Sequential honing process is usually implemented in engine cylinder bore processing to obtain the cross-hatched surface texture with excellent function to balance lubricant storage capacities and supporting performance. Many researches have devoted to correlating honed surface quality of cylinder bore with honing process parameters by means of experiments or simulations. Quite a few efforts have addressed the effect of sequential multiple steps on the surface texture in the honing of engine cylinder bore. However, these researches cannot provide an explicit and analytical methodology to predict honed surface texture efficiently and accurately. This paper presents an analytical and explicit methodology to incorporate a proposed microscale abrasive model into the analytical simulation process of sequential honing. The proposed abrasive model synthetically considers the shape, size, posture, and position of abrasives randomly distributed in honing stone, which is incorporated into honing head motions in terms of rotation, oscillation and feeding. The kinematics of honing head is calculated by space-time discretization to capture the interaction between honing stones and cylinder bore surface. The above procedure acts as each single step for the sequential honing processes. This study investigates the sequential honing of two stages including semi-finish honing and plateau honing at different feeding speeds by applying the abrasive model with different abrasive sizes. The formation of cross-hatched surface texture was successfully achieved sequentially by semi-finish honing and plateaus honing. Then the Abbott-Firestone Curve of the honed surface can be obtained to analyze the influences of abrasive size and honing time of two stages on the surface roughness. Correctness of surface roughness predicted by the model is verified by comparing with a group of experiment measurements in terms of Abbott-Firestone Curve. Most errors of all the predicted R k roughness family roughness parameters in the two honing stages are less than 15%. Based on the model, simulations are done to analyze the influences of abrasive size and honing duration time of two stages on the surface roughness. The result shows that the larger abrasive used in finish honing leads to the decrease of the material portions M r1 , M r2 and the increase of the reduced valley depth R vk . The longer plateau honing duration time is preferred to produce the larger M r1 , M r2 and the smaller R vk .

In this paper, a profile design of surface texture was applied for improving the tribological performance of piston ring–cylinder pair. The design of texture pattern was implemented by numerous textures of different depths in sliding speed direction to imitate the outline of barrel-shaped ring. The thickness and pressure distribution of oil film were obtained through a joint solution of modified Reynolds equation and other governing equations for textured surface. The results indicate that the novel texture pattern has the best overall performance in oil film thickness and friction force compared with normal surface textures, and the average friction power is 10.04% and 16.85% less than normal surface textures and barrel-shaped ring in the whole working cycle. Extra microhydrodynamic lubrication can be observed in the middle region of textured piston ring through the pressure distribution of oil film. At last, the experiment was conducted in a motored test rig and exhibited up to 3% reduction in friction power.

This study investigates the effects of the microdimple texture on the friction and surface temperature performances of a ball-on-disk contact, operating under the speed and load ranges that cover typical gearing applications. Circular-shaped microdimple arrays with different dimple center distances and dimple depths are implemented on the ball surface to quantify the impacts of these two parameters on the friction coefficient and the maximum ball surface temperature. In addition, the contacts of three surface texture combinations, namely microdimpled and polished ball surface versus polished disk surface, polished ball surface versus polished disk surface, and ground ball surface versus ground disk surface, are compared to demonstrate any beneficial or detrimental effect of microdimples in heavily loaded high-speed applications. This study adopts a thermal mixed EHL point contact model, whose capability and accuracy have been well demonstrated by comparing to the experimental measurements, to quantify the deterministic tribological behavior within the contact, allowing the exploration of the underlying mechanism that governs the role of microdimples in the elastohydrodynamic lubrication (EHL).

The aim of this technical brief is to provide a numerical approach to investigate the lubricity enhancement effect of microgrooves texture on tools' rake face. The key parameters related to cutting condition and grooves morphology were considered in the analytical model of tool–chip friction pair. The fully textured surfaces with the periodic microgrooves were systematically studied by solving the nondimensional Reynolds equation with the multigrid method. The results indicated that the microgrooves texture generates extra carrying capacity comparing to the flat tool and the optimum grooves direction is vertical to the chip sliding. Higher area density and optimum grooves width can further promote hydrodynamic lubrication. By modifying the tool rake face geometry to restrict the tool–chip slope angle, efficiency of surface texture could be greatly extended. In addition, the film's average pressure was nearly proportional to the chip velocity. Hence, the textured tool is more effective in high-speed cutting.

An analytical numerical model to optimize the shape of concave surface texture for the achievement of low friction in reciprocating sliding motion has been developed. The model uses: (i) average Reynolds equation to evaluate friction coefficient and (ii) genetic algorithm (GA) to optimize and obtain several preferable texture shapes. Analysis of distribution contour maps of hydrodynamic pressure gives the possible mechanisms involved. Moreover, experimental comparisons of tribological performances between the optimized and the circular textures were conducted to verify the simulation results. It is shown that surface textures of the elliptical and fusiform shapes can effectively enhance the load bearing capacity and reduce the friction coefficient compared with circular textures. The increase in hydrodynamic pressure for these optimized texture shapes is considered to be the major mechanism responsible for improving their tribological performance. Experimental results confirm that the elliptical-shaped textures have preferable tribological behaviors of low friction coefficient under the operating condition of light load.

