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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.

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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)

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What is Friction
Force tangential to Coefficient of friction
s and d
the interface of two
contacting bodies =
Ff.
Dynamic and static
Dynamic produces
Ff N
heat

Normal Force
Friction Force

Assumptions: Ff independent of contact area, = constant


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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??

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More Complicated Models Exist:

F = Fa + Fp + Fs + Fn Ff N

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

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How to Measure ???
Do you want s or d???
For most stress analysis want s why??

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

Good for measuring s


and d.

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Typical Friction Force Curves

s = Fa/N
d = Fb/N

Stick- Slip difficult


to get a

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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.

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CASE Study:
Compression seal. Coefficient of friction
was key for proper design and analysis.

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Friction Testing Slide flat EPDM samples across ABS slab

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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

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Test Set-up for K and Stress
Relaxation: Fixed to
load frame

ABS

Polycarbonate

Seal glued with Actuator


3M CA40H 4 seal section shown Force/Disp
Adhesive lacement

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L/D Curves for All 4" Samples

350

300

4" Sample #1
4" Sample#2
250
4" Sample #3
4" Sample w/ Polycarbonate contact
200 4" Sample #1 Immersed
Load (lb)

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)

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L/D Curves - FEA vs. Measured Results

350
Measured - Incumbent Sample #1 Note:
Measured - Incumbent Sample#2 1. All results for 4" seal length.
300 2. FEA results - hyper data, 60 duro
Measured - QC-19095 Sample 1"
EPDM, friction = 0.25.
Measured - QC-19095 Sample 2"
FEA Results - Incumbent Seal
250
FEA Results - QC-19095
FEA Results - Modified QC-19095

200
Load (lb)

150
Note,
modified seal
slightly stiffer
100 at lower
deflections
and softer at
higher
deflections!
50

0
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14
Deflection (in)

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Stiffness Summary:

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WEIGHT USED: SLED + 1LB
WEIGHT (704g)

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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

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Figure 5.14 Major Categories of wear and specific types of wear in
each category.

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Types of Wear:

adhesion Figure 5:20 Adhesion


wear localized
bonding between
contacting surfaces

Figure 5-21: Galling wear


adhesion severe adhesion actually leads
to material flow up from the
surface.

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Figure 5-23:
Fretting wear
of splined
shaft small
oscillatory
motion
adhesion
abrades
surface
looks like rust
surface
looks pitted.

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abrasion

F5-24: low stress abrasion wear bushing sliding


on shaft

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F 5-27 Pitting surface
fatigue large roller
thrust bearing race
Surface fatigue
compressive stress
developed between roller
bearing and race =
pitting. Material actually
fatigued and removed
from surface!!

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Surface fatigue

F5-28: Impact wear


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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.
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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
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Figure 5-15: Types of Erosion Note all involve fluids or smoke
(particulates)

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Types of Erosion
Fig5 16: solid
particle erosion
erosion due to fly ash.

5-17: Slurry
erosion
erosion due to
pumping slurry
mixture of silica
and water

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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.

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Joy Continuous Mining Machines

12CM Series 12HM Series 14CM Series

14CM series targeted for noise reduction

2010 SME Annual Meeting & Exhibit


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Commitment to Health & Safety

Industry Leading Dust and Noise Reduction Initiatives

Wethead Cutterhead System Dual Sprocket Conveyor

2010 SME Annual Meeting & Exhibit


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Ongoing Developments

Coated Dual Sprocket Chain

2010 SME Annual Meeting & Exhibit


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Figure 7-14
abrasion wear
of various
plastics

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Taber Test common test
for abrasion resistance of
elastomers/polymers

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Compound
No. Rheometer Data Original Physical Properties After Aging 70 hrs at 70C Compression Set Taber

tan Cure 100% 100% Cure


Delta @ Cure Temper Modulu Elong Duro Modulu Elong Duro Cure Temper 22 hrs mg loss
Ml Mh ts1 tc90 Mh Time ature s ation Tensile meter s ation Tensile meter Time ature @ 70 C per rev.

XM-AR (1) 3.28 19.59 114 335.97 0.095m35s 155 496 479 3439 67.6 6.1 -1.5 -2.2 210m35s 155 24.4 0.0892

XM-AR (2) 3.72 26.56 105 319.98 0.095m20s 155 870 290 2504 75.1 2.5 -4.5 -5.5 2.810m20s 155 25.3 0.0305

XM-AR (3) 3.56 19.96 111 311.4 0.095m11s 155 590 451 3405 70.6 2.7 -0.7 -3.7 0.810m11s 155 27.4 0.006

XM-AR (4) 2.41 23.36 121.2 355.65 0.075m55s 155 736 352 2562 72 12.9 5.4 8.8 2.210m55s 155 20.3 0.0187

XM-AR (5) 2.62 20.94 126 321.16 0.075m21s 155 498 423 2981 65.6 7.7 8.7 4.7 2.610m21s 155 19.6 0.0163

XM-AR (6) 3.31 24.85 127.8 359.58 0.076m0s 155 683 393 2856 72 3.5 2.3 0.7 2.211m0s 155 9.4 0.0163

XM-AR (7) 0.49 17.82 150 404.82 0.036m45s 155 780 527 4318 68.5 12.3 -20.3 -14.5 1.811m45 155 45.4 0.0261

XM-AR (8) 0.77 20.58 114 381.98 0.046m22s 155 1306 517 4032 74.2 -0.3 -10.8 0.6 2.611m22s 155 34.2 0.164

XM-AR (9) 0.74 23.83 123.6 434.22 0.047m14s 155 695 524 4577 71.2 23.2 -12.4 -2.6 3.612m14s 155 39.2 0.0239

XM-AR (10) 3.69 26.06 61.2 286.38 0.074m37s 155 912 310 2691 76.2 3.6 -9.4 -5.8 0.49m37s 155 25.7 0.0108
Incumbent
Mat'l 0.0154

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300,000 tons

Key Property: Abrasion resistance?? Tear


Strength?? Coef of Friction??
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