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WEAR
INTRODUCTION
SURFACE TOPOGRAPHY
All solid surfaces are uneven.
Surfaces composed of peaks and valleys
called ASPERITIES
When su
FRICTION
Types of friction:
1. Dry friction
static friction ("stiction") between non-moving surfaces
kinetic friction between moving surfaces
2. Fluid friction
3. Lubricated friction etc.
Mathematically,
Where,
Ff frictional force
N total normal reaction/load at contact interface
- coefficient of friction
Second Law
Frictional force is independent of the
apparent area of contact
Experiment Normal load, held constant,
apparent area of contact increased
is independent of apparent are of contact
NOTE: Second
POLYMERS
law
not
obeyed
by
Third Law
Found by Coulomb
Coefficient of Friction
Independent of:
Normal Force
Apparent Area of contact
Nearly independent of sliding velocity
WEAR
Classifying wear:
1. Based on the conditions in which the wear
occurs:
1.
2.
Seizure
Melt
Oxidation
Plasticity
SLIDING WEAR
Also known as adhesive wear
Terms associated with sliding wear:
Scuffing: (UK)
localized surface damage due to lubrication breakdown
at high sliding speeds.
Scoring: (US)
synonymous with scuffing
Galling:
Severe from of scuffing
Gross surface damage
Damage resulting from un-lubricated sliding at low
speeds
TESTING METHODS
Used to:
Study wear mechanisms
To extract useful design data (wear rates, etc.)
Asymmetrical
Most commonly used
E.g. Pin of disk
Specimen Dimensions:
Few mm to tens of mm
Asymmetric test specimen dimensions
usually less than 25mm, while counter-face
larger.
Testing Standards:
Sphere on disk (DIN 50324)
Pin on Disk (ASTM G 99)
Block on Ring (ASTM G 77)
Quantification of Wear:
Several parameters are used
quantify wear. The most important are:
3.
4.
1.
2.
Also,
to
TESTING PARAMETERS
1. Loads:
Range: fractions of N to several kN
3. Sliding Speed:
Range: fractions of mm/s to hundreds of m/s
Affects rate of frictional heat dissipation, thus contact
interface temperature.
4. Duration of test
5. Atmospheric Conditions
Water vapour, oxygen etc.
6. Presence of lubricant
Derivation
Assumptions:
True contact area will be sum of individual
contact areas.
This area is proportional to the normal load.
Under most conditions, the local deformation
of asperities will be plastic.
dW = Pa2
Where,
P yield pressure of plastically deforming
asperity (close to indentation hardness, H)
W = dW = P a2 (2)
From (2),
a2 = W/P..(3)
(3) in (1):
Q = kW/3P
Hence, the Archard Wear equation:
Q= KW/H
Where,
Q = Overall Wear rate
K = Wear coefficient/coefficient of wear = k/3
H = Hardness of the softer material (=P)
K wear coefficient:
Dimensionless
Always less than unity
Higher value indicates increased wear severity
In engineering applications,
(K/H) = k (dimensional wear coefficient)
is more useful.
k = Q/W
Statement 1:
Found to be experimentally true.
Transient behaviour is sometimes noted at the start,
where wear during the initial running in period may
be higher/lower that steady state wear rate (where
equilibrium surface conditions have been established)
Statement 2:
Strict proportionality not found b/w Q and normal
load (W)
Over limited ranges, Q varies directly with W.
Abrupt transitions from low to high Qs and vice
versa is observed.
This case can be understood better by considering
the example of sliding contact of leaded Brass
against Hard Stellite ring.
At Low loads,
Q increases with W
K 2 x 10 -6
At loads of 5 to 10 N,
Sharp increase in wear rate (100x)
Transition point
Follows archard eqn
At even high W,
Still follows archard eqn
K 10 -4
MILD WEAR:
SEVERE WEAR:
Larger particles
Metallic debris
Roughened surface
Metal to metal contact
High (0.25- 0.3)
Temperature
Most direct factor
Temp at sliding interface depends upon:
Ambient temp
Frictional power dissipation (Ff x sliding speed)
(depends upon)
Sliding Speed
Load
UNLUBRICATED WEAR OF
METALS
As sliding conditions vary the
mechanism of wear changes
One mechanism cannot be attributed to
wear over a wide range of conditions
Main factors controlling wear mechanism:
Mechanical Stresses
Temperature
Oxidations phenomenon
MECHAINCAL STRESSES
Two types:
Normal Stresses
Shear stress
REGIME 1(SEIZURE)
Very high contact pressures
Gross seizure of surfaces
Growth in asperity junctions
Real area of contact apparent area of
contact
NOTE:
Regime II and III- thermal effect negligible.
Regime IV and V - thermal effect - important
REGIME V (MILD)
Interface temp is high , but below melting
point.
Rapid surface oxidation
Extreme type of oxidation wear takes
place
Thick oxide layer forms and deforms
plastically
Wear debris consists of oxide
Regime VI:
Regime VII:
Regime VIII:
Higher flash temp that in regime VI
Leads to formation of martensite
Interface temperature above 9100C, so that
allotropic transformation can take place
High strength of martensite provide local
mechanical support to surface oxide film
Mild wear proceeds with removal of oxide
MECHANISMS OF SLIDING
WEAR
the