Chapter 5 The Role of Tribology

in Engineering Materials
Tribology comprises the science and technology of
interacting surfaces in relative motion; that is, friction,
lubrication and wear. Tribology is a vast and
interdisciplinary subject, ranging from the fundamental
physics of surface contact and adhesion to the
application of advanced materials and lubricants to solve
practical industrial friction and wear problems.

RJM, 9/16/06

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Motivation:
Most common forms of metal failure:
Corrosion
Fatigue (cyclic loading)
Wear (surface abrasion due to excessive
friction or lack of lubrication) = TRIBOLOGY
CASE STUDIES (my own)

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What is Friction
Force tangential to
the interface of two
contacting bodies =
Ff.
Dynamic and static
Dynamic produces
heat

Coefficient of friction
s and d

Ff N
Normal Force

Friction Force
Assumptions: Ff independent of contact area, = constant
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More Complicated Models Exist:

Contact Mechanics
In actuality, as N
increases,
contact area
increases,
thereby affecting
. is a nonlinear function of
N. What else
might vary
with??

RJM, 9/16/06

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More Complicated Models Exist:

F = Fa + Fp + Fs + Fn
RJM, 9/16/06

Ff N
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What about contact

stresses???
Recall: Pitting stress
in gear teeth

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How to Measure ???

Do you want s or d???
For most stress analysis want s why??

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Good for measuring s.

You should know how
to derive this.

Good for measuring s

and d.

RJM, 9/16/06

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Typical Friction Force Curves

s = Fa/N
d = Fb/N

Stick- Slip difficult

to get a

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Figure 3-8: Average n

for various materials
in reciprocating
motion of an annular
ring rider (.1 sq in) on
a type 316 stainless
steel counter face at
20 C 50% relative
humidity at various
normal forces. The
stroke was 50 mm
and the frequency
was 0.5 Hertz. The
friction force was
averaged for eight
cycles for each test.

RJM, 9/16/06

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CASE Study:
Compression seal. Coefficient of friction
was key for proper design and analysis.

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Friction Testing Slide flat EPDM samples across ABS slab

RJM, 9/16/06

CASE Study

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Coefficient of Friction Results:

Incumbent Material = 0.15, 0.13
M-858-2(2) = 0.23, 0.17
M-858-2(6) = 0.30, 0.30
M-858-2(7) = 0.24, 0.21
M-858-2(8) = 0.23, 0.22
M-858-2(9) = 0.37, 0.38
M-858-2(10) = 0.31, 0.31
M-858-2(12) = 0.36, 0.33
M-858-2(13) = 0.25, 0.29
M-858-2(14) = 0.29, 0.25
M-858-2(15) = 0.21, 0.24
M-858-2(16) = 0.21, 0.28

RJM, 9/16/06

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Test Set-up for K and Stress

Relaxation:

Fixed to
load frame

ABS
Polycarbonate

Seal glued with

3M CA40H
Adhesive

RJM, 9/16/06

4 seal section shown

Actuator
Force/Disp
lacement
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RJM, 9/16/06

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Load Only

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Note,
modified seal
slightly stiffer
at lower
deflections
and softer at
higher
deflections!

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Stiffness Summary:

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WEIGHT USED: SLED + 1LB

WEIGHT (704g)

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RJM, 9/16/06

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5.4 Definition of Surface Wear

Wear - Damage to a solid surface

involving progressive loss of material due

to contact and relative motion with another
surface. 13 types of wear!!
Erosion Damage to a solid surface
involving progressive loss of material due
to mechanical interaction between that
surface and a fluid, impinging liquid or
solid particles. 5 kinds of erosion
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Figure 5.14 Major Categories of wear and specific types of wear in

each category.

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Types of Wear:

adhesion

adhesion

RJM, 9/16/06

Figure 5:20 Adhesion

wear localized
bonding between
contacting surfaces

Figure 5-21: Galling wear

severe adhesion actually leads
to material flow up from the
surface.

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adhesion

RJM, 9/16/06

Figure 5-23:
Fretting wear
of splined
shaft small
oscillatory
motion
abrades
surface
looks like rust
surface
looks pitted.

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abrasion

F5-24: low stress abrasion wear bushing sliding

on shaft

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Surface fatigue

RJM, 9/16/06

F 5-27 Pitting surface

fatigue large roller
thrust bearing race
compressive stress
developed between roller
bearing and race =
pitting. Material actually
fatigued and removed
from surface!!

