You are on page 1of 38

13‐Sep‐2017

Welcome To The Course


ME 369 Tribology

Er. CHACKO PRENO KOSHY


Assistant Professor (Sr. Grade)
Department of Mechanical Engineering
SAINTGITS College of Engineering, Kottayam

E-mail ID: chacko.preno@saintgits.org


Mob: +91 9447369296
Prepared By: Er. Chacko Preno Koshy          
1
S5 ‐ ME ‐ A ‐ SAINTGITS

Course Details
Course No. Course Name L-T-P-Credits

ME369 TRIBOLOGY 3-0-0-3

Prerequisite : Nil L – Lecture hours


T – Tutorial hours
P – Practical hours

Prepared By: Er. Chacko Preno Koshy          
2
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 1
13‐Sep‐2017

Course Objectives
• To provide broad based understanding of the subject ‘Tribology’ and its
technological significance

• To understand the genesis of friction, the theories/laws of sliding and rolling


friction and the effect of viscosity

• To learn about consequences of wear, wear mechanisms, wear theories and


analysis of wear problems

• To learn about the principles of lubrication, lubrication regimes, theories of


hydrodynamic and the advanced lubrication techniques and the application of
lubrications in metal working

• To understand the importance of adhesion property in different applications


and to get knowledge about different bearing materials

• To understand the nature ofPrepared By: Er. Chacko Preno Koshy          


engineering surfaces, their topography and learn
3
about surface characterization techniques
S5 ‐ ME ‐ A ‐ SAINTGITS

SYLLABUS
• Introduction to Tribology - Tribology in Design,
Tribology in Industry, Tribological Parameters
Like Friction, Wear and Lubrication, different
types of lubrication techniques and applications,
measurement of friction and wear

• The Topography of Engineering Surface, Contact


Between Surfaces, surface modification
techniques- Adhesion properties, Adhesion in
Magnetic Recording Systems, Types of Bearings,
Comparison of Sliding and Rolling Contact
Bearings
Prepared By: Er. Chacko Preno Koshy          
4
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 2
13‐Sep‐2017

Expected Outcome
The students will be able to:

1. Understand the subject ‘tribology’ and its technological significance

2. Understanding the theories/laws of sliding and rolling friction and


the effect of viscosity

3. Get basic idea on consequences of wear, wear mechanisms, wear


theories and analysis of wear problems

4. Get an exposure to theories of hydrodynamic and the advanced


lubrication techniques and the application of lubrications in metal
working

5. Gain overview of adhesion property in different applications and to


get knowledge about different bearing materials

6. Get basic idea aboutPrepared By: Er. Chacko Preno Koshy          


the nature of engineering surfaces, their
topography and learn about surface
S5 ‐ ME ‐ characterization techniques 5
A ‐ SAINTGITS

Text Books
1. Ernest Rabinowicz, Friction and Wear of Materials,
John Wiley & Sons, 1995
2. I. M. Hutchings, Tribology: Friction and Wear of
Engineering Materials, Butterworth-Heinemann, 1992
3. Prasanta Sahoo, Engineering Tribology, PHI Learning
Private Ltd, New Delhi, 2011
Reference Books
1. B. Bhushan, Introduction to Tribology, John Wiley & Sons Inc,
New York, 2002
2. B. Bhushan, B. K. Gupta, Handbook of Tribology: Materials,
Coatings and Surface Treatments, McGraw-Hill,1997
3. Halling J., Principles of Tribology, McMillan Press Ltd.,1978
Prepared By: Er. Chacko Preno Koshy          
6
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 3
13‐Sep‐2017

Course Plan
• Module I
– Introduction to tribology
– Topography of engineering surface
– Types of bearings
• Module II
– Types, laws and theories of friction
– Measurement of friction
– Stick-slip
• Module III
– Types and theories of wear
– Measurement of wear, wear regime maps
– Lubricated and unlubricated wear of metals
• Module IV
– Lubrication and lubricants – Properties
– Regimes of lubrication
– Lubrication in metal working
• Module V
– Adhesion
– Bearing materials
• Module VI Prepared By: Er. Chacko Preno Koshy          
7
S5 ‐ ME ‐ A ‐ SAINTGITS
– Surface engineering, modification and coating

