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Viscoelastic Effects in MIL-L-7808-Type Lubricant, Part


I: Analytical Formulation
a b b c c
P. K. Gupta , H. S. Cheng , D. Zhu , N. H. Forster & J. B. Schrand
a
PKG Inc. , Clifton Park, New York, 12065
b
Northwestern University , Evanston, Illinois, 60208
c
Wright Patterson Air Force Base, Ohio, 45433
Published online: 25 Mar 2008.

To cite this article: P. K. Gupta , H. S. Cheng , D. Zhu , N. H. Forster & J. B. Schrand (1992) Viscoelastic
Effects in MIL-L-7808-Type Lubricant, Part I: Analytical Formulation, Tribology Transactions, 35:2, 269-274, DOI:
10.1080/10402009208982117

To link to this article: http://dx.doi.org/10.1080/10402009208982117

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Viscoelastic Effects in MIL-L-7808-Type Lubricant, Part I:
Analytical Formulation@
P. K. GUPTA (Member, STLE)
PKG Inc.
Clifton Park, New York 12065
H. S. C H E N G (Member, STLE) a n d D. ZHU
Northwestern University
Evanston, Illinois 60208
N. H . FORSTER (Member, STLE) a n d J. B. SCHRAND
Wright Patterson Air Force Base, Ohio 45433
Downloaded by [University of Cambridge] at 04:19 28 December 2014

Analytical formulations for the computation of lubricant film IN'rRODUC'rION


thickness and traction in a high-speed rolling-sliding contact are
T h e frictional behavior between interacting mechanical
presented with the objective of investigating the viscoelastic response
elements plays a dominant role in the overall performance
of the MIL-L-7808-type lubricant. Two typcs of relations are wed a n d life of intricate mechanical components, such as rolling
lo lhe viscous shear rate. In the Type I a bearings, gears a n d transmissions. It is well known that proper
hyperbolic sine relation is wed to model the viscow effect which lubrication prevents excessive metallic contacts, recluces
becomes signiJicant when the shear stress reaches a critical value. friction and wear of interacting elements, a n d often serves
The Type II model employs a limiting shear stress, which the lu- as a n effective cooling- media. While the design - of a lubri-
bricant can withstand, and an inverse hype~bolictangent function cation system assures the flow of lubricant to the contact
is considered to model the viscow behavior. Both models are based interface between mating elements, the rheological behavior
on threefundamen~alproperties:lubricant ukcosity, shear modulm of the lubricant in the contact zone determines the frictional
and a critical shear stress. while the may be stability of t h e contact a n d the overall performance of the
obtained by direct measurements, estimates of shear modulus and comPonent Or the entire mechanical 'Ystem. For exam~'ley

in rolling bearings, the tractive forces at the rolling elemend


critical shear stress may be derived by curve-fitting the model pre-
race interface greatly influence the orbital acceleration o r
dictions to experimental traction data.
rolling elements which, in turn, determines the extent of
rolling elemendcage collisions a n d associated cage instabil-
KEY WORDS ities. T h u s , cage instabilities, ball a n d roller skid, roller skew
~ ~~ i ~~~ ~ ~h~ ~ ~ ~~ , ~ F ~ ~ i ~ d~ ,~~ i ~ l ~a~~
n~d excessive
~ ~ ~l ~ wear, ~, associatedi with the~ highly dynamic
~ in-
Thickness, Traction Modeling teraction between the bearing elements a r e often attributed
to the traction behavior of the lubricant.
Over the past three decades, a significant
" fraction of the
Presented at 45th Annual Meeting mechanical engineering literature has been devoted to
In Denver, Colorado
May 7-10, 1990 elastohydrodynamic lubrication a n d lubricant rheology. In-
Final manuscript approved March 8,1991 vestigations have ranged from the most fundamental prob-

