AMERICAN JOURNAL OF SCIENTIFIC AND INDUSTRIAL RESEARCH

2011, Science Hu, http://www.scihub.org/AJSIR ISSN: 2153-649X doi:10.5251/ajsir.2011.2.99.106

Effect of loads, sliding speeds and times on the wear rate for different materials
Hani Aziz Ameen1, Khairia Salman Hassan2 and Ethar Mohamed Mhdi Mubarak3
1

Technical College Baghdad - Iraq . E-mail:haniazizameen@yahoo.com

Institute of Technology Baghdad / Mechanical Dept.-Iraq. E-mail:almaden20002000@yahoo.com Institute of Technology Baghdad / Mechanical Dept.-Iraq. E-mail:etharmubark@yahoo.com
ABSTRACT

A study has been made on the wear rate for different materials (Steel, Aluminum and brass) under the effect of sliding speed, time and different loads, where the apparatus pin on disc has been used to study the specification of the adhesion wear. The experiments has been performed on a group of specimens under different cases of times (5 to 30) minutes, and under different loads (0.5 to 2) Kg, and different speeds (2.5 to 9) m/sec. A mathematical model has been made for all cases that were studied depending on the method of least squares which helps in foretelling about the wear rate through the knowledge of time limits as a variable with fixing the other variables; also building a model with the same method by which foretelling the rate of adhesive wear through knowing the sliding speed as a variable after fixing the other variables, also making another model foretelling the rate of adhesive wear through knowing the variable loads. A study was made for the damaged surface from wearing for the aluminum alloy as a sample to illustrate the wear lines to the direction of the formation of wear; and from the results, it was clear that the cracks which are vertical on the direction of sliding and will meet together with the lines of weariness, and the results will show that the rate of adhesion wear will be direct proportional with (time, sliding speed and load) , and the low carbon steel has less wear rate than the other materials. Keywords: Wear, Steel, Aluminum alloy 2017, Low carbon steel, Brass, Sliding speed INTRODUCTION The adhesive wear occurs when two surfaces are moving relatively one over the other, and this relative movement is in one direction or a successive movement under the effect of the load so that the pressure on the adjacent projections is big enough to make a load plastic deformation and adhesion. This adhesion will be at a high grade of efficiency and capability in relative to the clean surfaces, and adhesion will take place between a number of these projections whose sizes will be bigger and the area will be increased during movement (Eyre 1976, Halling 1976). At the end there will be some relative wear in the superficial tissues in the weak points of the noticeable places as shown in Fig.(1) bellows :

Fig.1 The mechanism illustration of adhesion wear (Buckley,1981)

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This adhesion wear is proportional directly to the load applied and the sliding distance and indirectly with the hardness of the metal. The adhesion wear is one of the most prevailing wears, it forms 15% of the industrial wear (Daries 1980 , Scott 1979) , which happens when the surfaces are sliding one over the other, so that the pressure between the adjacent projections is enough to produce some local formation adhesion and plastic (Eyre 1976). The mechanism of the formation of the adhesion wear could be explained as follows: Every surface, however, smoothly appears, it will be rough in the microscopic scale and contains a range of tops and lows, and when two surfaces meet then this contact takes place at these projections which are little and relatively isolated; thus when applying a load on these surfaces, then locally there will be a high pressure and heat which will cause overtaking the elastic limits of one surface or both surfaces and the deformation of the projections in a plastic way, so that, the real contacting areas are increased to a limit to support the applied load. The contacting areas are inclined to be damaged under the effect of the relative movements between the two surfaces. The weariness occurs usually at one surface, because of the resistance of the in between surface to breaking and weariness due to the reaction of strain hardness during the adhesion of projections (Yust 1985, Grainger 1994, Askwith 1980). The removed substance (due to the shearing of projections) will take the shape of small foils which is usually transferred to the opposite surface or it is found separately between the two surfaces. Fabijanic et al. 2005, studied the resistance of wear and corrosion for the carbonic tool steel formed by hot forming through the couple surface heat treatments followed by heat treatments at low temperatures aiming not to precipitate the carbides at the core and retaining a structure similar to the original metal. Galvanetto et al. 2006, studied the improvement of wear and corrosion resistance of RPS Ti-TiN coating by mean of thermal oxidation, and they found that the wear and its rate will be less in the specimens which were painted and oxidized and this will increase in the metals already coated without its oxidization also with the chemical corrosion. In the current research the effect of loads, sliding speeds and times on the wear rate for different materials are investigated. Wear Theories There are several theories which were found to explain the phenomenon of adhesion wear, and from that the simple adhesion wear theory. Archard (Smart,1979) assumed that the contact occurs

