Visualization of Lubrication Conditions Using the Electrical Impedance Method Considering Surface Roughness

In this study, we developed an improved electrical impedance method for measuring oil film thickness with a correction for surface roughness effects. Statistical analysis of the oil film thickness distribution revealed that rough surfaces exhibit higher capacitance values than those predicted by the ideal parallel-plate model, despite having the same mean film thickness. Consequently, a corresponding roughness correction formula was derived. The accuracy of the method was verified in ball-on-disk type apparatus using balls with a rough surface. The corrected oil film thickness agreed more closely with the Hamrock–Dowson equation and with optical interferometry measurements than did the uncorrected result. These outcomes confirm that oil film thickness can be estimated considering surface roughness. The technique is therefore expected to facilitate the optimization of lubrication conditions and enable more reliable bearing-life prediction.