Bruker SlidingFriction Presentation 07262013 PDF

1
The Connection between Surface Texture and Sliding Friction

by
Donald K. Cohen, Ph.D.
Gwidon W. Stachowiak and Andrew W. Batchelor (2005), Engineering Tribology, Elsevier Butterworth-Heinemann, UK
Bharat Bhushan, (2002), Introduction to Tribology, J ohn Wiley & Sons, New York.
Duncan Dowson, (1998), History of Tribology, Bookcraft (Bath) Ltd. Great Britain.
Peter J . Blau Friction Science and Technology, 1996, Marcel Decker, Inc. New York, NY 10016
Kenneth C. Ludema, Friction, Wear and Lubrication, 1996, CRC Press, Boca Raton, FLA 33431
Ernest Rabinowicz, Friction and Wear of Materials, J ohn Wiley & Sons, 1995, New York, NY
Frank Phillip Bowden and David Tabor (1982), Friction, An Introduction to Tribology, Robert E. Kreiger. Floriday, USA.
Key References:
2
Surface Texture - Basics
Surface: The boundary that separates an object from another object,
substance, or space
Texture: The composite of certain deviations that are typical
of the real surface. It includes roughness and waviness
X
Y
Z
Surface Roughness, Ra (2D), Sa (3D) is the average of the absolute
value of profile heights over a given length (area).
dxdy y x Z
A
S
Lx Ly
a

=
0 0
) , (
1
L
R
L
Z x dx
a
L
=

1
0
( )
2D
3D
ASME B46.1 2009
X
Z
3
dxdy
Ly
Lx
y x Z
A
q
S

=
0 0
2
)) , ( (
1
Sq: The Root-mean-square deviation of the
surface
X
Y
Z
Height Parameters
Ssk: Skewness of surface height distribution

dxdy
Ly
Lx
y x Z
A Sq
sk
S

=
0 0
3
)) , ( (
3
1
Sku: Kurtosis of surface height distribution

dxdy
Ly
Lx
y x Z
A Sq
ku
S

=
0 0
4
)) , ( (
4
1
Sa: The average deviation of the surface
dxdy
Ly
Lx
y x Z
A
S
a

=
0 0
) , (
1
ASME B46.1 / ISO 25178-2
Ssk<<0.0 Ssk>>0.0
Sku<3.0 Sku>3.0
4
What is Friction?

Friction is the resistance to motion during sliding or rolling that is
experienced when one solid body moves tangentially over another with
which it is in contact. The resistive tangential force, which acts in a direction
directly opposite to the direction of motion is called the friction force
(Bhushan)

F
f
= W is the coefficient of friction

Friction is NOT strictly a property of the material
its a system response
Sliding Friction and Surface Texture Introduction
F

F
f
W
F

F
f
W
Sliding Friction Rolling Friction
5
Friction Good or Bad?

Application Specific: Sometimes need friction
sometimes want it to be zero
www.animationfactory.com
6
Sliding Friction and Surface Texture
Ernest Rabinowicz, Friction and Wear of Materials, J ohn Wiley & Sons, 1995, New York, NY

7
History
1452-1519
1. The areas in contact have no effect on friction.
2. If the load (weight) of an object is doubled, its friction will also be doubled
Leonardo da Vinci
8
No Picture Exists!! It is impossible that these irregularities shall not be partly convex and partly
concave, and when the former enter upon the latter they shall produce a certain
resistance when there is an attempt to move them.
Considered the fundamental cause of friction being
surface roughness
force required to lift interlocking asperities
1663-1705
Guillaume Amontons
History
9
Sliding Friction and Surface Texture Introduction - History
Does friction primarily comes from surface roughness..?
1683-1744
J ohn Theophilus Desagulier
yet it is found by experience that the flat surface of metals or other
bodies may be so far polished as to increase the friction
Introduces the concept of cohesion (today we call it adhesion)
Trouble: Adhesion theory cant explain laws of
frictionApparent area
10
1736-1806
Charles Augustin Coulomb
Coefficient of friction is independent of velocity
Considers F
f
~ Adhesion + Roughness
Turned Surface Max Slope ~15
o

