Name: Experiments on Ultrasonic Lubrication Using a Piezoelectrically-assisted Tribometer and Optical Profilometer (Video) | JoVE Journal
Uploaded: 2015-09-28T14:00:00.000+00:00
Duration: 9 min 21 s
Description: Learn ultrasonic lubrication methods using a modified pin on disc tribometer and optical profilometer. This technique reduces friction by up to 62% and wear by 49% across varying linear velocities.

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The authors would like to acknowledge Tim Krantz from NASA Glenn and Duane Detwiler from Honda R&#38;D for their technical support and in-kind contributions. Financial support for this research was provided by the member organizations of the Smart Vehicle Concepts Center (www.SmartVehicleCenter.org), a National Science Foundation Industry/University Cooperative Research Center (I/UCRC). S.D. is supported by a Smart Vehicle Concepts Graduate Fellowship and a University Fellowship from The Ohio State University Graduate School.

1. Development of the Modified Tribometer
<ol>
	<li>Install chuck-motor subsystem.
	<ol>
		<li>Level vibration isolation table. Place DC motor on the table; level the motor with shims and fix it with struts and bolts. Place support frame around the motor.</li>
		<li>Connect splined shaft to the motor shaft using a key. Put support plate on the frame with the splined shaft going through the hole in the plate. Set thrust needle-roller bearing on the support plate and around the splined shaft. Lubricate the bearing with cutting fluids.</li>
		<li>Connect the splined shaft to the chuck through an adapter plate, which has a splined shaft coupling on one side and the chuck&#8217;s bolt pattern on the other side. At this point, the chuck is supported by the frame through the thrust bearing and connected to the motor through the adapter plate.</li>
	</ol>
	</li>
	<li>Install the gymbal assembly.
	<ol>
		<li>Build the support frame using U-channel struts, brackets, and bolts. Use four long struts as pillars, and use three shorter ones as cross beams.</li>
		<li>Secure the four pillars to the vibration isolation table using brackets and bolts. Connect the gymbal assembly to the middle cross beam using bolts and nuts.</li>
		<li>Install a horizontally-oriented load cell in the gymbal assembly; rigidly connect one side of the load cell to the gymbal assembly&#8217;s frame, while connecting the other side to the gymbal arm with a wire.</li>
	</ol>
	</li>
	<li>Assemble the piezoelectric actuator.
	<ol>
		<li>Insert 3 in long, fully-threaded rod through the hole of the piezoelectric stack; put one washer and one nut at each end of the stack; leave about 1/8 in of thread protruding from the end of one nut.</li>
		<li>Tighten the nuts at both ends to create a preload in the stack. Connect the long, exposed threads to the gymbal arm using nuts and washers. Thread acorn nut onto the other end of the piezo-actuator and insert disc in the chuck (this acorn nut and disc are used for set-up purposes, not for testing).</li>
		<li>Adjust the height of the gymbal assembly so that the acorn nut is in contact with the top of the disc and the gymbal arm is level.</li>
		<li>Adjust the position of the gymbal assembly so that the contact point between the acorn nut and disc is about 25 mm away from the rotational center of the disc. Tighten all bolts in the set-up to ensure stability.</li>
	</ol>
	</li>
	<li>Set up signal generation, signal amplification, and data acquisition subsystems.
	<ol>
		<li>Connect data acquisition system to a lab computer. Connect the output of signal generator to the input of an electrical amplifier. Connect the amplifier output with the input wires of the piezoelectric stack. Connect the amplifier monitors to the data acquisition system.</li>
		<li>Connect the load cell to a signal conditioner, and then connect the output of the signal conditioner to the data acquisition system.</li>
	</ol>
	</li>
	<li>Additional set-up.
	<ol>
		<li>Connect air hose to shop air. Fix the end of the hose to the frame such that its outlet points at the piezo-actuator. Tape the tip of thermocouple to the piezo-actuator. Connect the thermocouple leads to reader; hang the reader on the frame.</li>
	</ol>
	</li>
</ol>
2. Pre-test Preparation
<ol>
	<li>Calibrate the rotational speed of the motor.
	<ol>
		<li>Attach magnet to the rim of the chuck. Place Hall-effect probe close to the chuck. Connect the output of the Hall-effect probe to gaussmeter that is connected to the data acquisition system.</li>
		<li>Open the data acquisition software and start data acquisition. Turn on the motor; turn the speed knob of the motor controller to 10 (the lowest rotational speed the motor provides). After the motor rotates for 10 revolutions, turn off the motor. End data acquisition.</li>
		<li>Analyze the saved data; the time between two peaks of the output signal from the gaussmeter is the time for the motor to rotate one full revolution.</li>
		<li>Turn the knob from 10 to 100 (the highest rotational speed the motor provides) in increments of 10; repeat steps 2.1.2 to 2.1.3.</li>
