An analytical friction model is presented, predicting the coefficient of friction in elastohydrodynamic (EHD) contacts. Three fully formulated SAE 75W-90 axle lubricants are examined. The effect of inlet shear heating (ISH) and starvation is accounted for in the developed friction model. The film thickness and the predicted friction are compared with experimental measurements obtained through optical interferometry and use of a mini traction machine. The results indicate the significant contribution of ISH and starvation on both the film thickness and coefficient of friction. A strong interaction between those two phenomena is also demonstrated, along with their individual and combined contribution on the EHD friction.
A tribo-dynamics model, predicting the conjunctional inefficiency and dynamic response of automotive hypoid gear pairs is presented. A dynamics model is coupled with an analytical friction model (viscous and boundary). The temperature rise at the centre of the conjunction is accounted for through use of thermal network model and Time Temperature Superposition (TTS) method, as well as the time varying geometry of the meshing gear teeth. Newtonian and non-Newtonian lubricant shear behaviour are both considered Surface topography measurements of a run-in pinions are obtained. Inefficiency calculations are performed for typical automotive drive cycle snapshots. Precisely measured lubricant shear characterstics for lubricants different blended viscosity modifiers and evolving surface topography are used in the study of transmission inefficiency. The integrated thermal-tribodynamic analysis is shown to distinguish between different viscosity modifier types, an approach not hitherto reported in literature.
It is anticipated that many future electrified vehicle transmissions and axles will incorporate the electric motor within the unit housing. In such an arrangement, the lubricant will be in direct contact with powered motor windings, which raises new concerns regarding its electrical conductivity and its propensity to corrode copper. The heat produced at the motor windings will challenge the lubricant's heat transfer ability and its thermal stability. Expected high temperature excursions warrant the use of new plastics, which may give rise to new compatibility concerns. In this paper we share our learnings regarding the electrical properties of lubricants and discuss new methods to characterize copper corrosion. We review the factors that affect the heat transfer characteristics of lubricants and illustrate how improving heat transfer will favor the use of lower viscosity lubricants. We also share our early efforts to quantify lubricant compatibility with higher temperature plastics using tensile strength measurements. Finally, we discuss how these new concerns will shift the perception of what is required for lubricants used in different types of electrified transmission hardware.
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