Frank Phillip Bowden and David Tabor (1982), Friction An Introduction to Tribology,
11
1. The apparent area of contact has no effect on friction.
2. If the load (weight) of an object is doubled, its friction will also be doubled
Refresh!!
So which is it? Roughness?, Adhesion?, Shearing of Asperities (Lesile, Phillipe de la
Hire)?
F
f
= W
12
Frank Phillip Bowden(1903-1968)
Abbott and Firestone (1933) ( U of Michigan)-Invent Profilometer
David Tabor (1913-2005)
putting two solids together is rather like turning Switzerland upside
down and standing it on Austria their area of intimate contact will be
small (1950)
more closely Iowa on top of the Netherlands (Thomas 1973)
13
Sliding Friction Strength of Materials Review
Bharat Bhushan, (2002), Introduction to Tribology, J ohn Wiley & Sons, New York
Stress =Force/area
Strain L/L
E Young's Modulus of Elasticity
Y - Yield Strength
H - Hardness Resistance of metal to plastic deformation, usually by indentation
H ~3Y (metals)
14
Sliding Friction- Physics
Bowden/Tabor revisit adhesion theory....why?
Asperity slopes << 15
o,
also - Smooth metals increase in friction, lubricants
Consider the Real Area (A
rp
) of contact vs Apparent Area A
a
of contact
Plastic Deformation
Assume plastic flow at the asperity mini hardness test
Form enough junctions to support the applied force (W)

W=A
rp
H (H~3Y) (Y is the yield strength)
W/A
a
= (A
rp
/A
a
)H
A
rp
/A
a
= (W/A
a
)/H
Steel Y~ 10
5
PSI , so 200 psi load on 1in
2
steel A
rp
/A
a
~0.05%
Aluminum Y~3000 PSI, so 200 psi load on 1in
2
A
rp
/A
a
~2%
W
A
a
A
rp
15
Sliding Friction - Physics
Bowden/Tabor key point

A
rp
= W/H;
Real area of contact
1) Proportional to Force
2) Independent of apparent area of contact

sounds like friction!

Maybe friction will be related to the real area of contact??
Friction (F
f
) is the force required to shear intermetallic junctions plus the force required to
plow the surface of the softer material by asperities of the harder surface
(Bowden/Tabor).Consider the shear term
F
fp
= A
rp
s (s is shear strength of junctions)
Recall (pure plastic): A
rp
= W/H so F
fp
= W(s/H) =s/H

metals, s~0.5Y=H/6
So =1/6 (~0.2)
16
Sliding Friction - Physics
Bowden/Tabor:
F
fp
proportional to normal force
F
fp
not dependent on the apparent area of contact
F
fp
will be reduced by lubricants that lower shear strength of asperities
F
fp
(adhesion) not dependent on the surface roughness ???
BUT:
Are all contacts purely plastic?
How about elastic deformation?
Typically surface deforms plastically (work hardens?) then stabilizes-elastic support
Experience indicates some frictional dependence on surface roughness
F
f
= W(s/H)
17
Sliding Friction Strength of Materials Review again
Stress =Force/area
- Strain L/L
E Young's Modulus of Elasticity
Y - Yield Strength
H - Hardness Resistance of metal to plastic deformation, usually by indentation
H ~3Y (metals)
- Poissons ratio
= -
trans
/
longitudinal
= L/L
http://silver.neep.wisc.edu/~lakes/PoissonIntro.html
18
Sliding Friction Physics Real Contact Hertz
1880s
R
1

R
2

W
Elastic Real Area of Contact, A
re

3 / 2
*
4
3
|
.
|
\
|
=
E
WR
A
re

2 1
1 1 1
R R R
+ =
2
2
2
1
2
1
*
1 1 1
E E E

+
=
1857-1894
Heinrich Hertz
19
Sliding Friction Physics Real Contact
3 / 2
*
4
3
|
.
|
\
|
=
E
WR
A
re

In words
Smaller Asperity Radii Smaller real area
Larger Elastic Modulus Smaller real area
GPa E
steel
200
1 GPa = 1x 10
9
N/M
2
= 1.45 x 10
5
psi
GPa E
lead
15
GPa E
SiC
500
GPa E
rubber
001 . 0
20
Greenwood & Williamson - 1966
W
A
a
Apparent Area
A
a

W
Asperities of same radii
Asperities of random distribution of heights (e.g. Gaussian, exponential etc..)
Asperities separated no interaction
Exponential Distribution success!!
2 / 1
*
|
|
.
|
\
|
|
.
|
\
|
R
E
W
A
re
W - force applied
E
*
- composite Elastic Modulus
R summit radius of curvature
is the standard deviation of the peak heights
21
Greenwood Williamson - 1966
W
A
a

W
Recall:
F
fe
= A
re
Substituting for A
re

F
fe
~ W
F
fe
has no dependence on Apparent Area

Consistent with Amonton
2 / 1
*
|
|
.
|
\
|
|
.
|
\
|
R
E
W
s F
fe
A
a

22
2 / 1
*
|
|
.
|
\
|
|
.
|
\
|
R
E
W
A
re
Dry Friction Physics Real Contact
Greenwood Williamson - 1966
In Words
Larger the applied force larger real area of contact (friction )
Larger Elastic Modulus smaller area of contact (friction)
Larger Summit Radii larger area of contact (friction)
Larger the roughness smaller area of contact (friction)
*

