Industrial Tribology E-Book

Theo Mang

• Herausgeber: Wiley-VCH
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 1047

Veröffentlichungsjahr: 2011

Beschreibung

Integrating very interesting results from the most important R & D project ever made in Germany, this book offers a basic understanding of tribological systems and the latest developments in reduction of wear and energy consumption by tribological measures.
This ready reference and handbook provides an analysis of the most important tribosystems using modern test equipment in laboratories and test fields, the latest results in material selection and wear protection by special coatings and surface engineering, as well as with lubrication and lubricants.
This result is a quick introduction for mechanical engineers and laboratory technicians who have to monitor and evaluate lubricants, as well as for plant maintenance personnel, engineers and chemists in the automotive and transportation industries and in all fields of mechanical manufacturing industries, researchers in the field of mechanical engineering, chemistry and material sciences.

Leseprobe

Contents

Cover

Related Titles

Title Page

Copyright

Preface

Abbreviations

Chapter 1: Introduction

1.1 The Term Tribology

1.2 Importance of Tribology

1.3 History of Tribology

References

Chapter 2: The Tribological System

2.1 Tribological Surfaces

2.2 Wetting of Solid Surfaces

2.3 Tribo Contact Surfaces

2.4 Tribological Loading

References

Chapter 3: Friction

3.1 Kinetic and Static Friction

3.2 Coefficient of Friction

3.3 Stick-Slip

3.4 Sliding and Rolling Friction

3.5 Friction Regimes: Friction and Lubrication Conditions

3.6 Hydrodynamic and Elastohydrodynamic Lubrication

References

Chapter 4: Wear

4.1 Wear Mechanisms

4.2 Types of Wear

4.3 Wear Parameters

References

Chapter 5: Tribological Materials

5.1 Basic Principles of Materials Science

5.2 Metallic Materials

5.3 Non-Metallic Inorganic Materials

5.4 Organic Materials

5.5 Composite Materials

References

Chapter 6: Surface Engineering

6.1 Introduction to Surface Engineering

6.2 Processes of Surface Engineering

References

Chapter 7: Lubricants

7.1 Lubricants and their Market

7.2 Mineral Base Oils

7.3 Synthetic Base Oils

7.4 Rheology of Lubricants

7.5 Additives

7.6 Lubricants for Internal Combustion Engines

7.7 Gear Lubrication Oils

7.8 Hydraulic Oils

7.9 Turbine Oils

7.10 Compressor Oils

7.11 Metal-Working Fluids

7.12 Lubricating Greases

7.13 Solid Lubrication

7.14 Laboratory Methods for Testing Lubricants

7.15 Lubricants in the Environment

7.16 Disposal of Used Lubricants

References

Chapter 8: Mechanical—Dynamic Tribology and Testing Methods

8.1 Introduction

8.2 Tribological System Categories within Mechanical–Dynamic Tests

8.3 Simple Tribological Mechanical–Dynamic Test Machines and Test Methods

8.4 Tribology of the Gearbox, Transmission, and Transfer Case

8.5 Tribology of Internal Combustion Engines

8.6 Tribology of Hydraulic Pump and Circuit Design

8.7 Interpretation and Precision of Tribological Mechanical–Dynamic Testing

Acknowledgments

References

Index

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The Authors

Prof. Dr.-Ing. Theo Mang

Holzweg 30

69469 Weinheim

Germany

Prof. Dr.-Ing. Kirsten Bobzin

RWTH Aachen University

(IOT)

Intzestr. 10

52072 Aachen

Germany

Dr.-Ing. Thorsten Bartels

RohMax Additives GmbH

Kirschenallee

64293 Darmstadt

Germany

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Library of Congress Card No.: applied for

British Library Cataloguing-in-Publication Data

A catalogue record for this book is available from the British Library.

Bibliographic information published by the Deutsche Nationalbibliothek

The Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data are available on the Internet at http://dnb.d-nb.de.