	</ol>
	</li>
	<li>Place load sensor pad between the acorn nut and the disc to measure the normal force at the interface. Finely machine the surface of testing discs using a lathe.</li>
	<li>Clean the acorn nut and disc to be tested immediately before test.
	<ol>
		<li>Put on plastic gloves and face mask.Prepare pieces of lab wipes; fold them into 1 inch squares. Spray ethanol on the tissue squares; gently wipe the surface of the acorn nut and disc with them.</li>
	</ol>
	</li>
	<li>Install the clean acorn nut and disc.
	<ol>
		<li>Thread the acorn nut onto the piezo-actuator, tighten it with an open-end wrench. Insert the disc in the chuck; adjust the position to make sure the tip of the acorn nut is in contact with the disc surface.</li>
		<li>Align the top surface of the disc and the gymbal arm. Tighten the chuck so that the disc is held firmly.</li>
	</ol>
	</li>
	<li>Measure the runout of the disc rotation.
	<ol>
		<li>Install laser displacement sensor in a fixture, and place the fixture next to the tribometer. Adjust the height and angle of the sensor so that the disc is within the sensor&#8217;s range and the laser beam is normal to the disc.</li>
		<li>Connect the sensor&#8217;s output to the data acquisition system. Start the data acquisition. Turn on the motor and rotate the disc for 10 revolutions; turn off the motor. End data acquisition.</li>
	</ol>
	</li>
</ol>
3. Perform Testing
<ol>
	<li>Tests with ultrasonic vibrations.
	<ol>
		<li>Hang 2 N weight on one hook that connects to the gymbal arm through wire and two pulleys. The weight is used to apply a normal load between the acorn nut and the disc.</li>
		<li>Hang another 2 N weight on the other hook that connects to the gymbal arm to provide a horizontal pretension to the load cell.</li>
		<li>Set the signal generator to provide a continuous sinusoidal signal with DC offset of 3 V, amplitude of 3 V, and frequency of 22 kHz (the resonance frequency of the piezo-actuator). Note that the 3 V offset is used to prevent tension in the piezo-actuator.</li>
		<li>Start data acquisition (reduced friction force). Turn on the amplifier and turn the gain knob to 15, which corresponds to an actual gain of 4.67 (the numbers on the gain knob are arbitrary).</li>
		<li>Turn on the motor; set the rotational speed to 6.67 rpm to provide a linear velocity of 20.3 mm/sec. Run the test for 4 hr.</li>
		<li>Turn off the motor and amplifier, and then stop the data acquisition. Remove the tested acorn nut and disc from the set-up; Repeat steps 2.3 to 2.5 to install new acorn nut and disc.</li>
		<li>Repeat steps 3.1.1&#160;to 3.1.6. In step 3.1.5, set the rotational speed to 13.3 rpm and 28.7 rpm to provide linear velocities of 40.6 mm/sec and 87 mm/sec, respectively; run the tests for 2 and 0.94 hr&#160;correspondingly.</li>
	</ol>
	</li>
	<li>Tests without ultrasonic vibrations.
	<ol>
		<li>Repeat step 3.1.6 to change acorn nuts and discs. Repeat steps 3.1.1&#160;to 3.1.6 with the signal generator and signal amplifier off (the friction measured is intrinsic friction ).</li>
	</ol>
	</li>
</ol>
4. Optical Profilometer Measurements
<ol>
	<li>Measurement preparation
	<ol>
		<li>Clean the discs immediately before measurements using step 2.3. Make eight evenly distributed marks around the rim of the disc. Open the profilometer software.</li>
		<li>Raise the lens so that there is sufficient clearance between the lens and sample platform. Level the sample platform. Place a piece of lab wipe on the platform.</li>
		<li>Gently place the sample on top of the tissue with one of the eight marks facing the front of the profilometer.</li>
	</ol>
	</li>
	<li>Measurement settings.
	<ol>
		<li>Choose VSI (Vertical-Scanning Interferometry) as the processing type. Select 5X lens for large field of view and overall shape. Pick 0.55X magnification for a scan area of 1.8 mm by 2.4 mm.</li>
		<li>Choose 1X scan speed. Set scan range to -100 m to 100 m. Bring the lens downward toward the sample until there is a blurry image on the screen. Adjust the height of the lens until the image is clear.</li>
		<li>Choose 2 as the number of scans to average for each measurement. Click the measurement button.</li>
	</ol>
	</li>
	<li>Post-measurement procedures.
	<ol>
		<li>Use the vision recipe that defined in the software to correct the raw image for tilt of the whole sample. Open the analysis toolbox in the software.</li>
		<li>Obtain the measured roughness values from the &#8220;Basic Stats&#8221; item. Obtain the measured volume loss of the wear scar within the scan area from the &#8220;Volume&#8221; item.</li>
		<li>Save the images of 1D profiles in x and y directions, the 2D profile, the 3D profile, as well as the table of roughness values. Turn the sample clockwise until the next mark faces the front of the profilometer.</li>
	</ol>
	</li>
	<li>Repeat steps 4.2&#160;to 4.3&#160;for the remaining 7 marks.</li>
	<li>Repeat steps 4.1.&#160;to 4.4 on all six discs.</li>
</ol>