ME369 TRIBOLOGY
Module 1
• Introduction to Tribology - Tribology in Design,
Tribology in Industry, Economic Aspects of Tribology

• Tribological Parameters Like Friction, Wear and


Lubrication

• The Topography of Engineering Surface, Contact


Between Surfaces

• Types of Bearings, Comparison of Sliding and Rolling


Contact Bearings
Prepared By: Er. Chacko Preno Koshy          
8
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 4
13‐Sep‐2017

TRIBOLOGY
 "Tribology" is a combination of two Greek words - "tribos" and "logy".

 "Tribos" means rubbing and "logy" means knowledge.

 The study of tribology dates back to 1800 B.C. or earlier.

 Egyptians using lubricant to aid movement of colossus, El-Bersheh, Circa 1880 B.C.

Prepared By: Er. Chacko Preno Koshy          
9
S5 ‐ ME ‐ A ‐ SAINTGITS

BRIEF HISTORY OF TRIBOLOGY


 Egyptian ball bearings with animal fat lubrication dating back to 1000 B.C.
 Roman thrust bearings dating back to 40 A.D.
 Leonardo da Vinci’s (1452-1519) friction postulate
 Amontons’s theory
 Industrial Revolution (1750 – 1850)
 Coulomb verification of Amontons’s theory
 Hydrodynamic lubrication theory - Petroff(1883), Tower(1884) & Reynolds (1886)
 From ‘Rubbing and Scrubbing Department’ to Tribophysics
 Tribology – The word was first reported in a landmark report by Dr. H. Peter Jost
(1966) in England
 Tribology - The science and technology of interacting surfaces in relative
motion and of associated subjects and practices - Jost Committee Report of
1966
 Tribology – Science of interacting surfaces in relative motion
 Tribology is essentially the study of friction, wear and lubrication

 Friction is a principal cause of energy dissipation


 Wear is the major cause of material wastage and loss of mechanical performance
 Lubrication is an effective means of controlling wear and reducing friction10
Prepared By: Er. Chacko Preno Koshy          
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 5
13‐Sep‐2017

JOST GAVE BIRTH TO THE WORD “TRIBOLOGY”

Prepared By: Er. Chacko Preno Koshy          
11
S5 ‐ ME ‐ A ‐ SAINTGITS

ADVENT OF TRIBOLOGY
The Jost Report 1966 coined the word Tribology for the new interdisciplinary
science and technology of interacting surfaces in relative motion and brought
out the potentials of saving through correct usage of Tribology principles and
practices as shown in the pie chart.

Prepared By: Er. Chacko Preno Koshy          
12
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 6
13‐Sep‐2017

LUBRICATION

Leonardo da Vinci (1452-1519)

“All things and everything whatsoever, however thin


it be, which is interposed
in the middle between objects that rub together,
lighten the difficulty of their
friction”

CONCEPT OF LUBRICATION
Prepared By: Er. Chacko Preno Koshy          
13
S5 ‐ ME ‐ A ‐ SAINTGITS

Leonardo da Vinci’s Experiments

Prepared By: Er. Chacko Preno Koshy          
14
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 7
13‐Sep‐2017

Industrial Significance of Tribology


• Jost Report (1966) – United Kingdom made a wastage of 500 million
pounds per annum, due to the ignorance of mechanical surface interaction
phenomena in machinery
– At present it is known that the report greatly under-estimated the real
financial importance of tribology (Report neglected loss due to wear)
• United States (1976) – estimated a possible savings of at least 16 billion
dollars per annum by better tribological practices

