Development of SiO2 nanolubrication system to be used in sliding bearings
S. Y. Sia, Eman Z. Bassyony & Ahmed A. D. Sarhan
The International Journal of Advanced Manufacturing Technology ISSN 0268-3768 Volume 71 Combined 5-8 Int J Adv Manuf Technol (2014) 71:1277-1284 DOI 10.1007/s00170-013-5566-9
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Author's personal copy Int J Adv Manuf Technol (2014) 71:1277–1284 DOI 10.1007/s00170-013-5566-9
ORIGINAL ARTICLE
Development of SiO2 nanolubrication system to be used in sliding bearings S. Y. Sia & Eman Z. Bassyony & Ahmed A. D. Sarhan
Received: 22 July 2012 / Accepted: 16 December 2013 / Published online: 5 January 2014 # Springer-Verlag London 2014
Abstract New technology using nanoparticles as an additive in lubricants is recently becoming an attractive topic of study. The performance of SiO2 nanoparticles in the lubrication system is investigated. Tests were conducted for nanolubrication mixing ratios of 0.0, 0.1, 0.2, 0.5, 0.55, 0.6, and 0.8 wt% with plain bearings rotated by a 2,750-rpm high-speed motor. For each mixing ratio, the frictional temperature and wear rate of the rotating sliding bearings were recorded and compared. During surface testing, the surface roughness values of the sliding bearings were compared and the results showed an improvement in surface roughness after the tests. According to the outcome, the optimum tribological performance of nanolubricant was obtained at 0.5 wt% mixing ratio. Keywords Nanolubricant . SiO2 . Wear . Bearing
1 Introduction Thanks to the industrial revolution of the eighteenth century, bearings approached the forefront of engineering endeavors. Machine speed increased dramatically and bearings were S. Y. Sia : A. A. D. Sarhan (*) Centre of Advanced Manufacturing and Material Processing, Department of Engineering Design and Manufacture, Engineering Faculty, University of Malaya, 50603 Kuala Lumpur, Malaysia e-mail:
[email protected] S. Y. Sia e-mail:
[email protected] E. Z. Bassyony Centre of Advanced Manufacturing and Material Processing, University of Malaya, 50603 Kuala Lumpur, Malaysia e-mail:
[email protected] A. A. D. Sarhan Department of Mechanical Engineering, Faculty of Engineering, Assiut University, 71516 Assiut, Egypt
central to rotary and linear movement. In addition, accuracy and repeatability of positioning gained emphasis. The advent of railroad trains in the nineteenth century sparked further development in bearing technology. So, not only did bearings need to operate at high speed, but also heat, vibration, and shock loads greatly increased, and since railroad cars were a commodity, cost was paramount. Today, bearing design continues to progress with advanced materials and new geometries enabled by computer-aided design. Computer-aided manufacturing, such as computer numerical-controlled machining, has drastically improved the accuracy of massproduced bearings. Accurate and position-repeatable bearings, especially linear ones, have become crucial for robot implementation. Bearings are required whenever one part of a machine slides against another, and they can be classified as either providing sliding or rolling contact. A sliding bearing typically uses a lubricant to reduce friction between the sliding surfaces. The fluid lubricant forms a film between the sliding surfaces so there is no contact between solid components. Rolling bearings have balls or rollers to minimize rubbing, and lubricant can also be used. In sliding bearings, the load is transmitted over a considerable area while in rolling bearings, the contact area and load transmission are both actually small. The use of sliding bearings is fairly widespread. Some of the areas in which sliding bearings are employed include the following: oil and gas pipelines, waterways and water pipelines, conveyor systems, boiler plants, minor bridges, and power plants. The compact size and overall effectiveness of the bearing makes it an ideal choice in lower load applications (below 100 t). Furthermore, the simplicity of slide bearing design ensures that as long as the basic design specifications are adhered to, there is plenty of latitude as to the exact dimensions and form of the bearing. This is valuable for clients who prefer to design their structures independently and have the bearing modified to suit their overall design.