© 2011 WILEY-VCH Verlag & Co. KGaA, Boschstr. 12, 69469 Weinheim, Germany

All rights reserved (including those of translation into other languages). No part of this book may be reproduced in any form – by photoprinting, microfilm, or any other means – nor transmitted or translated into a machine language without written permission from the publishers. Registered names, trademarks, etc. used in this book, even when not specifically marked as such, are not to be considered unprotected by law.

ISBN: 978-3-527-32057-8

ePub: 978-3-527-63259-6

Preface

The main areas of tribology – friction, wear, and lubrication – include all sciences and technologies relating to interacting surfaces in relative motion. Studies conducted during the 1980s and 1990s have defined the potential savings of tribology as a percentage of the GDP, with between 1.3% and 1.6% being gained by the correct application of actual tribological knowledge. Such benefits are mainly defined as energy savings and the protection of resources. Currently, an increasing number of modern aspects of life cycle assessment are taken in account, with the main targets being economic and environmental performance.

In this book, attention is focused on tribological activities in surface engineering, in lubricants and lubrication as well as in mechanical dynamic tribology and testing methods. The first of these areas includes wear mechanisms, tribological materials with basic principles of the materials sciences, coating developments, surface engineering as converting processes, physical and chemical vapor deposition, sol–gel deposition, electrochemical metal deposition, thermal spraying, deposition welding, brazing, and thermochemical surface treatments. In the area of lubrication, an introduction is provided to the base oils, to the rheology of lubricants, to lubricant additives and the main families of lubricants, to lubricants in the environment, and to the disposal and re-refining of lubricants. For the system analysis, the book presents details of simple tribological test machines and methods, as well as the tribology of the gearbox, transmission and transfer case, of internal combustion engines, and of hydraulic pumps and circuit design.

This book offers all researchers, graduate students and practicing engineers and chemists working in the field of tribology a quick, yet concise, introduction to this area of study.

The authors thank the following persons for their specialist contributions:Dr.-Ing. Nazlim Bagcivan, Dipl.-Ing. Wolfgang Bock., Dr.rer.nat. Jürgen Braun, Dipl.-Ing. Markus Brühl, Prof. Dr.-Ing. Christian Busch, Robert Cybert, Dipl.-Ing. Daniel Debus, Dr.rer.nat Wilfried Dresel, Dr.rer.nat. Manfred Harperscheid, Ludwig Herdel, Dipl.-Ing. Nils Kopp, Dipl.-Ing. Anika Krämer, Fabienne Loodts, Dipl.-Phys. Rolf Luther, Dr.-Ing. Katharina Richardt, Dipl.-Ing. Arne Schlegel, Dipl.-Ing. Thomas Schläfer, Marcus Stephan, Dipl.-Ing. Lucas Voigt, and Dr.-Ing. Jochen Zwick.

