Technical and business transformations are reshaping the business of Diesel engine builders, Diesel lubricant marketers and additive companies. Key issues facing engine builders and end users under these transformations include: -Emission regulations -Vehicle operating costs -Evolving business environments With these challenges come opportunities. For equipment builders and lubricant marketers, these include: -Lubricants meeting global performance requirements -High value lubricant applications -Profitable new businesses

An experimental study was performed to discover the effect of environmental conditions on the rolling resistance behavior of pure silver and lead coated 52100 bearing steel. Pure silver and lead coating were produced by a thermal evaporation coating method. Experiments using a thrust ball bearing-typed rolling test-rig were performed under vacuum, dry air and controlled humidity conditions. Results showed that agglomeration of particles were prevented in vacuum environment and as it showed low and stable rolling resistance by shakedown phenomena. Also, humidity relates closely to the agglomeration of particles and increased the rolling resistance after the failure of coated layer.

The fretting wear characteristics of Zircaloy-4 tube in light water were investigated experimentally. A fretting wear tester was designed to be suitable for this fretting test. This study was focused on the effects due to the combination of normal load, slip amplitude and number of cycles as the main factors of fretting. The results of this study showed that the wear volume increased abruptly at slip amplitude above 100$\mu$m, which is defined as critical slip amplitude of Zircaloy-4 tube in light water, and that under 160$\mu$m the wear volume decreased as load increased at the same slip amplitude.

본 연구에서는 다양한 종류의 섬유를 일방향으로 배향시켜 제작한 복합재료의 트라이볼로지 연구를 수행하였으며 특히 섬유의 배향과 활주속도가 트라이볼로지 성질에 미치는 영향을 연구하였다. 실험에 쓰인 시편은 유리 섬유, 아라미드 섬유, 그리고 고탄성 탄소 섬유를 보강재료로 에폭시 수지를 모재로 사용한 일방향섬유 복합재료이며 각각의 시편을 스테인레스 강 상대 마찰면에 마찰시켜 마모량과 마찰 계수를 구하였다. 실험조건으로 사용한 여러 활주속도에서 탄소섬유복합재료가 모든 섬유배열방향에서 아라미드섬유복합재료와 유리섬유 복합재료보다 마모율과 마찰계수가 낮은 경향을 보였으며 특히 높은 속도에서는 탄소섬유복합재료의 특성이 뛰어남을 알 수 있었다.

A precision wear tester is developed to measure the wear rate of a high friction and high pressurized cylinder. The tester consists of indentor system and optical measuring system. The indentor system has two diamond indentors so that they make indents on the inside of the cylinder by using compressed air system. The X-Y-$\theta$ stage of the measuring system can trace the positions of the indents and can measure the diameters of them. The variation of the diameter of each indent after test is converted into the wear rate.

The Part of slot on rotary compressor which plays an important part of the reliability and performance is studied on machinability and the wear characteristics for the specimen made by sand mold and permanent mold. The experiment are used the face cutter of milling machine which make the processing surface like broaching process and rollblock wear test machine. Permanent-mold casting iron is not affected by variation of RPM of milling machine, but sand-mold cast-iron is improved to increasing RPM. Also sand-mold casting iron shows superior wear characteristic to permanent-mold casting iron. This results from harder matrix of pearlite structure and self-lubrication characteristics of graphite. And wear particles in tested oil show shape and size similar to severe wear particles of oil taken from rotary compressor. The material and surface condition of slot play important part of the reliability and performance.

The morphologies of the wear debris are directly indicative of wear processes occuring in machinery and their severity. The neural network was applied to identify friction condition from the lubricated moving system. The four parameter(50% volumetric diameter, aspect, roundness and reflectivity) of wear debris are used as inputs to the network and learned the friction coefficient. It is shown that identification results depend on the ranges of these shape parameter learned. The three kinds of the wear debris had a different pattern characteristic and recognized the friction condition and materials very well by neural network. We dicuss between the characteristic of wear debris and the friction coefficient and how the network determines difference in wear debris feature.