Minimization of parasitic losses in the internal combustion (IC) engine is essential for improved fuel efficiency and reduced emissions. Surface texturing has emerged as a method palliating these losses in instances where thin lubricant films lead to mixed or boundary regimes of lubrication. Such thin films are prevalent in contact of compression ring to cylinder liner at piston motion reversals because of momentary cessation of entraining motion. The paper provides combined solution of Reynolds equation, boundary interactions, and a gas flow model to predict the tribological conditions, particularly at piston reversals. This model is then validated against measurements using a floating liner for determination of in situ friction of an engine under motored condition. Very good agreement is obtained. The validated model is then used to ascertain the effect of surface texturing of the liner surface during reversals. Therefore, the paper is a combined study of numerical predictions and the effect of surface texturing. The predictions show that some marginal gains in engine performance can be expected with laser textured chevron features of shallow depth under certain operating conditions.

Benefits of surface textures for improving the performance behaviors of tribo-contacts are being explored and established by the investigators across the globe. But the consolidated information of findings of such explorations are spread. Therefore, the objective of this paper is to summarize the information available related to the preparation of surface textures and performance outcomes in the presence of surface textures at the concentrated contacts. Mainly, recent research findings and practices followed for the study of friction, wear, lubrication, contact fatigue, vibration, and noise at the generic concentrated contacts in presence of surface textures are reviewed for current status of research in the area and outlining the future prospects.

It has been recognized that purposefully designed surface texturing can contribute to the improvement of tribological performance of elements and friction reduction. However, its optimal parameters may depend on the operating conditions. This paper investigated the effect of a triangle-shaped dimples array on the tribological performance of the lubricated point-contacts under different lubrication regimes, based on the rotational sliding experiment of a patterned steel disk against smooth steel balls. The dimples arrays were produced by laser process and characterized by the 3D profilometer. A series of tests were conducted with different dimple parameters including depth, coverage ratio, size, and direction. Stribecklike curves were obtained to depict the transition of lubrication regimes, and the electrical contact resistance was utilized to qualitatively characterize the lubrication status. The test results showed that the dimples arrays with different sizes, depths and coverage ratios had a distinct effect on the friction behaviors. Compared with the nontextured surfaces, when the dimple depth decreased from 30μm to zero with fixed coverage ratio and size, the friction coefficient firstly decreased, and then increased. The friction coefficient finally approached that of the nontextured surface, during which the lowest value appeared at the dimple depth of approximately 10∼15μm. The coverage ratio of texture showed the similar effect on the friction coefficient. Usually, the coverage ratio of approximately 10% resulted in the lowest friction coefficient. The dimple size and direction also had obvious effects on the friction coefficient. Thus, it can be concluded that there exists a set of optimal values for the dimple depth, coverage ratio, size, and direction to realize the friction reduction.

In an effort to study the role of strain rate response on the tribological behavior of metals, room temperature experiments were conducted by sliding commercially pure titanium and a-iron pins against an H-11 die steel flats of various surface textures. The steel flat surface textures were specifically prepared to allow for imposing varying amounts of strain rates at the contacting interface during sliding motion. In the experiments, it was observed that titanium (a harder material than iron) formed a transfer layer on H-11 steel surface textures that produced higher strain rates. In contrast, the titanium pins abraded the steel surfaces that produced lower strain rates. The iron pins were found to abrade the H-11 steel surface regardless of the surface texture characteristics. This unique tribological behavior of titanium is likely due to the fact that titanium undergoes adiabatic shear banding at high strain rates, which creates pathways for lower resistance shear planes. These shear planes lead to fracture and transfer layer formation on the surface of the steel flat, which ultimately promotes a higher strain rate of deformation at the asperity level. Iron does not undergo adiabatic shear banding and thus more naturally abrades the surfaces. Overall, the results clear indicated that a materials strain rate response can be an important factor in controlling the tribological behavior of a plastically deforming material at the asperity level.

A mass-conservative algorithm that implements the Jakobsson–Floberg–Olsson cavitation theory is used to predict the performances of seal-like structures and thrust bearings with a dimpled surface texture. The results of a series of simulations for load-carrying capacity, film thickness, dimple depth, dimple density, cavitation pressure, leakage, and friction force are presented, and the relationship between these performance parameters is studied. It is shown that, under the conditions simulated, surface roughness can improve the load-carrying capacity, but its effect is limited.

