Chapter 5 Tribology

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
All photos and figures Copyright, Prentice Hall
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)
RJM, 9/16/06
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

RJM, 9/16/06
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
More Complicated Models Exist:
F = Fa + Fp + Fs + Fn
RJM, 9/16/06
Ff N
What about contact stresses??? Recall: Pitting stress in gear teeth
RJM, 9/16/06
How to Measure ???

Do you want s or d??? For most stress analysis want s why??
RJM, 9/16/06
Good for measuring s. You should know how to derive this.
Good for measuring s and d.
RJM, 9/16/06
Typical Friction Force Curves
s = Fa/N d = Fb/N
Stick- Slip difficult to get a
RJM, 9/16/06
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
CASE Study:
Compression seal. Coefficient of friction was key for proper design and analysis.
RJM, 9/16/06
Friction Testing Slide flat EPDM samples across ABS slab
RJM, 9/16/06
CASE Study
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
Test Set-up for K and Stress Relaxation:
Fixed to load frame
ABS
Polycarbonate
Seal glued with 3M CA40H Adhesive
4 seal section shown
Actuator Force/Disp lacement
RJM, 9/16/06
RJM, 9/16/06
L/D Curves for All 4" Samples

350
300 4" Sample #1 250 4" Sample#2 4" Sample #3 4" Sample w/ Polycarbonate contact
Load (lb)
200
4" Sample #1 Immersed 4" Sample #2 Immersed
150
100
Load Only
50
0 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14
Deflection (in)
RJM, 9/16/06
L/D Curves - FEA vs. Measured Results

350
Measured - Incumbent Sample #1 Measured - Incumbent Sample#2 Note: 1. All results for 4" seal length. 2. FEA results - hyper data, 60 duro EPDM, friction = 0.25.
300
Measured - QC-19095 Sample 1" Measured - QC-19095 Sample 2"
250
FEA Results - Incumbent Seal FEA Results - QC-19095 FEA Results - Modified QC-19095
Load (lb)
200
150
Note, modified seal slightly stiffer at lower deflections and softer at higher deflections!
100
50
0 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14
Deflection (in)
RJM, 9/16/06 All photos and figures Copyright, Prentice Hall
Stiffness Summary:
RJM, 9/16/06
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
Figure 5.14 Major Categories of wear and specific types of wear in each category.
RJM, 9/16/06
Types of Wear:
adhesion
Figure 5:20 Adhesion wear localized bonding between contacting surfaces
adhesion
Figure 5-21: Galling wear severe adhesion actually leads to material flow up from the surface.
RJM, 9/16/06
adhesion
Figure 5-23: Fretting wear of splined shaft small oscillatory motion abrades surface looks like rust surface looks pitted.
RJM, 9/16/06
abrasion
F5-24: low stress abrasion wear bushing sliding on shaft
RJM, 9/16/06
Surface fatigue
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!!
RJM, 9/16/06
Surface fatigue
F5-28: Impact wear

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.
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

Figure 5-15: Types of Erosion Note all involve fluids or smoke (particulates)
RJM, 9/16/06
Types of Erosion
erosion
Fig5 16: solid particle erosion due to fly ash.
erosion
5-17: Slurry erosion due to pumping slurry mixture of silica and water
RJM, 9/16/06
RJM, 9/16/06
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
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
Commitment to Health & Safety Industry Leading Dust and Noise Reduction Initiatives
Wethead Cutterhead System Dual Sprocket Conveyor