Weinheim, Aachen, Darmstadt August 2010

Theo Mang, Kirsten Bobzin, and Thorsten Bartels

Abbreviations

µ-Combµ-Comb synchronizer testing machineAASAtomic absorption spectrometryABSArc bond sputteringACAlternating currentAC6Reference elastomer (seal material)ACEAAssociation des Constructeurs Européens d'Automobiles (Association of the European Car Manufacturers)ADAshless dispersant (additive)AESAuger electron spectroscopyAFNORAssociation Francaise de Normation (French Association for Normalization)AGGArbeitsgemeinschaft der Deutschen Galvanotechnik (German Society of Galvanotechnics)AGMAAmerican Gear Manufacturers' Association (USA)AIPArc ion platingAOAntioxidant, oxidation inhibitorAPAtmospheric pressureAPIAmerican Petroleum Institute (USA)APSAtmospheric plasma spraying; air plasma sprayingARKLAxial-Rillenkugellager Adapter (axial thrust ball bearing adapter)ASTMAmerican Society of Testing Materials (USA)ASTMEAmerican Society of Tool and Manufacturing Engineers (USA)ATCAdditives Technical Committee (Technical Committee of Petroleum Additive Manufacturers in Europe)ATFAutomatic transmission fluidATIELAssociation Technique de L'Industrie Européen des Lubrifiants (Technical Association of the European Lubricant Industry)AUPolyurethane-caoutchouc (polyesterurethane-caoutchouc)AWAntiwear agent (additive)AWDAll-wheel driveAWTAlmen–Wieland testBAMBundesanstalt für Materialprüfung (German Federal Institute for Materials Research and Testing)bccbody-centered cubicB-CVTBelt-CVTbfBasic moleculeBMBFBundesministerium für Bildung und Forschung (German Federal Ministry of Research and Education)BMWiBundesministerium für Wirtschaft (German Federal Ministry of Economics)BODBiological oxygen demandBW6100Friction plate material (organic paper lamella)CAFECalifornian Act for Fuel Emission (USA)CBNCubic boron nitrideCCCemented carbideCCELChina Certification Committee for Environmental Labeling of ProductsCCMCCommittee of Common Market Automobile Constructors (EU)CCSCold-cranking simulatorCECCoordinating European Council (for the development of performance tests for lubricants and engine fuels)CETOPComité Européen des Transmissions Oleohydrauliques et Pneumatiques - European Oil Hydraulic and Pneumatic (Committee)CFMSClosed-field magnetron sputteringCFT 23ZF CVT transmission series 23CFT 30ZF CVT transmission series 30CGSCold gas sprayingCICorrosion inhibitorCODChemical oxygen demandCONCAWEThe oil companies' European association for environment, health and safety in refining and distributioncphClosed-packed hexagonalCRChlorobutadiene–caoutchoucCRCCoordinating Research Council (US committee for engineering and interaction between automotive/other mobility equipment and petroleum products)CSTCCContinuously slipping torque converter clutchCVDChemical vapor depositionCVTContinuously variable transmissionDBTTDuctile-brittle transition temperatureDCDirect currentDDDetergent and dispersant (additive)DGMKDeutsche Wissenschaftliche Gesellschaft für Erdöl, Erdgas und Kohle (German Scientific Society for Mineral Oil - Natural Gas and Coal)DINDeutsches Institut für Normung (German Institute for Normalization)DKADeutscher Koordinierungsausschuß im CEC (German Committee for Coordination in the CEC)DLCDiamond-like carbonDMFDual-mass flywheelDSCDifferential scanning calorimetryEB-PVDElectron beam–physical vapor depositionEBTElectron beam texturingECMEngine control moduleECPEnvironmental choice program (CDN)ECTCCElectronically controlled converter clutchECUEngine control unitEFIElectronic fuel injectorEHDElastohydrodynamic (lubrication regime)EHEDGEuropean Hygienic Equipment Design GroupELGIEuropean Lubricating Grease InstituteEMCOREMCOR Group Inc. (manufacturer of mechanical and electrical construction, energy and facilities services)EMFElectromotive forceENEuropean