In recent years, the tribological behavior of coated ceramic material has been the topic of much interest. Particularly, the understanding of the tribological performance of thin film under light load is important for potential applications in MEMS. In this work under light load and low speed, the tribological behavior of coated silicon was investigated. The results show that both adhesive and abrasive wear occur depending on the sliding condition. Also the effect of humidity on friction was influenced by the apparent ares of contact between the two surfaces. Finally, undulations on the silicon wafer were found to be effective in trapping wear particles.

Three different kinds of brake discs including two coated brake discs and one steel disc were tested under the same experimental conditions on a reduced scale braking test bench. Braking test bench was specially designed to analyse thermo-mechanical and frictional behaviors of two sizes of brake discs in stop and hold braking modes. And Plasma spray coating technique was used to coat ceramic powder on the discs. In the test four commercial brake pads were coupled with discs. Ceramic coated discs had shown good stability in friction coefficient at high speed and high energy braking conditions. But they caused large pad mass wear loss compared with the steel disc. It was shown that thermal barrier effect in ceramic coated discs adjusted the thermal partition between pad and disc. For a steel disc, it had shown fluctuating friction coefficient at high speed but a fittie pad mass wear loss compared with ceramic coated discs.

The mechanical characteristics of the high speed steel by powder metallurgy process(PM-HSS) has been reported to improve with several alloying constituents, such as high carbon, vanadium and cobalt. In this paper, sliding wear test has been conducted using a pin-on-disc machine for three PM-HSS which contains 0%, 5% and 12% cobalt respectively, in order to evaluate the effect of cobalt on wear properties of PM-HSS. The results of this study showed that the wear resistance of PM-HSS has been increased by the addition of cobalt on the range of experimental friction velocities. When compared with the effect of addition of cobalt, the wear resistance of PM-HSS with 5% cobalt has been found to be superior to that of PM-HSS with 12% cobalt.

A $Si_3N_4$ tappet shim was devdoped in a direct OHC engine for the friction reduction of valve train system that contributes significantly to the engine friction in real driving condition. For commercializing $Si_3N_4$ tappet shim, it is important to reduce the machining cost. Therefore we analytically and experimentally figure out the optimum condition. Using ceramic tappet shims machined with different surface roughness, the effects of roughness on the friction loss were analyzed in view of the lubrication behavior. From this results it is shown that the friction torque of valve train system quickly drops at a certain surface roughness of ceramic tappet shim and its value remains constant despite further smoothing.

A mathematical model describing gear pump flow degradation in the presense of abrasive particles is presented. The model considers the operating parameters as Sommerfeld number, so that contamination sensitivity test results could be conversed to field application to predict contamination service life. A method to estimate the volumetric efficiency and the contamination level of a pump is proposed by measuring the temperature differences in the fluid. Test results show the validity of the theoretical establishments.

In this study, a numerical procedure to solve a contact problem has been developed. The procedure takes the advantage of signal processing technique in frequency domain to achieve the shorter computer processing time. The Boussinesq's equation was adopted as the response function. This procedure is applicable to the non-periodic surface profile as well as the periodic one. The validity of this procedure has been established by comparing the numerical results with the exact solutions. The effectiveness of this procedure is lied on the shorter computing time than any other contact analysis algorithm.

This paper addresses the R-curve properties, wear resistance, and erosion resistance of the two silicon carbide ceramics with different microstructures, i.e. , fine grained SiC and in situ-toughened SiC(IST SIC). Fine grained SiC exhibits a relatively flat R-curve behavior whereas the IST SiC exhibits a increasing R-curve behavior. The increasing R-curve behavior in IST SiC is attributed to relatively weak grain boundaries. The rate of material removal during wear tests and erosion tests was higher for IST SiC than that for fine grained SiC. This is attributed to the weaker grain boundaries in IST SiC than that in fine grained SiC. It is implied that fracture toughness in short crack regime should be taken into consideration in the interpretation of the microscopical material removal process. We show that the higher the strength of grain boundaries is, the higher wear and erosion resistances are.