T = temperature, K
a = major half-width of contact, M To = reference temperature, K
b = minor half-width of contact, M U I = Rolling velocity of body I . MIS
El elastic modulus of interacting body 1 , Pa
= U:,= rolling velocity of body 2, MIS
E2 = elastic modulus of interacting body i!,Pa a = pressure viscosity coefficient, 11Pa
G = shear modulus, Pa p = temperature-viscosity coefficient, 11K of K
h = lubricant film thickness, M y = pressure-temperature-viscosity coefficient, IIKIPa or KIPa
hi,,= isothermal film thickness, M K~ = maximum traction coefficient
Kf = thermal conductivity, NISIK p = viscosity at any pressure and temperature Pa.S
p, = Hertz contact pressure, Pa p, = reference viscosity, Pa.S
Q = applied load, N vl = Poisson's ratio for body 1
R I = radius of body 1 in rolling direction, M v:, = Poisson's ratio for body 2
R2 = radius of body 2 in rolling direction, M T = shear stress, Pa
i = shear strain rate, 11s T. = critical shear stress, Pa
269
Iem of lubricant behavior at a molecular level to very applied In addition to the lubricant constitutive equation, an im-
problems where the global hydrodynamics intricately cou- portant input to most of the traction models discussed above
ples rvitli the elastic distortion of the load bearing contacts is the lubricant film thickness in the contact. Again, the
in a rolling bearing. 'The rolling-disk type of test rigs have available literature is too vast to be reviewed here. For the
prove11to be very effective for the evaluation of the tractive computation of isothermal film thickness in elliptical con-
I)chavior of a lubricant. The most commonly used military tacts, the formulae presented by Hamrock and Dowson (5)
oil, with a specification of MIL-L-7808 has been tested by are well accepted. It is also well understood that the iso-
:I 11~11iiber of investigators. However, due to both the com- thermal conditions are only valid under relatively low speeds.
plexities in Ii~brica~it behavior and the experimental diffi- At high rolling speeds, and also at high slip velocities, the
culties i l l traction measurement, the range of operation over film thickness must be corrected for thermal effects. Per-
wliicli tlie data have been obtained is limited. In an attempt haps the first thermal solution to the line contact problem
to wiclcn this data range, traction experiments with a num- was developed by Cheng (6), where not only the viscous
ber of clifferent specimens,providing a range of contact el- shear heating effects and heat transfer in the lubricant film
lipticity ratios, are undertaken in the present investigation. were modeled but also the heat conducted to the moving
Also, particular emphasis is given to rolling velocities higher surfaces was taken into account. Subsequent to this work,
than those considered in the past. there have been a number of investigations aimed at mod-
Analytical development for understanding lubricant eling the thermal effects in concentrated rolling/sliding con-
rlieology and rnocleling traction behavior in concentrated tacts. The formulation used in the present investigation is
Downloaded by [University of Cambridge] at 04:19 28 December 2014

