The measurement of the reflection of ultrasonic waves from a partially contacting solid-solid interface can be used to study the contact conditions at that interface. This paper describes measurements and predictions of the reflection of ultrasonic waves from partially contacting aluminium-aluminium interfaces, performed in the low frequency regime where the wavelength of the ultrasound is large compared to the size of the gaps. The proportion of the incident wave which is reflected at the interface (the reflection coefficient) was measured as a function of frequency with a single wideband ultrasonic transducer. When load was applied across the interface three regions of contact can be seen; no contact, partial contact and perfect contact. In the no contact region the measured reflection coefficient was unity at all frequencies. In the partial contact region the measured reflection coefficient increased with frequency. No measurements were taken in the perfect contact region in which the reflection coefficient is known to be zero at all frequencies as this state is the same as a continuous piece of aluminium. The reflection coefficient variation with frequency was modelled using a spring model, good agreement between experiments and predictions being achieved. Reflection coefficient measurements were then used to study the contact between two aluminium surfaces under repeated loading and unloading cycles. Plastic flow on first loading was evident while subsequent loading cycles revealed largely elastic behaviour. Both elastic and plastic statistical contact models, as well as a numerical contact model, were used to predict the variation of interfacial stiffness with pressure. These models agreed qualitatively with the experimentally determined stiffness variations and the predicted stiffness was within an order of magnitude of the measured value in all cases.

Ultrasound is reflected from a liquid layer between two solid bodies. This reflection depends on the ultrasonic frequency, the acoustic properties of the liquid and solid, and the layer thickness. If the wavelength is much greater than the liquid–layer thickness, then the response is governed by the stiffness of the layer. If the wavelength and layer thickness are similar, then the interaction of ultrasound with the layer is controlled by its resonant behaviour. This stiffness governed response and resonant response can be used to determine the thickness of the liquid layer, if the other parameters are known. In this paper, ultrasound has been developed as a method to determine the thickness of lubricating films in bearing systems. An ultrasonic transducer is positioned on the outside of a bearing shell such that the wave is focused on the lubricant–film layer. The transducer is used to both emit and receive wide–band ultrasonic pulses. For a particular lubricant film, the reflected pulse is processed to give a reflection–coefficient spectrum. The lubricant–film thickness is then obtained from either the layer stiffness or the resonant frequency. The method has been validated using fluid wedges at ambient pressure between flat and curved surfaces. Experiments on the elastohydrodynamic film formed between a sliding ball and a flat surface were performed. Film–thickness values in the range 50–500 nm were recorded, which agreed well with theoretical film–formation predictions. Similar measurements have been made on the oil film between the balls and outer raceway of a deep–groove ball bearing.

The need to improve safety and reduce costs means that new specifications are being imposed on railway wheel wear. These mean that more durable wheel steels are required. In order to develop such materials, a greater understanding is needed of the wear mechanisms and transitions occurring in wheel steels. In this work, twin-disc wear testing has been carried out to study the wear characteristics of R8T railway wheel steel. The results have indicated that, compared with previous wheel steels, R8T offers greater wear resistance. Three wear regimes were identified; mild, severe, and catastrophic. Wear rates were seen to increase steadily initially and then to level off, before increasing rapidly as the severity of the contact conditions increased. This paper is concerned with the form of the data and the reasons for the transitions. Analysis of the contact conditions indicated that the first transition in the wear rate was caused by the change from partial slip to full slip conditions at the disc interface. Temperature calculations for the contact showed that the large increase in wear rates seen at the second wear transition may result from a thermally induced reduction in yield strength and other material properties. This improved understanding will help in progressing towards the aim of eventually attaining a wear modelling methodology reliant on material properties rather than wear constants derived from testing.

This paper presents a review of existing theory and practice relating to main bearings for wind turbines. The main bearing performs the critical role of supporting the turbine rotor, with replacements typically requiring its complete removal. The operational conditions and loading for wind turbine main bearings deviate significantly from those of more conventional power plants and other bearings present in the wind turbine power train, i.e. those in the gearbox and generator. This work seeks to thoroughly document current main-bearing theory in order to allow for appraisal of existing design and analysis practices, while also seeking to form a solid foundation for future research in this area. The most common main-bearing setups are presented along with standards for bearing selection and rating. Typical loads generated by a wind turbine rotor, and subsequently reacted at the main bearing, are discussed. This is followed by the related tribological theories of lubrication, wear and associated failure mechanisms. Finally, existing techniques for bearing modelling, fault diagnosis and prognosis relevant to the main bearing are presented.

The measurement of ultrasonic reflection has been used to study the contact between rough surfaces. An incomplete interface will reflect some proportion of an incident wave; this proportion is known as the reflection coefficient. If the wavelength is large compared with the width of the gaps in the plane of the interface then the reflection mechanism can be modeled by considering the interface as a spring. The proportion of the incident wave reflected (reflection coefficient) is then a function of the stiffness of the interface and the frequency of the ultrasonic wave. The sensitivity of the ultrasonic technique has been quantified using a simple model, from which the stiffness of individual gaps and contacts are calculated and their effect on the ultrasonically measured stiffness predicted. The reflection of ultrasound at a static interface between a rough, nominally flat aluminum plate and a rough, nominally flat hardened steel punch has been investigated. Plastic flow on first loading was evident, while repeated loading was largely elastic. However, subsequent cycles indicate a small amount of further plasticity and contact irreversibility. The effect of surface roughness on the resultant contact has also been investigated. A simple plastic contact model is described which allows prediction of the average size of the asperity contacts and their number. This model shows that the average size of the contacts remains constant over most of the loading whereas the number of contacts increases almost linearly. The contact stiffness has also been modeled with two well known elastic rough surface contact models. These models predicted a lower interface stiffness than was observed in the experiments. However they provide a useful way of interpreting the ultrasonically measured interface stiffness data.