The thermal deformation of the contact seal components has been analyzed using the finite element method. The temperature distributions, the thermal deformations and contact stresses are solved numerically for the contact surface with wear coning effects. The thermal deformation is always shown to distort the sealing surface along the radius of the seal ring. The results show that the deformations of inner radius side are significant compared with those of outer radius. Thus, the thermal deformation due to thermal heatings may promote the coned face wear or wear related thermal cracks at the contacting face of the seal ring component.

본 연구에서는 공기포일 베어링으로 지지된 로터 베어링 시스템을 구성하고 실험을 수행함으로써 시스템의 진동을 측정하고 그 결과를 해석함으로써 로터 베어링 시스템의 안정성 검토한다. 또, 초기 구동 마찰을 고려하여 공기윤활로만 구동되는 경우와 초기에 베어링 표면에 오일이 도포된 경우를 비교한다. Transient data를 해석 함으로써 로터 베어링 시스템의 startup 및 shutdown에 대한 특성 파악이 가능해지며 시스템의 동적 특성에 대한 더욱 정확한 해석을 가능케한다.

An algorithm of Thermal-elastohydrodynamic lubrication analysis for the piston ring is developed. This algorithm contains cavitation boundary condition so it automatically satisfies conservation of mass. 1-D Reynolds equation and 2-D energy equation are solved simultaneously by using Gauss-Jordan method and Newton-Raphson method. Minimum film thickness and friction force are calculated for 1 cycle. There is little difference between the results caculated by isothermal rigid and EHL analysis in entire cycle. In the results of THL, shear heating effect and temperature boundary condition affect the minimum film thickness and friction force prediction. The minimum film thickness and the friction force calculated by THL are lower than those caculated using isothermal assumption.

The processing conditions for the synthesis of platelet WS$_2$ lubricant powder through the solid-gas reaction were optimized. The tungsten and sulfur powders were sealed in a vacuum of 10$^{-6}$ torr, prior to heat-treating at 850$\circ$C for 8 days. The react~on product showed the well-developed platelet WS$_2$ powder with an average size of 3.8 $\mu$m. The synthesized WS$_2$ powder was coated on the commercial deep grooved ball bearing (No. 6203) to examine the effects of WS$_2$ coating layer on the noise and endurance of the ball bearing. The level of noise obtained from WS$_2$ coated-ball bearing was higher (56 dB) than the value occurred in the case of greece (37 dB). The life-time of the ball-bearing assembled after coating WS$_2$ powder increased 50 times compared to the non-coated bali-bearing.

This paper was undertaken to do shape analysis of wear debris on oiliness agent and extreme pressure agent. The lubricating wear test was performed under different experimental conditions using the wear test device was made in our laboratory and were- specimens of the pin on disk type was rubbed in paraffine series base oil by materials, varying applied load, sliding distance, oil additives such as stearine acid, DBDS, TCP. The four shape parameters (50% volumetric diameter, aspect, roundness and reflectivity) on a kind of the additives are different on applied load and sliding distance and Its are affected by absorbed film and reaction film. DBDS and TCP have a role of extreme pressure agent but a role of absorbed film of stearic acid decrease in high load. The maximum wear volume on applied load be in existence in three kinds of the specimens because of reaction characteristics of the additives.

A new bearing concept, the wave journal bearing, has been developed to improve the steady and dynamic performance of a hydrodynamic journal bearing. This concept features a wave in inner bearing surface. Not only straight but also twisted wave journal bearing are investigated numerically. The performances of straight and twisted bearings are compared to a plain journal bearing over a relatively wide range of eccentricity. The bearing load and stability characteristics are dependent on the geometric parameters such as the number of waves, the amplitude and the starting point of the wave relative to the applied load. The wave journal bearing, especially for the twisted one, offers better stability than the plain journal bearing under all eccentricity and all wave to load orientation.

Recently, according as the supply of power steering system has been diffused, for the comfortable driving condition, the problem to reduce the noise and vibration of this system suddenly appeared. This system can be classified two systems of the pipe line and the pump. In this paper, it is described about the noise characteristic with the camring profile of the hydraulic vane pump. As a result, when it excesses tolerance, the noise is increased. Moreover, in the case of the same of cam-ring, the effect of the rotating speed is larger than the discharge pressure.