contacts has been a subject of many researchers. The amount based on the work by Cheng (6)and by Wilson and Sheu (7).
of available literature is rather vast, and a fair review is This paper is the first part of an overall investigation and
beyond tlie limits of this paper. Both Newtonian and non- it presents the analytical formulation of the models used.
Newtonian types of rheological behaviors have been inves- Experimental procedures and data correlations are subjects
tigatccl. 'The experimentally observed tractionlslip slopes at of the second paper, and the application of the traction
low sliding velocities, and an asymptotic nature of traction model to a rolling bearing will be the subject of the third
:it very liigli sliding velocities have prompted the investi- paper.
gations based on viscoelastic behavior. Johnson and Te- Analytical formulation of a traction model may be divided
vaarwerk ( I ) have proposed an Eyring sinh law as a non- into three basic parts: viscosity-pressure-temperature rela-
linear viscous function for a number of lubricants. The tions, computation of lubricant film thickness, and the de-
constitutive relation is expressed in terms of three funda- velopment of traction-slip relation in a concentrated con-
mental parameters: the shear modulus, the zero rate vis- tact. A discussion of the formulations used in these various
cosity and a reference shear stress. A slightly different re- analytical steps is the subject of this paper.
lation which modifies the classical Maxwell equation by a
limiting shear stress has been proposed by Bair and Winer
VISCOSITY RELATIONS
(2). Again, the constitutive equation is defined by three fun-
damental properties: low shear stress viscosity, limiting shear Characterization of lubricant viscosity behavior is a first
moclulus, and the limiting shear stress which the fluid can step in the development of a traction model. The general
witlistand. Based on these two common models, the objec- approach is to measure the viscosity at prescribed pressures
tive of the present investigation is to evaluate the viscoelastic and temperatures and then fit empirical relations to the
effects in tlie MIL-L-7808 type lubricant. data. Analytical expressions used to describe the viscosity-
Direct measurement of the required fundamental prop- pressure-temperature behavior are commonly of two types.
erties of the lubricant is, indeed, very difficult. Correlations For the present investigation, these relations are referred
of the traction behavior to the fundamental properties of to as Type I and Type 11.
tlie lubricant require that the rheological behavior be mea- The first type of viscosity relation, Type I, simply permits
sured at very high pressures and carefully controlled tem- an exponential variation of viscosity as a function of pres-
peratures. Although viscosity measurements as a function sure and temperature. When there is a coupling between
of pressure and temperature have been possible ( 3 ) ,direct pressure and temperature, an additional term may be jldded
mc:isilrement of shear modulus and critical shear stress has to represent such a coupling. With the various symbols de-
been far too complex. An acceptable approach has been to .scribed in the nomenclature, the viscosity is written as:
estimate these constitutive constants from experimental
traction data obtained with a rolling-disk type of traction CL = CL, ~ X P ~+ P(P + YP) ( T o - T ) } [ll
ap~):ir;itus(4). A given model is basically curve-fitted to the
experimental data to estimate the rheological constants. It The Type I1 relation is quite similar to Eq. [I], except
is quite true that since the overall measured traction includes that the temperature variation is expressed as the inverse
significant effects, such as tangential deformation of the of absolute temperature. The viscosity relation is written as:
disk specimens, such an approach may not provide the true
values of fundamental properties, such as shear modulus
or critical shear stress. However, the curve-fitted values may
be acceptably used as effective values for traction predic-
tions when the data correlation is good. Such a hypothesis It is clear that with increasing temperature, the viscosity
is the foundation of the present approach. approaches an asymptotic value with the Type I1 relation,
Viscoelastic Effect:; in MIL-L-7808-Type Lubricant, Part I: Analytical Formulation 27 1

while it continues to decrease exponentially with the Type I


relation. Aside from this observation, there is no real dif-
ference between the two relations.
where the various dimensionless parameters are defined, in
LUBRICANT FILM THICKNESS MODtZLlNG terms of t h e fundamental variables included in the
nomenclature, as:
Modeling of lubricant film thickness in an elastohydro-
dynamic contact is accomplished in two steps. First, the film U = P u , the speed parameter
-
profile is computed by solving the coupled problem asso- E'R
ciated with the elastic distortion of the interacting surfaces
and the fluid hydrodynamics. Then, a correction to account
for thermal effects is applied to derive the final film thick- U = + u2, the rolling speed
2
ness in the contact. In view of the very high surface finish
of the test specimens and the flooding. of the contact with
lubricantjets, as discussed in the second part of this paper,
the surface roughness and starvation effects on the lubri-
I - I { ~-
E' 2 El
v2 + -I E2
, the materials parameter