between a number of projections of diameter (d) and the contact area will be ( , thus this area will bear a load of ( where ( ) is the yield stress of the material during the sliding where it will pass through a sliding of length (2ro). Archard also assumed that the fragments resulted will be of hemispherical shape, and the volume will be ( ) . Thus the volume of the weariness (Q) for the whole distance of sliding can be determined by the equation :-

(1) Where no is the number of point of contact. As at every point of contact, the projection is carrying a load of ( will be , then the total applied load

....(2) Also the amount of volume of the weariness will be .(3) This equation is depending on the theory that all the projections were contact by the load which will produce fragments. It was proved that a percentage of these contacts will result particles of weariness (Sam Sonov, 1984) . Thus the equation becomes . (4) Where is the possibility of producing these particles at the projections contacts, this equation is known a Archard Equation (Halling, 1979). Rowe (Smart,1979) was able to modify the simple adhesion wear theory to represent the surface films after reconsideration Archart equation by adding some new variations on it which is ( a coefficient which represents the particulars of the sliding metals upon each other and does not depent on the particulars of the lubricant, also (B) is the coefficient that represents the lubricant or the surface films, and the equation which expresses the volume (Q) of weariness becomes as follows (5) And this equation expresses " Rowe Modified Adhesion Theory" . Wear Apparatus: The rate of wear will be relatively small in most of the machinery and engineering tool,

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and mostly the value of the change in dimensions is only few microns every year (Halling, 1976), and for measuring wear they are using some apparatuses and instruments which give results about the rate of wear happening in the tools and machinery. From these apparatus which is used in high pressure contact tests where it is able to get very quick results by applying loads on very small areas of contact and

to achieve this test there are some different engineering arrangement as shown in Fig.(2), and for each of these tests , the part (A) is the metal subjected to wear, then the measurement of wear will be known by one of the measurement methods. In the current study the apparatus pin on disc has been used to study the specification of the adhesion wear.

Fig.2 Three common methods to test wear (Halling, 1976)

Measurement Methods of wear: The widely known methods in studying wear, depend on choosing the sliding surfaces, and then measuring, before testing the removal material, and after that, and any change taking place, will be attributed to the resulted wear (Rabinowicz,1965). There are several methods to specify wear such as: 1-Weighting method 2- Mechanical gauging method 3- Optical method 4- Methods for the measurement wear using radio tracers techniques (measurement of radioactive pickup method).

5- Methods for the measurement wear using radio tracers techniques (measurement of non adherent debris method) In the current research the weighting method is used, that is considered from the easiest methods followed to fix and measure the wear. This method is summarized in weighting the sample before the test and after that, then the rate of wear will be calculated from the lost weight. Experimental Metal Selection: Three different materials (Steel, Aluminum and brass) are selected. The chemical composition is get by ARL Spectrometer apparatus. i- Steel with low carbon 1020 according to AISI was chosen, the chemical composition shown in Table(1).
Si 0.019 S 0.014 P Mn 0.65 C 0.169

Table 1 Chemical composition of Low carbon steel 1020 (AISI) Element% V Cu Mo Cr Ni Actual Value 0.002 0.022 0.054 0.024 0.004

Standard 0.05 0.40.14Value 0.65 0.22 ii- Aluminum 2017 according to DIN 1725/1 was chosen. The chemical composition is given in table(2). Table 2 Chemical composition of aluminum 2017 Element% Si Mg Fe Actual Value 0.1 0.301 0.675 Standard 0.2-0.8 0.4 Value

Cu 3.606 3.5-4.5

Zn 0.153

Pb 0.0756 -

Mn 0.215 0.4

iii- Brass according to DIN 17660 was chosen. The chemical composition is given in table(3).

