CHAPTER 32

Tribology: Friction, Wear, and Lubrication

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-1

Contact Between Two Bodies

Figure 32.1 Schematic illustration of the interface of two bodies in contact, showing real areas of contact at the asperities. In engineering surfaces, the ratio of the apparent to real areas of contact can be as high as 4-5 orders of magnitude.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-2

Range of Coefficients of Friction in Metalworking Processes

TABLE 32.1

Process
Rolling Forging Drawing Sheet-metal forming Machining

Coefficient of friction ( ) Cold Hot

0.050.1 0.050.1 0.030.1 0.050.1 0.52 0.20.7 0.10.2 0.10.2

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-3

Ring Compression Tests

(b)

Figure 32.2 Ring compression test between flat dies. (a) Effect of lubrication on type of ring specimen barreling. (b) Test results: (1) original specimen and (2)-(4) increasing friction. Source: A. T. Male and M. G. Cockcroft.
Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-4

Friction Coefficient from Ring Test

Figure 32.3 Chart to determine friction coefficient from ring compression test. Reduction in height and change in internal diameter of the ring are measured; then is read directly from this chart. Example: If the ring specimen is reduced in height by 40% and its internal diameter decreases by 10%, the coefficient of friction is 0.10

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-5

Effect of Wear on Surface Profiles

Figure 32.4 Changes in originally (a) wire-brushed and (b) ground-surface profiles after wear. Source: E. Wild and K. J. Mack.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-6

Adhesive and Abrasive Wear

Figure 32.5 Schematic illustration of (a) two contacting asperities, (b) adhesion between two asperities, and (c) the formation of a wear particle.

Figure 32.6 Schematic illustration of abrasive wear in sliding. Longitudinal scratches on a surface usually indicate abrasive wear.
Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-7

Types of Wear Observed in a Single Die

Figure 32.7 Types of wear observed in a single die used for hot forging. Source: T. A. Dean

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-8

Types of Lubrication
Figure 32.8 Types of lubrication generally occurring in metalworking operations. Source: After W.R.D. Wilson.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-9

Rough Surface
Figure 32.9 Rough surface developed on an aluminum compression specimen by the presence of a highviscosity lubricant and high compression speed. The coarser the grain size, the rougher the surface. Source: A. Mulc and S. Kalpakjian.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 7-10