Wear Mechanisms - Definition Analysis Protective Techniques

19-Feb-15
Lecture 6 Wear Mechanisms - Definition,

Analysis & Protective Techniques
I.
II.
III.
IV.
V.
VI.
Wear
Adhesive Wear
Abrasive Wear
Corrosive Wear
Fatigue Wear
Other Types of Wear
Wear
The importance of wear is evident in the number of parts

and components that continually have to be replaced or
repaired.
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Manufacturing Processes & Metrology
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Wear
Wear
Examples of Wear in manufacturing processes include;
Although wear generally alters a parts surface topography and

may result in severe surface damage, it can also have a beneficial
effect.
The running-in period for various machines and engines
produces wear in order to remove the peaks from asperities (Fig.
below).
Wear plates, placed in dies and sliding mechanisms where the

loads are high, are an important component in some
metalworking machinery.
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Wear
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Adhesive Wear
If a tangential force is applied to the model shown in next
Fig., shearing can take place either;
Because of factors such as strain hardening at the asperity

contact, diffusion, and mutual solid solubility, the adhesive
bonds often are stronger than the base metals.
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Adhesive Wear
Adhesive Wear
Although this fragment is typically attached to the harder

component (the upper surface in Fig. c), it eventually becomes
detached during further rubbing at the interface and develops
into a loose Wear particle.
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Adhesive Wear
Adhesive Wear
In more severe cases, such as ones with high loads and strongly
bonded asperities, adhesive wear is described as scuffing,
smearing, tearing, galling, or seizure (severe wear).
Adhesive wear can be reduced by one or more of the following

methods:
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Abrasive Wear
Abrasive Wear
This type of wear is caused by a hard, rough surface or a surface

containing hard, protruding particles sliding across another
surface.
As a result, Microchips or silvers are produced as wear
particles, thereby leaving grooves or scratches on the softer
surface (Next Fig.).
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Abrasive Wear
In fact, processes such as filing, grinding, ultrasonic machining,
and abrasive-jet and abrasive water-jet machining act in this
manner.
Abrasive Wear
There are two basic types of abrasive wear.
In two-body wear, abrasive action takes place between
two sliding surfaces or between a hard, abrasive particle
in contact with a solid body.
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Abrasive Wear
Abrasive Wear
In three-body wear, an abrasive particle is present

between two sliding solid bodies, such as a wear particle
carried by a lubricant.
The abrasive-wear resistance of pure metals and ceramics has

been found to be directly proportional to their hardness.
Thus, abrasive wear can be reduced by increasing the
hardness of materials (usually by heat treating) or by reducing
the normal load.
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Corrosive Wear
Corrosive Wear
Also known as oxidation or chemical wear, this type of wear

is caused by chemical and electrochemical reactions
between the surface and the environment.
When the corrosive layer is destroyed or removed through

sliding or abrasion, another layer begins to form, and the
process of removal and corrosive layer formation is repeated.
Among corrosive media are:
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Corrosive Wear
Corrosive wear can be reduced by:
Fatigue Wear
Fatigue wear, also called surface fatigue or surfacefracture wear, is caused when the surface of a material is
subjected to cyclic loading, such as rolling contact in
bearings.
The wear particles usually are formed through spalling or
pitting.
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Fatigue Wear
Fatigue Wear
Thermal fatigue is another type of fatigue wear, whereby

surface cracks are generated by thermal stresses from thermal
cycling, as when a cool die repeatedly contacts hot
workpieces.
Fatigue wear can be reduced by:
The cracks then join, and the surface begins to spall,

producing fatigue wear in a phenomenon known as heat
checking.
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Other Types of Wear
Other Types of Wear
Several other types of wear can be seen in manufacturing

operations.
Erosion
Fretting corrosion
Impact Wear
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Wear of Thermoplastics
Wear of Reinforced Plastics
The wear behavior of thermoplastics is similar to that of metals.
The wear resistance of reinforced plastics depends on the type,

amount, and direction of reinforcement in the polymer matrix.
Their abrasive-wear behavior depends partly on the ability of

the polymer to deform and recover elastically, as in elastomers.
Typical polymers with good wear resistance are;
Carbon, glass, and aramid fibers all improve wear resistance.

Wear takes place when fibers are pulled out of the matrix (fiber
pullout).
Wear is highest when the sliding direction is parallel to the
fibers, because they can be pulled out more easily in this case.
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Wear of Ceramics
When ceramics slide against metals, wear is caused by:
a)
b)
c)
d)
small-scale plastic deformation and brittle surface fracture,

surface chemical reactions,
plowing, and
fatigue.
Metals can be transferred to the oxide-type ceramic surfaces,

forming metal oxides.
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Lecture 6 Summary
I.
II.
III.
IV.
V.
VI.
Wear
Adhesive Wear
Abrasive Wear
Corrosive Wear
Fatigue Wear
Other Types of Wear
BIBLIOGRAPHY:
1. Kalpakjian S, Schmid SR. Manufacturing Engineering and Technology,
Sixth ed. Singapore: Prentice Hall; 2010. Copyright 2014 by Pearson
Education South Asia Pte Ltd. All rights reserved. PEARSON
2. Groover, M.P (2010) Fundamentals of Modern Manufacturing, 4th edn.,
USA: John Wiley & Sons, Inc
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19-Feb-15

Lecture 6 Wear Mechanisms - Definition,

The importance of wear is evident in the number of parts

Examples of Wear in manufacturing processes include;

Although wear generally alters a parts surface topography and

Wear plates, placed in dies and sliding mechanisms where the

Because of factors such as strain hardening at the asperity

Although this fragment is typically attached to the harder

Adhesive wear can be reduced by one or more of the following

This type of wear is caused by a hard, rough surface or a surface

In three-body wear, an abrasive particle is present

The abrasive-wear resistance of pure metals and ceramics has

Also known as oxidation or chemical wear, this type of wear

When the corrosive layer is destroyed or removed through

Thermal fatigue is another type of fatigue wear, whereby

Fatigue wear can be reduced by:

The cracks then join, and the surface begins to spall,

Other Types of Wear

Other Types of Wear

Several other types of wear can be seen in manufacturing

Wear of Reinforced Plastics

The wear behavior of thermoplastics is similar to that of metals.

The wear resistance of reinforced plastics depends on the type,

Their abrasive-wear behavior depends partly on the ability of

Carbon, glass, and aramid fibers all improve wear resistance.

small-scale plastic deformation and brittle surface fracture,

Metals can be transferred to the oxide-type ceramic surfaces,

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