<ol><li>Bhushan, B. <a target="_blank" href="http://scholar.google.com/scholar?hl=en&safe=off&q=author%3aBhushan%2C+B+%22Introduction+to+tribology%22">Introduction to tribology</a>. , John Wiley & Sons. New York. (2002).</li>
<li>Severdenko, V., Klubovich, V., Stepanenko, A. <a target="_blank" href="http://scholar.google.com/scholar?hl=en&safe=off&q=author%3aSeverdenko%2C+V+%22Ultrasonic+rolling+and+drawing+of+metals%22">Ultrasonic rolling and drawing of metals</a>. , Consultants Bureau. New York and London. (1972).</li>
<li>Taylor, R., Coy, R. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Improved+fuel+efficiency+by+lubricant+design%3A+a+review%5BTitle%5D)+AND+%22Proc.+Instit.+Mech.+Eng.%2C+Part+J%3A+J+Eng.+Tribol%22%5BJournal%5D)">Improved fuel efficiency by lubricant design: a review.</a> Proc. Instit. Mech. Eng., Part J: J Eng. Tribol. 214 (1), 1-15 (2000).</li>
<li>Littmann, W., Storck, H., Wallaschek, J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Sliding+friction+in+the+presence+of+ultrasonic+oscillations%3A+superposition+of+longitudinal+oscillations%5BTitle%5D)+AND+%22Arch.+Appl.+Mech%22%5BJournal%5D)">Sliding friction in the presence of ultrasonic oscillations: superposition of longitudinal oscillations.</a> Arch. Appl. Mech. 71 (8), 549-554 (2001).</li>
<li>Littmann, W., Storck, H., Wallaschek, J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Reduction+in+friction+using+piezoelectrically+excited+ultrasonic+vibrations%5BTitle%5D)+AND+%22Proc.+SPIE%22%5BJournal%5D)">Reduction in friction using piezoelectrically excited ultrasonic vibrations.</a> Proc. SPIE. 4331, (2001).</li>
<li>Bharadwaj, S., Dapino, M. J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Friction+control+in+automotive+seat+belt+systems+by+piezoelectrically+generated+ultrasonic+vibrations%5BTitle%5D)+AND+%22Proc.+SPIE%22%5BJournal%5D)">Friction control in automotive seat belt systems by piezoelectrically generated ultrasonic vibrations.</a> Proc. SPIE. 7645, 7645E(2010).</li>
<li>Bharadwaj, S., Dapino, M. J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Effect+of+load+on+active+friction+control+using+ultrasonic+vibrations%5BTitle%5D)+AND+%22Proc.+SPIE%22%5BJournal%5D)">Effect of load on active friction control using ultrasonic vibrations.</a> Proc. SPIE. 7290, 7290G(2010).</li>
<li>Kumar, V., Hutchings, I. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Reduction+of+the+sliding+friction+of+metals+by+the+application+of+longitudinal+or+transverse+ultrasonic+vibration%5BTitle%5D)+AND+%22Tribol.+Int%22%5BJournal%5D)">Reduction of the sliding friction of metals by the application of longitudinal or transverse ultrasonic vibration.</a> Tribol. Int. 37 (10), 833-840 (2004).</li>
<li>Pohlman, R., Lehfeldt, E. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Influence+of+ultrasonic+vibration+on+metallic+friction%5BTitle%5D)+AND+%22Ultrasonics%22%5BJournal%5D)">Influence of ultrasonic vibration on metallic friction.</a> Ultrasonics. 4 (4), 178-185 (1966).</li>
<li>Popov, V., Starcevic, J., Filippov, A. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Influence+of+Ultrasonic+In-Plane+Oscillations+on+Static+and+Sliding+Friction+and+Intrinsic+Length+Scale+of+Dry+Friction+Processes%5BTitle%5D)+AND+%22Tribol.+Lett%22%5BJournal%5D)">Influence of Ultrasonic In-Plane Oscillations on Static and Sliding Friction and Intrinsic Length Scale of Dry Friction Processes.</a> Tribol. Lett. 39 (1), 25-30 (2010).</li>
<li>Dong, S., Dapino, M. J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Piezoelectrically-induced+ultrasonic+lubrication+by+way+of+Poisson+effect%5BTitle%5D)+AND+%22Proc.+SPIE%22%5BJournal%5D)">Piezoelectrically-induced ultrasonic lubrication by way of Poisson effect.</a> Proc. SPIE. 8343, 83430L(2012).</li>
