On Limiting Shear Stress-Based Friction Modeling Under Boundary Lubrication

The common view is that, in boundary lubrication, the load is transmitted solely through directly contacting asperities due to the extremely limited lubricant availability or lacking hydrodynamic force generation. The asperities may transmit force via their boundary layers or a thin liquid lubricant film in between. Hypothesizing that the latter mechanism dominates, a friction simulation model was developed for the boundary lubrication regime to investigate whether the contact shear force, and consequently the friction coefficient, are exclusively governed by the shearing of this thin lubricant film between the contacting asperities. In the very thin films at the asperity contacts, the extremely high pressures suggest that the limiting shear stress regime prevails. This means that the shear stress between two asperities sliding relative to each other is equal to the limiting shear stress corresponding to the local pressure. The model is applied to calculate the friction coefficient of a lubricated two-disc tribological contact before and after a wear experiment. It comprises a contact model, based on the Boundary Element Method (BEM), to determine the pressure distribution at the asperity level; a limiting shear stress model to evaluate the corresponding shear stress as a function of pressure; and a friction model to compute the overall coefficient of friction. Two base oils are considered in the analysis, a mineral oil and a synthetic oil, both unadditivated. The calculated coefficients of friction are compared with experimental results, the limitations of the modeling approach are discussed, and an updated model is proposed for the specific case of two contacting steel bodies lubricated with additive-free oil.