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& Design
Materials and Design 26 (2005) 680–689
www.elsevier.com/locate/matdes
Abstract
A novel pressurised chamber was designed to construct a special purpose test rig to achieve saturated liquid state of refrigerants
for lubricated rolling contact fatigue experiments. Traditional bench testing using refrigerants as the lubricant is difficult due to the
gaseous phase at standard atmospheric conditions. Pressurising the concentrated contact test chamber is therefore necessary to eval-
uate at a liquid state and therefore simulate practical applications. The gas/liquid phase transitions have a significant influence on
the lubricant properties and hence wear mechanisms. It is necessary to modify the wear test conditions for the Hydrocarbon (HC)
and Hydrofluorocarbon refrigerants to obtain realistic simulation of refrigerator compressor tests. The chamber design and test rig
are described in this paper. A preliminary experimental study of the influence of the HC (R600a) on rolling wear of the silicon nitride
(Si3N4)/steel elements using the pressurised chamber is presented. Rolling fatigue test methods are adopted to measure the wear per-
formance of silicon nitride/steel bearing materials. In this case the rolling wear mechanisms of Si3N4 were measured using R600a
refrigerant lubrication.
2004 Elsevier Ltd. All rights reserved.
1. Rolling contact fatigue test machines tions have shown that, except for very specialized condi-
tions of load or local chemistry, solid or liquid
Many rolling contact fatigue (RCF) test machines are lubrication is required to effectively utilize silicon nitride
in use to study the wear performance of materials and in wear applications. Dry, rolling wear rates on silicon
lubricants in rolling contact. In rolling contact, surface nitride were measured by Kato et al. [19,18]. Generally,
and subsurface initiated fatigue is observed due to re- wear occurs either by mechanical or chemical means and
peated loading. At critical number of fatigue cycles the has six principal, quite distinct phenomena that have
break-up of material surface results in the formation one thing in common, removal of material from the rub-
of small pits, also known as pitting or spalling. Several bing surfaces [6]. These types of wear mechanisms are
investigators, prompted by increasing application of sil- adhesive wear, abrasive wear, fatigue wear, impact wear,
icon nitride in bearing systems, have documented wear corrosive wear, electrical-arc-induced wear and fretting
and fatigue behaviour of these materials [23]. Investiga- and fretting Corrosion.
*
Corresponding author. Tel.: +44 1202 595 079; fax: +44 1202 595 1.1. Modified four-ball machine
314.
E-mail addresses: zkhan@bournemouth.ac.uk (Z.A. Khan),
mhadfield@bournemouth.ac.uk (M. Hadfield), ywang@bournemouth. The modified four-ball machine simulates deep
ac.uk (Y. Wang). groove ball bearing environment. This test configuration
0261-3069/$ - see front matter 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2004.08.006
Z.A. Khan et al. / Materials and Design 26 (2005) 680–689 681
Collet Load
Load (L)
Collet
Upper ball
Lubricant
Lower ball Upper ball
Lower ball
Steel cup
Fig. 1. Loading configuration of modified four-ball machine. Fig. 2. Loading configuration of five-ball machine.
has three lower balls free to spin and revolve with an Load
upper fixed ball having one degree freedom and only
Ball or
translating spindle motion. The lower three balls revolve
Roller
in a cup that simulates the bearing outer race, while the
upper ball represents the inner bearing race. The lower
Ball Retainer
planetary balls representing the rolling elements within
the bearing. Loading geometry for a modified four-ball
machine is shown in Fig. 1. This machine has been very
Test piece
useful in the study of RCF performance of materials
subjected to various tribological conditions. The influ- Fig. 3. Loading configuration of ball-on-plate machine.
ence of lubricants on steel ball RCF was evaluated using
the machine [4,22,27]. The Institute of Petroleum com- loaded between a stationary flat and a rotating grooved
piled numerous papers [31] that describe various test re- washer. Rotating washers produce motion and transmit
sults, kinematics, ball dynamics using modified four ball load to the rollers/balls and the flat washer.