<li>Dong, S., Dapino, M. J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Elastic-plastic+cube+model+for+ultrasonic+friction+reduction+via+Poisson+effect%5BTitle%5D)+AND+%22Ultrasonics%22%5BJournal%5D)">Elastic-plastic cube model for ultrasonic friction reduction via Poisson effect.</a> Ultrasonics. 54 (1), 343-350 (2014).</li>
<li>Dong, S., Dapino, M. J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Wear+Reduction+Through+Piezoelectrically-Assisted+Ultrasonic+Lubrication%5BTitle%5D)+AND+%22Smart.+Mater.+Struct%22%5BJournal%5D)">Wear Reduction Through Piezoelectrically-Assisted Ultrasonic Lubrication.</a> Smart. Mater. Struct. 23 (10), 104005(2014).</li>
<li>Chowdhury, M., Helali, M. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((The+effect+of+frequency+of+vibration+and+humidity+on+the+wear+rate%5BTitle%5D)+AND+%22Wear%22%5BJournal%5D)">The effect of frequency of vibration and humidity on the wear rate.</a> Wear. 262 (1-2), 198-203 (2014).</li>
<li>Bryant, M., Tewari, A., York, D. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Effect+of+Micro+%28rocking%29+vibrations+and+surface+waviness+on+wear+and+wear+debris%5BTitle%5D)+AND+%22Wear%22%5BJournal%5D)">Effect of Micro (rocking) vibrations and surface waviness on wear and wear debris.</a> Wear. 216 (1), 60-69 (1998).</li>
<li>Bryant, M., York, D. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Measurements+and+correlations+of+slider+vibrations+and+wear%5BTitle%5D)+AND+%22J.+Tribol%22%5BJournal%5D)">Measurements and correlations of slider vibrations and wear.</a> J. Tribol. 122 (1), 374-380 (2000).</li>
<li>Goto, H., Ashida, M., Terauchi, Y. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Effect+of+ultrasonic+vibration+on+the+wear+characteristics+of+a+carbon+steel%3A+analysis+of+the+wear+mechanism%5BTitle%5D)+AND+%22Wear%22%5BJournal%5D)">Effect of ultrasonic vibration on the wear characteristics of a carbon steel: analysis of the wear mechanism.</a> Wear. 94, 13-27 (1984).</li>
<li>Goto, H., Ashida, M., Terauchi, Y. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Wear+behaviour+of+a+carbon+steel+subjected+to+an+ultrasonic+vibration+effect+superimposed+on+a+static+contact+load%5BTitle%5D)+AND+%22Wear%22%5BJournal%5D)">Wear behaviour of a carbon steel subjected to an ultrasonic vibration effect superimposed on a static contact load.</a> Wear. 110 (2), 169-181 (1986).</li>
<li>Robinowicz, E. <a target="_blank" href="http://scholar.google.com/scholar?hl=en&safe=off&q=author%3aRobinowicz%2C+E+%22The+friction+and+wear+of+materials%22">The friction and wear of materials</a>. , Wiley. New Jersey. (1965).</li>
<li>Bowden, F., Freitag, E. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((The+friction+of+solids+at+very+high+speeds%5BTitle%5D)+AND+%22Proc.+R.+Soc.+A%22%5BJournal%5D)">The friction of solids at very high speeds.</a> Proc. R. Soc. A. 248 (1254), 350-367 (1985).</li>
<li>Burwell, J., Rabinowicz, E. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((The+nature+of+the+coefficient+of+friction%5BTitle%5D)+AND+%22J.+Appl.+Phys%22%5BJournal%5D)">The nature of the coefficient of friction.</a> J. Appl. Phys. 24 (2), 136-139 (1953).</li>
<li>Cocks, M. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/pubmed?term=((Interaction+of+sliding+metal+surfaces%5BTitle%5D)+AND+%22J.+Appl.+Phys%22%5BJournal%5D)">Interaction of sliding metal surfaces.</a> J. Appl. Phys. 33 (7), 2152-2161 (1962).</li>
<li>Rusinko, A. <a target="_blank" href="http://scholar.google.com/scholar?hl=en&safe=off&q=author%3aRusinko%2C+A+%22Ultrasound+and+Irrecoverable+Deformation+in+Metals%22">Ultrasound and Irrecoverable Deformation in Metals</a>. , LAP Lambert Academic Publishing. Saarbrücken. (2012).</li>
</ol>