This paper presents the deformation characteristics of cam ring in a balanced type vane pump. Cam ring is operated in the condition of high pressure. Therefore the local deformation of cam ring affects the characteristics of compression, vane motion and noise and vibration. We analyzed the deformation of cam ring in three types by using the finite element method. As results of analysis, deformed shape of cam ring and the effects of deformation on the compression are presented.

Reynolds equation, which describes behavior of fluid film in journal bearing, basically satisfies mass conservation. But, boundary conditions usually used with this equation, e.g. half Sommerfeld or Reynolds boundary conditions, cannot fulfill this natural law of conservation. In the case of connecting rod bearing, where applied load is dynamic and its magnitude is relatively large, such unrealistic boundary conditions have serious influence on calculation results, especially on lubricant flow rate or power dissipation which are important parameters in thermal analysis. Another important factor in the analysis of connecting rod bearing is elastic deformation of bearing support structure which is relatively flexible. In this paper, EHL analysis of connecting rod beating is performed using mass-conserving boundary condition. Elastic deformation of bearing support structure and application of mass-conserving boundary condition have significant effects on the performances of connecting rod bearing.

Present study is undertaken to optimize the lubrication reliability and frictional loss of the dynamically-loaded journal bearing in hermetic reciprocating compressor with alternative refrigerant R600a application. Thermodynamic and dynamic analysis has been conducted to investigate cylinder pressure variations by substitution alternative refrigerant R600a for R12. The modeling of the dynamics of the compressor mechanism has been performed with lumped mass method. A mathematical model is developed for analyzing the dynamics of the journal bearing system with the mobility method. It takes into account the effects of the refrigerant species, aspect ratio, clearance ratio and surface roughness. A corresponding computer program is described which enables to obtain the minimum film thickness and frictional loss. Design optimization is graphically performed by parametric studies of the aspect ratio and clearance ratio.

The aim of this paper is to study the characteristics of thermo-hydrodynamic lubrication in the bimetal bearings. Bimetal bearing is composed of lining and back metal. The THD model is proposed to calculate oil film temperature and pressure in the bimetal bearing. As results of analysis, comparative results of maximum bearing temperature are presented for the various materials and thickness of lining metal.

The inlet pressure build-up at the leading edge of bearings and its effects on the static performances are investigated theoretically. The performance analyses of air-lubricated tilting pad bearings are carried out considering the inlet pressure which is obtained by means of momentum conservation method. The results show that inlet pressure is above atmosphere pressure in front of leading edge of tilting pad bearing and there is a significant influence of the inlet pressure on the performance of bearings.

The traditional approach is to characterize the behavior and performance of fluid film hydrodynamic journal bearings by means of linearized bearing analysis. The objective of this paper is to examine the nonlinear characteristics of the journal bearing when an external sinusoidal shock is given to the system. The oil film force is obtained by solving the finite width Reynolds equation at each time step by the solution of the column method. Frequency response functions obtained from both linear and nonlinear bearing simulations are compared with each other.

To increase the efficiency of the hydraulic axial piston pumps, we have to know the various characteristics in the sliding parts of them. Especially, friction characteristics between the cylinder block and the valve plate in the hydraulic axial piston pumps plays an important role to high power density. In this paper, we tried to clarify friction characteristics between the cylinder block and the spherical valve plate in bent-axis-type axial piston pump by using of modeling experiment. The main results of this study are these; (1) Friction torque between the cylinder block and the spherical valve plate has a proportional relation to weight or rotational speed, and is strongly affected by temperature. (2) Friction torque strongly depends on force balance ratio. (3) In this experiment, lubrication condition between the cylinder block and the spherical valve plate is under hydrodynamic lubrication.