cant film thickness are not considered in the present inves-


R = - R 1 R 2 the equivalent radius
tigation. T h e ratio of lubricant film thickness to surface *
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RI RP'
finish ranges from 7 to 20. As shown schematically in Fig. 1 ,
the overall shape of the lubricant f i l n ~is well established G = aE', the elasticity parameter
within the current theory of elastohydrodynamic lubrica-
tion. T h e film thickness is fairly constant over most of the
contact zone, and the well defined dip near the exit region W =-4 , the load parameter
E'R
determines the minimum film thicknes:~.Based on the com-
plete numerical solutions, formulae for the computation of
both the nominal and minimum film th:icknessare available. k = ab , the ellipticity parameter
While the minimum film thickness is of significance in par-
tial elastohydrodynamic lubrication where direct interaction T h e isothermal film thickness compi~tedabove is modi-
between surface asperities may occur, the nominal, or cen- fied by a thermal reduction factor, aT,to derive the final
tral, film thickness holds for most of the contact zone. It is, value of film thickness, h, in the contact under prescribed
therefore, the primary input to the con~putationof traction operating conditions.
in well-lubricated elastohydrodynamic contacts. Emphasis
is therefore placed on the conlputation of nominal film
thickness in the present investigation.
T h e isothermal film thickness, h,,, in the present inves- Modeling of thermal effects is based on the work by Cheng
tigation is computed by the Hamrock and Dowson (5)for- (6)and Wilson and Sheu (7). An attempt is made to modify
mula, which is written as: the Wilson and Sheu formula to account for load effects as
done by Cheng. This resulted in considerable computer
analysis of both models, and empirical curve-fitting of the
numerical solutions. T h e result is the following equation
for the thermal reduction factor:

/ : H e r t z Solution 4z \i
where the thermal loading parameter, L, and the slicle-to-
roll ratio, S, are defined as

The effect of contact load is indicated by the term con-


taining the Hertzian pressure p,. It is found that this effect
is only significant at high values of slide-to-roll ratios ancl
the thermal loading parameter. Figure 2 compares the var-
iation in thermal reduction factors as computed by the al~ove
equation and those obtained by the original Wilson and
Flg. 1-Schernatlc representation of an elastohytlrodynarnlc contact zone. Sheu formula.
C L ~
D = -, the Deborah Number
Gb

the dimensionless strain rate.

Similar to the Newtonian model, the functional relation-


ship, f (T), in the above equation defines the type of a visco-
elastic model. T h e two common types of this function are:

1,
,,, Wllson and She" (7)
I ' Type I:

0.01 I I 1 1 1 1 1 1 1 I I 1 1 1 1111 I I 1 1 1111 f (T) = sinh (T), the Johnson and Tevaarwerk model (1)
0.1 I 10 100
L
Type 11:
Flg. 2-Comparlson of thermal reductlon factors as predicted by Eq. [5]
and the Wllson and Sheu formula (7). f (T) = tanh-'(T), the Bair and Winer model (2)
Downloaded by [University of Cambridge] at 04:19 28 December 2014