normEPExtreme pressure (additive)EPDMEthylene–propylenediene–caoutchoucESCAElectron spectroscopy for chemical analysis (identical to XPS)ESMAElektronenbeam-MicroanalysisEUEuropean UnionFAGSchaeffler Technologies GmbH & Co. KG (former FAG Kugelfischer, Germany; manufacturer of bearings and units, seals, mechatronics, and lubrication systems)FCCFuel catalytic crackerfccface-centered cubicFDAFood and Drug Administration (USA)FE8Roller bearing test apparatusFE9Roller bearing test apparatusFISSTFuel injector shear-stability testFMFriction modifierFPMFluoro-caoutchouc (also named FKM)FSFlame sprayingFTMSFederal Test Methods Standardization (USA)FVAForschungsvereinigung Antriebstechnik (German Research Association for Drive Technology)FZGForschungsstelle für Zahnräder und Getriebebau (German Research Center for Toothed Wheel and Gearing Engineering in Garching)FZG SSP180FZG SSP180 synchronizer testing machineGCGas chromatographyGDIGasoline direct injection (ICE)GFKTGraufle ckentragfähigkeitskurzte st (micro-pitting short test)GfTGesellschaft für Tribologie (German Society of Tribology)GL-4API GL-4 performance standard of gear oil (application: manual transmission and differential)GL-5API GL-5 performance standard of gear oil (application: axel oil)GNIGross National IncomeHHydraulic fluids type H (also HH), classified in: ISO 6743/4, ISO 11 158 and DIN 51 524HCHydrocracked base oilHCCIHomogeneous charge compression ignitionH-CVTHydraulic-CVTHDHeavy-duty engine oil application (commercial vehicles and trucks)HDDHeavy-duty dieselHDDOHeavy-duty diesel oilHEESSynthetic ester types (non-water-soluble), environmentally friendly, rapidly biodegradable hydraulic fluid according to ISO 15 380 and ISO 6743/4HEPGPolyglycol types (water-soluble), environmentally friendly, rapidly biodegradable hydraulic fluid according to ISO 15 380 and ISO 6743/4HETGTriglyceride (non-water-soluble, vegetable oil types), environmentally friendly, rapidly biodegradable hydraulic fluid according to ISO 15 380 and ISO 6743/4HFHigh-frequencyHF1ISO VG 46 monograde fluid (model test fluid 1)HF2ISO VG 46 multigrade fluid (model test fluid 2)HFAFire-resistant hydraulic fluid classified according to ISO 6743/4 and DIN 51502 (fluid concentration of HFAE emulsions or synthetic HFAS solutions is between 1% and 5% in water)HFBFire-resistant hydraulic fluid classified according to ISO 6743/4 and DIN 51502 (water-in-oil emulsions with a (flammable) mineral oil content of about 60% mass)HFCFire-resistant hydraulic fluid classified according to ISO 6743/4 and DIN 51502 (mixture of min. 35–50% fully demineralized water and polyglycols – monomers or polymers – as thickeners)HFDFire-resistant hydraulic fluid classified according to ISO 6743/4 and DIN 51502 (synthetic and water-free)HFRRHigh-frequency reciprocating rigHIPHigh-ionization pulsingHISHigh-ionization sputteringHLHydraulic fluids type HL, classified in: ISO 6743/4, ISO 11 158 and DIN 51 524 Part 1HLBHydrophilic–lyophilic balanceHLPHydraulic fluids type HL, classified in: ISO 6743/4, ISO 11 158 and DIN 51 524 Part 2HLPDHLP hydraulic fluid plus DD additives, which disperse, suspend and emulsify water, dirt, aging products, and contaminantsHNBRHydro-treated acrylonitrile–butadiene–caoutchoucHPDSCHigh-pressure differential scanning calorimetryHPLCHigh-pressure liquid chromatographyHPPMSHigh-power pulse magnetron sputteringHPPSHigh-power plasma sprayingHRCRockwell hardness (cone measurand)HSSHigh-speed steelHTHigh-temperatureHTBTHigh-temperature bearing testerHT-CVDHigh-temperature chemical vapor depositionHTHSHigh-temperature–high-shear fluid measurementHVAFHigh-velocity air-fuel sprayingHVIHigh-viscosity indexHVOFHigh-velocity oxy-fuel sprayingIAEInstitute of Automotive EngineersIARCInternational Agency for Research on