An Evaluation of The Average Flow Model (1) For Surface Roughness Effects in Lubrication
An Evaluation of The Average Flow Model (1) For Surface Roughness Effects in Lubrication
Teale
Research Assistant.2
An Evaluation of the Average Flow
A. 0. Lebeck
Associate Professor,
Model [ 1 ] for Surface Roughness
Effects in Lubrication1
The University of New Mexico,
Albuquerque, New Mexico
The average flow model presented by Patir and Cheng [1] is evaluated. First, it is shown
that the choice of grid used in the average flow model influences the results. The results
presented are different from those given by Patir and Cheng. Second, it is shown that the
introduction of two-dimensional flow greatly reduces the effect of roughness on flow. Re-
sults based on one-dimensional flow cannot be relied upon for two-dimensional problems.
Finally, some average flow factors are given for truncated rough surfaces. These can be
applied to partially worn surfaces. The most important conclusion reached is that an even
closer examination of the average flow concept is needed before the results can be applied
with confidence to lubrication problems.
Introduction
The analysis of surface roughness effects on lubrication has gained factors are altered by the choice of numerical representation of contact
considerable attention in recent years since it is widely recognized that shape and size and boundary conditions.
surface roughness can alter the solution for pressure and leakage in This work is intended to clarify the issues created by the non-
hydrodynamic bearings from that given by classical theory such as uniqueness of flow factors. In some cases enhancements of the flow
described by Cameron [2]. Several concepts of analysis have evolved, model have been suggested, such as the corner point method and
the goal of each being to derive an average Reynolds equation gov- truncated roughness distribution described later. Recommendations
erning expected pressure in rough bearings such that equations rely are made for further work to explain these issues, particularly in the
on surface roughness statistics rather than a specific topography. area of numerical analysis. It is concluded that the boundary depen-
The first concept is based on averaging the Reynolds equation prior dence issue limits the applicability of the average flow model.
to solution and relies on stochastic methods. Equations of this type
have been derived by Christensen and Tonder [3], [4], [5j. A second R e v i e w of t h e A v e r a g e F l o w M o d e l
concept involves perturbation techniques such as used by Elrod [6]. The average Reynolds equation as developed by Cheng and Patir
However, the equations derived using the first concept are limited [1] is derived by considering mean flow through the rectangular
to specific roughness configurations and using the second concept are control volume shown in Fig. 1. This volume has base area Ax Ay
limited to noncontacting situations. which is small relative to the bearing dimensions but contains nu-
A third concept as introduced by Tzeng and Saibel [7] involves merous asperities and possible asperity contacts. Surfaces bounding
averaging the results of solutions of the Reynolds equation. Recently, this volume have motion U; in the x direction and a height H(x, y)
Patir and Cheng [1] developed an average flow model based on aver- which can be represented as composed of a nominal part h and a
aging results of numerical solutions to the Reynolds equation. In this random component b for each surface. Referring to Fig. 1, total film
technique flow factors are defined which are applied as correction thickness is given by
terms to smooth bearing equations. While this method overcomes
some limitations of the other concepts, it will be shown herein that H = h + o1 + 82 if h + «i + 02 > 0
the quantitative results for flow factors presented by Patir and Cheng # = 0 if h + 5! + 82<0 CD
[1] are not unique. Certain fundamental questions are raised which Assuming that the lubricant is incompressible and isothermal, then
at the present time cast some doubt on the validity of this otherwise the volumetric flows per unit width are expressed as:
very useful concept. The results herein demonstrate that the flow
H3ap + / u 1 ± m H
12/j.dx \ 2 /
1
This research sponsored in part by the Office of Naval Research. (2)
2
Author currently located at IBM General Products Division, Tucson, Ariz. H3 dp
Contributed by the Lubrication Division of THE AMERICAN SOCIETY OF <Jy:
12ndy
MECHANICAL ENGINEERS and presented at the ASME-ASLE Lubrication
Conference, Dayton, Ohio, October 16-18,1979. Manuscript received at ASME Now the expected value of these flows can be approximated by the
Headquarters, July 27,1979. Paper No. 79-Lub-37. average flows in the sample control volume:
; qydx
E{qy) =* qy D i s c u s s i o n of t h e A v e r a g e F l o w H y p o t h e s i s
Ax Jx
Patir and Cheng assert that the pressure flow factors 0X, (j>y com-
where the bars designate average quantities and the expected value pare flow in a rough bearing to that predicted by smooth bearing
E is defined in conjunction with the distribution function / of the equations. The shear flow factor </>s is purported to account for addi-
variable: tional flow in rough bearings due to sliding that is presumably net
"fluid carried in the valleys" [8]. Furthermore, it is stated that the flow
E(x) = f_lxfix)dx (4) factors depend only upon the statistics of the rough surfaces.