Prepared By: Er. Chacko Preno Koshy          
15
Economic importance of tribology in USA
S5 ‐ ME ‐ A ‐ SAINTGITS

Loss of usefulness of material objects


with their economic importance

Prepared By: Er. Chacko Preno Koshy          
16
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 8
13‐Sep‐2017

Application of Tribology

Prepared By: Er. Chacko Preno Koshy          
17
S5 ‐ ME ‐ A ‐ SAINTGITS

Application of Tribology Contd…

Prepared By: Er. Chacko Preno Koshy          
18
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 9
13‐Sep‐2017

Application of Tribology Contd…

Super-hydrophobicity: Lotus Leaf


Prepared By: Er. Chacko Preno Koshy          
19
On/Off Stiction: Gecko Feet S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared By: Er. Chacko Preno Koshy          
20
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 10
13‐Sep‐2017

The Topography of Engineering Surface

Prepared By: Er. Chacko Preno Koshy          
21
S5 ‐ ME ‐ A ‐ SAINTGITS

Surface Interactions
 Surface interactions take place
at regions where atom-to-atom
contact occurs
 These regions are called
junctions
 Real Area of Contact, Ar
 Sum of the areas of all the
junctions
 Nature of interaction
between two surfaces is
determined by Ar Ar ⁓ (Load, L) / (Penetration Hardness, p)

 Apparent Area of Contact, Aa


 Total interfacial area (as
appeared from outside)
Prepared By: Er. Chacko Preno Koshy          
22
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 11
13‐Sep‐2017

Surface Topography
All solid surfaces are found to be uneven (except
carefully cleaved mica)
Surface roughness is the departure of the surface
shape from some ideal or prescribed form
Different methods to study the topography:
Stylus measurements
Electrical or thermal measurements
Electron or light microscopy
Other optical methods

Prepared By: Er. Chacko Preno Koshy          
23
S5 ‐ ME ‐ A ‐ SAINTGITS

Stylus Profilometer
• A fine stylus is dragged
smoothly and steadily
across the surface under
examination

• Vertical displacement of
the stylus is picked up by
a transducer and plotted
against its travel along
the surface

• This method gives


roughness in one
dimension Prepared By: Er. Chacko Preno Koshy          
24
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 12
13‐Sep‐2017

Stylus Profilometer Contd…


• Since the
vertical and
horizontal
magnifications
are generally
different, the
generated
profile appears
to be different
from the actual
one
Prepared By: Er. Chacko Preno Koshy          
25
S5 ‐ ME ‐ A ‐ SAINTGITS

Stylus Profilometer Contd…


• An unavoidable
limitation of this
method results
from the shape of
the stylus

• The stylus tip


cannot fully
penetrate into
deep narrow
features of the
surface

Prepared By: Er. Chacko Preno Koshy          
26
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 13
13‐Sep‐2017

Digital Optical Interferometer

• Determines surface profile without mechanical contact


Prepared By: Er. Chacko Preno Koshy          
S5 ‐ ME ‐ A ‐ SAINTGITS
27

Three-dimensional Profile Map


(a) A ground steel surface

(b) A shot blasted steel


surface

(c) A diamond-turned surface


Prepared By: Er. Chacko Preno Koshy          
28
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 14
13‐Sep‐2017

Two/Three-dimensional Profile Map

Prepared By: Er. Chacko Preno Koshy          
29
S5 ‐ ME ‐ A ‐ SAINTGITS

Atomic Force Microscope (AFM)


• Developed by Gerd Binnig et al. in 1985

• AFM is a high-resolution scanning probe


microscopy (SPM), with a resolution in the order of
fractions of a nanometer.

• It is capable of investigating surfaces of scientific


and engineering interest, on an atomic scale.