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With respect to sliding bearings, Dilbag and Rao [1] revealed that surface roughness generally plays an important role, as it affects the fatigue strength, wear rate, coefficient of friction, and corrosion resistance of the machines’ components. In order to investigate surface characteristics, surface roughness, morphology as well as the friction coefficient, are investigated. Many papers from literature show the relationship between surface roughness or surface textures and friction in machine components [2–4]. Correct lubricant application has been proven to greatly reduce friction, which results in significantly enhanced surface roughness. Although the significance of lubrication is widely recognized, the usage of conventional lubrication processes has become an enormous liability. Not only does the Environmental Protection Agency regulate the disposal of such mixtures, but many states and localities have also classified them as hazardous waste. Recently, studies on lubricants with additives such as nanoparticles have attracted the interest of many researches. Polytetrafluoroethene, graphite, and molybdenum disulphide are the more common commercial particles employed. Besides these materials, current research is involved with the effects of additives, whereby the performance of inorganic composites and ceramics as additives is to be further determined. One type of nanoparticles, silicone dioxide (SiO2), is well known as a hard material and is easily acquired on the market at affordable prices. It can be found in sizes ranging from 5 to 100 nm. The mechanical properties of SiO2 are listed in Table 1. SiO2 nanoparticles are known as a hard material that helps reduce direct surface contact in friction applications. Market availability is another principal consideration, which enables the commercialization of research at affordable cost. Besides, regarding material safety concerns, low doses of SiO2 particle were not found to be toxic in experiments performed on laboratory animals (in vivo) [5]. SiO2 can safely be utilized as an additive to nanolubricant in this present research, and its performance is investigated. Nanolubricant is prepared by blending nanoparticles with ordinary mineral oil. A few nanoparticle types are available commercially [6] and regular mineral oil is effortlessly obtained on the market. Sarhan et al. [7] prepared a nanolubricant
by adding SiO2 (0.2 wt%) nanoparticles with average size of 5–15 nm to neat mineral oil (ECOCUT SSN 322, Fuchs, Malaysia) with 40.2 cSt at 40 °C. Sonification (240 W, 40 kHz, 500 W) was done for 48 h in order to suspend the particles homogeneously in the mixture. Rahmati et al. [3] reported that cutting force and power were considerably reduced when using a nanoparticle lubricant, since lubricant functions via billions of rolling elements in the tool-chip interface. Correct application of lubricants has been proven to greatly reduce friction, which results in reduced power consumption. According to Lee et al. [8], 0.1 vol% of graphite particles (average size of 55 nm and specific gravity of 2.26), 0.5 vol% of dispersant (alkyl-aryl-sulfonate), and commercial mineral oil (Supergear EP220, SK, Korea) were mixed using an ultrasonic homogenizer at ambient temperature. The surfaces of the nanoparticles were modified by the dispersant, facilitating the suspension of particles in the as-prepared nanolubricant. The nanolubricant was more stable by having added the dispersant. This is mainly accredited to the repulsive force provided by the dispersant between the nanoparticles’ surfaces inside the nanolubricant. Li et al. [9] revealed that nanolubricant, a mixture of nanoparticles and lubricating oil, increases the extreme pressure of the lubricant and reduces the friction coefficient, making the bearing more durable. Their research observed smoother contact surfaces when using nanolubricant compared to raw lubricant. Nanolubricants with different mixing nanoparticle ratios were tested. The comparison results indicate that 0.1 wt% fraction concentration of nanoparticles provided optimum tribological effects in terms of wear rate, surface analysis, and average friction coefficient. On the other hand, the embedding effect of nanoparticles was observed in several cases and reported [9, 10]. The reports demonstrate how the nanoparticles get embedded in the friction surfaces or fill surface grooves. In addition, the deposition of nanoparticles on rubbing surfaces can contribute to lessening of the applied load, duration, and operating temperature [11]. The present study aims to investigate the effect of various mixing concentrations with SiO2 nanoparticles on lubricity to be used in sliding bearings.
