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A Study on Wear and Friction of Passenger Vehicles Control Arm Ball Joints

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A Study on Wear and Friction of Passenger Vehicles Control Arm Ball Joints energies Article A Study on Wear and Friction of Passenger Vehicles Control Arm Ball Joints Marek Wozniak 1,* , Krzysztof Siczek 1 , Gustavo Ozuna 2 and Przemyslaw Kubiak 3 1 Department of Vehicles and Fundamentals of Machine Design, Lodz University of Technology, 90-537 Łód´z,Poland; [email protected] 2 Department of Industrial Engineering and Systems, University of Sonora, Hermosillo 83000, Mexico; [email protected] 3 Institute of Vehicles and Construction Machinery Engineering, Warsaw University of Technology, 02-524 Warszawa, Poland; [email protected] * Correspondence: [email protected]; Tel.: +48-691-554-535 Abstract: The following paper describes research on vehicle suspension elements: the ball joints. The worn surface roughness of selected ball pins and their bearings was compared in terms of vehicle mileage, utilization period, and car model. Ball pin roughness was measured using a scanning tunneling microscope (STM), whereas for the bearing surface, a profilometer was used. The aim of this study was to determine the resistive torque in an unloaded ball joint. Using the finite element method, models of the unloaded ball joint were analyzed in two scenarios: with and without interference between the worn ball and its bearing. Calculated values of resistive torques in the ball joint were compared, and recommendations were given relative to the mileage and the time after which it was necessary to perform verification or replacement of the ball joints. Keywords: ball joint; suspension; vehicle; STM microscope; roughness; finite element method Citation: Wozniak, M.; Siczek, K.; Ozuna, G.; Kubiak, P. A Study on Wear and Friction of Passenger Vehicles Control Arm Ball Joints. 1. Introduction Energies 2021, 14, 3238. https:// A vehicle suspension is defined as a group of elastic elements and rods. It connects doi.org/10.3390/en14113238 axles or individual wheels with the frame or vehicle body. The function of a suspension is to absorb bumps coming from an unleveled surface by separating the wheels from the Academic Editor: Aldo Sorniotti body of a car. Furthermore, its target is to assure the maximum comfort and protection of transported objects against shocks and harmful vibrations. Securing from too strong Received: 1 February 2021 shocks has a huge influence on the durability of various mechanisms as well. One of the Accepted: 20 May 2021 main components of the vehicle suspension is a control arm. The task of the control arms is Published: 1 June 2021 to connect the stub axles with the body of a vehicle. There are three types of control arms distinguished—transverse, longitudinal, and diagonal, depending on the clamping and Publisher’s Note: MDPI stays neutral driving of the wheel. The control arm consists of a ball joint and one or two sleeves [1,2]. with regard to jurisdictional claims in An interesting case is the McPherson strut suspension. Its characteristic feature is that published maps and institutional affil- there is only a lower ball joint. In this design, the lower ball joint is a follower, with the bottom iations. of the strut connected directly to the steering knuckle and wheel. The bearing plate of the upper strut mount carries the vehicle’s weight, leaving the lower to act only as a pivot point. During preliminary observations, it was noted that there is some resistance when moving the ball joint pin relative to the ball joint body with the bearing (ball joint seat). Copyright: © 2021 by the authors. The technology, diagnosis, and repair methods of the suspension system as well as Licensee MDPI, Basel, Switzerland. its components were presented and discussed in [3]. According to [4], the driveline and This article is an open access article chassis components account for only 2% (approximately) of the total mechanical losses in distributed under the terms and passenger vehicles. conditions of the Creative Commons Yao et al. [5] proposed the direct tilt control (DTC) strategy allowing actively control- Attribution (CC BY) license (https:// ling the vehicle to tilt during a curve, which improved the vehicle performance during creativecommons.org/licenses/by/ cornering. Such a control limited the occupant’s felt lateral acceleration and the lateral load 4.0/). Energies 2021, 14, 3238. https://doi.org/10.3390/en14113238 https://www.mdpi.com/journal/energies Energies 2021, 14, x FOR PEER REVIEW 2 of 29 Yao et al. [5] proposed the direct tilt control (DTC) strategy allowing actively control- Energies 2021, 14, 3238 ling the vehicle to tilt during a curve, which improved the vehicle performance during2 of 29 cornering. Such a control limited the occupant’s felt lateral acceleration and the lateral load transfer ratio during turning of the car and allowed proper path-tracking perfor- mance. However, it simultaneously changed the loading of the suspension ball joints. transfer ratio during turning of the car and allowed proper path-tracking performance. Heißing and Ersoy [6] stated that the structure of the chassis itself is