machine. This machine has been used to study the RCF
performance of hot pressed silicon nitride bearing mate- 1.4. Ball-on-rod machine
rials [29,28]. Recently, a modified four-ball machine has
been used to simulate the rolling contact in hybrid (cera- This machine has a cylindrical rod of 9.53 mm in
mic/steel) rolling element bearings [13–15]. diameter. A motor coupled in line with the rod drives
the rod. Combination of a lower and upper cup provides
1.2. Five-ball machine housing for three balls of 12.7 mm in diameter. Oil drip-
ping on the rod provides lubrication. Pre-calibrated
Fig. 2 shows contact geometry and rotating mecha- mechanical springs are used to apply load by driving
nism of a five-ball machine. The four lower balls are dri- the upper cup towards the lower. This machine was
ven in a race by an upper ball. This arrangement used to investigate rolling contact wear [3,8,10,23]. Ball-
simulates rolling and sliding of angular-contact ball on-rod machine is shown in Fig. 4.
bearings. This machine has been used to investigate
the fatigue life of high-speed rolling elements including 1.5. Disc-on-rod machine
hot pressed silicon nitride balls [9,26].
This machine is shown in Fig. 5. A long straight
1.3. Ball-on-plate machine cylindrical specimen 76 mm in diameter is held between
two discs 177.7 mm in diameter and 12.7 mm thick.
The ball-on-plate machine shown in Fig. 3 was used These discs can press against the specimen which is held
to investigate the RCF performance of silicon nitride in position by a spindle and can rotate up to 10,000 rpm.
[12,20]. This machine has a unidirectional thrust bearing The geometry of the machine enables to calculate the
consisting of three balls or roller positioned at 120 contact stresses as a function of load. The machine pro-
each. The balls/rollers are retained by a retainer and vides condition for rapid testing in nearly pure rolling.
682 Z.A. Khan et al. / Materials and Design 26 (2005) 680–689
Rod
specimen
Load
Ceramic
Balls roller
Driving
roller
movement is restricted by the strain gauge transducer, saturated liquid state of the refrigerant as fluid at oper-
thus giving direct friction torque measurements. The ating conditions by using the pressurised chamber. The
adapters also include integral electrically heated sup- tests were conducted in HC (R600a) and HFC
ports for tests up to 200 C. The software includes an (R134a) refrigerants as lubrication.
8-channel chart recorder simulation for data output to
a printer. At the end of the test the data may be manip- 2.3. Test rig modification
ulated for calculation or graphical presentation on the
integrated spreadsheet software programme. Tests are 2.3.1. Basic design
defined by a series of steps, each step containing load, The pictorial and the cross-sectional views of the
temperature and speed set-points, data recording and pressurised chamber are shown in Figs. 7 and 8, respec-
alarm level information. Set-points may be adjusted by tively. A coiled copper tube is fitted on the surface of the
step change or ramp. The test sequence is followed un- pressurised chamber. The cooling liquid is circulated in
less interrupted by the operator or an alarm. the tube with the help of a peristaltic pump. The cooling
circuit has a heat sink where the liquid is cooled down
2.2. Rolling contact fatigue testing with refrigeration and re-circulated on the pressurised chamber surface.
A schematic of the cooling arrangement is shown in
Refrigerant lubrication has a direct affect on the Fig. 14.
durability of the rolling element bearings within indus-
trial compressors. In addition, refrigerants have evolved
rapidly over the last decade due to sustainable develop-
ment legislation. Therefore, the tribology of the refriger-
ants [HC Hydrocarbon, (R600a, CH(CH3)3,2-methyl
propane (isobutane) and HFC tetrafluoroethane
(CH2FCF3, HFC-134a)] used in industrial application
systems must be studied. The refrigerant dissolved in
the oil brings about lubricating behaviour different from
that in an ambient environment, especially for boundary
lubrication [16,17]. The lubricants are easily deteriorated
in the presence of refrigerant because the two react
chemically [30,32].
Komatsuzaki and Homma [21] used a four-ball tester
to evaluate the extreme pressure (EP) properties of pure
refrigerants and oil refrigerant mixtures. They found
that R-134a in Polypropylene glycol gave higher rates
of wear than R-12 and R-22 in mineral oil. Although
the HFC-134a had showed some capability of forming Fig. 7. Isometric view of the pressurised chamber.
a fluoride layer on the sliding surface, it did not exhibit
good lubricating quality. The reason for that is the con-
dition for the HFC to form a protective layer during
sliding is more severe than in the actual compressors
[25]. The gas/liquid phase transition has a significant
influence on the wear mechanisms of traditional lubri-
cants and is therefore a useful experimental study [11].