Aside from the above functional relationship, certain as-


TRACTION MODELS sumptions about the pressure and temperature distribution
T h e lubricant viscosity relations and the formulae for the in the contact are essential before Eq. [7] may be applied to
comput.ation of lubricant film thickness in a contact are two a contact. It is generally reasonable to assume that the pres-
of tlie three inputs required in the prediction of traction in sure conforms to the Hertzian contact solution. T h e com-
;in el;~stoliyclrodynaniiccontact. T h e shear stress and strain putation of temperature distribution, however, is a more
rate constiti~tiveequation, is the final input which completes complex task. Generally, the interacting surfaces have to be
t.he reqi~irementsof a traction model. It is the nature of modeled as a moving heat source, and the heat transfer
equations have to be solved to obtain a temperature distri-
this relat.ionsliip which determines the type of a model. A
bution along the rolling direction for heat generated in the
conililon form oC the shear stress and strain rate equation
contact due to lubricant shear. For the present investigation,
for ;I viscoelastic model is written as (I):
a simplified assumption that the interacting surfaces main-
tain a constant temperature, To, is made, and Eq. [7] is ap-
plied to the central plane through the film where the tem-
perature rise is simply computed by conduction through
the film for the given heat generated at any point in the
In tlie above equation, the three fundamental properties,
contact:
G, T,,, and p,, are respectively, the shear modulus, critical
shear stress and lubric:mt viscosity. All these properties are,
i l l gcncral, functions of pressure and temperature.
When the rolling velocity is U , the convective derivative It is, of course, assumed here that the strain rate resulting
term, as explained by Johnson and Tevaarwerk (1) can be from the sliding velocity, Us, is in the viscous regime.
rcplaced as shown: For a given pressure and temperature, the fundamental
properties, G , T, and p,, may be defined at any point in the
contact, and Eq. [7] can then be applied to compute traction.
When the slip is completely in the rolling direction, as is
the case in the rolling disk apparatus, Eq. [7] is essentially
where y is the coordinate along the rolling direction, as integrated numerically over the range - 1 < j 1 with the
shown in Fig. I. initial condition:
Also, when the sliding velocity is Us,lubricant film thick-
ness is /L, and the contact half width is 6, the following quan-
tities may be defined to express Eq. [6] in a more convenient
form: The computed shear stress may then be integrated over
the contact ellipse to determine the total traction.
Effective values for the fundamental properties, shear
modulus, critical shear stress and lubricant viscosity are de-
rived by curve-fitting the model predictions to the experi-
[GI may now be written as:
Eqi~:~tion mental data. While estimates of viscosity may be obtained
directly from the viscosity measurements and from Eqs. [ l ]
and [2], the effective shear modulus and critical shear stress
are back-calculated by fitting the model to measured trac-
tion data. As a first step to such a curve fitting, o r regression
analysis, both the shear modulus and critical shear stress
Viscoelastic Effects in MIL-L-7808-Type Lubricant, Part I: Analytical Formulation 273

are assumed to have a constant value over the entire contact viscous conditions, the algebraic relationship between the
area for a given operating environment. Under such sim- traction coefficient, K,, at a fairly large slide-to-roll ratio,
plified assumptions, Figs. 3 and 4 show typical variation of (UsIU)m, may be shown to be:
traction as a function of the shear modulus G, and the
critical shear stress, 7 0 , respectively for the Type I visco-
elastic function. For a relatively high Deborah number, the
behavior is essentially elastic at very small strain rates (i.e.,
very low slip velocities). Thus, by negleciing the viscous where 5, is the average viscosity over the contact.
term, assuming a constant average value for the shear mod- Thus, for any given maximum traction coefficient, at a
ulus, and carrying out straightforward algebra, it can be relatively large slide-to-roll ratio, the average value of the
shown that the slope of the traction curve, tan 0, is (4): critical shear stress can be readily determined by solving the
above algebraic equation.
4Cb T h e behavior of traction with the Type 11 viscoelastic
tan 0 = -
.rrp,h function is quite similar to that seen above for the Type I
model. At low slip rates, the behavior is purely elastic and
Thus, the effective shear modulus is directly proportional Eq. [9] is valid for high Deborah numbers. At high slip rates,
to the slope of the traction curve,. however, as seen in Fig. 5, traction approaches a constant
Downloaded by [University of Cambridge] at 04:19 28 December 2014

As the slip increases, the viscous term becomes significant, value which is defined by a limiting shear stress. Thus the
and at high values of slip, the behavior is basically viscous. critical shear stress, T,, is actually a limiting shear stress
T h e traction coefficient in the purely viscous region in- which the material can withstand (2). Under such a con-
creases very slowly with slip rate. In fact, as seen in Fig.'4, dition, the maximum or limiting traction coefficient may be
the traction may be assumed to be practically constant. If simply written as:
the Type I constitutive equation is applied under purely

VISCO-ELASTIC MODEL TYPE 1

C O N S ~ A N T PROPERTIES MU (Pa.S) G (Pa) TAU (Pa)


Thus, for any given value of maximum traction, the ef-
fective value of the limiting shear stress can be readily
determined.
TRAC COEFF x1o2 For a given traction curve, the above equations provide
preliminary values of G and TO. An adjustment to these
values is now applied while minimizing the squared devia-
tion between the predicted traction and the experimental
data obtained over a range of operating conditions. Such a
regression analysis also defines the variation of shear mod-
ulus and critical shear stress as a function of pressure and
temperature.
A discussion of the results and final conclusions is de-
ferred until the presentation of the experimental part of
this investigation, which is the subject of the second part of
Flg. 3-Predlctlon of Type I vlscoelastic modal as a function of shear this paper.
modulus.