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Table 3 Chemical composition of brass

Element% Actual Value Standard Value

Fe 0.062 0.05

Zn 8.201 8.1

Pb 0.0474 0.05

Al 0.02 0.02

Mn 0.045 0.05

Ni 0.1 0.2

Sn 0.039 0.05

Fabrication of Specimens: Cylindrical specimens for the adhesion wear tests were fabricated with dimensions (10x20mm) according to ASTM specifications for all metals used. Classification of Specimens: After completing the fabrication of specimens, these specimens were classified and sorted into groups as shown in table(4). Adhesion Wear Tests Adhesion wear test is done by the weighing difference method on the specimens in table(4) on the apparatus of wear test shown in Fig.(3). And the wear rate is get according to the following steps:

1- Weighing the specimen before test by digital sensitive balance, with accuracy 0.0001g of type XB 220 A Precisa , as shown in Fig.(4). Table 4 classification of the specimens
State of specimens Fabricated specimens of Aluminum Fabricated specimens of Brass Fabricated specimens of Steel Specimen symbol A B C

Fig.3 Apparatus of adhesive wear test

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Fig.4Apparatus of the digital sensitive balance

2- Specify the variables which want to know its effect on the wear rate like time and fixing other variables (load , sliding speed). 3- Specify the hardness of the steel disc and it was found, HRC=68 RC 4- Fixing the specimen by the bearer in vertical position on disc. 5- Fitting the operation time. 6- Checking the cleanness of the disc before the test start . 7- Operate the apparatus with select specified times with fixing other variables. 8- Stopping the operation and weighing the specimen. 9- Repeat the process with fixing time and changing other variables. The wear rate is calculated from the following equation: ..(6)

where

is the sliding distance (cm) , and n= 940 rpm

RESULTS AND DISCUSSION The tests on the adhesion wear has been done on the groups of specimens given in table(4) as follows: A- Variable time Variable times 5 , 10 , 15, 20 and 30 minutes, with fixed load 1 Kg and fixed distance 5 cm. Results are shown in table (5). B-Variable loads Variables of loads (0.5 , 1 , 1.5 and 2 ) Kg with fixing the time at 10 min. and the distance for 5 cm. Results are shown in table (6). C- Variable sliding speed Variable sliding speed (2.5, 5, 7, 8 and 9) m/sec with fixing the time 10 minutes and the load 1Kg. Results are shown in table (7).

Table 5 Wear rate for variable time

Time (min.) 5 10 15 20 30 Aluminum 1.1 E7 4.5 E7 4 E7 3.6 E7

Wear rate (g/cm) Brass 1.5 E8 2 E8 8 E8

Steel 0.029 E6 0.035 E6 0.043 E6

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Table 6. Wear rate for variable loads

load (Kg) 0.5 1 1.5 2 2.5 Aluminum 0 0 6 E7 1.1 E6

Wear rate (g/cm) Brass 0.5 E8 1.5 E8 5.4 E8

Steel 0.023 E6 0.025 E6 0.0256 E6

Table 7. Wear rate for variable sliding speed

Sliding speed (m/s)

Aluminum Steel 2.5 0.09 E6 5 1 E7 2.5 E8 0.068 E6 7 9 E7 1.1 E7 0.05 E6 8 0.046 E6 9 0 1.5 E7 Aluminum specimen was taken as a sample to study the topography of the surface, as shown in Fig.(5).

Wear rate (g/cm) Brass

5 min.

10 min.

15 min.

20 min.

