Executive Summary
TLT asked readers: If you could create a new tribological test, what would you make?
• A test that accurately replicates real-world environments.
• A test that measures coefficient of friction in a number of modes and conditions.
• A test that provides instantaneous and accurate oil analysis data with no wait time.
What are the greatest benefits and significances from tribological testing?
• Optimizing machine life, reducing downtime and accidents.
• Obtaining performance information faster and less expensively than testing under operating conditions.
• Creating more efficient lubricants, increasing efficiency in every way, generating energy savings, monitoring environmental impact, reducing costs.
Shorten time of test and quality results.
Effectiveness.
A single-step field test that operations could use to quickly diagnose a lubricant’s remaining life and contaminant level. Needs to be quick, repeatable and accurate.
I’d create a test that accurately replicated problems in the field. Most tribotesters don’t correlate to field tests. For example, you might have a gear test that simulates micropitting observed in the field.
A test that measures film thickness and friction at the same time under different pressures.
Improved reciprocating tester for accelerated testing.
Test equipment should be as robust and flexible to simulate as many practical applications as possible to provide useful, repeatable results. Ideally it would be monitored using multiple methods to gain as much information as possible from each test.
One that requires a small amount of lubricant, can be run quickly and accurately predicts in-use performance.
It’s not a new test, but I would like to see improved compatibility testing.
Bearing grease test under shock-loaded conditions.
Tackiness measurement.
Current observation of rising wear particles and surface changes during the test to determine the existing wear mechanism. Also, I’d develop a test strategy to show how the change in the lubricant applied to the movement friction and the wear of cooperating surfaces under certain conditions is possible (it also is possible to introduce a specific dynamic change of one of these conditions).
Something that can measure coefficient of friction in a number of modes and conditions so that the values could be more easily made to fit with simulation models.
Develop tests that have relevance in reality and correctly simulate the phenomena.
I would minimize sample volumes in most tribological tests. Many standards require excessive quantities of lubricants.
Obviously a debris sensor that can classify the debris in size correlation between debris analysis and vibration analysis.
A flexible and affordable bearing test, as today tests for grease life and bearing lubricity are few and expensive.
Lubrication condition test.
Being involved in metalworking, it is critical that bench scale testing involve actual metal cutting that simulates as nearly as possible the in-plant conditions.
Functional boundary layer thickness in application or measurement of load-carrying ability.
Connect and piece together a picture of tribology at work.
Instant, real-time in-field tests that eliminate the need and time delay in sending to remote labs.
Something fast, accurate and inexpensive.
Operating conditions need to be understood and evaluated to give accurate recommendations. A questionnaire that is specific to the system being tested would give enough data to understand the fluid samples.
Something to measure film thickness instantaneously and accurately and something to measure tribochemistry during rubbing.
A trifecta test for energy efficiency, environmental impact and cost balance.
I would like to know in real time the metallic wear particles present in the equipment at the time that I need to know it instead of sending a sample to a laboratory that can take five to 10 days.
A scale that relates rotor dynamic performance, including lubricants.
A five-star test: viscosity, acid number, FTIR, water, particulate count.
A one-check test that would tell you if you have the oil you think you have. Something beyond viscosity and elements that would be available in one test.
Tests for accelerated life testing for the specific lubricant.
A run-to-failure test. For example, for hydraulics heat the oil to 200 F and run the system at maximum capacity unfiltered until it can no longer do the work. The longer the run time, the better the hydraulic oil is at preventing wear and resisting oxidation.
A lubricity tester that helped with viscosity selection.
Something to estimate product life under various conditions.
A test to identify whether the lubrication fluid is doing what it is supposed to do.
A universal database into which all test conditions and results data could be fed.
An instrument that mimics the field application inexpensively, doesn’t use large amounts of fluid and provides a lot of data in a relatively short amount of time.
An inexpensive test to more accurately check for compatibility between two greases.
An instrument that allows the most common machining conditions, including tool and workpiece materials, to be accurately reproduced.