The authors have nothing to disclose.

Experiments were conducted using this protocol to study the effect of linear speed on ultrasonic friction and wear reduction. The measurements show that ultrasonic vibrations effectively reduce friction and wear at three linear speeds.&#160;Consistent with prior observations, the amount of friction reduction decreases from 62.2% at 20.3 mm/sec to 29.3% at 87 mm/sec. Wear reduction is negligible with changing linear speed (45.8% to 48.6%).
Material properties such as Young&#8217;s modulus and y...

Friction exists at the interface of two contacting surfaces when they slide or roll relative to each other. Friction usually occurs along with abrasive or adhesive wear.1 Ultrasonics is the science behind high frequency phenomena, that is, waves traveling at frequencies above the acoustic range (20 kHz). The field of ultrasonics encompasses two fundamentally different regimes. One regime involves low intensity waves like those utilized in imaging processes such as medical ultrasound or non-destructive inspection of structures. The other is a high power regime in which high-energy waves are utilized to execute or assist engineering processes such as welding of plastics and metals. It has been shown that application of the latter kind of ultrasonic vibrations at the interface of two surfaces in sliding contact reduces the effective friction force at the interface. This phenomenon is known as ultrasonic lubrication.
To achieve ultrasonic lubrication between two sliding objects, relative vibration at ultrasonic frequencies must be established between them. Vibrations are typically applied to one of the two objects, either in the longitudinal, transverse, or perpendicular direction relative to the sliding velocity. In this study, a tribometer&#8217;s pin is fitted with a piezoelectric actuator so that its tip vibrates in the direction perpendicular to the tribometer&#8217;s rotating disc. Piezoelectric materials are a class of &#8220;smart&#8221; materials that deform when exposed to electric fields, vibrating at the same frequency as the excitation field. Piezoelectric materials can vibrate at frequencies well into the MHz range. Being superimposed to the macroscopic velocity, ultrasonic vibrations have the effect of alternating the direction of the instantaneous friction force and the contact between the surfaces, which in combination leads to a reduction of the effective friction force and surface wear.
Ultrasonic friction reduction has been demonstrated in practical manufacturing systems. For example, this technology has been utilized to reduce the force between tool and work piece in metal machining and forming processes such as drilling, pressing, sheet rolling, and wire drawing. Benefits include improved surface finish2 and a reduced need for expensive and environmentally harmful detergents to remove lubricants from the final product. There are potential applications of ultrasonic lubrication in other areas as well. For example, ultrasonic lubrication can substantially enhance the user experience in personal health care products by eliminating the need for lubricants or coatings. In automobile applications, friction modulation can improve the performance of ball joints whereas friction reduction between vehicle seats and rails facilitates seat movement, saving space and mass that would otherwise be occupied by traditional components and mechanisms. Ultrasonic lubrication can also help to improve fuel efficiency by reducing friction in powertrain and suspension systems.3 In space applications, where traditional lubricants cannot be used, ultrasonic lubrication can be employed to reduce wear and dramatically extend the life of critical components.
Laboratory demonstrations of friction reduction through ultrasonic lubrication are numerous. Friction reduction is quantified as the difference between the friction force measured without ultrasonic lubrication and the friction force with ultrasonic vibrations applied. In either case, the friction force is directly measured with force sensors. Littmann et al. 4-5 connected a piezoelectrically-driven actuator to a slider, on which a force sensor and a frame were installed for measuring friction forces and applying normal loads. A pneumatic actuator was employed to push the slider together with the actuator along a guide rail. Ultrasonic vibrations were applied in the direction longitudinal to the sliding velocity. Bharadwaj and Dapino6-7 conducted similar experiments using a piezoelectric stack actuator connected to a conical waveguide at either end of the stack. Contacts took place between the spherical edges of the cones and the surface of the guide rail. The effects of system parameters such as contact stiffness, normal load, and global stiffness were studied. Kumar and Hutchings8 installed a pin on a sonotrode which was energized by an ultrasonic transducer. Ultrasonic vibrations were generated and transmitted to the pin, which was placed in contact with a tool steel surface. Normal force was applied by a pneumatic cylinder and measured by a load cell. The relative motion between the pin and the disc was created by a reciprocating table.
Pohlman and Lehfeldt9 also implemented a pin-on-disc experiment. Unlike other studies, they employed a magnetostrictive transducer to generate ultrasonic vibrations. To study the optimum direction for ultrasonic friction reduction, the transducer was carefully aligned so that the vibrational direction was longitudinal, transverse, and vertical to the macroscopic velocity. They studied ultrasonic friction reduction on both dry and lubricated surfaces. Popov et al.10 utilized an actuator with conical waveguides. The actuator was placed in contact with a rotating base plate. Cones made of nine materials with various hardnesses were adopted to study the influence of material hardness on ultrasonic friction reduction. Dong and Dapino11-13 used a piezoelectric transducer to generate and transmit ultrasonic vibrations to a prismatic waveguide with rounded edges. The longitudinal vibration causes vertical vibration due to Poisson&#8217;s effect. A slider with a curved top was placed under and in contact the waveguide. A frame was built to apply normal forces at the contact interface. The slider was pulled manually around the center area of the waveguide; the friction force was measured by a load cell that was connected to the slider.
Ultrasonically-induced wear reduction was also investigated and demonstrated. Volume loss, weight loss, and surface roughness changes are employed to quantify the severity of wear.Chowdhury and Helali14 vibrated a rotating disc in a pin-on-disc setup. The vibrations were generated by a support structure of two parallel plates located under the rotating disc. The top plate has a spherical ball installed off-center on the bottom surface, which slides in a slot that was engraved at the top surface of the bottom plate. The slot was machined with a periodically variable depth so that the top plate moves vertically during rotation. The frequencies ranged around 100 Hz according to the rotational speed.
Bryant and York15-16 studied the effect of micro-vibrations on wear reduction. They inserted a carbon cylinder through a holder with one end rested on a spinning steel disc and the other end connected to a coil spring. In one case, the cylinder was snug fitted in the holder so that there was no space for vibration. In other cases, clearances were left to allow micro-vibrations of the cylinder while the cylinder was in contact with the spinning disc. The weight loss of the cylinder was measured to calculate the wear rate. It was shown that the self-generated micro-vibrations helped reduce wear by up to 50%.
Goto and Ashida17-18 also adopted a pin-on-disc experiment. They connected pin samples with a transducer via a tapered cone and a horn. The pin vibrated in the direction perpendicular to the disc surface. A mass was connected to the transducer on its top for applying normal loads. Friction forces were translated from the torque that was applied to rotate the disc. Wear was identified as adhesive because both pin and disc were made of carbon steel. Wear rates were calculated from volume loss measurements.
It has been shown that linear speed plays an important role in ultrasonic lubrication. The experimental component of this research focuses on the dependence of friction and wear reduction on linear speed.

