Browsing by Author "Bayer, Gernot"

Now showing 1 - 3 of 3
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    Beyond Starvation: Amplitude-Dependent Grease Replenishment Mechanisms in Oscillating Rolling Bearings
    (2025) Liu, Muyuan; Wandel, Sebastian; Bader, Norbert; Lin, Zongyu; Bayer, Gernot; Poll, Gerhart; Marian, Max
    This experimental study addresses grease replenishment mechanisms under varying oscillation amplitudes for deep groove ball bearings with different cage structures. This is complemented by an optical elastohydrodynamic lubrication tribometer. Thereby, three distinct lubrication mechanisms are identified. At small amplitudes, lubrication of the contact area is primarily determined by the lubricant supply from the grease side bands. Under medium-amplitude conditions, interaction between the cage and the side bands on the rolling elements substantially enhances lubrication. At large amplitudes, when the rolling track on the rolling elements connects both the inner and outer rings, grease flow between the rings emerges as a dominant mechanism, effectively reducing wear.
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    Biogenic palm oil-based greases with glycerol monostearate and soy wax: A rheological and tribological study
    (2025) Nassef, Belal G.; Moradi, Amirreza; Bayer, Gernot; Pape, Florian; Abouelkasem, Zeyad A.; Rummel, Florian; Schmoelzer, Stefan; Poll, Gerhard; Marian, Max
    The increasing environmental concerns associated with conventional lubricants have led to a growing interest in sustainable alternatives, particularly biogenic grease. This study introduces a novel approach to synthesizing and characterizing fully biodegradable greases using palm oil as the base oil and renewable biothickeners, namely glycerol monostearate (GMS) and soywax (SW). The innovation lies in utilizing the distinct properties of these biothickeners to optimize the grease structure and performance for industrial applications. GMS enhances the consistency and mechanical stability, while SW controls the elasticity and oil bleeding. Rheological analysis shows that GMS exhibits the thickening capabilities at room temperature (RT) to achieve common grease consistencies, while SW enhances elasticity, achieving a unique balance of firmness and flexibility. Thermal analysis indicates that GMS-based greases had higher thermal stability, while SW enhance low-temperature performance. Tribological testing reveals a reduction in friction and wear, with an earlier transition to the mixed lubrication regime compared to a reference commercial grease (CG). Under boundary lubrication, GMSbased samples perform better than the CG, particularly under higher contact pressures. In contrast, SW-based formulations demonstrate better lubrication at lower contact pressures. In fluid friction regimes, almost all biobased samples outperform the CG, showing potential for high-speed applications. When tested in angular contact ball bearings under oscillating motion (a typical moderate temperature application), the bio-greases show decent results in preventing false brinelling. This study highlights the potential of these eco-friendly formulations as a viable alternative to conventional greases.
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    Towards lifetime lubrication of wind turbine gearboxes: Technical and physical investigations on used oils
    (Elsevier Ltd, 2025) Liu, Muyuan; Bayer, Gernot; Reimers, Merle; Schunemann, Wilhelm; Konig, Florian; Jacobs, Georg; Schelenz, Ralf; Bader, Norbert; Poll, Gerhard; Marian, Max
    Modern geared wind turbines rely on the adequate performance of their lubricant to ensure optimum operation of their main gearboxes. Potential oil ageing mechanisms, such as oxidation or additive depletion, can degrade oil performance over time. An oil that performs satisfactorily throughout the entire life of the turbine can reduce the downtime, resources, and costs associated with oil changes or repairs. Therefore, the purpose of this study is to investigate the ageing of field oil through oil analysis and artificial ageing. In addition, the possibility of oil service life extension by top-treating used oils with additives was investigated. For the field oil evaluation, oil samples were taken from operating wind turbines with lifespans up to 16 years. The deterioration of their copper corrosion, foaming, and wear performance was assessed using standard tests and its influence on gearbox operation was identified. Although these properties had degraded to some extent, most oils continued to perform satisfactorily. To counteract oil ageing, top-treating (adding additives to the field oils) was performed to restore the corresponding properties of oils. Subsequent standard tests confirmed that this approach is generally effective, but there are still some potential problems. To further investigate the oils' lifespan limits, field oils were subjected to artificial ageing. This process involved oil heating and the artificial, accelerated consumption of anti-wear additives. Experimental results indicated that artificial ageing has only a minor influence on wear despite a significant reduction in additive concentration. In conclusion, proper monitoring of oils and timely top-treat have the potential to achieve lifelong wind turbine gearbox lubrication.