RJM, 9/16/06
Phoenix, Arizona
Ongoing Developments
Coated Dual Sprocket Chain

RJM, 9/16/06
Phoenix, Arizona
Figure 7-14 abrasion wear of various plastics
RJM, 9/16/06
Taber Test common test for abrasion resistance of elastomers/polymers
RJM, 9/16/06
Compound No.
Rheometer Data
Original Physical Properties
After Aging 70 hrs at 70C
Compression Set
Taber
Ml XM-AR (1) XM-AR (2) XM-AR (3) XM-AR (4) XM-AR (5) 3.28 3.72 3.56 2.41 2.62
Mh 19.59 26.56 19.96 23.36 20.94
ts1
tc90
tan Delta @ Cure Mh Time 0.09 5m35s 0.09 5m20s 0.09 5m11s 0.07 5m55s 0.07 5m21s
Cure 100% 100% Temper Modulu Elong Duro Modulu Elong Duro ature s ation Tensile meter s ation Tensile meter 155 155 155 155 155 496 870 590 736 498 479 290 451 352 423 3439 2504 3405 2562 2981 67.6 75.1 70.6 72 65.6 6.1 2.5 2.7 12.9 7.7 -1.5 -4.5 -0.7 5.4 8.7 -2.2 -5.5 -3.7 8.8 4.7
Cure Time
Cure Temper 22 hrs mg loss ature @ 70 C per rev. 155 155 155 155 155 24.4 25.3 27.4 20.3 19.6 0.0892 0.0305 0.006 0.0187 0.0163
114 335.97 105 319.98 111 311.4
2 10m35s 2.8 10m20s 0.8 10m11s 2.2 10m55s 2.6 10m21s
121.2 355.65 126 321.16
XM-AR (6)
XM-AR (7) XM-AR (8) XM-AR (9) XM-AR (10) Incumbent Mat'l
3.31
0.49 0.77 0.74 3.69
24.85
17.82 20.58 23.83 26.06
127.8 359.58
150 404.82 114 381.98 123.6 434.22 61.2 286.38
0.07 6m0s
0.03 6m45s 0.04 6m22s 0.04 7m14s 0.07 4m37s
155
155 155 155 155
683
780 1306 695 912
393
527 517 524 310
2856
4318 4032 4577 2691
72
68.5 74.2 71.2 76.2
3.5
12.3 -0.3 23.2 3.6
2.3
-20.3 -10.8 -12.4 -9.4
0.7
-14.5 0.6 -2.6 -5.8
2.2 11m0s
1.8 11m45 2.6 11m22s 3.6 12m14s 0.4 9m37s
155
155 155 155 155
9.4
45.4 34.2 39.2 25.7
0.0163
0.0261 0.164 0.0239 0.0108 0.0154
RJM, 9/16/06
300,000 tons Key Property: Abrasion resistance?? Tear Strength?? Coef of Friction??

Chapter 5 Tribology

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Chapter 5 Tribology

Uploaded by

Copyright:

Available Formats

Chapter 5 The Role of Tribology in Engineering Materials

All photos and figures Copyright, Prentice Hall

All photos and figures Copyright, Prentice Hall

Friction Force Assumptions: Ff independent of contact area, = constant

More Complicated Models Exist:

All photos and figures Copyright, Prentice Hall

More Complicated Models Exist:

What about contact stresses??? Recall: Pitting stress in gear teeth

All photos and figures Copyright, Prentice Hall

How to Measure ???

All photos and figures Copyright, Prentice Hall

Good for measuring s. You should know how to derive this.

Good for measuring s and d.

All photos and figures Copyright, Prentice Hall

Typical Friction Force Curves

Stick- Slip difficult to get a

All photos and figures Copyright, Prentice Hall

All photos and figures Copyright, Prentice Hall

All photos and figures Copyright, Prentice Hall

Friction Testing Slide flat EPDM samples across ABS slab

All photos and figures Copyright, Prentice Hall

Coefficient of Friction Results:

All photos and figures Copyright, Prentice Hall

Test Set-up for K and Stress Relaxation:

Fixed to load frame

Seal glued with 3M CA40H Adhesive

4 seal section shown

Actuator Force/Disp lacement

All photos and figures Copyright, Prentice Hall

All photos and figures Copyright, Prentice Hall

L/D Curves for All 4" Samples

4" Sample #1 Immersed 4" Sample #2 Immersed

0 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14

All photos and figures Copyright, Prentice Hall

L/D Curves - FEA vs. Measured Results

Measured - QC-19095 Sample 1" Measured - QC-19095 Sample 2"

0 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14

All photos and figures Copyright, Prentice Hall

5.4 Definition of Surface Wear

All photos and figures Copyright, Prentice Hall

Figure 5:20 Adhesion wear localized bonding between contacting surfaces

All photos and figures Copyright, Prentice Hall

All photos and figures Copyright, Prentice Hall

F5-24: low stress abrasion wear bushing sliding on shaft

All photos and figures Copyright, Prentice Hall

All photos and figures Copyright, Prentice Hall

F5-28: Impact wear

Key: Bonds between atoms!

F 3-27: Factors that affect wear at various size levels.

Key: Surface asperities

Key: Surface confromanc e

All photos and figures Copyright, Prentice Hall

Fig5 16: solid particle erosion due to fly ash.

All photos and figures Copyright, Prentice Hall

All photos and figures Copyright, Prentice Hall

All photos and figures Copyright, Prentice Hall

Joy Continuous Mining Machines

14CM series targeted for noise reduction

2010 SME Annual Meeting & Exhibit

All photos and figures Copyright, Prentice Hall

2010 SME Annual Meeting & Exhibit

All photos and figures Copyright, Prentice Hall

Coated Dual Sprocket Chain