CancerIBIon-beam sputteringIBADIon-beam-assisted depositionICPSInductive coupled radiofrequency plasma sprayingICEInternal combustion engineICPInductively coupled plasma atomic emissionIFPInstitute Française de Petrole (French Institute of Petroleum)ILMAIndependent Lubricant Manufacturers' Association (USA)ILSACInternational Lubricant Standardization and Approval CommitteeIPInstitute of Petroleum (UK)IPSInert gas plasma sprayingIRM2Special hydraulic test fluid no. 2, specified by ASTMIRM3Special hydraulic test fluid no. 3, specified by ASTMISOInternational Standard OrganizationISO VGISO normed viscosity grade (classification at 40 °C)JASOJapanese Automotive Standards OrganizationJEAJapanese Environmental AssociationJISJapanese Industrial StandardKpKsCVT variator efficiency characteristic numberkVKinematic viscosityLDFLong-drain field testLIMSLaboratory information and management systemLOWCVT variator gear “start-up”LPLow-pressureLPGLiquid petroleum gas (autogas)LPPSLow-pressure plasma sprayingLSLoad stage at the FZG test rigLT-CVDLow-temperature chemical vapor depositionLUKLuK GmbH & Co. KG (German component supplier for the automotive industry)LVDLow-voltage arc dischargeLVFALow-velocity friction apparatusLVILow-viscosity indexMAKMaximale Arbeitsplatzkonzentration (maximum workplace concentration)MDMetal deactivator additiveMFMedium-frequencyMILMilitary Standard (USA)MLDWMobile-lube dewaxingMMCMetal matrix compositeMO-CVDMetal organic chemical vapor depositionMPRMicro-pitting test rigMPSMicro-plasma sprayingMQLMinimum-quantity lubricationMRVMini-rotary viscosimeterMSMass spectroscopyMSMagnetron sputteringMSDWMobile-selective dewaxingMSIPMagnetron sputter ion platingMTMetric tonneMT-CVDMiddle-temperature chemical vapor depositionMTFManual transmission fluidMTMMini-traction machine (manufactured by PCS Instruments Inc., London)MWMMWM GmbH (German manufacturer of ICE for energy production)n·dmBearing classification number for bearing kinematic, combining speed and geometryNASNational Academy of Sciences, testing chemicals on humansNBR1Reference elastomer (seal material)N-D-MAnalysis using refractive index n, density d and molecular weight mNFPANational Fluid Power Association (USA)NLGINational Lubricating Grease Institute (USA)NMMAAmerican National Marine Manufacturers AssociationNMRNuclear magnetic resonanceO&KOrenstein & Koppel OHG (German manufacturer of mobile hydraulic equipment, such as shovels and excavators)ODCVT variator gear “overdrive”ODSOxide dispersion-strengthenedOECDOrganization for Economic Cooperation and Development (EU)OEMOriginal equipment manufacturerPACVDPlasma-assisted chemical vapor depositionPAOPoly-alphaolefin base oilPCPassenger car applicationPCBPrinted circuit boardPCDPolycrystalline diamondPCMOPassenger car motor oilPCSPCS Instruments Inc. (GB manufacturer of test machines for tribological applications)PDPumpe-Düse Kraftstoffeinspritzung (pump-nozzle fuel injection)PECVDPlasma-enhanced chemical vapor depositionPEOPlasma electrolytic oxidationPEPPassive extreme pressurePLDPulsed-laser depositionPPDPour point depressantPSZPartially stabilized zirconiaPTFEPolytetrafluorethylene (Teflon)PTWAPlasma transfer wire arc sprayingPVDPhysical vapor depositionRAL UZReichsausschuß für Lieferbedingungen und Gütesicherung, Umweltzeichen (German Imperial Committee for Quality Control and Labeling, Environmental Symbol)RNTRadionuclide techniqueRPSReactive plasma sprayingRVTReichert-Verschleiß Test (Reichert wear test)SAESociety of Automotive Engineers (USA)SBRStyrene–butadiene–caoutchoucSCDSCSealed capsule differential scanning calorimetrySEMScanning electron microscopySHEStandard hydrogen electrodeSHPDSuper high-performance dieselSKFSKF Group (Swedish manufacturer of bearings and units, seals, mechatronics, and