Numerical and experimental analysis of surface textures – towards a reproducible and robust design of textures in conformal contacts
Coating and Surface Technology
Synthesis and Properties of Functional Materials
Final Report Abstract
Textured surfaces have shown significant potential in improving the tribological performance of engineering elements under liquid lubrication. However, a big variety of results in terms of optimal texture shape were reported from experiments in the literature, which were often not supported by the numerical models. One of the most important factors for the controversial results is the fact that these studies are often carried out using different experimental set-ups where the macro geometry of test samples in conformal contact were not consistent. The present research project evaluates the effects of macro geometry and surface textures by a joint experimental-numerical approach of employing a digital twin of a pin-on-disc tribometer. The results show that macro geometry can generate a significant impact on frictional behaviour under oil-lubricated conditions, which may overweight the influence of texture elements. Numerical study shows good agreement of the friction behaviour for experiments with untextured specimens. Furthermore, the suitability of numerical models to replicate the underlying friction reducing mechanism of the textures is discussed and the applicability of simulations for texture design optimizations is evaluated.
Publications
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An EHL extension of the FBNS algorithm, presentation at the 7th World Tribology Congress (WTC), Lyon, Jul. 2022
E. Hansen, B. Frohnapfel & A. Codrignani
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An EHL Extension of the Unsteady FBNS Algorithm. Tribology Letters, 70(3).
Hansen, Erik; Kacan, Altay; Frohnapfel, Bettina & Codrignani, Andrea
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Numerical and experimental analysis of surface textures – towards a reproducible and robust design of textures in conformal contacts, poster at the 7th World Tribology Congress (WTC), Lyon, Jul. 2022
G. Vaitkunaite, E. Hansen, J. Schneider, B. Frohnapfel & P. Gumbsch
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'MATLAB solver for the deformation of an elastic half-space based on the Boundary Element Method (BEM)’, last commit on 21.11.2023
E. Hansen
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Effect of height waviness on the friction behavior of 100Cr6 steel under mixed or hydrodynamic lubrication, presentation and conference paper at the 64th German Tribology Conference, Göttingen, September 2023
H. Yue, G. Vaitkunaite, Y. Li, J. Schneider, C. Greiner & P. Gumbsch
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Establishment and Calibration of a Digital Twin to Replicate the Friction Behaviour of a Pin-on-Disk Tribometer. Lubricants, 11(2), 75.
Hansen, Erik; Vaitkunaite, Gerda; Schneider, Johannes; Gumbsch, Peter & Frohnapfel, Bettina
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Numerical Analysis of Friction Reduction due to Surface Textures in the Mixed Lubrication Regime, Dissertation, KIT
E. Hansen
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Scaling of Friction Behaviour in the Mixed Lubrication Regime through a Modified Hersey Number, presentation at the 77th STLE Annual Meeting & Exhibition, Long Beach, May 2023
E. Hansen, G. Vaitkunaite, J. Schneider, P. Gumbsch & B. Frohnapfel
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‘EHL-FBNS Solver’, last commit on 21.11.2023
E. Hansen
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‘Exemplary code and data files for the submission of the article “Establishment and Calibration of a Digital Twin to Replicate the Friction Behaviour of a Pin-on-Disk Tribometer” in Lubricants’, 16.01.2023
E. Hansen
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The Influence of Pin Inclination on Frictional Behavior in Pin-on-Disc Sliding and Its Implications for Test Reliability, presentation at the Tribology International conference 2024, Vienna, April 2024
H. Yue, J. Schneider, B. Frohnapfel & P. Gumbsch
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The influence of pin inclination on frictional behaviour in pin-on-disc sliding and its implications for test reliability. Tribology International, 200, 110083.
Yue, Hongzhi; Schneider, Johannes; Frohnapfel, Bettina & Gumbsch, Peter