Time

0.5 Kg

1 Kg

1.5 Kg

2 Kg

Load

Fig.5 Topography of the aluminum specimen surface

It has been studied, the damaged surface due to the adhesion wear for the various loads of aluminum specimens and photos taken by the light microscope which can show that the lines in the direction of weariness is in the same direction with the fragment

left from weariness. Also it was found that the cracks are vertical on the direction of sliding and their meeting together with the lines of weariness cause the separation and dislocation of slight layers from the surface of the specimen, forming by that the

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damage of weariness as shown in Fig.(5) which shows the distortion took place in the surface of the specimen. Mathematical Model: After completion of the adhesion wear tests and taking into consideration that the sliding speed is variables which will be effected with other variables like loads and time which were fixed in finding the model which was found after relying on the method of the simplest linear deviation to show the relation between the basic variables to test wear. The model included the following steps:1- Writing the general formula for extracting the rate of wear from the Eq.(6). 2- The Ordinary Least Square (OLS) method is applied in estimating the Eq.(6) through minimizing the total value of the total error squares and the error is the difference between the actual value and the estimated value according to the steps, where it was built a model the simplest linear deviation representing the relation between the dependent variable (wear rate) Wr and the independent variable (time) t. whereas : (7) following is summarize of OLS steps which basically depend on minimizing the total errors. .(8)

(14) ..(15) In the similar way the relationships of wear rate with sliding speed and variables load are derived. Thus the mathematical model of wear rate will be as follows: Variable Speed Wr= 5.08*107 0.25 *107 V for Aluminum Wr= 1.22*107 + 0.31 *107 V for Brass Wr= 0.1176*106 0.01 *106 V for Steel Variable Time Wr= 1.55*107 + 0.14 *107 t for Aluminum Wr= 2.667*108 +0.65 *108 t for Brass Wr= 0.0217*106 0.0007 *106 t for Steel Variable Load Wr= 0.2575*106 + 0.134 *106 F for Aluminum Wr= 2.433*108 + 4.9 *108 F for Brass Wr= 0.022*106 + 0.0015 *106 F for Steel where V, t, and F are the sliding speed , time and load respectively. CONCLUSIONS In this research it was intended to study the rate of adhesion wear for different metals under the influence of different cases (time, loads and sliding speed); also to make a mathematical model which can tell the rate of adhesion wear through the knowledge of the time period, sliding speed and loads , these models are for experiments and applications. It was concluded that the cracks which are vertical on the direction of sliding and will meet together with the lines of weariness, and the results will show that the rate of adhesion wear will be direct proportional with (time, sliding speed and load) , and the low carbon steel has less wear rate than the other materials.

..(9) Then derive Eq.(9) with respect to

..(10)

(11) After that the derived equation is equalized to zero, the estimated values follows: are determined as

.(12) (13) where

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REFERENCES
Eyre T.S. "Wear Characteristic of Metals", Tribology International, P(203-212), 1976. Halling J. " Introduction to Tribology", University of Salford , P(42-46), 1976. Buckely D.H. " Surface Effects in Adhesion , Friction, Wear, and Lubrication", Tribology Series , Eleserier Scientific Publishing Company , P( 446-449), 1981. Daries V.H. and Botton L.A. " Weld Surfacing and Hard Facing", P(4-10), 1980. Scott D. " Treastic on Materials Science and Technology", Academic Press, New York, Vol. 13, P.(364370),1979. Yust C.S. , " International Metal Rev." , Vol. 30, P.141, 1985. Grainger S. " Engineering Coatings ( Design and Application)", Wood Head Publishing, P(19-21), 1994.

Askwith T.C. " Surface Journal " , Vol.11, P.2, 1980. Galvanetto E. , Borgioli F., Galliano F.P. and Bacci T. " Surface and Coating Technology", 2006. Fabijanic D.M. , Kelly G.L., Long J. and Hodgson P.D. " A nitrocarburising and Low- Temperature Chromising Duplex Surface Treatment" Deankin University, School of Engineering and Technology, 2005. Smart R.F. " The Selection of Surface Coating for Reclamation ", Surfacing Journal, Vol. 10, No.2, P(94109), 1979. Sam Sonov G.V. (Ed.) " Protective Coatings on Metals", Amerind Publishing Co., Pvt. Ltd. Kiev., Vol.6, P(9195), 1984. Halling J. " Principles of Tribology", Published by the Macmillan Press Limited (London), P(94-109),1979. Rabinowicz E. " Friction and Wear of Materials", John Wiley and Sons. Inc., New York, P(113-130), 1965.

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