VISCO-ELASTIC MODEL TYPE 1 VISCO-ELASTIC MODEL TYPE 2

CONSTANT PROPERTIES MU (Pa.S'l t (Pa) TAU (Pa) CONSTANT PROPERTIES MU (Pa.$> t (Pa> TAU (Pa>

TRAC COEFF x1e2 TRAC COEFF xle2

-0.20 -0.15 -0.10 -0.01 0.00 0.05 0.10 8 . 0.20


SLIDE/ROLL

Flg. 4--Traction predlctlon of Type I viscoelastlc model as a functlon of Flg. 5--Traction predlctlon of Type II vlscoelastic model as a function of
crltlcal shear stress. ' the llmitlng shear stress.
SUMMARY tract n u m b e r F33615-86-C-2696, u n d e r the Defense Small
Business Innovation Research Program. Computational
An;~lytical formulation for viscoelastic traction is pre-
support was provided by the ASD Computer Center at
selltccl in three parts: viscosity-pressure-temperature rela-
Wright-Patterson Air Force Base.
tions, computation of lubricant film thickness, a n d shear
stress and strain rate relations. T w o types of relations a r e
usccl to model the viscous shear strain rate. I n the T y p e I REFERENCES
model, a hyperbolic sine relation is used to model the viscous
(I) Johnson, K. L. and Tevaarwerk, J. L., "Shear Behavior of EHD Oil Films:'
cffcct which becomes significant when the shear stress reaches Proc. Roy. Soc. London, A356, p 215 (1977).
;I critical value. 'l'he T y p e I1 rnodel employs a limiting shear (2) Bair, S. and Winer, W. 0.. "A Rheological Model for EHD Contacts based
stress, which the lubricant can withstand, a n d a n inverse on Primary Laboratory Data," ASME Jour.' of Lubr. Tech., 101, 3, p 258
(1979).
hyperbolic tangent function is considered t o model the vis- (3) Bossert. A. J. and Hopkins, V., "Determination of Changes in Lubricant
cous I)chavior. Both models basically employ three funda- Viscosities at High Pressures and Temperatures," Air Force Tech. Rpt.
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AFML-TR-74-195 (1974).
mental qu:un~ities, i.e., lubricant viscosity, shear modulus,
(4) McCool, J. I., "Traction Model Development," Air Force Mats. Lab., Tech.
;IIICI critical shear stress. While the viscosity behavior may Rpt. AFWAL-TR-87-4079 ( 1987).
IIC clcrivecl h o r n direct measurements, estirnates of average (5) Hamrock, B. J . and Dowson, D., "Isothermal Elastohydrodynamic Lu-
shear ~ n o d i ~ l auns d critical shear may be obtained by curve- brication of Point Contacts, Part Ill-Fully Flooded Results," ASMEJour.
of Lubr. Tech., 99, 2, pp 264-276 (1977).
lilting thc model predictions to experimental traction data. (6) Cheng, H. S., "A Refined Solution to the Thermal-Elastohydrodynamic
Lubrication of Rolling and Sliding'Cylinders:' ASLE Tram., 8, p p 397-
410 (1965).
ACKNOWLEDGMENTS (7) Wilson, W. R. D. and Sheu, S., "Effect of Inlet Shear Heating Due to
Sliding on Elastohydrodynamic Film Thickness," ASME Jour. of Lubr.
'I'his work was sponsored by the Aero Propulsion a n d Tech., 105, p p 187-188 (1983).
IJowcr Laboratory at Wright-Patterson Air Force Base, con-