Effect of Lubricant Properties and Contact Conditions on False Brinelling Damage

False brinelling is a type of fretting wear that occurs in rolling bearings when the contacts of bearing rings and rolling elements are subjected to small-amplitude oscillatory motion. It manifests itself as deep craters with relatively polished bottoms that are evenly spaced around the bearing rings. This work investigates the influence of lubricant properties and contact conditions, including oil viscosity, applied load, and amplitude and frequency of oscillations, on the onset and progression of false brinelling damage. Experiments were conducted with AISI 52100 bearing steel specimens in a ball-on-flat configuration under small-amplitude oscillating conditions. A set of base oils and a group of custom-made greases with systematically varying properties were employed. Importantly, the same ball-on-flat setup was adapted to allow optical access to the contact by employing a sapphire disc instead of a steel one. This allowed direct observation of the damage onset and progression to better elucidate the mechanisms taking place. Additional experiments were conducted with the same lubricants on a thrust ball bearing rig and the observed trends were compared to those from the ball-on-disc setup. Results show that false brinelling damage initiates locally at discrete asperity microcontacts and then spreads relatively quickly with continued rubbing to cover the whole contact area. Oscillation amplitudes shorter than the Hertz contact width (A/D < 1) were shown to be most damaging, while the damage reduces drastically for amplitudes larger than the Hertz contact width (A/D > 1). For the more important case of A/D < 1, oils and greases with lower viscosities produced less damage. Oils in general produced somewhat less damage than the equivalent lithium- or urea-thickened greases with the same base oil. Lower oscillation frequencies and lower contact pressures also produced less damage. The corresponding friction and electrical contact resistance measurements indicate that under these conditions of A/D < 1 the contact operates under boundary lubrication at best but can intermittently approach effectively dry conditions, depending on lubricant properties and applied conditions. These observations indicate that the key variable that controls damage when the oscillation amplitude is less than the contact width is the ability of the lubricant to penetrate and remain in the oscillating contact. Therefore, lubricant properties and contact conditions that promote this penetration, which may be different from those that promote hydrodynamic film formation, can mitigate against false brinelling.