Table 1 The mechanical properties of SiO2 [1] Properties
SiO2
Structure Melting point (°C) Density (g/cm3) Refractive index Dielectric constant Thermal conductivity at 300 K (W/cmK) Dielectric strength
Amorphous Approx 1600 2.2 1.46 3.9 0.014 107
Table 2 Physical and chemical characteristics of FUCHS Ecocut HSG 905 lubricant Properties
FUCHS Ecocut HSG 905
Density at 15 °C Viscosity at 20 °C Viscosity at 40 °C Flash point Evaporation loss
0.826 g/ml 8.0 mm2/s 4.6 mm2/s 130 °C 90 %
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Fig. 1 Sliding bearing
2 Experimental work 2.1 Nanolubricant preparation The two types of lubricant employed in this research are ordinary lubricant and nanolubricant. The ordinary oil, brand name Ecocut HSG 905, was purchased from Fuchs Petrolube (M) Sdn
Bhd. This oil is free from chlorine and other additives. The typical physical and chemical characteristics of the lubricant are shown in Table 2. The nanolubricant was prepared by adding ALDRICH nano-sized silicone dioxide (average size of 5–15 nm) to the lubricant, followed by sonification (140 W, 240 V, 50 °C, 28–34 kHz) for 2 h in order to homogeneously suspend the particles in the mixture. The mixing ratios of nanosilicone dioxide were 0.0, 0.1, 0.2, 0.5, 0.55, 0.6, and 0.8 wt%. The 0.0 wt% mixing ratio represents a neat lubricant. 2.2 Experimental materials and setup Plain bearings (GEZ40ET-2RS LS) with 40-mm bore diameter were used in this research, as shown in Fig. 1. Both the outer and inner race of the bearing are made of carbon chromium steel and the sliding surfaces are treated with hard chromium plating. There are two holes on the outer race of the bearings to enable lubrication. The permissible operating temperature range of the bearing is −30 to 130 °C. The experimental setup is shown in Fig. 2. One and a half grams of the lubricant is supplied through the hole to provide a lubrication film between the sliding surfaces so there is no contact between solid components. The outer bearing race is fixed to the adaptor while the motor (0.5HP, 240 V, 370 W, and 2,750 rpm) is rotating the inner race. In this experiment, the motor rotates the inner race while the outer race is fixed for 2 h; hence, the energy dissipated in overcoming friction is
Table 3 The parameters of the experiment
Fig. 2 Schematic of the experiment setup
Parameters
Unit
Motor rotation Duration
2,750 rpm 2 h (120 min)
Weight of lubricant supplied Additive percentage in the lubricant
1.5 g 0.0, 0.1, 0.2, 0.5, 0.55, 0.6, 0.8 wt.%
Author's personal copy 140.0
0.700
1.400
120.0
0.600
1.200
0.500
1.000
0.400
0.800
0.300
0.600
0.200
0.400
0.100
0.200
100.0 0.0wt% 0.1wt% 0.2wt% 0.5wt% 0.55wt% 0.6wt% 0.8wt%
80.0 60.0 40.0 20.0 0.0
0.000
0
20
40 60 80 Time (Minutes)
100
120
Fig. 3 Graph of friction temperature vs time
converted into heat. Some of the heat will be stored in the deformed surface, thus raising the interface temperature. Temperature changes due to friction between the contacting surfaces are recorded every 10 min with an infrared temperature tester (Raytek Minitemp MT4). The experimental parameters are given in Table 3. The changes in the outer diameter of the inner race (contacting surfaces) are measured using a micrometer and the results are compared. The bearing’s wear characteristics are determined in two ways: in the first method, the change in inner bearing race diameter is measured and recorded. In the second method, the weight loss difference is calculated. The results are recorded and compared. Finally, the tested bearings are analyzed with a surface roughness tester, profilometer. The tested bearing is fixed into a jig and surface scanning is carried out across the outer surface of the inner race. In the experiments, the scanning line is perpendicular to the lay of bearings and the cut-off distance is 0.25 mm. The results are recorded and compared.