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Surface fatigue

F5-28: Impact wear

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Surface fatigue

F 5-30: Brinelling brinelling of bearing race due to static overload. Note

brinelling more of a static failure (indentation) versus fatigue or wear failure.
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Key: Bonds
between
atoms!

Key:
Dislocation
s

F 3-27: Factors that affect wear

at various size levels.
Key: Grain
Size

Key:
Surface
asperities

Key:
Surface
confromanc
e
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Figure 5-15: Types of Erosion Note all involve fluids or smoke

(particulates)

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Types of Erosion

erosion

erosion

RJM, 9/16/06

Fig5 16: solid

particle erosion
due to fly ash.

5-17: Slurry
erosion due to
pumping slurry
mixture of silica
and water

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RJM, 9/16/06

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Case Study WEAR

Requirement: Coat steel flight bars on conveyor of continuous
miner with soft material for noise reduction. Must meet life
requirement of 500,000 tons of coal (min) without significant wear.

RJM, 9/16/06

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Joy Continuous Mining Machines

12CM Series

12HM Series

14CM Series

14CM series targeted for noise reduction

2010 SME Annual Meeting & Exhibit

RJM, 9/16/06

Phoenix, Arizona

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Commitment to Health & Safety

Industry Leading Dust and Noise Reduction Initiatives
Wethead Cutterhead System

Dual Sprocket Conveyor

2010 SME Annual Meeting & Exhibit

RJM, 9/16/06

Phoenix, Arizona

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Ongoing Developments

Coated Dual Sprocket Chain

2010 SME Annual Meeting & Exhibit
RJM, 9/16/06

Phoenix, Arizona

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Figure 7-14
abrasion wear
of various
plastics

RJM, 9/16/06

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Taber Test common test

for abrasion resistance of
elastomers/polymers

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Compound
No.

Rheometer Data

Ml

Mh

ts1

tc90

Original Physical Properties

tan
Delta @
Mh

Cure
Time

After Aging 70 hrs at 70C

Compression Set

Cure
100%
100%
Temper Modulu Elong
Duro Modulu Elong

Duro
ature
s
ation Tensile meter
s
ation Tensile meter

Cure
Time

Taber

Cure
Temper 22 hrs mg loss
ature @ 70 C per rev.

XM-AR (1)

3.28

19.59

114 335.97

0.095m35s

155

496

479

3439

67.6

6.1

-1.5

-2.2

210m35s

155

24.4

0.0892

XM-AR (2)

3.72

26.56

105 319.98

0.095m20s

155

870

290

2504

75.1

2.5

-4.5

-5.5

2.810m20s

155

25.3

0.0305

XM-AR (3)

3.56

19.96

111

311.4

0.095m11s

155

590

451

3405

70.6

2.7

-0.7

-3.7

0.810m11s

155

27.4

0.006

XM-AR (4)

2.41

23.36

121.2 355.65

0.075m55s

155

736

352

2562

72

12.9

5.4

8.8

2.210m55s

155

20.3

0.0187

XM-AR (5)

2.62

20.94

126 321.16

0.075m21s

155

498

423

2981

65.6

7.7

8.7

4.7

2.610m21s

155

19.6

0.0163

XM-AR (6)

3.31

24.85

127.8 359.58

0.076m0s

155

683

393

2856

72

3.5

2.3

0.7

2.211m0s

155

9.4

0.0163

XM-AR (7)

0.49

17.82

150 404.82

0.036m45s

155

780

527

4318

68.5

12.3

-20.3

-14.5

1.811m45

155

45.4

0.0261

XM-AR (8)

0.77

20.58

114 381.98

0.046m22s

155

1306

517

4032

74.2

-0.3

-10.8

0.6

2.611m22s

155

34.2

0.164

XM-AR (9)

0.74

23.83

123.6 434.22

0.047m14s

155

695

524

4577

71.2

23.2

-12.4

-2.6

3.612m14s

155

39.2

0.0239

XM-AR (10)

3.69

26.06

61.2 286.38

0.074m37s

155

912

310

2691

76.2

3.6

-9.4

-5.8

0.49m37s

155

25.7

0.0108

Incumbent
Mat'l

RJM, 9/16/06

0.0154

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300,000 tons
Key Property: Abrasion resistance?? Tear
Strength?? Coef of Friction??
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