<table><tbody><tr><td>DC Motor&amp;nbsp;</td><td>Minarik&amp;nbsp;</td><td>SL14</td><td></td></tr><tr><td>Electrical amplifier</td><td>AE Techron</td><td>LVC5050</td><td></td></tr><tr><td>Signal conditioner&amp;nbsp;</td><td>Vishay Measurements Group</td><td>2310</td><td></td></tr><tr><td>Signal generator</td><td>Agilent&amp;nbsp;</td><td>33120A</td><td></td></tr><tr><td>Piezoelectric stack</td><td>EDO corporation</td><td>EP200-62</td><td></td></tr><tr><td>Load cell</td><td>Transducer Techniques</td><td>MLP-50</td><td></td></tr><tr><td>Load sensor pad</td><td>FlexiForce</td><td>A201</td><td></td></tr><tr><td>Laser meter</td><td>Keyence corporation&amp;nbsp;</td><td>LK-G32</td><td></td></tr><tr><td>Hall-effect probe and gaussmeter</td><td>Walker Scientific, Inc.</td><td>MG-4D</td><td></td></tr><tr><td>Data acquisition module</td><td>Data Physics</td><td>Quattro</td><td></td></tr><tr><td>Data acquisition software</td><td>Data Physics</td><td>SignalCalc Ace</td><td></td></tr><tr><td>Thermocouple reader</td><td>Omega</td><td>HH22</td><td></td></tr><tr><td>Optical profilometer</td><td>Bruker</td><td>Contour GT</td><td></td></tr><tr><td>Profilometer operation software</td><td>Bruker&amp;nbsp;</td><td>Vision 64</td><td></td></tr></tbody></table>

experiments on ultrasonic lubrication using a piezoelectrically-assisted tribometer and optical profilometer