3 Results and discussion 3.1 Friction temperature The bearings are tested for different nanolubricant mixing ratios. The friction temperatures are recorded and plotted as
Fig. 4 The mechanism of nanoparticles during the experiment (Modified from [10])
Weight loss (g)
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Diameter change (mm)
Temperature (°C)
1280
0.000 0.0
0.1
0.2
0.5
0.55
0.6
0.8
Mixing ration (wt%) Diameter change (mm)
weight loss (g)
Fig. 5 The outer diameters change and weight loss of bearings vs mixing ratio
seen in Fig. 3. The friction between the shaft and the bearing causes the temperature of the frictional surface to rise, temperature which was assumed as friction criteria [12]. Figure 3 indicates that the friction temperature changes along the testing period according to different nanolubricant mixing ratios. The 0.0 wt% neat lubricant manifests the highest friction temperature, while the lowest friction temperature is observed at 0.5 wt% additive. This is mainly attributed to the fact that the nanoparticles in the nanolubricant act as billions of rolling elements between the moving parts, which helps reduce the friction at the contacting surfaces [13]. Thin films of nanolubricant form between the contacting surfaces, are embedded therein, and/or fill the surface grooves. The nanoparticles thus have a combination of sliding and rolling effects [7, 9, 10, 13]. Furthermore, Fig. 3 displays that the lowest average friction temperature is obtained when 0.5 wt% nanolubricant is used. However, when higher nanolubricant mixing ratios are used (0.55, 0.6, and 0.8 wt.%), higher friction temperatures are obtained. This may be because higher mixing ratios cause greater friction, as the tendency of the hard SiO2 particles to collide with each other increases, leading to higher shearing possibility. The sheared nanoparticles are not perfectly spherical, but contain many sharp angles. These sheared, hard SiO2 particles are further in contact with, and rubbing against the surfaces, causing more asperities [14]. The mechanisms of nanoparticles in the sliding bearing can be categorized as follows: (a) rolling and sliding on the surfaces, (b) polishing and shearing the partially embedded nanoparticles, and (c) the sheared nanoparticles filling the surface grooves (Fig. 4) [14]. On the other hand, in Fig. 3, it is observed that the friction temperature of the 0.0 wt% (pure ordinary oil) drops significantly after the bearing reaches a critical temperature of 130 °C (at nearly 60-min running time, where the permissible operating temperature range for bearings is −30 to 130 °C). This may be on account of the evaporating oil lubricant. As a consequence of oil
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Fig. 6 Graph of surface roughness of bearing before test Roughness value [um]
40.0 30.0 20.0 10.0 0.0 -10.0 -20.0 -30.0 -40.0 0.0
0.2
0.4
0.6
0.8
1.0
1.2
cut-off distance [mm]
2.0
Fig. 7 Graph of surface after test with neat lubricant (0.0 wt.%)
1.5
Roughness value [um]
1.0 0.5 0.0 -0.5 -1.0 -1.5 -2.0 -2.5 0.0
0.2
0.4
0.6 Cut-off distance [mm]
0.8
1.0
1.2
0.2
0.4
0.6 Cut-off distance [mm]
0.8
1.0
1.2
0.2
0.4
0.8
1.0
1.2
2.0
Fig. 8 Graph of surface after test with nanolubricant (0.1 wt.%)
1.5
Roughness value [um]
1.0 0.5 0.0 -0.5 -1.0 -1.5 -2.0 -2.5 -3.0 0.0
2.5
Fig. 9 Graph of surface after test with nanolubricant (0.2 wt.%)
2.0
Roughness value [um]
1.5 1.0 0.5 0.0 -0.5 -1.0 -1.5 -2.0 -2.5 0.0
0.6 Cut-off distance [mm]
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Fig. 10 Graph of surface after test with nanolubricant (0.5 wt.%)
1.0
Roughness value [um]
0.5 0.0 -0.5 -1.0 -1.5 -2.0 -2.5 -3.0 0.0
0.4
0.6 Cut-off distance [mm]
0.8
1.0
1.2
0.2
0.4
0.6 Cut-off distance [mm]
0.8
1.0
1.2
0.2
0.4
0.6 Cut-off distance [mm]
0.8
1.0
1.2
0.2
0.4
0.6
0.8
1.0
1.2
1.5 1.0
Roughness value [um]
Fig. 11 Graph of surface after test with nanolubricant (0.55 wt.%)
0.2
0.5 0.0 -0.5 -1.0 -1.5 -2.0 -2.5 0.0
4.0
Fig. 12 Graph of surface after test with nanolubricant (0.6 wt.%)
3.0
Roughness value [um]
2.0 1.0 0.0 -1.0 -2.0 -3.0 -4.0 -5.0 0.0
1.5
Fig. 13 Graph of surface after test with nanolubricant (0.8 wt.%) Roughness value [um]
1.0 0.5 0.0 -0.5 -1.0 -1.5 -2.0 -2.5 0.0
Cut-off distance [mm]
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0.5 0.4 0.3 0.2 0.1 0
Table 4 Comparison of surface roughness of bearing samples
1
2
3 4 5 Mixing ratio (wt%)
6
Bearing
