamic lubrication model for coated surfaces in point contacts. ASME J. Tribol. 129(4), 509–516 (2007). doi:10.1115/1.2736433
Fujinoa, T., Iwamotob, K., Tanakab, K., Shima, M.: Stress distribution of coated film with a range of coated film thickness and elastic properties under a single EHL operating condition. Tribol. Int. 40(10–12), 1638–1648 (2007). doi:10.1016/j.triboint.2007.02.012
Stewart, S., Ahmed, R.: Rolling contact fatigue of surface coatings—a review. Wear 253(11-12), 1132–1144 (2002). doi:10.1016/S0043-1648(02)00234-X
Michalczewski, R., Piekoszewski, W., Szczerek, M., Tuszynski, W.: The lubricant-coating interaction in rolling and sliding contacts. Tribol. Int. 42(4), 554–560 (2009). doi:10.1016/j.triboint.2008.05.001
Evans, R.D., Cogdell, J.D., Richter, G.A., Doll, G.L.: Traction of lubricated rolling contacts between thin-film coatings and steel. STLE Tribol. Trans. 52(1), 106–113 (2009). doi:10.1080/10402000802180144
Bair, S., Winer, W.O.: A rheological model for elastohydrodynamic contacts based on primary laboratory data. ASME J. Lubric. Technol. 101(3), 258–265 (1979)
Lee, R.T., Hamrock, B.J.: A circular non-newtonian fluid model, Part I—used in elastohydrodynamic lubrication. ASME J. Tribol. 112(3), 486–496 (1990). doi:10.1115/1.2920285
Gecim, B., Winer, W.O.: Lubricant limiting shear-stress effect on EHD film thickness. ASME J. Lubric. Technol. 102(2), 213–221 (1980)
Iivonen, H., Hamrock, B.J.: New non-Newtonian fluid model for elastohydrodynamic lubrication of rectangular contacts. Wear 143(2), 297–305 (1991). doi:10.1016/0043-1648(91)90103-2
Wang, W.Z., Wang, S., Shi, F.H., Wang, Y.C., Chen, H.B., Wang, H., Hu, Y.Z.: Simulations and measurements of sliding friction between rough surfaces in point contacts: from EHL to boundary lubrication. ASME. J. Tribol. 129(3), 495–501 (2006). doi:10.1115/1.2736432
Pettersson, U., Jacobson, S.: Friction and wear properties of micro textured DLC coated surfaces in boundary lubricated sliding. Tribol. Lett. 17(3), 553–559 (2004). doi:10.1023/B:TRIL.0000044504.76164.4e
Svahn, F., Rudolphi, A.K., Hogmark, S.: On the effect of surface topography and humidity on lubricated running-in of a carbon based coating. Wear 261(11-12), 1237–1246 (2006). doi:10.1016/j.wear.2006.03.012
Alanou, M.P., Evans, H.P., Snidle, R.W.: Effect of different surface treatments and coatings on the scuffing performance of hardened steel discs at very high sliding speeds. Tribol. Int. 37(2), 93–102 (2004). doi:10.1016/S0301-679X(03)00039-2
Hu, Y.Z., Zhu, D.: A full numerical solution to the mixed lubrication in point contacts. ASME J. Tribol. 122(1), 1–9 (2000). doi:10.1115/1.555322
Liu, S.B., Wang, Q., Liu, G.: A versatile method of discrete convolution and FFT (DC-FFT) for contact analyses. Wear 243(1–2), 101–110 (2000). doi:10.1016/S0043-1648(00)00427-0
Dowson, D., Higginson, G.R.: Elasto-Hydrodynamic Lubrication: The Fundamentals of Roller and Gear Lubrication. Pergamon, Oxford (1966)
Houpert, L., Flamand, L., Berthe, D.: Rheological and thermal effects in lubricated E.H.D. contacts. ASME J. Lubric. Technol. 103(4), 526–532 (1981)
Stahl, J., Jacobson, B.O.: A lubricant model considering wall-slip in EHL line contacts. ASME J. Tribol. 125(3), 523–532 (2003). doi:10.1115/1.1537750
Rabinowicz, E.: Friction especially low friction. In: Suh, N.P., Saka, N. (eds.) Proceedings of the International Conference on the Fundamentals of Tribology, pp. 351–364. MIT Press, Cambridge, MA (1980)
Hoglund, E.: Influence of lubricant properties on elastohydrodynamic lubrication. Wear 232(2), 176–184 (1999). doi:10.1016/S0043-1648(99)00143-X
Wang, S., Hu, Y.Z., Wang, W.Z., Wang, H.: Transition of frictional states and surface roughness effects in lubricated contacts. Proc. Inst. Mech. Eng. Part J: J. Eng. Tribol. 222(3), 407–414 (2008). doi:10.1243/13506501JET346
Ahmed, A., Hadfield, M.: Failure modes of plasma sprayed WC–15%CO coated rolling elements. Wear 230(1), 35–39 (1999). doi:10.1016/S0043-1648(99)00083-6
Dahm, K.L., Torskaya, E., Goryacheva, I., Dearnley, P.A.: Tribological effects on subsurface interfaces. Proc. Inst. Mech. Eng. Part J: J. Eng. Tribol. 221(3), 345–353 (2007). doi:10.1243/13506501JET248
Polonsky, I.A., Keer, L.M.: Stress analysis of layered elastic solids with cracks using the fast Fourier transform and conjugate gradient techniques. ASME J. Appl. Mech. 68(5), 708–714 (2001)
Acknowledgments
The authors would like to thank the support of the National Basic Research Program of China (973 Program), under Grant No. 2006CB705403, and National Science Foundation of China, under Grant Nos. 50675111 and 50721004.
Author information
Authors and Affiliations
Corresponding author
Appendix
Appendix
1.1 Response Functions for Stresses and Surface Normal Displacement in Layered Elastic Half-Space due to a Normal Traction
or
where G k is the Shear modulus and ν k is the Poisson’s ratio, k = 1 means in the coating, and k = 2 means in the substrate.
1.2 Response Functions for Stresses in Layered Elastic Half-Space due to a Tangential Traction
where G k is the Shear modulus and ν k is the Poisson’s ratio, k = 1 means in the coating, and k = 2 means in the substrate.
where
Rights and permissions
About this article
Cite this article
Wang, Zj., Wang, Wz., Wang, H. et al. Stress Analysis on Layered Materials in Point Elastohydrodynamic-Lubricated Contacts. Tribol Lett 35, 229–244 (2009). https://doi.org/10.1007/s11249-009-9452-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11249-009-9452-4