Many lubricated systems experience boundary, lubrication condition during operation. However, the friction and wear characteristics of boundary lubrication are not clearly understood. In this work the factors which affect the friction and wear between boundary lubricated metallic surfaces are investigated. Experiments were performed on atuminium, copper, and SM45C with bearing ball using a pin-on disk type tester. The experimental conditions were determined by Taguchi experimental method. From the experimental results, the major factors that influence the friction and wear characteristics of boundary lubrication could be identified.

상용화된 박막 코팅 자기 저장 디스크의 기계역학 및 윤활적 물성치를 도출하기 위하여 Nano-Indentation 과 Nano-Scratch 실험이 수행되었다. 자기 디스크는 원주방향으로 일정한의 분석을 위하여 AFM(Atomic Force Microscopy)이 사용되었다. 텍스처 방향에 따른 표면조도의 변화는 가우스 확률 분포(Gaussian probability distribution)와 Weibull누적 확률 이론(Weibull cumulative probability theory)에 의하여 분석되었다. 표면 조도와 마찰계수는 텍스처의 스캐닝(scanning) 방향에 의존한다는 것이 확인 되었다.

To apply the wear resistant steel plate for heavy duty vehicle, the wear characterisms of various kinds of commercial steel plates were invesigated by dry sand/rubber wheel tester which was tested under scratch abrasion mode. The wear tested pnaterials were boron steels which were manufactured by thereto machanical control process (TMCP) in order to achieve higher hardness. As the result of the test, wear resistance of steel plate increases with the hardness and carbon content. The wear loss of wear resistance steel plate (Hv440) is a half times than tinat of SWS490A (Hv160) steel plate in dry sand-rubber wheel test and the result in field test is similar to this dry sand/rubber wheel test result. Therefore, dry sand/rubber wheel tester can be used to predict the scratch abrasion life of the parts for heavy duty vehicle.

This paper presents the deformation characteristics of the moving pressure plate in a balanced type vane pump that widely used automotive power steering systems. Moving pressure plate can control the clearance between rotor and plate in accordance with load pressure variation; it always guarantees that pump to have optimal volumetric efficiency. In this paper, firstly, we calculate the acting force on the pressure plate, which is used to determine the angular position and load condition for analyzing the deformation of pressure plate. Secondary, finite element method is used for the deformation analysis. As results of acting force analysis, it is found that maximum difference of forces occurs at angular position 28$\circ$ from the small arc center of cam ring and load pressure is a dominant factor to affect acting force variation. The deformation of pressure plate increases as load pressure increases. At high load pressure, the deformation of pressure plate becomes larger than the initial clearance between rotor and plate. Therefore, it is required to design the plate for controlling the deformation.

The aim of this paper is to measure the tappet rotation in OHC valve train system. Tappet is eccentric from the cam center to rotate for preventing the partial wear. The experimental system is developed to measure the tappet rotation by using the laser beam and optical fiber. The characteristics of tappet rotation is presented for various operating conctitions. Specially, it is observed that tappet is rotated at the base circle.

Case hardening behavior of tool steel(SK5) was investigated after YAG laser irradiation. In the case of beam passes, martensite formed in the melt zone and in former pearlite regions of the austenization zone exhibited very high Vickers Hardness values. The molten depth and radius, micro structure, hardness were investigated as a function of defocusing distance, pulse width, and power density.

A high precision angular contact ball bearing is developed by Hanwha Machinery Co. The developed bearing is 7004C with P4 class. The performance test was succeful until 60,000 rpm.

This paper presents the experimental results of the friction characteristics of double lip-type oil seals which show an improvement in sealing performance over single lip-type oil seals. The major differences between two oil seals are the number of contact lip and seal materials; Nitrile Butadine Rubber(NBR) and urethane rubber. The measured results show that the friction torque of double lip seals shows 12-17% increases compared with those of single lip-type seals. But the sealing performance and service life of double tip oil seals have been increased and stabilized due to an optimized design of the seal lip and material properties.