F
fe
= A
re
s
Friction ~ shear strength of the real regions of contact
* elastic domain
23
Greenwood Williamson 1966

1) Only Exponential law gives Laws of Friction results
2) Other frictional mechanisms (e.g. plowing) not considered
3) Asperity on asperity/ resolution - reality
4) Assumes elastic contact only next step is plasticity

Laws of friction follows since all surfaces have texture
The mean asperity real contact area is independent of applied force -Exp dist onlyR
The mean asperity real pressure very weak dependence on applied force -Exp dist onlyE
*
(/R)
1/2

The number of contacts are proportional to applied force -Exp Dist only W/(E
*

(
3
R)
1/2
)
Good News
Bad News
24
Sliding Friction Physics Elastic and Plastic
Greenwood & Williamson 1966

2 / 1
*
|
|
.
|
\
|
|
.
|
\
|
R
E
W
A
re
A
rp
= W/H
Pure Elastic
Pure Plastic
Plastic deformation will begin when the pressure at the asperity is greater than H.
Calculate for various distribution (e.g. Exp) the probability of plastic deformation
...) , ( W f
A
A
re
rp
=
2
1
*
|
.
|
\
|
|
|
.
|
\
|
=
R H
E
Plasticity Index
(very weak dependence on W)
H- hardness of lowest hardness surface at interface
25
2
1
*
|
.
|
\
|
|
|
.
|
\
|
=
R H
E
r
A
2 / 1
*
|
|
.
|
\
|
|
.
|
\
|
R
E
W
A
re
A
rp
= W/H
1.0
0.6

<0.6 elastic regime Larger A
r
higher friction (Too Smooth)
>1.0 plastic regime, lower Ar,but..
deformation, wear etc. eventually back to elastic regime or
.scoring scuffing galling failure etc..
26

2
1
*
|
.
|
\
|
|
|
.
|
\
|
=
R H
E
160 nm
R 10 um
100 nm
R 70 um
Likely - Elastic Deformation
Likely - Plastic Deformation
27
Sliding Friction Physics Reset Real Area of Contact

2 / 1
*
|
|
.
|
\
|
|
.
|
\
|
R
E
W
A
re
A
rp
= W/H
Elastic Mode
Plastic Mode 2
1
*
|
.
|
\
|
|
|
.
|
\
|
=
R H
E
Plasticity Index - Predicts Elastic or Plastic
Friction relates to the Adhesion between surfaces at the real area of contact.
Adhesion chemical bonds, mechanical, etctotally different/new field
F
fp
= A
rp
Recall (pure plastic): A
rp
= W/H so F
fp
= W(s/H)
ap
=s/H

F
fe
= A
re
Recall (pure elastic):
2 / 1
*
|
|
.
|
\
|
|
.
|
\
|
R
E
W
A
re
sW
E
R
F
fe
2 / 1
2 *
|
.
|
\
|
2 / 1
2 *
|
.
|
\
|
E
R
s
ae
28
Dry Friction Physics Elastic and Plastic - Models
AF- Abbot Firestone 1933 Pure Plastic (Truncation Model)
GW Greenwood and Williamson 1966- Elastic only spherical contacts etc.
CEB Cheng, Etsion, Bogy 1987 Elastic/Plastic
KE Kogut and Etsion 2004 - Elastic/Plastic and tangential loading effects
J amari and Schipper 2006 Elastic/Plastic Ellipsoids asperities
J . J amari and D.J . Schipper, An elastic-plastic contact model of ellipsoid bodies, Tribology Letters, Vol. 21 No. 3 march 2006.
F=external Load
P=Aspertiy Contact Force
Fs=Total Adhesive Force
Qmax-Static Friction Force
29
Friction Physics Rough Surface Contacts
C.Y. Poon and R. S. Sayles, The Classification of rough surface contacts in relation to tribology, J . Phys D: Appl.
Phys. 25 (1992) A249-A256
F
r
i
c
t
i
o
n

C
o
e
f
f
i
c
i
e
n
t

30
2
1
*
|
.
|
\
|
|
|
.
|
\
|
=
R H
E
r
A
2 / 1
*
|
|
.
|
\
|
|
.
|
\
|
R
E
W
A
re
A
rp
= W/H
1.0
0.6
Unworn
high friction - deformation
Worn- run-in
Minimal friction
Very worn
high friction larger A
r
adhesion
Sliding Friction -- Engine- Valve Train Components

31
Sliding Friction
Transmission Components

2 / 1
*
|
|
.
|
\
|
|
.
|
\
|
R
E
W
A
re
32
Sliding Friction Physics Plowing Term

) tan( 2
=
d
Assumes isotropic material
Gear Surface
6 deg
d
0.06
100:1 Vertical Magnification
33

