Influence of Test Equipment and Working Conditions on the Coefficient of Friction Values

PhD DISSERTATION Demfilo Maldonado Corts MSc Eng

University of Monterrey (UDEM) Mechanical Engineering Faculty San Pedro Garza Garca, Mxico

Supervisor: Prof Marian Szczerek PhD DSc Eng

Instytut Technologii Eksploatacji - Pastowowy Instytut Badawczy (ITeE-PIB) Radom, Poland

Cracow University of Technology, 29th of June, 2010

INDEX
1. Introduction

2. Thesis and Purpose of Work 3. Originality of the Work

a. Objective and approach b. Tribological Tests

4. Results of the Research 5. Taguchi Analysis

a. Approach for coefficient of friction

6. Verification Tests
a. Best and worst cases b. Reproducibility and Repeatability

7. Summary and Conclusions 8. Acknowledges

1. Introduction
Reproducibility and repeatability are still problems to solve in tribological science, specifically in coefficient of friction (COF) and wear results obtained from tribotesters.

Coefficient of friction from 0,1 to 1,2 for steel-TiN

Tests

Those results evidence a lack of test parameters controlling in order to achieve a good reproducibility and repeatability of coefficient of friction values. 3

COF

1. Introduction
There are plenty of papers and reports that shown how different are the tribological test conditions in terms of standardization and scatter results of coefficient of friction in dry conditions.
Coefficient of Friction
Bibliographic Entry Technical Physics .USA. Wiley Encarta Encyclopedia 2004 CRC Handbook of Physical Quantities College Physics- 4th Edition. USA: McGraw-Hill Determining the Coefficient of Friction Succeed in Physical Science.

Materials
Steel on Steel Steel on Steel (dry) Steel on Steel Steel on Steel (dry)

Static friction 0.7 0.7

Kinetic friction 0.6

0.6
0.57

0.74 0.15
0.6

0.09
0.4

Steel on steel (dry)

Source: The Physics Factbook

Despite of that, the existing literature concerning coefficient of friction values does not specify enough information in order to trust in the presented results.
4

2. Thesis and Purpose of Work

Thesis:
The coefficient of dry friction is influenced by materials but it is also affected by operating conditions such as load, velocity, temperature, as well as the geometry and configuration of the friction elements and the surrounding atmosphere.

2. Thesis and Purpose of Work

Purpose of Work:
To acknowledge the influence of operating conditions (controlled and uncontrolled inputs) and test equipment on the coefficient of friction values and suggest improvements for the tribotest methods.

Objective and approach

Define a test method for a operating conditions (controlled inputs) in order to reduce scatter of coefficient of friction on ball-on-disk tribological tests.
Examination of typical model friction couple: ball-on-disk, taking into account usually controlled and uncontrolled inputs of a tribotesting system.

Objective and approach

Tribological Tests Parameters

Controlled Input

Characteristics 35%, 50% and 80% 5N, 10N and 15N.

Humidity Load

Speed
Sliding distance

0.1m/s, 0.2m/s and 0.3m/s.

1,000 meters.
steel disk (AISI 52100) steel ball steel disk (AISI 52100) ceramic ball (Al203) coated steel disk (CrN) ceramic ball (Al203) (S/S) (S/C) (P/C)

Materials
Sliding track radius

10mm for T-11, and 18mm for T-10.

Ball Diameter
Load direction

10mm.
T-10 and T-11 vertical and horizontal for T-10.

Tribological Tests Parameters

MATERIALS Steel disk and steel ball (S/S). Humidity (%) Load (N) Velocity (m/s)

35

0.1

50
80 35

10
15 10

0.2
0.3 0.3

G1
Steel disk and ceramic ball (S/C).

50
80 35

15
5 15

0.1
0.2 0.2

Coated steel disk and ceramic ball (P/C).

50
80

5
10

0.3
0.1

G2
MATERIALS

Additional one test of each was performed in order to measure acceleration of vibration. Humidity (%) Load (N) 10 Velocity (m/s) 0.1 0.2 0.3 5

G3

Coated disk and ceramic ball (P/C).