It was necessary to simulate actual operating condi-
tion for rolling contact hybrid ceramic-steel ball bearing
with refrigerant as lubrication. A novel pressurised
chamber was designed and manufactured. Rolling con-
tact hybrid ceramic-steel tests can be performed with
refrigerant in liquid state without generating severe fric-
tional heat. TE92 Microprocessor Controlled Rotary
Tribometer offers facilities to run high and low load tests
over a wide range of speeds, coupled with the latest con-
trol and instrumentation. Test rig was fitted to the Ro-
tary Tribometer with novel pressurised chamber. The
pressurised chamber offers controlled conditions of tem-
perature(s) and pressure(s). It is now possible to get Fig. 8. Cross-sectional view of the pressurised chamber.
684 Z.A. Khan et al. / Materials and Design 26 (2005) 680–689
Load (L)
Rotary
Chamber Tribometer
Upper Part Spindle
Coolant flow Coolant
Direction pipe
Pressure
Gauge
Heat
Exchange
Shaft
Seal Vacuum
Shut-off
Chamber Pump
valve
Lower Part
Collet Refrigerant
'O' rings Charging
Liquid Ceramic ball
refrigerant
Steel ball
Steel cup Thermocouple
Fig. 14. Schematic of rig for the high speed rotary tribometer.
686 Z.A. Khan et al. / Materials and Design 26 (2005) 680–689
Fig. 16 shows light microscopic result of the test A. Fig. 17. Light micrograph failure due delamination.
This result was recorded at 4 h and 1 min. The shaft
speed was 2000 rpm and shaft load was 3 GPa. An obvi- Fig. 20 shows scanning electron micrographs for
ous crack development and propagation helps in delam- specimen C. The maximum contact pressure in this test
ination. Fig. 17 shows the failure in the lower indent as was 6 GPa with 2000 rpm spindle speed and R600a as
delamination. lubrication environment. The fatigue life of the speci-
Figs. 18 and 19 showing scanning electron micro- men was recorded to be 19 · 102 cycles while the time
graphs for specimen B. The maximum contact pressure to failure was 9 min. Fig. 21 shows surface fatigues dam-
in this test was 7 GPa with 2000 rpm spindle speed age for specimen D the maximum contact pressure was 6
and R600a as lubrication environment. The fatigue life GPa with R600a refrigeration. The fatigue life of the
of the specimen was recorded to be 83 · 102 cycles while specimen was recorded to be 13 · 103 cycles while the
the time to failure was 2 min. time to failure was 7 min.
Table 1
Test programme for preliminary experiments
Test Contact stress (GPa) Time to failure Indent load (kg) Shaft speed (rpm) Fatigue cycles
A 3 4 h 30 min 5 2000 5.39 · 105
B 7 2 min 5 3000 8.34 · 103
C 6 9 min 1 2000 1.93 · 104
D 6 7 min 1 2000 1.33 · 104
E 3 13 h 30 min 1 2000 1.61 · 106
F 3 6h C-crack 2000 7.19 · 105
G 6 0 h 42 min C-crack 2000 8.21 · 104
H 6 0 h 04 min C-crack 2000 7.71 · 103
Z.A. Khan et al. / Materials and Design 26 (2005) 680–689 687
Fig. 18. SEM showing surface fatigue damage. Fig. 21. SEM showing surface fatigue damage.
References
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[28] Scott D, Blackwell J. Hot pressed silicon nitride as a rolling [31] Tourret R, Wright EP. Rolling contact fatigue: performance
bearing material – a preliminary assessment. Wear 1973;24:61–7. testing of lubricants. London: Heyden and Son Limited; 1977.
[29] Scott D, Blackwell J, et al.. Silicon nitride as a rolling bearing [32] Walker W, Levy SL. Stability of mixtures of refrigerants and
material – a preliminary assessment. Wear 1971;17:73–82. refrigerating oils. ASHRAE Trans 1962;68:360–89.