Contours of surface texture of contact faces are not always parallel to the directions of the axis in solving Reynolds equations with finite difference method, and this often induces significant pressure saw-tooth effect, which results in an unignored analysis error. In this paper, pseudo-nine-point finite difference, as a new finite difference method, is introduced to solve the lubrication numerical problem of pressure saw-tooth. Also, application is carried out in gas lubrication of hard disk systems to verify the validity of the new method. In analysis, pressure distributions and gas floating forces are calculated for two different types of sliders, and the astringency and efficiency of the new method is discussed. Numerical results show that the pseudo-nine-point finite difference method can restrain pressure saw-tooth evidently, and presents better astringency and efficiency than the traditional five-point finite difference method. With the increase in mesh density, pressure distribution and gas floating force trend to steady. Also, numerical values of the floating force agree well with the experimental ones.

Surface texture plays an important role in the frictional behavior and transfer layer formation of contacting surfaces. In the present investigation, basic experiments were conducted using an inclined pin-on-plate sliding apparatus to better understand the role of surface texture on the coefficient of friction and the formation of a transfer layer. In the experiments, soft HCP materials such as pure Mg and pure Zn were used for the pins and a hardened 080 M40 steel was used for the plate. Two surface parameters of the steel plates—roughness and texture—were varied in tests that were conducted at a sliding speed of 2 mm/s in ambient conditions under both dry and lubricated conditions. The morphologies of the worn surfaces of the pins and the formation of the transfer layer on the counter surfaces were observed using a scanning electron microscope. In the experiments, the occurrence of stick-slip motion, the formation of a transfer layer, and the value of friction were recorded. With respect to the friction, both adhesion and plowing components were analyzed. Based on the experimental results, the effect of surface texture on the friction was attributed to differences in the amount of plowing. Both the plowing component of friction and the amplitude of stick-slip motion were determined to increase surface textures that promote plane strain conditions and decrease the textures that favor plane stress conditions.

A flow analysis is carried out for an inclined slider bearing with the aim of showing the governing mechanism at conditions where an optimum in load carrying capacity is achieved. The effects of surface texture on pressure buildup and load carrying capacity are explained for a textured slider bearing geometry. Numerical simulations are performed for laminar, steady, and isothermal flows. The energy transferred to the fluid from the moving wall is converted into pressure in the initial part of the converging contact and into losses in the second part. The convergence ratio can be increased, in order to get the greatest pressure gradient, until the limiting value where flow recirculation begins to occur. The texture appears to achieve its maximum efficiency when its depth is such that the velocity profile is stretched at its maximum extent without incurring incoming recirculating flow. The wall profile shape controlling the velocity profile can be optimized for many hydrodynamic contacts.

In this paper a multiscale method is presented that includes surface texture in a mixed lubrication journal bearing model. Recent publications have shown that the pressure generating effect of surface texture in bearings that operate in full film conditions may be the result of micro-cavitation and/or convective inertia. To include inertia effects, the Navier–Stokes equations have to be used instead of the Reynolds equation. It has been shown in earlier work ( de Kraker et al., 2006, Tribol. Trans., in press ) that the coupled two-dimensional (2D) Reynolds and 3D structure deformation problem with partial contact resulting from the soft EHL journal bearing model is not easy to solve due to the strong nonlinear coupling, especially for soft surfaces. Therefore, replacing the 2D Reynolds equation by the 3D Navier–Stokes equations in this coupled problem will need an enormous amount of computing power that is not readily available nowadays. In this paper, the development of a micro–macro multiscale method is described. The local (micro) flow effects for a single surface pocket are analyzed using the Navier–Stokes equations and compared to the Reynolds solution for a similar smooth piece of surface. It is shown how flow factors can be derived and added to the macroscopic smooth flow problem, that is modeled by the 2D Reynolds equation. The flow factors are a function of the operating conditions such as the ratio between the film height and the pocket dimensions, the surface velocity, and the pressure gradient over a surface texture unit cell. To account for an additional pressure buildup in the texture cell due to inertia effects, a pressure gain is introduced at macroscopic level. The method also allows for microcavitation. Microcavitation occurs when the pressure variation due to surface texture is larger than the average pressure level at that particular bearing location. In contrast with the work of Patir and Cheng (1978, J. Lubrication Technol., 78, pp. 1–10) , where the microlevel is solved by the Reynolds equation, and the Navier–Stokes equations are used at the microlevel. Depending on the texture geometry and film height, the Reynolds equation may become invalid. A second pocket effect occurs when the pocket is located in the moving surface. In mixed lubrication, fluid can become trapped inside a pocket and squeezed out when the pocket is running into an area with higher contact load. To include this effect, an additional source term that represents the average fluid inflow due to the deformation of the surface around the pocket is added to the Reynolds equation at macrolevel. The additional inflow is computed at microlevel by numerical solution of the surface deformation for a single pocket that is subject to a contact load. The pocket volume is a function of the contact pressure. It must be emphasized that before ready-to-use results can be presented, a large number of simulations to determine the flow factors and pressure gain as a function of the texture parameters and operating conditions have yet to be done. Before conclusions can be drawn, regarding the dominanant mechanism(s), the flow factors and pressure gain have to be added to the macrobearing model. In this paper, only a limited number of preliminary illustrative simulation results, calculating the flow factors for a single 2D texture geometry, are shown to give insight into the method.