• AFM relies on a scanning technique to produce very


high-resolution three-dimensional images of the
sample surfaces Prepared By: Er. Chacko Preno Koshy          
30
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 15
13‐Sep‐2017

AFM Contd…
• AFM measures ultra small forces (less than 1 nN)
present between the AFM tip surface mounted on a
flexible cantilever beam, and a sample surface

• These small forces are measured by measuring the


motion of a very flexible nano-sized cantilever beam
having an ultra small mass, by a variety of measurement
techniques including optical deflection, optical
interference, capacitance, and tunneling current

• The deflection can be measured to within 0.02 nm, so


for a typical cantilever force constant of 10 N/m, a force
as low as 0.2 nN can be detected.
Prepared By: Er. Chacko Preno Koshy          
31
S5 ‐ ME ‐ A ‐ SAINTGITS

AFM Contd…

Prepared By: Er. Chacko Preno Koshy          
32
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 16
13‐Sep‐2017

Advantages of the AFM for tribological studies


• AFM investigations are usually made in ambient air
environment
– AFM studies in a vacuum or liquid environment is also
possible
• Direct 3-dimensional visualization of wear tracks
and scars is possible
– Images may be displayed in 2-D projection and 3-D
projection
• AFM can be routinely used on all types of materials
– ceramics, metals, polymers, semiconductors, magnetic,
optical, and biomaterials
Prepared By: Er. Chacko Preno Koshy          
33
S5 ‐ ME ‐ A ‐ SAINTGITS

AFM Images
Three-dimensional atomic force
microscope (AFM) image of a
polish mark on a piece of steel.
The scan range in X and Y is 3
μm and the entire Z range is 40
nm

Metrological study of a scratch


mark in the surface of a
polished material (stainless
steel). Because the AFM directly
measures three dimensional
data, the depth of the scratch
Prepared By: Er. Chacko Preno Koshy          
S5 ‐ ME ‐mark is easily quantified. 34
A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 17
13‐Sep‐2017

AFM Images Contd…

Prepared By: Er. Chacko Preno Koshy          
35
S5 ‐ ME ‐ A ‐ SAINTGITS

Quantification of Surface Roughness


• Roughness : Small scale irregularities of a surface

• Form error : Measure of the deviation of the shape of the surface from its
intended ideal shape (plane, cylindrical etc.)

• Waviness : Periodic surface undulation intermediate in scale between


roughness and form error

• Roughness is extracted from the surface profile recorded by a profilometer,


by subtracting form error and waviness

 Mechanical filtering is achieved by supporting the measuring head on a


small skid which rides on the surface just behind or in front of the stylus

 The profilometer records the displacement of the stylus relative to


the skid
Prepared By: Er. Chacko Preno Koshy          
 Electrical or electronic filtering can
S5 ‐ ME ‐ A ‐ also be done
SAINTGITS
36

Prepared by Er. Chacko Preno Koshy 18
13‐Sep‐2017

Quantification of Surface Roughness Contd…


• Graph of the surface profile contains most of the information needed to
describe the topography along one direction
 Several typical quantities can be computed from the surface profile

 Average Roughness, Ra (Centre Line Average)


 Arithmetic mean deviation of the surface height from the mean line
through the profile
 Mean line is defined so that equal areas of the profile lie above and
below it

y(x) = height of surface above the datum


L = sampling length
Prepared By: Er. Chacko Preno Koshy          
37
S5 ‐ ME ‐ A ‐ SAINTGITS

Quantification of Surface Roughness Contd…


 R.M.S roughness, Rq (Standard deviation)
 Root mean square deviation of the profile from the mean line
 Rq and Ra are similar
 For a Gaussian distribution of surface heights, Rq = 1.25 Ra

 Amplitude density function, p(y)


 Proportional to the probability of finding a point on the surface at height y above the
mean line
 Describes the distribution of surface heights

Prepared By: Er. Chacko Preno Koshy          
38
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 19
13‐Sep‐2017

