Executive Summary
About half the readers responding to this month’s survey say computer modeling plays an important role in their product-development processes. Citing its advantages in efficiently and inexpensively testing assumptions, lubricant marketers use computer modeling to make predictions in areas that include the lifespan of components and assemblies, viscosity, film thickness, pollution’s effect on lubricants, bearing life, frictional losses and lubrication regimes. Some STLE members make computer modeling part of customer presentations. Moving forward, TLT readers expect the technique to play a significant role in lubricant-product development and evolution. Said one reader: “The information available through computers should shorten the time needed to develop better lubricants and supply a better understanding of wear and ways to better prevent it.”
Several cases. One was thermal flow modeling in a friction material in an oil-lubricated LSC transmission element.
The last 15 years we’ve used it more and more, especially in the field of lubrication and film thickness calculations, pollution and its impact on film thickness and to estimate lubrication regimes.
Every time.
We used it a lot. With computer modeling, we can make changes and see what it does.
Has been part of our process since the early 1980s.
Modeling of lubricating fluid mixtures to predict viscosity. Modeling of various bearing types to predict film thickness, frictional losses and bearing life.
This is sort of an open-ended question with a lot of range from costs to production process optimization, but let’s pick a tribology example. Using stress and temperature models, it is possible to define the working conditions to help down-select material or surface treatment options and help design lab tests that better simulate working conditions.
It’s not reliable until proven.
We create stats from oil analysis and do a presentation for the customer. We trend results for compliance.
For us it predicts the lifespan and durability of components and assemblies.
Product strength and stress concentration analysis.
It’s somewhat helpful.
We do not use computer modeling for product development directly. Our product development needs are driven solely based on market needs. Any product development based on computer modeling would be indirect through additive suppliers should they incorporate computer modeling procedures.
For blend studies and new product formulations.
I haven’t used it but have seen different examples of how computer modeling has been used.
3D CAD directly to CNC machining option to 3D print or animate model to show motions or perform stress analysis.
I have tried blending programs in the past, and they were more work than just common knowledge and trial and error.
I have not used computer-aided modeling for tribology, but I have for structural analysis.
In all phases of element development, I check stress and temperature distributions.
Do you think surface damages have significant impact on product value?
Definitely
89%
Somewhat
9%
Not really
0%
Definitely not
2%
Based on responses sent to 15,000 TLT readers.
© Can Stock Photo / hKuprevich
Q2: How will computer modeling impact future lubricant-product development?
Easier access to required data. Analysis info will be current, and action can be taken without delays. Better accuracy of results.
Predictive modeling should enable smarter design and material selection as well as more intelligent material development.
As you can model around existing structures, you can add depth to the interpretation of experimental results. Also, you can extend beyond the physical bounds and visualize and test extreme case solutions.
It will be increasingly important.
Surely the precision will be good at lab scale assumptions.
CAD is a true tool for fine estimates and simulations for the future. Also, today TELOS, coating and roughness impact simulations are possible.
I am interested in moving to computer-aided tribology but haven’t found an appropriate platform (likely related to my lack of effort in searching—nothing has fallen into my lap yet!).
There is a huge scope for trending to improve and determine superior products to reduce operating costs. Also an opportunity to prove the correct application for the correct product, something severely lacking in today’s tribology practices, which are closely profit oriented by majors.
I expect simulation accuracy to increase, reducing the need for expensive testing and experimentation. It also should improve bearing life predictions, allowing smaller design margins that enable higher equipment efficiency and lower costs.
Mistakes will be made by optimizing lubricants via computer.
Expanded research and development.
We only use a little. Sometimes it provides insights.
Positively. Product performance can be better judged, and suitability of application can be better determined. These eventually lead to even better-performing live products and machinery.
Increased use for product education.
It can potentially make formulating and testing more efficient.
Lubricant flow rheology and fluid modeling within hardware assemblies.
Develop specific products according to the needs of the customer.
Additive suppliers will most likely utilize computer-aided programs to develop their additive systems. Finished lubricant suppliers will benefit by incorporating those additive systems into their finished lubricant formulations.
Maybe it will improve the precision and level of detail in measurement and analysis.
I think it has potential to be a very valuable tool.
To provide an easier way to select proper lubricants.
Root cause analysis to identify potential failure points/occurrences and how to prevent them in the future. Computer modeling tied into virtual reality to allow maintenance tech, reliability engineer, etc., to have simulated access to the event in question.
I expect it to grow modestly and robotics to be used as well.
Modeling of surface effects in non-contacting or Hertzian contact will provide analysis of bearing designs. Severe contact involving EP additives will be less effective. More important, high-speed DAQ will allow better tribotest data to be collected, improving friction data used in computer modeling of metal-forming processes.
I can see it on the equipment and materials side.
I have no expectations for computer-aided tribology at the moment.
It will be required.
Institute better preventive measures.
I think it will save a lot of trial-and-error approach time.
The application of nanotribology needs proper modeling in nano-scale to avoid phenomena like agglomeration of nanoparticles.
In terms of necessities and logics.
It will make things waaaaay easier.
It’ll play a huge role.