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This paper aims to address the influence of tribofilms and running-in on failures and friction of gears. The operation regime of gears is increasingly shifted to mixed and boundary lubrication, where high local pressures and temperatures occur at solid interactions in the gear contact. This results in strong tribofilm formation due to interactions of lubricant and its additives with the gear flanks and is related to changes of surface topography especially pronounced during running-in.

Experiments at a twin-disk and gear test rig were combined with chemical, structural and mechanical tribofilm characterization by surface analysis. Pitting lifetime, scuffing load carrying capacity and friction of ground spur gears were investigated for a mineral oil with different additives.

Experimental investigations showed a superordinate influence of tribofilms over surface roughness changes on damage and friction behavior of gears. Surface analysis of tribofilms provides explanatory approaches for friction behavior and load carrying capacity. A recommendation for the running-in of spur gears was derived.

Experimental methods and modern surface analysis were combined to study the influence of running-in and tribofilms on different failures and friction of spur gears.

This paper aims to address the influence of diamond-like carbon (DLC) coatings on the frictional power loss of spur gears. It shows potentials for friction and bulk temperature reduction in industrial use. From a scientific point of view, the thermal insulation effect on fluid friction is addressed, which lowers viscosity in the gear contact due to increasing contact temperature.

Thermal insulation effect is analyzed in detail by means of the heat balance and micro thermal network of thermal elastohydrodynamic lubrication contacts. Preliminary results at a twin-disk test rig are summarized to categorize friction and bulk temperature reduction by DLC coatings. Based on experiments at a gear efficiency test rig, the frictional power losses and bulk temperatures of DLC-coated gears are investigated, whereby load, speed, oil temperature and coatings are varied.

Experimental investigations at the gear efficiency test rig showed friction and bulk temperature reduction for all operating conditions of DLC-coated gears compared to uncoated gears. This effect was most pronounced for high load and high speed. A reduction of the mean gear coefficient of friction on average 25% and maximum 55% was found. A maximum reduction of bulk temperature of 15% was observed.

DLC-coated gears show a high potential for reducing friction and improving load-carrying capacity. However, the industrial implementation is restrained by the limited durability of coatings on gear flanks. Therefore, a further and overall consideration of key durability factors such as substrate material, pretreatment, coating parameters and gear geometry is necessary.

Thermal insulation effect of DLC coatings was shown by theoretical analyses and experimental investigations at model test rigs. Although trial tests on gears were conducted in literature, this study proves the friction reduction by DLC-coated gears for the first time systematically in terms of various operating conditions and coatings.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2020-0257/

This paper aims to address the influence of lubrication methods on operational characteristics, power losses and temperature behavior of gears and bearings. It contributes to the improvement of resource and energy efficiency of geared transmissions.

Experimental investigations were performed at a gear and bearing power loss test rig. Thereby, dip lubrication, injection lubrication with injection volumes from 0.05 to 2.00 l/min and minimum quantity (MQ) lubrication with an injection volume as little as 28 ml/h were considered. Measurements were evaluated in terms of no-load and load-dependent power loss, bulk temperatures and mean gear coefficients of friction.

Results show strongly reduced no-load gear and bearing losses for lubrication methods with low lubricant quantities. Load-dependent losses are similar to conventional lubrication methods and tend to be lower at high speed. This is related to higher bulk temperatures, as the heat dissipation of lubrication methods with low oil quantities is limited. Limited thermal load limits were shown to be extended by LowLoss gears.

Systematic investigations were conducted to evaluate the influence of dip, injection and MQ lubrication on power loss and temperature behavior of gears and bearings. The results of this study support further research on needs-based lubrication methods for gearboxes.

Internal gearings are commonly used in transmissions due to their advantages like high-power density. To ensure high efficiency, load-carrying capacity and good noise behavior, a profound knowledge of the local gear mesh is essential. The tooth contact of internal gears relates to a convex and concave surface that form a conformal contact. This is in contrast to external gears, where two convex surfaces form a contraformal contact. This paper aims at a better understanding of conformal contacts under elastohydrodynamic lubrication (EHL) to improve the design of internal gearings.

An existing numerical EHL model is used for studying the characteristic properties of a hard conformal EHL line contact. A hard contraformal EHL line contact is studied as reference. Non-Newtonian fluid behavior and thermal effects are considered. By taking into account the local contact conformity and kinematics, the effects and relevance of the curvature of the lubricant gap and micro-slip are analyzed. In a parameter study, scale effects of the contact radii on film thickness, temperature rise and friction are examined.

The curvature of the lubricant gap and effects of micro-slip are small in hard conformal EHL line contacts. For high micro-slip, it can be neglected. Hence, the modeling of conformal contacts using an equivalent geometry of the contact problem is reasonable. The parameter study shows beneficial tribological aspects of the conformal contact compared to the contraformal contact. Higher film thickness and lower fluid coefficient of friction are observed for conformal contacts, which can be attributed to lower pressures for the case of the same external normal force, or to a higher contact temperature rise for the case of equivalent contact pressure.

Despite its widespread existence, the local geometry and kinematics in hard conformal EHL line contacts like in internal gearings have been rarely studied. The findings help for a better understanding of local contact characteristics and its relevance. The quantified scale effects help to improve the efficiency and load-carrying capacity of machine elements with hard conformal EHL contacts, like internal gearings.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2022-0366/

This paper aims to address the coating and compound analysis of diamond-like carbon (DLC) on steel, to understand the frictional behavior in tribological gear systems presented in paper Part I. Here, the Ti and Zr modified DLC coating architectures are analyzed regarding their chemical, mechanical and thermophysical properties. The results represent a systematic analysis of the thermal insulating effect in tribological contact of DLC coated gears.