lubrication systems)SLPMStandard liters per minuteSMFSingle-mass flywheelSNRSNR Roulements (French bearing manufacturer)SPSShrouded plasma sprayingSREStandard reference elastomerSRVSchwing-Reibverschleiß Gerät (translatorisches Oszillations-Prüfgerät) (Translatory oscillation apparatus)STLESociety of Tribologists and Lubrication Engineers (USA)STOUSuper tractor oil universalSUSSaybolt universal secondsTANTotal acid numberTBCThermal barrier coatingTBNTotal base numberT-CVTTraction-drive CVTTDAThermal deasphaltingTDITurbo-diesel direct injection (ICE)TEIThailand Environment InstituteTEOSTetraethylorthosilicateTEWLTransepidermal water lossTGThermogravimetryTGLTechnische Normen, Gütevorschriften und Lieferbedingungen (former DDR calculation and test standards)TGOThermally growth oxideTLPTransient-liquid-phaseTLVThreshold limit valueTOPCVT variator gear “highway”TOSTTurbine oil oxidation stability testTRIPTransformation induced plasticityTRKTechnische Richtkonzentration (German technical guideline concentration)TSSITemporary shear stability indexUEILUnion Européens des Indépendents en Lubrifiants (European Union of Independent Lubricant Manufacturers)UHPDUltra high-performance diesel (ICE)UHVUltra-high vacuumUHVIUltra-high viscosity indexUNITIBundesverband Mittelständischer Mineralöluntemehmen (Germany) (Federal Association of the Middle-Class Oil Companies)UPSUnder-water plasma sprayingUSDAUnited States Department for AgricultureUTTOUniversal tractor transmission oilVAMILRegeling Willekeurig Afschrijving Milieu-Investeringen (NL) (regulation of discretion deductions for investments into the environment)VCIVapor-phase (volatile) corrosion inhibitorVDAVerband der Automobilindustrie (German automobile industry association)VDEhVerein Deutscher Eisenhüttenleute (Technical Association for Iron Metallurgy)VDIVerein Deutscher Ingenieure (German society of mechanical engineers)VDMAVerband Deutscher Maschinen- und Anlagenbau (German engineering federation)VDSVolvo oil-drain specificationVDTVan Doorne Transmission (Belgium) (manufacturer of belt/pulleys for CVT applications)VGBTechnische Vereinigung der Großkraftwerkbetreiber (Germany) (Technical Association of Large Power Plant Operators)VGOVacuum gas oilVHVIVery high-viscosity indexVIViscosity indexVIEViscosity index extendedVIIViscosity index improver (additive)VKAVier-Kugel-Apparat (Four-Ball apparatus)VKISVerbraucherkreis Industrieschmierstoffe (assosiation of industrail lubricant consumers)VOCVolatile organic compoundsVpViscosity–pressure behaviorVPIVapor-phase inhibitorVPSVacuum plasma sprayingVSFTVariable-speed friction testerVTViscosity–temperature behaviorVTCViscosity–temperature coefficientVWVolkswagen (OEM; German car manufacturer)VW-PVVolkswagen Prüfvorschrift (internal test procedure approved by Volkswagen)WGKWassergefährdungsklasse (Water-hazardous class, water-pollution class)XHVIExtra high-viscosity indexXPSX-ray photoelectron spectroscopy (identical to ESCA)XRFX-ray fluorescence spectrometryYPSZYttria partially stabilized zirconiaZAFZinc and ash-freeZFZF Friedrichshafen AG (OEM; automotive supplier for driveline and chassis technology)

Chapter 3

Friction

Friction is the mechanical force which resists movement (dynamic or kinetic friction) or hinders movement (static friction) between sliding or rolling surfaces. This force of friction is also called “external friction.” The work done by friction can translate into deformation, wear, and heat.

Internal friction as part of external friction when lubricants are used results from the friction between lubricant molecules; this is described as viscosity (see Chapter 7) (The meaning of internal friction in material science is the force resisting motion between the elements making up a solid material while it undergoes deformation).