Experiments on Ultrasonic Lubrication Using a Piezoelectrically-assisted Tribometer and Optical Profilometer

Friction and wear are detrimental to engineered systems. Ultrasonic lubrication is achieved when the interface between two sliding surfaces is vibrated at a frequency above the acoustic range (20 kHz). As a solid-state technology, ultrasonic lubrication can be used where conventional lubricants are unfeasible or undesirable. Further, ultrasonic lubrication allows for electrical modulation of the effective friction coefficient between two sliding surfaces. This property enables adaptive systems that modify their frictional state and associated dynamic response as the operating conditions change. Surface wear can also be reduced through ultrasonic lubrication. We developed a protocol to investigate the dependence of friction force reduction and wear reduction on the linear sliding velocity between ultrasonically lubricated surfaces. A pin-on-disc tribometer was built which differs from commercial units in that a piezoelectric stack is used to vibrate the pin at 22 kHz normal to the rotating disc surface. Friction and wear metrics including effective friction force, volume loss, and surface roughness are measured without and with ultrasonic vibrations at a constant pressure of 1 to 4 MPa and three different sliding velocities: 20.3, 40.6, and 87 mm/sec. An optical profilometer is utilized to characterize the wear surfaces. The effective friction force is reduced by 62% at 20.3 mm/sec. Consistently with existing theories for ultrasonic lubrication, the percent reduction in friction force diminishes with increasing speed, down to 29% friction force reduction at 87 mm/sec. Wear reduction remains essentially constant (49%) at the three speeds considered.

The representative measurements presented here were obtained from the modified tribometer shown in Figure 1. The piezoelectric actuator generates vibrations with amplitude of 2.5 μm at a frequency of 22 kHz. To study the dependence of friction and wear reduction on linear velocity, three different speeds (20.3, 40.6, and 87 mm/sec) were applied to the disc by changing the rotational speed of the motor. For all three groups, the number of disc revolutions and the travel distance of the pin were chosen as ...

We present a protocol for using a piezoelectrically-assisted tribometer and optical profilometer to investigate the dependence of ultrasonic wear and friction reduction on linear velocity, contact pressure, and surface properties.

Friction and wear are detrimental to engineered systems. Ultrasonic lubrication is achieved when the interface between two sliding surfaces is vibrated at ...