Quantification of Surface Roughness Contd…


 Skewness : Measure of the asymmetry of the amplitude density curve

 Kurtosis : Measure of the sharpness of the peak of the distribution curve

 Gaussian (normal) probability distribution has a skewness value of zero


and kurtosis of 3.0

 Bearing Ratio : Ratio of the contact length to the total length of the profile

 Bearing ratio curve is a plot of bearing ratio against surface height


Prepared By: Er. Chacko Preno Koshy          
39
 Differentiation of bearing ratio curve yields amplitude density function
S5 ‐ ME ‐ A ‐ SAINTGITS

Quantification of Surface Roughness Contd…


 Autocorrelation function, C(β) : Describes the distribution of hills
and valleys

 Power spectral density function, P(ω) : Conveys information about


the spatial frequencies (i.e. wavelengths) present in the surface profile

 Fourier Transform of the autocorrelation function

Prepared By: Er. Chacko Preno Koshy          
40
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 20
13‐Sep‐2017

Contact Between Surfaces

Prepared By: Er. Chacko Preno Koshy          
41
S5 ‐ ME ‐ A ‐ SAINTGITS

Contact Between Surfaces


Conforming Contact
 Surfaces of the two bodies ‘fit’ exactly or even closely together
without deformation
 Eg: Flat Slider bearings, journal bearings etc.

Non-Conforming Contact
 Bodies which have dissimilar profiles
 When brought into contact without deformation, “point contact” or
“line contact” occurs
 Eg: Contact between races and balls in a ball or roller bearing,
Contact between a cam and follower, etc.
 On application of normal load, contact area is small
 Stresses are highly concentrated in the vicinity of contact
 Effect is unaffected by the shape of the bodies away from
contact area
Prepared By: Er. Chacko Preno Koshy          
42
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 21
13‐Sep‐2017

Contact Stresses - Hertz Theory of Elastic Contact


Two contacting surfaces under load will deform

Deformation may be either plastic or elastic depending on


the magnitude of the applied load and the material’s
hardness

To determine stresses acting in contacts of rolling contact


bearing, cams, gears, seals, etc. an analytical formulae based
on the theory of elasticity was developed by Hertz in 1881.

Hertz developed these formulae during his Christmas


vacation in 1880 when he was 23 years old

Prepared By: Er. Chacko Preno Koshy          
43
S5 ‐ ME ‐ A ‐ SAINTGITS

Elastic Half Space


 When the dimensions of the body are large compared to the contact
area, stresses in this region are unaffected by the shape of the
contacting bodies far away from the contacting region

 The stresses may be calculated to a good approximation by


considering each body as a semi-infinite elastic solid bounded by a
plane surface: i.e. an elastic half space

 Bodies of any profile may be regarded as semi-infinite in extent


and having a plane surface
 If the loading is along a narrow strip, a state of plane strain is
assumed
• Justified when the thickness of the solid is large compared
with the width of the loaded region

 Classical theory of Prepared By: Er. Chacko Preno Koshy          


elasticity can now be used to determine the
contact pressure and subsurface stresses
S5 ‐ ME ‐ A ‐ SAINTGITS
44

Prepared by Er. Chacko Preno Koshy 22
13‐Sep‐2017

Elliptical Contact Between Two Elastic Bodies – General Case


P

Prepared By: Er. Chacko Preno Koshy          
45
P
S5 ‐ ME ‐ A ‐ SAINTGITS

Hertz Theory (1881-82)


 When two spheres are in contact with a normal force P, Hertz made the
hypothesis that the contact area is, in general elliptical

 For calculating local deformations, each contacting body can be


regarded as an elastic half space, loaded over a small elliptical region
of its plane surface

 The significant dimensions of the contact area must be small


compared to the dimensions of each body and with the relative
radii of curvature of each surface

 Strains in the contact region are considered to be sufficiently small so


as to lie within the scope of the linear theory of elasticity

 The surfaces are assumed to be frictionless so that only a normal


pressure is transmitted between them
Prepared By: Er. Chacko Preno Koshy          
46
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 23
13‐Sep‐2017