The effects of textured tubes on the tribological performance in tube hydroforming (THF) are discussed. Textured surfaces, namely sand blasted, knurled, electrical discharge machined (EDM), and as rolled surfaces, were tested under various interface pressure conditions. Sand blasted textured tubes were found to have the best tribological performance. The study has demonstrated that the increase in the interface pressure between the tube and the die can result in either lower or higher interface friction depending on the surface texture conditions. The study has also shown that different surface texture treatment methods can alter the hardness of the tube surface with significant influence on the tribological performance.

This paper presents a numerical study of the effects of different shapes of deterministic microasperities in sliding surface lubrication when hydrodynamic films are found. Positive (protruding) and negative (recessed) asperities of constant height (depth) are considered with circular, square, diamond, hexagonal and triangular cross-sections. Of particular interest is the impact of asperity/cavity cross-sectional geometry on friction and leakage, which has importance in sealing applications. The results indicate that the friction coefficient is insensitive to asperity/cavity shape, but quite sensitive to the size of the cross-section. By contrast, leakage rates are found to be quite sensitive to both cross-sectional shape and size, with triangular asperities giving the smallest leakage rate and square asperities giving a largest leakage rate. The minimum coefficient of friction for all shapes is found to occur at an asperity area fraction of 0.2 for positive asperities and 0.7 for negative asperities. Finally, the results indicate the existence of a critical asperity area fraction where the performance curves for positive and negative asperities cross over. These cross-over points are identified for friction coefficient and leakage rate.

The purpose of this work was to use new scale-sensitive fractal parameters to characterize the surface topography of computer hard disks and to correlate the fractal parameters with measured start-up friction (or stiction) behavior of textured hard disks. The topographies of glass disks with three different surface textures and aluminum disks with two different textures were measured using an atomic force microscope. Two parameters derived from area-scale fractal analysis by the patchwork method were chosen to characterize the surface topography: smooth-rough crossover and area-scale fractal complexity. The two fractal parameters were found to be characteristic of the disks’ texture; disks which had been processed in the same batch had similar values of complexity and smooth-rough crossover, but those values differed for disks subjected to a different texturing process. Friction behavior of unlubricated glass disks and lubricated aluminum disks was determined at startup and during low speed drag testing. The results show a high correlation between the smooth-rough crossover parameter and start-up friction (stiction) for both lubricated and unlubricated disks. Additional tests showed that the area-scale fractal parameter is related to low speed sliding friction. The friction results for the unlubricated glass disks were dependent on humidity and roughness in a manner that is consistent with a meniscus model of stiction.

This three part paper presents the experiment and numerical analysis of the friction of a thin-film rigid disk with circumferential surface texture. In Part III, we examine the friction of a disk on the unworn virgin and worn tracks at various relative humidities. The real contact areas and pressures on both tracks are estimated using the Hertz contact model of two-dimensional asperities in Part I and related to the frictional coefficients on the basis of the meniscus model in Part II. The analysis yields that the effect of meniscus is predominant in the flat contact situation, particularly on the worn track at high humidity, while the effect is negligible in the taper/flat edge contact situation on both the tracks even at high humidity.

This series of three papers presents an experimental and numerical analysis of the friction between a head slider and a thin-film rigid disk with circumferential surface texture, under various humidities. In Part I, we develop a model of a cylindrical contact of a slider rail with strong anisotropic asperities under dry conditions. This model predicts that the real contact pressure is primarily determined by the height distribution and geometry of asperities on the disk, whereas it is very weakly dependent on the surface curvature of the rail. The result of the latter calculation suggests that the frictional coefficient is insensitive to variation in the head contact angle due to head pitching motion.

This series of three papers presents an experimental and numerical analysis of friction in a thin-film rigid disk with a circumferential surface texture, under various humidities. In Part II, we develop a theoretical formulation of the meniscus force of elliptical contact at isolated liquid bridges. This model predicts that the mean real pressure due to the meniscus force apparently decreases the net real contact pressure p r and increases the frictional coefficient. This effect becomes significant when the relative surface energy of the liquid 2γ/σ is comparable to p r , where σ is the standard deviation of asperity height distribution. When the disk is covered with lubricant and the liquid bridges are connected with each other, the solid noncontacting asperities play an important role in the formation of the meniscus force, and the relative lubricant thickness t/σ is the critical factor determining the friction.