Average Root-mean-square roughness, roughness, Rq Ra (μm) (μm)
Maximum different roughness, Rz (μm)
Raw (before test) 0.0 wt.% 0.1 wt.% 0.2 wt.% 0.5 wt.% 0.55 wt.% 0.6 wt.% 0.8 wt.%
3.35 0.32 0.28 0.27 0.18 0.22 0.30 0.25
17.91 1.95 1.68 1.71 1.18 1.51 1.99 1.54
7
Fig. 14 Graph of root-mean-square roughness (Ra) vs mixing ratio (wt%)
evaporation, the contact between the bearing surfaces increases, causing higher abrasion and wear rates. However, in case of using nanolubricant, much improvement is demonstrated, as the melting point of the solid nanoparticles is 1,600 °C. As a brief conclusion to the above results, in terms of friction temperature, the performance of sliding bearings ascends as follows: 0.5>0.55>0.6>0.2>0.0 wt%. 3.2 Wear characterization Bearing wear characteristics are determined, and the results are recorded and plotted as per Fig. 5. The outcome is discussed in two parts. First, wear represents damage to a solid surface, generally involving progressive loss of material due to the relative motion between a surface and a contacting substance(s) (ASTM40 Standard). A lower friction temperature of the bearing when using 0.5 wt.% nanolubricant signifies the least weight loss [15]. The nanolubricant forms thin, solid layers between the contacting surfaces and separates them. Lower surface contact causes less weight loss. Secondly, weight loss increases when the mixing ratios increase from 0.55 toward 0.8 wt.%, as the more numerous nanoparticles collide with each other and cause less nanoparticle deposition into surface grooves. Weight loss occurs when deposition is less than mass loss, something reported as a selfhealing deposition mechanism [9, 16]. That is, mass loss caused by friction and nanoparticle deposition onto the rubbing surfaces both exist. If wear was faster than deposition, loss of mass would occur [17, 18]. Otherwise, the weight of the bearing would increase. These findings are justified by the surface roughness results in Figs. 6, 7, 8, 9, 10, 11, 12, 13, and 14 and Table 4. The surface roughness is supposed to be smoother with increasing SiO2 percentage due to selfhealing deposition. However, it is not so, as the greater amounts of nanoparticles are colliding with each other and cause less deposition. This theory has also been reported in other research [11, 19]. The wear characterization results are in accordance with the friction temperature results. 3.3 Surface roughness The bearings are scanned with a profilometer. The surface of the inner, raw bearing race is considered a rough surface, whereby Ra=3.35 μm is recorded. The measured Ra of all
4.01 0.41 0.35 0.34 0.23 0.27 0.39 0.31
bearing surfaces range between 0.32 and 0.18 μm. The 0.5 wt% bearing showed the lowest average surface roughness (Ra=0.18 μm). The reduction of Ra is mainly attributed to abrasive wear and the potential material transfer [14]. Figures. 6, 7, 8, 9, 10, 11, 12, and 13 are important graphs that illustrate the surface conditions after the test. The surface in Fig. 6 (0.0 wt%) is very rough compared to the one in Fig. 10 (0.5 wt%). Numerous impedances and grooves exist on the surface, which cause wear and abrasiveness. However, Fig. 10 portray a more even surface. It has the lowest Ra value, which is mainly owing to the polishing effect of SiO2 nanoparticles. The sheared nanoparticles are embedded into the grooves. However, the surface roughness increases when the mixing ratio rises from 0.5 to 0.8 wt%. It is largely due to more nanoparticles colliding with each other and causing less deposition into the surface grooves.
4 Conclusions In this research work, a SiO2 nanolubrication system to be used in sliding bearings was developed. The following conclusions are drawn: 1. Optimum lubricity in terms of frictional temperature, wear rate, and surface roughness was found at 0.5-wt% nanolubricant. 2. The mechanisms of nanoparticles in the sliding bearing can be categorized as follows: (a) rolling and sliding on the surfaces, (b) polishing and shearing the partially embedded nanoparticles, and (c) the sheared nanoparticles filling the surface grooves. 3. Weight loss and surface roughness increase when the mixing ratio increases from 0.55 wt% upwards to 0.8 wt%, which can be explained by the larger amounts of nanoparticles that collide with each other and cause less deposition into the surface grooves.
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