Now, considering the Patir-Cheng hypothesis in greater detail,
At this point Patir and Cheng hypothesize that the expected unit rearrangement of equations (2), (3), and (5) results in
flows can be expanded as follows:
fefes j l J l + \J2\ fUt - u 2 ^ E\m ,ap
^l = 0 x h 3
^ ^ - 6/to-(Ui - U 2 )0 8
d p
dx dx
dp' , M?(p)
dp E\H3 (7)
Qy= - -
dy] dy
12^ dy It is acknowledged that Patir and Cheng have not expressed their
These relations define pressure flow factors <f>x, 4>y and the shear flow hypothesis in this form explicitly, but this is the only reasonable in-
factor ips- Quantity a is the combined RMS roughness of the surfaces, terpretation of flow factor definitions.
i.e., a2 = <TI + a\. Although there is some support for this hypothesis [9], equations
After performing a mean flow balance on the control volume, ex- (7) do remain strictly a hypothesis and must be verified as such. As
pressions for average flow (5) are substituted to obtain the average the results will later show, the first of equations (7) appears to be valid
Reynolds equation proposed by Patir and Cheng: based on one-dimensional flow. However, the introduction of two-
_d_ Uxh3dp\ _d_ Uyh* dpi _ IVI + U2\ dff dimensional flow leads to flow factor values which differ from those
derived on the basis of one-dimensional flow. The explanation for this
dx \ 12/u dx] dy \ 12/i fa] \ 2 ) dx difference may simply be that the hypothesis above is not generally
valid.
q + -r-2- Ay S o l u t i o n of F l o w F a c t o r s
M
ASPERITY y ay In the Patir-Cheng method, average flow in a small bearing segment
NTACTSy
\ is analyzed to determine flow factors. Figure 2 is an illustration of the
NO FLOW AT CONTACTS-
<
8 D aq P(X,L y ) J
-^^ x V x AX
0
,k
* 6
P(0,y) QP ^ P(Lx.y)
P °
P (X.O)
Fig. 1 Control volume for average flow analysis showing edge view of surface #— Lx »
roughness functions. Dashed lines are nominal geometries from which
roughness is measured Fig. 2 Model to analyze flow factors
.Nomenclature.
E = expectancy operator qx, qy = leakage components ix = viscosity
/ = density function r = truncation level \x, Xy = delay lengths
h = nominal film thickness function t = time Xo.5 = 50 percent delay length
H = total film thickness function U = velocity a = standard deviation
Lx, Ly = dimensions of bearing segment x,y = Cartesian coordinates 0S = shear flow factor
p = pressure 7 = surface pattern parameter 4>x, <t>y = pressure flow factors
8 = surface roughness function $ s = shear flow factor
= 6MU1 + U 2 ) ^ + 6 M ( U 2 - U 1 ) ^ ^ ^ (8) I r D T
Pi,
' 1 v'
-1
1
1
-- r
1
•" r
,
1
-p—i
HIXTI.I
1
dx dx Ay .--I
-X-.
^nx,i
This equation presumes that Eulerian coordinate transformation on
the time derivatives of the roughness is valid:
»
•• 1 , 2 (9)
"4 Lx >
dt ' dx'
The boundary conditions are selected to inhibit all y leakage: — BOUNDS PRESSURE CONTROL VOLUME
— BOUNDS REGION OF CONSTANT FILM
p(0, y) = pa THICKNESS H
p(Lx, y) = Pb PRESSURE NODE
dp H
i,j
0 (10)
dy Fig. 3 Grid network for corner point method
X.5x
(12)
^.6y
2
^ f $,(/»/„, 72) ~ R *.Wc, 71) (13)
1.2
f CORNER POINT METHOD
1
9 0 % CONFIDENCE INTERVAL
0.5 1.0
§ PATIR METHOD
90_% CONFIDENCE INTERVAL
PATIR ELROD — PATIR
RESULT RESULT RESULTS
0.6
</>s
0 1 2 3 4 5 6 04
h
cr
Fig. 5 4>x for isotropic, Gaussian-symmetric surfaces 0.2
Fig. 7 tpx for nonisotropic, Gaussian-symmetric surfaces Fig. 8 $ „ for nonisotropic, Gaussian-symmetric surfaces
Roughness Distribution
All results presented to this point have assumed that the distri-
bution of asperity heights is Gaussian. While this is not a limitation
of the average flow model, there are some aspects of the analysis which
are of questionable validity when applied to Gaussian surfaces. The
use of this distribution requires that asperities are elastically deformed
at contact points and spring back to their original shapes subsequent
to deformation. While Patir has assumed that deformations are small,
it is unrealistic to assume that deformation rates will be small.
