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Elastohydrodynamic lubrication (EHL) theory has been used to model the lubrication state of antifriction machine elements, where initial viscosity and pressure viscosity coefficients are essential parameters in film thickness modeling. Since the pressures of lubricants in the contact zone can be very high, it is important to know the rheological properties of lubricants in these pressure and temperature regimes. The characteristics of viscosity behavior as a function of pressure are also essential for a universal definition of the pressure viscosity coefficient in order to estimate film thickness in an EHL regime. In this study, viscosities and pressure-viscosity coefficients of ten commercial engine and gear oils and seventeen laboratory-produced oil/polymer viscosity modifiers (VM) additives are measured up to 1.3 GPa at 40, 75 and 100 °C. For the first time, a sharp increase in the viscosity and piezoviscous factor is observed in both mineral-based and synthetic-based oils with different VMs. Analysis of the experimental results indicates that sharp increase in viscosity observed in these experiments are believed to arise from physical changes in the VMs, that is liquid-solid phase transition. Evidence is offered that polymer properties such as molecular weight, concentration and structure influence the onset of the phase transitions. A modified Yasutomi model, which normally describes the pressure dependence of the viscosity of lubricants very well, fails to predict the viscosity of the specimens above the onset of sharp increase in viscosity. A design of experiment (DOE) analysis using Design-Expert software indicates that pressure and temperature are the most critical parameters in the viscosity variation. Tribological tests demonstrate that wear in the contact, zone occurs at temperatures and stresses that coincides with the VM phase transitions in both commercial and laboratory synthesized oil/VMs. Tribological results also indicate that the onset of the sharp increase in viscosity can have significant and unanticipated consequences on the elastohydrodynamic contact and can adversely affect EHL theory. The onset of the steep rise in viscosity may also affect the torque and power losses in a mechanical system. Hence, this previously unknown behavior of the lubricant with VMs should be seriously considered in the application of lubricant in mechanical system. |