50

10
15

0.2
10

Tribological Tests Equipment

11

Tribological Tests Vibration measurement arrangement

T-10 Horizontal
1 2 1 1

T-10 Vertical

T-11 Vertical
2

LOAD

LOAD

LOAD

Contact point

Transducer

12

Tribological Tests Vibration Measurement

13

4. Results of the Research

Results of COF values (all tests made by the author)
1.20
0.990 0.861 0.663

Coefficient of Friction

1.00 0.80

COF from 0.1 to 1.2 (Santner)

0.60
0.40
0.277

0.20
0.123

0.204

0.00

Tests
S/S 0.540 S/C 0.713 P/C 0.657
14

Material Combination
Scatter of COF

Total scatter of all 229 tests: 0.867.

4. Results of the Research

Coefficient of friction and wear values for all tests Coefficient of Friction
0.9 0.3 0.25 0.2 0.15 0.1 0.05 0
T10HT11VT10V S/S S/C P/C TESTER MATERIAL 35 50 80 5 10 15 0,1 0,2 0,3 HUMIDITY % LOAD (N) SPEED (m/s)

0.8
0.7 0.6 0.5 0.4 0.3 0.2 0.1 0

COF

Wear

COF and wear values obtained from tests made by the author (group 1). 15

Wear (mm3)

4. Results of the Research

Coefficient of friction and acceleration of vibration (g)
0.8 180

Aceleration of Vibration (g)

140 120 100 80 60 40 20 0

5N 0,1 m/s 10N 0,2 m/s 15N 0,3 m/s 5N 0,2 m/s 10N 0,3 m/s 15N 0,1 m/s 5N 0,3 m/s 10N 0,1 m/s 15N 0,2 m/s 5N 0,1 m/s 10N 0,2 m/s 15N 0,3 m/s 5N 0,2 m/s 10N 0,3 m/s 15N 0,1 m/s 5N 0,3 m/s 10N 0,1 m/s 15N 0,2 m/s 5N 0,1 m/s 10N 0,2 m/s 15N 0,3 m/s 5N 0,2 m/s 10N 0,3 m/s 15N 0,1 m/s 5N 0,3 m/s 10N 0,1 m/s 15N 0,2 m/s

0.6 0.5

0.4
0.3 0.2 0.1 0

35%H 50%H 80%H 80%H 35%H 50%H 50%H 80%H 35%H 35%H 50%H 80%H 80%H 35%H 50%H 50%H 80%H 35%H 35%H 50%H 80%H 80%H 35%H 50%H 50%H 80%H 35%H steel / steel steel / ceramic T10 Horizontal coating / ceramic steel / steel steel / ceramic T10 Vertical coating / ceramic steel / steel steel / ceramic T11 Vertical coating / ceramic

VARIABLES

Ap-p (g)

COF
16

Acceleration of vibration and COF (results in all tribotesters, group 2).

Coefficient of Friction

160

0.7

4. Results of the Research

Acceleration of vibration and COF (results in all tribotesters, group 2).

17

4. Results of the Research

Coefficient of Friction and Acceleration of Vibration (g)
140.0 0.8 0.7 0.6

120.0

Acceleration of Vibration (g)

0.5
80.0 0.4 60.0 0.3 40.0 0.2 0.1 0

20.0

0.0

T10H

T10V

T11V

T10H

T10V

T11V

T10H

T10V

T11V

Coated/Ceramic (P/C)

Steel/Ceramic (S/C)

Steel/Steel (S/S)

Ap-p (g)

COF
18

Acceleration of vibration and COF sorted by couple materials (group 2).

Coefficient of Friction

100.0

4. Results of the Research

Results of COF values (all tests made by the author)
1.20
0.990 0.861 0.663

Coefficient of Friction

1.00 0.80

COF from 0.1 to 1.2 (Santner)

0.60
0.40
0.277

0.20
0.123

0.204

0.00

Tests
S/S 0.540 S/C 0.713 P/C 0.657
19

Material Combination
Scatter of COF

Total scatter of all 229 tests: 0.867.