Assumptions to Hertz’s Theory


 Materials in contact are homogeneous and the yield stress is not
exceeded
 The surfaces are continuous and non-conforming: a<<R, ie; contact
area is very small compared with the dimensions of the contacting
solids
 Strains are small: a<<R
 Each solid can be considered as an elastic half space: a<<R1,2, a<<l
 The surfaces are frictionless
 The two surfaces do not touch or interfere outside the loaded region
 Contacting solids are at rest and in equilibrium
 Effect of surface roughness is negligible
 Contact stress is caused by the load which is normal to the contact
tangent plane which effectively means that there are no tangential
forces acting between the solids

 P(x,y) is required to be found


Prepared By: Er. Chacko Preno Koshy          
47
S5 ‐ ME ‐ A ‐ SAINTGITS

CONTACT BETWEEN TWO ELASTIC SPHERICAL OR


SPHEROIDAL BODIES
 Elastic bodies in contact deform and the contact geometry, load and
material properties determine the contact area and stresses.

 The contact geometry depends on whether the contact occurs


between surfaces which are both convex or a combination of flat,
convex and concave.

 The shape of the contact area depends on the shape (curvature) of


the contacting bodies.
• For example, point contacts occur between two balls, line
contacts occur between two parallel cylinders and elliptical
contacts, which are most frequently found in many practical
engineering applications, occur when two cylinders are
crossed, or a moving ball is in contact with the inner ring of a
bearing, or two gear teeth are in contact.
 The curvature of the bodies can be convex, flat or concave. 48
Prepared By: Er. Chacko Preno Koshy          
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 24
13‐Sep‐2017

Geometry of two elastic bodies with convex surfaces in contact

Prepared By: Er. Chacko Preno Koshy          
49
S5 ‐ ME ‐ A ‐ SAINTGITS

Geometry of two bodies with one convex and one flat surface in
contact

Prepared By: Er. Chacko Preno Koshy          
50
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 25
13‐Sep‐2017

Geometry of two bodies with one convex and one concave surface in
contact

Prepared By: Er. Chacko Preno Koshy          
51
S5 ‐ ME ‐ A ‐ SAINTGITS

Reduced Radius of Curvature

Prepared By: Er. Chacko Preno Koshy          
52
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 26
13‐Sep‐2017

Contact Area, Pressure, Maximum Deflection and Position of the


Maximum Shear Stress
Most frequently used contact parameters are:
 the contact area dimensions,
 the maximum contact pressure, often called the Hertzian stress,
 the maximum deflection at the centre of the contacting surfaces,
 the position of the maximum shear stress under the surface.

Two balls in contact or when 2 cylinders are crossed at 90° :


circular contact
Two cylinders crossed at an angle ≠ 90° : contact area is
ellipse
Two parallel cylinders : narrow rectangle

Prepared By: Er. Chacko Preno Koshy          
53
S5 ‐ ME ‐ A ‐ SAINTGITS

Geometry of contact between two spheres

Prepared By: Er. Chacko Preno Koshy          
54
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 27
13‐Sep‐2017

Contact between a sphere and a plane (flat) surface

Prepared By: Er. Chacko Preno Koshy          
55
S5 ‐ ME ‐ A ‐ SAINTGITS

Geometry of contact between two parallel cylinders

Prepared By: Er. Chacko Preno Koshy          
56
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 28
13‐Sep‐2017

Geometry of contact between two cylinders of equal diameters with


axes perpendicular

Prepared By: Er. Chacko Preno Koshy          
57
S5 ‐ ME ‐ A ‐ SAINTGITS

General Notations
a = radius of the contact area (m)

P = normal load (N)

p = contact pressure (Hertzian stress) (Pa)

po = maximum pressure (Pa)

δ = total deflection at the centre of the contact; δ1 and δ2 are the


maximum deflections of body A (1) and body B (2), respectively, (m)

τ = shear stress (Pa)

E* = reduced Young’s Modulus (Pa)