The point above implies that the Eulerian coordinate transfor-
"0 0.2 0.4 0.6 0.8 1.0 mation used in equation (9) would not be correct because of an ad-
ditional 8(t) due to elastic deformation. Functional description of this
Fig. 9 Independence of <j>x and $ ,
additional term would add undesirable complexity to the flow model
0.5
0.3
n ^ C ,
0.5
£°-5x.
2 3 4 5 6
h
Fig. 12 <K for isotropic, truncated surfaces Fig. 13 0s for isotropic, truncated surfaces
\ \
<£x
Y--\
-C^A-
1.0
1/3
-B--'""^
1/6
0 1 2 3 4 5
h Rough Surfaces," Proc. Instn. Mech. Engrs., Tribology Group 184, Part 1, Vol.
ar 55,1969-70, p. 1013.
4 Christensen, H. and Tonder, K., "The Hydrodynamic Lubrication of
Fig. 14 <px for nonlsolropic, truncated surfaces Rough Bearing Surfaces of Finite Width," AMSE JOURNAL OF LUBRICATION
TECHNOLOGY, Vol. 93,1971, p. 324.
5 Christensen, H.," A Theory of Mixed Lubrication," Proc. Instn. Mech.
Engrs., Tribology Group, Vol. 186,1972, p. 421.
3
resistance to flow due in part to less contact and also because E{H ) 6 Elrod, H. G., "A General Theory for Laminar Lubrication with Reynolds
is greater than for Gaussian-symmetric surfaces. Roughness," Report for Department of Machine Design, Technical University
of Denmark, 1977
5. The independence of <f>x and 0S as implied by equation (7) is 7 Tzeng, S. T. and Saibel, E., "Surface Roughness Effect on Slider Bearing
verified at least for bearing segments with zero flow at the edges. More Lubrication," ASLE Trans., Vol. 10,1967, p. 334.
work is required to determine the applicability of this expression to 8 Patir, N., "Effects of Surface Roughness on Partial Film Lubrication
general two-dimensional lubrication problems. Using an Average Flow Model Based on Numerical Simulation," Dissertation
at Northwestern University, Evanston, 111., June 1978.
Continuing work with the average flow model will undoubtedly 9 Chow, L. S. H. and Cheng, H. A., "The Effect of Surface Roughness on
provide even more insight to the lubrication of rough surfaces. It is the Average Film Thickness Between Lubricated Rollers," ASME JOURNAL
recommended that the above aspects of the problem be investigated OF LUBRICATION TECHNOLOGY, Jan. 1976, pp. 117-124.
further. 10 Godet, M. and Berthe, D-, "A More General Form of Reynolds Equa-
tion—Application to Rough Surfaces," Wear, Vol. 27,1973, pp. 345-357.
11 Peklenik, J., "New Developments in Surface Characterization and
References Measurement by Means of Random Process Analysis," Proc. Instn. Mech.
1 Patir, N., and Cheng, H. S., "An Average Flow Model for Determining Engrs., Vol. 182, Part 3K, 1967-1968, p. 108.
Effects of Three-Dimensional Roughness on Partial Hydrodynamic Lubrica- 12 Castelli, V. and Pirvics, J., "Review of Numerical Methods in Gas
tion," ASME JOURNAL OF LUBRICATION TECHNOLOGY, Vol. 100, Jan. 1978, Bearing Film Analysis," ASME JOURNAL OF LUBRICATION TECHNOLOGY,
p. 2. Vol. 90, Oct. 1968, p. 777.
2 Cameron, A., The Principles of Lubrication, Longmans, Green and Co., 13 Teale, J. L., "Surface Roughness Effects in Hydrodynamic Lubrication,"
Ltd., London, 1966. Master's thesis, The University of New Mexico, Albuquerque, New Mexico,
3 Christensen, H., "Stochastic Models for Hydrodynamic Lubrication of Aug. 1978.
-DISCUSSION.