Plowing Term Not that big for typical machined surface textures
But! - debris and wear particlesanother story
Sand Particle (Ottawa 16)
Slope ~ 30 deg

d
0.36
Also --Sandpaper, brake pads etc
34
Sa: In spec
Sdq: Low
Sa: In spec
Sdq: High
Problem: Brake Rotor Sa inspec some work ..some have NVH issues
Solution: Quantify the surfaces Spec additional texture parameters q
Solution: Identify cause of texture variation..(materials? tools? setup?)
Glenn R. Weier, Kelsey Hayes 1995

dydx
y
y x Z
Ly
x
y x Z
Lx
A
Sdq
2
) , (
0
2
) , (
0
1
|
|
.
|
\
|
+
|
.
|
\
|
=
Sdq: Root-Mean Square Surface Slope
35
Sliding Friction Physics Surface Texture

Bottom Line What is the connection between Surface Texture and Friction?
1) Friction - adhesion at the real area of contact
2) Friction - the deformation of asperities
2) Friction - plowing of the harder asperities into the softer material
Other Texture Parameters can relate to the real area of contact/asperity slope
..this has been the source of confusion/speculation/empirical work
Surfaces are not a nice distribution of asperities of radius R
36
Kotwal, C.A. and Bhuhsan, B. (1996) Contact Analysis of Non-Gaussian Surface for
Minimum Static and Kinetic Friction and Wear Tribol. Trans. 39, 890-898
elastic limit
Sliding Friction Physics Surface Texture Parameters

Ssk
Sku
Sku=3.0
Ssk=0.0
Ssk<<0.0 Ssk>>0.0
Sku<3.0 Sku>3.0
37
Functional Bearing Area Parameters .. Spk, Sk Svk....
D C
B A
tp
=100% x (A +B +C +D )/L
Spk =Peak Height .. First Region of contact
Sk =Core Height... working Region ..Base
Svk =Valley Depth ... Lubricant Retention Region
tp
Peaks

Core

Valleys
100%
50%
0%
Min Ht
Max Ht
40%
Svk
Sk
Spk
Mr1 Mr2
mr
Friction Physics Surface Texture Parameters

Abbott and Firestone (1933)
38
Cylinder Bore Finishes and Their Effect on Oil Consumption
Stephen H. Hill,
SAE, 2001-01-3550
LD=Production Gasoline Auto Engines
Units in um unless specified
C
y
l
i
n
d
e
r

B
o
r
e

Best predictor of Oil Consumption, Vo,
Vo = Svk(100-Mr2)/200
Careful of Vo units etc.
39
Sliding Friction Physics Surface Texture Parameters

Functional Bearing Area Parameters .. Spk, Sk, Svk....
40
K
S
S
S
S S
S
S SI
z
a
sk
sm vk
pk
k
+
(
=
1
log
SI = Surface Index for TFM
SIW SI for Optical Profiler
SIT SI for Stylus Profiler
Largest SI Worst TFM
K for optical or stylus
Tribology Transactions, 51: 784-789, 2008
41
Effect of Roughness Parameter and Grinding Angle on Coefficient of
Friction When Sliding os Al-Mg Alloy over EN8 Steel
Pradeep L. Menezes Kishore and Satish V. Kailas,
ASME J ournal of Tribology, October 2006, Vol 128. p 697-704
The coefficient of friction and transfer layer formation were observed to depend
primarily on the direction of the grinding marks of the harder mating surface and
independent of the surface roughness of harder mating surface.
Direction of Motion
42
Modeling and Optimizing Honing Texture for Reduced Friction in Internal
Combustion Engines
J effrey J ocsak, Yong Li, Tian Tain and Victor K. Wong
SAE, 2006-01-0647
MIT-Ring-Pack Simulation Program
Reduce Cross Hatch Angle -reduces friction (less asperity contact/more hydrodynamic lift)
However, -Tradeoff- As reduce cross hatch angle increase risk of scuffing (TDC) / oil consumption
u
u
=
0 =
h
F
r
i
c
t
i
o
n

43
Cross Hatch Angle Analysis
Sliding Friction 3D Texture Directional Analysis

44
Conclusion Sliding Friction and Surface Texture
Friction relates to adhesion of surfaces at points of real contact
.Real area of contact relates to surface texture

Friction relates to deformation / plowing asperity shape/slope
Asperity Shape/Slope relates to surface texture

The challenge is choosing the right lateral/height resolution
for measurement and the appropriate texture parameters to
relate to friction and then to optimize for desired friction
What is clear, is that the study of surface roughness continues to get more
complicated and that we are a long way from understanding it.
J . A. Greenwood (1992)

I.L. Singer and H.M. Pollock (eds.) Fundamentals of Friction: Macroscopic and
Microscopic Processes 57-76 1992 Kluwer Academic Publishers, Netherlands.

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The Connection between Surface Texture and Sliding Friction

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