5. Taguchi Analysis
The Approach - The Taguchi Method is based on orthogonal array (OA) experiments. - The OA produces a set of well-balanced (minimum experimental runs) tests. - Taguchis method uses the statistical measure of performance called Signal-to-Noise ratios (S/N), which are functions of desired output that serve as objective functions for optimizations. S/N = Eta = -10 * log10 [(1/n) * (yi2)] - The ratio depends on the quality of the product/process to be optimized. The three categories of S/N ratios are: Lower-the-better Higher-the better Nominal-the-best - The parameter level combination that maximizes the appropriate S/N ratio is the optimal setting. 20

5. Taguchi Analysis
The Method
1. Selection of the factors that are affecting the results. 2. Selection of the appropriate levels that each factor may hold within the tests (3 levels each). 3. Selection of the orthogonal array determine the number of tests to run. to

Tribotester

Material
S/S

H%
35

N
5

m/s
0,1

50
80

10
15 10

0,2
0,3 0,3

Tribotester T10H

Material S/C

H% 50
80 35

35

N m/s 15 0,1
5 5 0,2 0,1

S/S
P/C

50
50

35

10
5

15

0,2
0,3

0,2

4. Conduction of the tests design (27 test instead of 229 test), Almost 9 time less effort.
5. Analyzing the results . 6. Prediction of the optimum performance and influence of factors. 7. Verification tests of the experimental.

T10H or T11V or T10V T10V

80 80
35 35

15 10
5 10

0,3 0,1
0,1 0,3

S/C S/S

50
80

50

15
15

10

0,1
0,3

0,2

80 35
S/C
50 35

10

5
5
5 5

0,2 0,3
0,1 0,2

15 15

P/C
P/C

50
35

80

15

0,3
0,2

0,2

80 50
35 50 80 35

10 5
10 15 10 15

0,1 0,3
0,1 0,2 0,3 0,3 0,1

S/S

T11V

The greatest advantage of this method is the optimization of0,2 80 5 35 time and efforts in conducting experiments. 15 21 0,2 P/C
50 5 0,3

S/C

50

Approach for COF identification

Controlled Input
T
K

Tribotester
Kind of motion

T-10

Sliding
S/S: 35%, S/C: 50% and P/C: 80% S/S, S/C and P/C: 10 N S/S: 0.2 m/s, S/C: 0.1 m/s and P/C: 0.1 m/s 1,000 meters Non lubricated Vertical Ball-on-disk, 10 mm ball Ceramic (Al203) or steel 0.045 m 58 to 63 HRC Keep levels between 4.8g and 10g (Acceleration = Ap-p) 22

RH
P v D1 D SC G M Ra H Vibr

Relative air humidity

Load Sliding speed Sliding distance Environment of spatial configuration Tribosystem spatial configuration Tribosystem geometry Counter body material Body roughness Body hardness Tribosystem vibrations

6. Verification Tests

Best case
Coefficient of Friction
1,2

Worst case
1,2

BEST CASES OF COEFFICIENT OF FRICTIOIN S/C, 50%h, 10n, 0.1m/S, T10V

WORST CASE OF COEFFICIENT OF FRICTION P/C, 50%H, 5N, 0,3 m/s, T11V
Test 1
Test 2

Coefficient fo Friction

1
0,8 0,6 0,4 Series1 Series2

0,8
0,6

Test 3 Test 4
Test 5

Series3

0,4 0,2

0,2
0

TIME

0
TIME

Optical Microscopy Image, 10X

23

6. Verification Tests
Optical Microscopy Image, 10X

Best case
3D Profilometer Image
m 7 6.5 6 5.5 5 4.5 4 3.5 3

Coefficient of Friction

1,2

BEST CASES OF COEFFICIENT OF FRICTIOIN S/C, 50%h, 10n, 0.1m/S, T10V

1
0,8 0,6 0,4

2.5 2 1.5 1 0.5 0

Series1 Series2

2D Profilometer Image
Dlugosc = 2.09 mm Pt = 4.39 m Skala = 5 m

Atomic Force Microscopy Image 50m x 50m

Series3

0,2
m 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 0 0.1 0.2 0.3 0.4 0.5 0.6