The overall goal of the following experiment is to investigate the dependence of friction and wear reduction on linear velocity in ultrasonic lubrication. This is achieved by first conducting tests on a modified pin on disc TER while recording real-time friction forces during the tests as a second step, an optical profilometer is utilized to characterize wear, providing 2D and 3D profiles, surface roughness and volume losses in the grooves. Next, friction and wear reduction at three.Linear velocities are quantified using measured friction forces and calculated wear rates. The results show that ultrasonic lubrication reduces effective friction force by up to 62%and surface wear by up to 49%Friction reduction decreases as linear velocity increases while wear reduction remains essentially constant at the three linear velocities. Considered Ultrasonic lubrication is a well-established technology for reducing and in fact controlling the effective friction coefficient between sliding objects.It works by vibrating one or both objects at ultrasonic frequencies that is frequencies above 20 kilohertz. Ultrasonic lubrication has been implemented in manufacturing processes such as extrusion and a wire drawing being a solid state lubrication technology. It can be used in applications where traditional lubricants are undesirable.For example, in space To build the necessary TER first, assemble the chuck motor subsystem, perform this assembly on an isolation table. First level, a DC motor with shims and fix its position using struts and bolts. Then position the support frame around the motor.Next, connect the spline shaft to the motor shaft using a key continue by sliding the support plate onto the spline shaft. Then position the thrust needle roller bearing on the support plate. Lubricate the bearing with cutting fluids if needed, to finish assembling the chuck motor subsystem.Connect the chuck to an adapter plate using three bolts and tighten the bolts. Place the chuck on the support plate through the thrust needle roller bearing. Put the gimbal assembly with the support frame in place.It has a horizontally oriented load cell connected to the gimbal arm by a wire to measure friction. Next, assemble the piso electric actuator. First, insert a three inch threaded rod through the Piso electric stack.Secure it with washers and nuts, leaving about one eighth inch of the rod available at one end. Then tighten the nuts to preload the stack. Next, connect the long exposed threads to the gimbal arm using nuts and washers.Thread an acorn nut onto the other end of the piso actuator for setup purposes, non-testing. Then insert the disc to the chuck and adjust the position of the disc so that the acorn nut is in contact with the top of the disc and the gimbal arm is level. Adjust the position of the gimbal assembly so the nut contacts the disc at about 25 millimeters from the disc's center.To finish, tighten all the bolts in the setup and attach the setup to the computer. The testing discs and nuts must be cleaned wearing gloves. Use ethanol to clean the surface of the testing disc and the acorn nut.Now remove the acorn nut used for setup purposes. Then thread on the new clean nut and firmly tighten it down. Once tightened, check the alignment and tighten the chuck so the disc is firm and make sure the acorn nut is firmly tightened to the actuator.It is critical to firmly tighten the acorn nut to the epi electric actuator, or it could become loose during the test resulting in the ultrasonic vibrations not being transmitted and thus becoming ineffective. To set up the test, apply a normal load between the test nut and disc by hanging a two newton weight on one hook that connects to the gimbal arm. Then hang another two Newton weight on the other hook that connects to the gimbal arm.This provides a horizontal pretension to the load cell. Next, connect the actuator and the signal generator to the amplifier. Set the signal generator to provide a continuous sinusoidal signal.Use an amplitude of three volts and a frequency of 22 kilohertz. The resonance frequency of the piso actuator include a DC offset of three volts to prevent tension in the pizo actuator. Now start collecting data to measure the reduced friction force.Turn on the amplifier and set the gain to 15, which corresponds to an actual gain of 4.67. Next, turn on the motor and set the rotational velocity as needed. Run the test for three hours, then turn off the motor and amplifier and end the data acquisition.Remove the acorn nut and test disc and label the test disc with the test conditions. Always use a new nut and test surface for each test. To measure the intrinsic friction, use the same linear velocity with the amplifier and signal generator off.Repeat the same testing for other linear velocities. There should be six wear grooves created in the end. In preparation, clean the test discs immediately before measurements.As before, It is important to clean the sample discs before perter measurements, and you loosely attach the wear particles or foreign matter on the wear groove. Were compromised the position of the measured profiles and volume loss. Next, make eight evenly distributed marks around the rim of the disc.Now open the profilometer software using the software. Raise the lens so that there is sufficient clearance between the lens and the sample platform. Then level the sample platform and place a piece of lab wipe on the platform.Gently place the sample on top of the tissue with one of the eight marks facing the front of the barometer. Set up scanning parameters in the software. Scan the groove and save the profile images and roughness data.Then turn the sample counterclockwise until the next mark faces the front of the profilometer and repeat the process for the remaining marks. Once done with one disc, repeat the measurements for the remaining five discs. The friction force was sampled at 400 hertz using two second sampling windows mean values of measured friction were calculated and plotted against the distance the pin travels.Intrinsic friction forces are represented with dots while friction forces with ultrasonic vibrations are shown. With xs, friction force remained virtually constant once a steady state operation was achieved. Next, the reduction percentage at each linear velocity was plotted against the distance traveled by the pin.Ultrasonic vibrations reduced the steady state friction force at each tested linear velocity. However, the benefits decreased as the linear velocity increased where grooves with and without ultrasonic vibrations were compared. It can be seen that grooves appear more uneven and non-reflective when ultrasonic vibrations were applied.3D profiles, surface roughness values and volume losses of the grooves were obtained from the profilometer scans. The 3D grooves with ultrasonic vibrations were narrow, rough, and shallow when compared to those without ultrasonic vibrations. This supports the notion that the ultrasonic vibrations reduce wear, wear rates and surface roughness parameters were smaller when ultrasonic vibrations were present, which is also an indicator of wear reduction.The wear reduction percentage remained virtually constant as the velocity increased. After watching this video, you should have a good understanding of how to conduct ultrasonic lubrication tests on a modified pin on disc ter and characterize where using optical prophy Using this ultrasonic friction and wear reduction can be studied with respect to not just linear velocity, but also key parameters such as normal stress, material combinations, and ultrasonic power consumption.

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Learn ultrasonic lubrication methods using a modified pin on disc tribometer and optical profilometer. This technique reduces friction by up to 62% and wear by 49% across varying linear velocities.

Experiments on Ultrasonic Lubrication Using a Piezoelectrically-assisted Tribometer and Optical Profilometer

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