Thin-Film Rheology and Tribology of Magnetorheological Fluids in Isoviscous-EHL Contacts

This article is concerned with an investigation of the tribological performance of magnetorheological (MR) fluids in pure sliding soft-elastohydrodynamic lubrication (EHL) steel/polytetrafluoroethylene (PTFE) point contacts. The lubricating properties of MR fluids were measured in thin film, lubricated conditions using a ball-on-three-plates tribometer and compared to base fluids in the form of Stribeck curves. A range of techniques was employed to interpret the possible mechanisms of friction and wear of dispersed iron microparticles. The friction surfaces were investigated using optical microscopy, environmental scanning electron microscopy (ESEM), X-ray photoelectron spectroscopy, and energy-dispersive spectroscopy (EDS). In all cases investigated, the friction coefficient is found to strongly depend on the viscosity of the lubricant oil. In the case of low-viscosity liquids, iron microparticles are entrapped in the contact and plow the PTFE surfaces resulting in a sensibly constant friction coefficient. For intermediate viscosities, friction decreases at low speeds because of the so-called "ball-bearing" effect, and later, friction increases as particles become embedded in the PTFE matrix. Finally, for high-viscosity fluids, iron particles either accumulate around the rubbing zone as a barrier that reduces the supply of oil available to the contact for boundary lubrication or the particles indent PTFE surfaces.