Tribology

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

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

N F
f

Friction Force
Coefficient of friction
s and d
Normal Force
Assumptions: Ff independent of contact area, = constant
More Complicated Models Exist:
Contact Mechanics
In actuality, as N
increases,
contact area
increases,
thereby affecting
. is a non-
linear function of
N. What else
might vary
with??
More Complicated Models Exist:
F = Fa + Fp + Fs + Fn
N F
f

What about contact
stresses???
Recall: Pitting stress
in gear teeth
How to Measure ???
Do you want s or d???
For most stress analysis want s why??
Good for measuring s.
You should know how
to derive this.
Good for measuring s
and d.
Typical Friction Force Curves
s = Fa/N
d = Fb/N
Stick- Slip difficult
to get a
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.
CASE Study:
Compression seal. Coefficient of friction
was key for proper design and analysis.
Friction Testing Slide flat EPDM samples across ABS slab
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
4 seal section shown
Actuator
Force/Disp
lacement
Fixed to
load frame
ABS
Polycarbonate
Test Set-up for K and Stress
Relaxation:
Seal glued with
3M CA40H
Adhesive
L/D Curves for All 4" Samples
0
50
100
150
200
250
300
350
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14
Deflection (in)
L
o
a
d

(
l
b
)
4" Sample #1
4" Sample#2
4" Sample #3
4" Sample w/ Polycarbonate contact
4" Sample #1 Immersed
4" Sample #2 Immersed
Load Only
L/D Curves - FEA vs. Measured Results
0
50
100
150
200
250
300
350
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14
Deflection (in)
L
o
a
d

(
l
b
)
Measured - Incumbent Sample #1
Measured - Incumbent Sample#2
Measured - QC-19095 Sample 1"
Measured - QC-19095 Sample 2"
FEA Results - Incumbent Seal
FEA Results - QC-19095
FEA Results - Modif ied QC-19095
Note:
1. All results f or 4" seal length.
2. FEA results - hyper data, 60 duro
EPDM, f riction = 0.25.
Note,
modified seal
slightly stiffer
at lower
deflections
and softer at
higher
deflections!
Stiffness Summary:
WEIGHT USED: SLED + 1LB
WEIGHT (704g)
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.
Types of Wear:
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.
adhesion
adhesion
Figure 5-23:
Fretting wear
of splined
shaft small
oscillatory
motion
abrades
surface
looks like rust
surface
looks pitted.
adhesion
F5-24: low stress abrasion wear bushing sliding
on shaft
abrasion
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!!
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.
F 3-27: Factors that affect
wear at various size levels.
Key: Bonds
between
atoms!
Key:
Dislocation
s
Key: Grain
Size
Key:
Surface
asperities
Key:
Surface
confromanc
e
Figure 5-15: Types of Erosion Note all involve fluids or smoke
(particulates)
Fig5 16: solid
particle erosion
due to fly ash.
Types of Erosion
5-17: Slurry
erosion due to
pumping slurry
mixture of silica
and water
erosion
erosion
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.
Joy Continuous Mining Machines
14CM series targeted for noise reduction
14CM Series 12HM Series 12CM Series
2010 SME Annual Meeting & Exhibit
Phoenix, Arizona
Commitment to Health & Safety
Industry Leading Dust and Noise Reduction Initiatives
Wethead Cutterhead System Dual Sprocket Conveyor
Phoenix, Arizona
Ongoing Developments
Coated Dual Sprocket Chain
Phoenix, Arizona
Figure 7-14
abrasion wear
of various
plastics
Taber Test common test
for abrasion resistance of
elastomers/polymers
Compound
No. Rheometer Data Original Physical Properties After Aging 70 hrs at 70C Compression Set Taber
Ml Mh ts1 tc90
tan
Delta @
Mh
Cure
Time
Cure
Temper
ature
100%
Modulu
s
Elong
ation Tensile
Duro
meter
100%
Modulu
s
Elong
ation

Tensile
Duro
meter
Cure
Time
Cure
Temper
ature
22 hrs
@ 70 C
mg loss
per rev.
XM-AR (1) 3.28 19.59 114 335.97 0.09 5m35s 155 496 479 3439 67.6 6.1 -1.5 -2.2 2 10m35s 155 24.4 0.0892
XM-AR (2) 3.72 26.56 105 319.98 0.09 5m20s 155 870 290 2504 75.1 2.5 -4.5 -5.5 2.8 10m20s 155 25.3 0.0305
XM-AR (3) 3.56 19.96 111 311.4 0.09 5m11s 155 590 451 3405 70.6 2.7 -0.7 -3.7 0.8 10m11s 155 27.4 0.006
XM-AR (4) 2.41 23.36 121.2 355.65 0.07 5m55s 155 736 352 2562 72 12.9 5.4 8.8 2.2 10m55s 155 20.3 0.0187
XM-AR (5) 2.62 20.94 126 321.16 0.07 5m21s 155 498 423 2981 65.6 7.7 8.7 4.7 2.6 10m21s 155 19.6 0.0163
XM-AR (6) 3.31 24.85 127.8 359.58 0.07 6m0s 155 683 393 2856 72 3.5 2.3 0.7 2.2 11m0s 155 9.4 0.0163
XM-AR (7) 0.49 17.82 150 404.82 0.03 6m45s 155 780 527 4318 68.5 12.3 -20.3 -14.5 1.8 11m45 155 45.4 0.0261
XM-AR (8) 0.77 20.58 114 381.98 0.04 6m22s 155 1306 517 4032 74.2 -0.3 -10.8 0.6 2.6 11m22s 155 34.2 0.164
XM-AR (9) 0.74 23.83 123.6 434.22 0.04 7m14s 155 695 524 4577 71.2 23.2 -12.4 -2.6 3.6 12m14s 155 39.2 0.0239
XM-AR (10) 3.69 26.06 61.2 286.38 0.07 4m37s 155 912 310 2691 76.2 3.6 -9.4 -5.8 0.4 9m37s 155 25.7 0.0108
Incumbent
Mat'l 0.0154
300,000 tons

Key Property: Abrasion resistance?? Tear
Strength?? Coef of Friction??

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RJM, 9/16/06 All photos and figures -

Copyright, Prentice Hall

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