Wear debris morphology is closely related to the wear mode and mechanism occured. Image recognition of wear debris is, therefore, a powerful tool in wear monitoring. But it has usually required expert's experience and the results could be too subjective. Development of automatic tools for wear debris recognition is needed to solve this problem. In this work, an algorithm for automatic wear debris recognition was suggested and implemented by PC base software. The presented method defined a characteristic 3-dimensional feature space where typical types of wear debris were separately located by the knowledge-based system and compared the similarity of object wear debris concerned. The 3-dimensional feature space was obtained from multiple feature vectors by using a multi-dimensional scaling technique. The results showed that the presented automatic wear debris recognition was satisfactory in many cases application.

This paper presented a case study on the application of on-line wear monitoring technique to a high duty air-turbo-compressor system. Main objects monitored were a gear unit and metal bearings, both shown frequent troubles due to the severe operation conditions at heavy dynamic load. The air-turbo-compressor system needs secure condition monitoring because it is one of the main utilities in steel making industry. Temperature and vibration characteristics have been mainly on-line monitored in this system for a predictive maintenance; however, it has been shown that they are not fairly good enough to give an early warning prior to the machine failure. In this work, an on-line Opto Magnetic Detector(OMD) was implemented for an on-line wear monitoring, which quantitatively measured the contamination level of both ferrous and non-ferrous wear particles by detecting the change in optical density of used oil. Results showed that the application of on-line OMD system was satisfactory in diagnosis of the machine system.

In this work, friction materials with three different formulations containing different amounts of the solid lubricants were investigated to study the role of lubricants on the friction performance. The three friction materials contained graphite 10 vol. %, graphite 7 vol. % + MoS$_2$ 3 vol.%, and graphite 7 vol. % + $Sb_2S_3$ 3 vol. %, respectively, with the same amount of other ingredients. Results of this work showed that each formulation with different lubricants had unique advantages and disadvantages. The friction materials containing graphite 7 vol. % + MoS$_2$ 3 vol. % and graphite 7 % + $Sb_2S_3$ 3 vol. % showed better resistance to fading and improved friction stability compare to the friction materials containing graphite only as a lubricant. However, the friction materials with two lubricants (graphite + MoS$_2$ or $Sb_2S_3$) showed disadvantages on stick-slip phenomena, amplitude of torque, and rotor wear.

In this study, the dynamic characteritics in various loading methods for wear tester were investigated experimentally. As for the dead-weight, the pneumatic, and the hydraulic method, the load control performance against external disturbances was estimated under the several loading conditions like the different sliding speed, the varied normal load, and the misaligument. The hydraulic loading method showed the most stable loading performance of all the loading methods in the experiment.

최근의 자동차엔진에서 사용되는 윤활유에는 여러 가지 첨가물이 사용된다. 특히 고분자량 폴리머계의 점도 지수 향상제를 윤활유의 원유에 첨가함으로써 온도 증가에 따른 점도 불안정성을 방지하는 다등급 윤활유 성격을 얻을 수 있다. 그러나 이러한 고분자량 폴리머계의 첨가물은 고온의 엔진 운전 조건에서 윤활유의 점도 안정성을 보장해줌에도 불구하고 엔진 부품들의 정상적인 운동 속도에서도($1-^6 S^{-1}$) 고 전단 변형율 속도로 인하여 유막 감소 효과를 발생 시킨다. 또한 이 첨가제들은 엔진 부품의 마찰 표면에 큰 전단 응력을 지닌 끈끈한 형태의 경계막을 형성한다. 고분자량 폴리머계의 점도 지수 향상제에 대한 예기치 못한 영향은 유막 감소 효과로 인하여 엔진 부품간의 마모를 증가 시키고 점도의 감소로 마찰을 감소 시키는 반면 경계막으로 인하여 고체면이 보호를 받는데 있다. 이러한 유막 형성의 물리적인 개념에 대하여 고체면의 끈끈한 경계막의 존재 효과와 두 경계막 사이에서 일어나는 유막 감소 효과를 표현할 수 있는 현실적인 해석의 필요성이 제기된다. 본 연구는 최근에 많이 쓰이고 있는 점도 향상제가 첨가된 윤활유가 자동차 밸브 트레인 시스템에서 유막 형성에 미치는 영향을 마찰 효율과 마모 방지의 입장에서 고찰하였다.