The approach was to evaluate the effect of the substitution of Zr through Ti at the reference coating ZrCg to TiCg and the effect on thermophysical properties. Furthermore, the influence of different carbon and hydrogen contents on the coating and compound properties was analyzed. Therefore, different discrete Ti or Zr containing DLC coatings were deposited on an industrial coating machine. Thereby the understanding of the microstructure and chemical composition of the reference coatings is increased.

Results prove comparable mechanical properties of metal modified DLC independent of differences in chemical compositions. Moreover, the compound adhesion between TiC_g/16MnCr5E was improved compared to ZrC_g/16MnCr5E. The effect of hydrogen content Ψ and carbon content x_c on the thermophysical properties is limited by Ψ = 18 at.% and x_c = 90 at.%.

The findings of the combined papers Part I and II show a high potential for industrial application of DLC on gears. Based on the results DLC coatings and gears can be tailored to each other.

Systematic analysis of DLC coatings were conducted to evaluate the effect of titanium, carbon and hydrogen on thermophysical properties.

The purpose of this study is to investigate lubricant film-forming capability of oil-impregnated sintered material in highly loaded non-conformal contacts. This self-lubrication mechanism is well described in lightly loaded conformal contacts such as journal bearings; however, only a little has been published about the application to highly loaded contacts under elastohydrodynamic lubrication regime (EHL).

Thin film colorimetric interferometry is used to describe the effect of different operating conditions on lubricant film formation in line contacts.

Under fully flooded conditions, the effect of porous structure can be mainly traced back to the different elastic properties. When the contact is lubricated only by oil bleeding from the oil-impregnated sintered material, starvation is likely to occur. It is indicated that lubricant film thickness is mainly governed by oil bleeding capacity. The relationship between oil starvation parameters corresponds well with classic starved EHL theory.

To show practical, relevant limitations of the considered self-lubrication system, time tests were conducted. The findings indicate that EHL contact with oil-impregnated sintered material may provide about 40 per cent of fully flooded film thickness.

For the first time, the paper presents results on the EHL film-forming capability of oil-impregnated sintered material by measuring the lubricant film thickness directly. The present paper identifies the phenomena involved, which is necessary for the understanding of the behavior of this complex tribological system.

A parallel linelet preconditioner has been implemented to accelerate finite element (FE) solvers for incompressible flows when highly anisotropic meshes are used. The convergence of the standard preconditioned conjugate gradient (PCG) solver that is commonly used to solve the discrete pressure equations, greatly deteriorates due to the presence of highly distorted elements, which are of mandatory use for high Reynolds‐number flows. The linelet preconditioner notably accelerates the convergence rate of the PCG solver in such situations, saving an important amount of CPU time. Unlike other more sophisticated preconditioners, parallelization of the linelet preconditioner is almost straighforward. Numerical examples and some comparisons with other preconditioners are presented to demonstrate the performance of the proposed preconditioner.

This article reviews the international literature of the last two decades on self‐injurious behaviour in prisons and jails and introduces the risk factors associated with this behaviour. Studies from a variety of countries investigated different samples (e.g. in jails or prisons; female or male inmates). We only chose those studies using a control group of inmates without self‐injurious behaviour. The findings on potential risk factors for self‐injurious behaviour are largely contradictory because of the differences in sample selection and dependent variables (deliberate self‐harm without suicidal intent vs. suicide attempts). We also discuss some methodological problems in predicting self‐injurious behaviour.

The purpose of this paper is to devise a tool based on computational fluid dynamics (CFD) and machine learning (ML), for the assessment of potential airborne microbial transmission in enclosed spaces. A gated recurrent units neural network (GRU-NN) is presented to learn and predict the behaviour of droplets expelled through breaths via particle tracking data sets.

A computational methodology is used for investigating how infectious particles that originated in one location are transported by air and spread throughout a room. High-fidelity prediction of indoor airflow is obtained by means of an in-house parallel CFD solver, which uses a one equation Spalart–Allmaras turbulence model. Several flow scenarios are considered by varying different ventilation conditions and source locations. The CFD model is used for computing the trajectories of the particles emitted by human breath. The numerical results are used for the ML training.

In this work, it is shown that the developed ML model, based on the GRU-NN, can accurately predict the airborne particle movement across an indoor environment for different vent operation conditions and source locations. The numerical results in this paper prove that the presented methodology is able to provide accurate predictions of the time evolution of particle distribution at different locations of the enclosed space.

This study paves the way for the development of efficient and reliable tools for predicting virus airborne movement under different ventilation conditions and different human positions within an indoor environment, potentially leading to the new design. A parametric study is carried out to evaluate the impact of system settings on time variation particles emitted by human breath within the space considered.

This paper gives a bibliographical review of the finite element and boundary element parallel processing techniques from the theoretical and application points of view. Topics include: theory – domain decomposition/partitioning, load balancing, parallel solvers/algorithms, parallel mesh generation, adaptive methods, and visualization/graphics; applications – structural mechanics problems, dynamic problems, material/geometrical non‐linear problems, contact problems, fracture mechanics, field problems, coupled problems, sensitivity and optimization, and other problems; hardware and software environments – hardware environments, programming techniques, and software development and presentations. The bibliography at the end of this paper contains 850 references to papers, conference proceedings and theses/dissertations dealing with presented subjects that were published between 1996 and 2002.