TIME
0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 mm

24

6. Verification Tests
Optical Microscopy Image, 10X

Worst case
3D Profilometer Image
m 7 6.5 6 5.5 5 4.5 4 3.5 3

1,2

WORST CASE OF COEFFICIENT OF FRICTION P/C, 50%H, 5N, 0,3 m/s, T11V

Coefficient fo Friction

2.5 2

1.5 1 0.5 0

Test 1
Test 2

0,8
0,6
2D Profilometer Image Atomic Force Microscopy Image 50m x 50m

Test 3 Test 4
Test 5

0,4 0,2 0
m 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 mm Dlugosc = 2.09 mm Pt = 2.35 m Skala = 5 m

TIME

25

6. Verification Tests
Reproducibility and Repeatability
Source of Data ASTM G-99 DIN 50324 and ASTM G-99 Preliminary tests made by this author Best cases of the optimization process made by the author Worst cases of the optimizacion process made by the autor COF Scatter 0,19 0,11 0,11 0,04 0,07 Improvement % 41% 78% 62%

In all cases, including the worst scenario, the results of repeatability were much better in all results made by the author

ND = No data Reproducibility

Repeatability

26

6. Verification Tests
Scatter of COF

Approach Data compiled by Santner

Preliminary tests made by the author Tests made by the author with optimization process

1.100
0.867 0.071

27

7. Summary and Conclusions

-Coefficient of friction values and the scatter of it depend on the speed, load and humidity of the surrounding air. -The each type of tribotesters, because of different rigidity (stiffness) characterized by vibration has different influence on the coefficient of friction results as well. -In case of COF results, the biggest influence the kind (or dynamic feature) of tribotester. - It is possible to design tribotesters and make rigorous test procedures that allow achieving low scatter results of coefficient of friction and wear. - The author proved there is very important to adopt a Taguchi approach to optimize the inputs that are needed for the definition of a tests method in order to reduce scatter of coefficient of friction.
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7. Summary and Conclusions

Having a standardized method (using Taguchi approach), good quality of input variables control and good quality of tribotester equipment, its possible to achieve low scatter and then, get a considerable improving in repeatability and reproducibility values of coefficient of friction.

29

Future Work

The proposed new approach for tribotesting make it possible to compare tribocharacteristics on a friction pair between different research centers in frame of a round robin using different tribotesters as well.
There is now a big opportunity to accomplish the VAMAS TWA # 1 objective and improve the reproducibility and comparability of wear tests by developing internationally agreed test methodologies for characterisation of wear behaviour of advanced materials.

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8. Acknowledges

Thanks to all colleagues from the Tribology department of the Institute for Sustainable Technologies - National Research Institute (ITeE-PIB) for all your technical support, advices and facilities. Thanks to the Scientific Board of Krakow University of Technology for your recommendations and support during this time.

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Influence of Test Equipment and Working Conditions on the Coefficient of Friction Values
PhD DISSERTATION Demfilo Maldonado Corts MSc Eng
University of Monterrey (UDEM) Mechanical Engineering Faculty San Pedro Garza Garca, Mxico

Supervisor: Prof Marian Szczerek PhD DSc Eng

Instytut Technologii Eksploatacji - Pastowowy Instytut Badawczy (ITeE-PIB) Radom, Poland

Cracow University of Technology, 29th of June, 2010

32

Technical added value

Now the design engineers has the possibility to obtain reliable values of COF useful for the mechanical design of machine elements.

Scientific added value

Triboscientifics has the possibility to apply the new approach to many different tribosystems, no matter the quantity of parameters and levels involved.

33