I would create a test to recreate real operation condition to better reveal lubrication issues.
A machine with interchangeable parts to simulate different real-world applications more accurately.
A uni-directional setup in which the contact is repetitively made only in one direction during the test. This could be potentially useful in testing surfaces having directional texture.
A better method for determining tool wear for metal-removal operations.
How do you normally conduct a tribological study?
Accelerated lab tests only
15%
Simulative lab tests only
6%
In-field tests only
8%
Lab tests and in-field tests
31%
Accelerated lab tests, simulative lab tests and in-field tests
40%
Based on responses sent to 15,000 TLT readers.
© Can Stock Photo / buhanovskiy
Q.2: What do you think are the greatest benefits and significances from tribological testing?
We can monitor equipment to avoid breakdown maintenance.
It adds value on the asset.
Learning how to reduce wear.
The greatest benefit I see is the ability to move rotating equipment fault detection further up the P-F curve to reduce/lessen process downtime.
Reduced need for bench and field-test screening.
Probably the best way to model tribological behavior and friction apart from the OEM devices.
Proof of concept before advancing to field testing.
Performance, differentiation.
If done correctly, tribotesting can cost-effectively screen lubricants and/or aid in selecting materials and surface treatments. Also it can isolate wear mechanisms in fundamental work and provide a data resource for future applications (if tests are done properly).
The greatest benefit in my mind is that it gives you confidence of success going into a field evaluation.
Improved lubricant formulations, better understanding of surface interactions.
Prediction of real-world performance.
Learning new ways to extend component life.
Industry cost savings due to reduced wear of machine components. Reduced downtime due to failure of mechanical parts.
Proper evaluation of tribological properties for different cases.
Standard methods can be generated that can be performed on globally available equipment so repeatability monitoring and cross referencing of results can be conducted.
It’s a cheaper alternative to finding solutions and screening between solutions.
Tribological tests tell what happen to surfaces and lubricants in friction zone conditions. It is up to engineers and researchers to determine whether those conditions simulate field application properly.
It enables us to keep a sharp eye on lube-quality degradation and also to see the wearing element trend for proactive decisions. By this we increase drain interval of lubricant.
The ability to simulate conditions in applications before field testing new lubricants.
Optimize the machine life. Avoid an accident with the machine.
These bench type tests often give critical information about performance in a shortened period of time at less expense compared to testing under actual operating conditions.
It detects failures before they happen and identifies areas for lubricant improvement to extend component life.
The insights to plan for servicing and extend machine or plant uptime and return on investment.
Objective data.
Predictive maintenance.
Material durability.
Create more efficient lubricants, increase efficiency in every way, generate energy savings, monitor environmental impact, reduce costs.
Tribological tests help us better understand the operation of the machinery and increase the reliability of the machine.
Reduced power consumption.
Be proactive instead of reactive.
Discover an issue before it leads to damage/failure.
Understanding the life of a lubricant in a given environment.
Getting a comprehensive look at what the oil is minimally capable of.
It helps you keep current with new technology.
Speeding up development, screening. Also good for cross-functional, interdisciplinary, exploratory studies.
Discover new concepts. Rapid assessment of new components and materials before scaling up into end use applications.
Product stewardship and integrity.
Predict equipment failure and determine the life of the lubricating fluid.
Testing can provide comparison data of like additives, provide confidence before going into a field trial and provide insight into additive behavior in different formulations.
Relative comparison of lubricity during product development or competitive product replacement.
Reduction in harm to equipment from needless full-scale testing.
Evaluating the performance of lubricant formulas.
I think it provides a good short-term testing and analysis for simulating and studying performance of lubricants, coatings and materials.
Improved reliability.
For us product development is where testing benefits most.
How often do you use accelerated lab tests to make a decision on tribology-related matters?
All the time
9%
Often
54%
Not often
28%
Never
9%
Based on responses sent to 15,000 TLT readers.