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Y. ASAI*
N. MOTOHASHI**
Y. SAKAKI**
* Research & Development Center, Automotive Unitized Product Engineering Development Department
**Automotive Engineering Center, Automotive Bearing Engineering Department
Peeling occurs on smooth rolling bearing raceways in contact with rough mating surfaces under poor lubrication
conditions. A relatively inexpensive manganese phosphate treatment was selected for preventing the contact surface from
peeling. We have confirmed by rolling fatigue test results that the manganese phosphate coating can prevent raceways from
peeling, and that its effect is a result of roughness truncation and the increase of oil film formation.
1. Introduction
As a result of environmental concerns in recent years, there
has been a trend among automobile manufactures to reduce
the frequency of engine and transmission oil changes, and
switch to low-viscosity oils. As lubrication condition becomes
increasingly severe, various types of surface damage tend to
occur. This requires higher performance and high reliability of
metal surfaces, but an increase in costs is severely restrained.
Peeling is a type of surface initiated failure, and is usually a
concentration of fine flakings of no more than 0.1 mm wide
and 10 m deep1). Peeling occurs on a component having a
smooth surface when the mating component is rough and the
lubricating film between the two surfaces is insufficient.
Peeling is often seen, for example, on the surface in contact
with automobile engine roller follower bearing cams and
rollers of needle roller bearings.
This paper reports on a newly developed peeling-resistant
bearing that is effective in preventing surface damage under
severe lubrication conditions and has low cost.
2. Concept of Development
Oil film thickness parameter is commonly used as the
parameter for expressing the severity of lubrication conditions.
The value of is usually defined as the ratio of minimum oil
film thickness h0 and combined roughness of the two surfaces
that make contact with each other. The lower the value of ,
the shorter the rolling contact fatigue life becomes2), and the
origin of damage shifts from subsurface to surface. Seizure
and abnormal wear, which occur when the oil film is broken,
are most likely connected with the value of . Lubrication
conditions must be improved in order to prevent damage,
including peeling, from occurring on the surface. The value of
is increased by using lubricants with higher kinematic
viscosities or by reducing surface roughness, but this leads to
higher fuel consumption and cost.
Machine parts are generally subjected to running-in
operation under moderate conditions to improve contact
surfaces before actual use in the machine. Initial contact
micro-roughness is improved by running-in. According to
F.Hirano, although the surface quality of machine parts must
be improved, there is a limit to improving the precision of
3. Peeling-Resistant Surfaces
3. 1 Application of Manganese Phosphate Coating
To apply manganese phosphate coating to the contact
surface of rolling elements, the coating and surface of the base
materials must be optimized. In the case of manganese
phosphate coating, various coatings and surface of base
materials are possible by combining chemicals (surface
adjustment agent, phosphating solution) and processing
conditions. The authors prepared various coated surfaces,
evaluated them for peeling resistance under rolling contact
conditions, and developed a new surface treated with a special
manganese phosphate coating.
Fig. 1 shows the schematic diagram of the developed antipeeling surface. The surface is coated with manganese
phosphate. The coating thickness is 1~4 m. The grains are
small, so the roughness is less than that of conventional
manganese phosphate coatings. The iron of the surface base
metal is dissolved during the initial manganese phosphate
coating process, forming pits in the surface of the base metal.
These pits are arranged at a moderate size, depth and density.
17
Base metal
2.25
1 000
Running time, h
20
0.55
Driven roller
3. 2 Anti-Peeling Performance
Anti-peeling properties for the newly developed surface
were evaluated with a two-ring type rolling fatigue tester for
20 hours. Test conditions are given in Table 1, and the
structure of the tester is shown in Fig. 2. The results are shown
in Figs. 3, 4 and 5.
Motor
Drive roller
80m
(a) Untreated
(b) Treated
Fig. 3 Appearance of surface after testing
10m
(b) P analysis
(c) Mn analysis
18
0.1
Contact voltage, V
Untreated
0
0.1
Treated
30minutes
20
Running time, h
40
36
35
30
25
2.25
1 000
0.84
0.45
20
15
13.5
10
5
0
0
Untreated
Treated
12
19
New
After 3 min.
After 60 min.
Untreated
Treated
1
0.9
Untreated
Treated
0.8
0.7
0.6
0.5
Radius of asperity R, m
7
6
5
4
3
2
1
0
10
20
30
40
50
60
2.25
1 000
Running time, h
20
10
20
30
40
50
60
Running time, h
0.68
E
H R
20
30
Peeling damage, %
25
20
15
10
5
0
Radius of asperity, m
200
Running time, h
150
100
50
0
Untreated
Peeling-resistant bearing
Coil spring
Specimen
Cam
6. Conclusion
Fig. 10 Cam follower test equipment
21
Lubricant
Lubricant amount, ml/min
1.0
3 000
SAE10-W30 engine oil
60
Oil temperature, ;
130
Running time, h
200
References
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