Experiments were conducted using a gear-cam adapter to simulate line-contact lubrication and wear in a lubricant with various additive concentrations. In this study, the growth of an adsorption film and a chemical film in oil lubrication can be detected by the electrical contact resistance (ECR) apparatus of a wear testing machine. A constant current source was applied; the electrical voltage is thus obtained if the ECR is available. Roller wear rate and wear loss are formulated in terms of roller-lower specimen contact temperature and several relevant parameters. In addition, wear loss is also related to the rise of electrical voltage during the period of lubrication. The experimental data for wear rate and wear loss can be regressed by the models proposed for various additive concentrations. The roller’s wear rate can be predicted through the investigation of the combined effect of growth in electrical voltage and its commencement. For lowering wear rate, the optimum additive concentration in a lubricating oil is determined under various operating conditions.

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