an origin of However, it simultaneously changed the loading of the suspension ball joints. vibrations and sound. The suspension components are subjected to contact pressures and Heißing and Ersoy [6] stated that the structure of the chassis itself is an origin of friction loads related to them in their contact zones. As a result, various coupled oscillation vibrations and sound. The suspension components are subjected to contact pressures and modes and self-noise are generated. The intensity of the transmitted oscillations/vibra- friction loads related to them in their contact zones. As a result, various coupled oscillation tions can vary in an unpredictable way during vehicle operation. modes and self-noise are generated. The intensity of the transmitted oscillations/vibrations can varyNowadays, in an unpredictable all of the car waymanufacturers during vehicle put emphasis operation. on enhancing the interior noise comfortNowadays, of their cars. all of Paulraj the car et manufacturers al. [7] claims that put emphasisthe Vehicle on Noise enhancing Comfort the Index interior (VNCI) noise iscomfort commonly of their utilized cars. Paulrajto estimate et al. the [7 ]sound claims feat thatures the of Vehicle vehicles. Noise The Comfort interior vehicle Index (VNCI) sound comfortis commonly is indicated utilized via to estimatea scale from the sound 1 to 10. features Major ofcontributors vehicles. The to interiorthe sound vehicle quality sound are usuallycomfort the is indicated sound volume via a scaleand its from sharpness 1 to 10. in Major the frequency contributors range to theof human sound hearing quality are(20 Hzusually ÷ 20 thekHz). sound A vehicle volume comfort and its level sharpness indicati inon, the based frequency on artificial range neural of human network, hearing can (20be applied Hz ÷ 20 to kHz) determine. A vehicle the comfort comfort level level in indication, vehicles. It basedcan prevent on artificial situations neural where network, driv- erscan and be applied passengers to determine are continuously the comfort exposed level to in high vehicles. levels It of can noise prevent and situationsvibration, wherewhich asdrivers a result and can passengers cause their are health continuously deterioration. exposed to high levels of noise and vibration, which as a result can cause their health deterioration. 1.1. Ball Joint 1.1. BallThe Joint ball joint of a control arm enables a rotational and oscillating movement of the joinedThe components ball joint of with a control respect arm to enablesone anothe a rotationalr. The pivot and point oscillating of the movementwheel lies on of thethe axisjoined of componentsthe pin. Additionally, with respect the to ball one joint another. enables The the pivot angular point deflection of the wheel and lies transmits on the theaxis shearing of the pin. and Additionally, longitudinal the loads ball (along joint enables the pin the axis). angular Sincedeflection it performs and rotationally transmits oscillatingthe shearing movement, and longitudinal it is greased loads by (along a grease the fitting pin axis). or with Since graphite it performs grease rotationally when the constructionoscillating movement, does not include it is greased a dedicated by a grease fitting fitting. A ball or joint with can graphite be loaded grease by axial when force the ofconstruction both tension does and not compression include a dedicated nature. It fitting. can also A ballbe subjected joint can beto loadedradial force, by axial limiting force theof both degrees tension of andfreedom compression to three-axis nature. rotation It can alsodirection be subjected without to torque radial force,transmission limiting the[8]. Thedegrees main of components freedom to three-axisof the ball rotation joint and direction their descriptions without torque are presented transmission in Figure [8]. The 1 [1,9,10].main components of the ball joint and their descriptions are presented in Figure1[ 1,9,10]. Figure 1. Components of a ball joint [[8].8]. Interestingly, Farfan-CabreraFarfan-Cabrera [[11]11] reportedreported thatthat ballball joints belonged to the main main tribo- tribo- logical elements causing resistanceresistance toto motionmotion inin electricelectric cars.cars. Such a joint can be enhanced by altering thethe ballball studstud andand bearing bearing depending depending on on its its elasticity, elasticity, surface surface roughness, roughness, resis- re- sistancetance to temperature,to temperature, and and by by improving improving the the durability durability of theof the boot. boot. The construction aims at minimizing friction byby polishingpolishing thethe pinpin ofof aa ballball joints.joints. The grease applied to a jointjoint andand additionaladditional polytetrafluoroethylenepolytetrafluoroethylene (PTFE) [[12],12], also calledcalled Teflon,Teflon, layerlayer onon the the pin pin also also contribute contribute to to the the smooth smooth working working and and quick quick reaction reaction time. time. The DLC cover on the ball joint pin [13] also allowed for extending the service life and lowering the friction. According to [8], the bearing of the ball joint can be also made of a synthetic resin.
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