R = reduced radius of curvature (m)

z = depth under the surfacePrepared By: Er. Chacko Preno Koshy          


where
S5 ‐ ME ‐the maximum shear stress acts (m)58
A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 29
13‐Sep‐2017

Two solids of general shape, after deformation


 Separation between the
two surfaces is given
by, h = Ax2 + By2
 Within the contact
region,

 S1, S2 are coincident


points within the
contact surface
 Outside the contact
region,

Prepared By: Er. Chacko Preno Koshy          
59
S5 ‐ ME ‐ A ‐ SAINTGITS

Geometry of contact between two spheres - Two Solids of revolution


P

Prepared By: Er. Chacko Preno Koshy          
60
P
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 30
13‐Sep‐2017

Two Solids of revolution Contd…


 Contact area is circular with radius, a
 Boundary conditions for displacements within the contact,

 Pressure distribution proposed by Hertz,

 Writing,

 Radius of the contact circle is,

 And the mutual approach of distant points in the two solids is given by,

Prepared By: Er. Chacko Preno Koshy          
61
S5 ‐ ME ‐ A ‐ SAINTGITS

Two Solids of revolution Contd…


 Total load compressing the solids is given by,

 In terms of total load,

 Area of contact increases as (normal load)2/3


 Before applying this equation,
 Uniqueness of the boundary conditions are to be checked
 Ensure that the surfaces do not touch or interfere outside the
contact region
Prepared By: Er. Chacko Preno Koshy          
62
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 31
13‐Sep‐2017

Two Solids of revolution Contd…


 Stress distributions at the surface (z = 0), inside the loaded circle (r <
a) are,

 Outside the circle (r > a) ,

Prepared By: Er. Chacko Preno Koshy          
63
S5 ‐ ME ‐ A ‐ SAINTGITS

Two Solids of revolution Contd…


 Stresses on the z-axis may be calculated by considering a ring of
concentrated force at radius r :

 Principal shear stress, has a maximum value of


0.31 po at a depth of 0.48a when ν = 0.3

 OR τmax = (1/3) po at a depth of z = 0.638a


Prepared By: Er. Chacko Preno Koshy          
64
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 32
13‐Sep‐2017

Stress and pressure distribution

Prepared By: Er. Chacko Preno Koshy          
65
S5 ‐ ME ‐ A ‐ SAINTGITS

Example
 Find the contact parameters for two steel balls. The normal force
is W = 5 [N], the radii of the balls are RA = 10 × 10-3 [m] and RB
= 15 × 10-3 [m]. The Young's modulus for both balls is E = 2.1 ×
1011 [Pa] and the Poisson's ratio of steel is ν = 0.3.
Solution
• Determine R, E*, a, po, δ, τmax., z, Average contact pressure (pavg.)
• R = 6 × 10-3 m
• E* = 1.15 × 1011 Pa
• a = 5.799 × 10-5 m
• po = 709.9 MPa
• δ = 5.6 × 10-7 m
• τmax = 236.6 MPa
• z = 3.7 × 10-5 m
Prepared By: Er. Chacko Preno Koshy          
• pavg. = P/πa2 = 473.3 MPa S5 ‐ ME ‐ A ‐ SAINTGITS 66

Prepared by Er. Chacko Preno Koshy 33
13‐Sep‐2017

Two-dimensional Contact of Cylindrical Bodies


• Separation between corresponding points on the unloaded surface is
given by;

• Within the contact area,

• Outside the contact region,

• Due to the inherent drawback of 2D problems, relationship with


reference to surface gradients are generally obtained;

Prepared By: Er. Chacko Preno Koshy          
67
S5 ‐ ME ‐ A ‐ SAINTGITS

Two-dimensional Contact of Cylindrical Bodies Contd…..


• Solving the equations,

Prepared By: Er. Chacko Preno Koshy          
68
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 34
13‐Sep‐2017

Stresses in 2D contact along z-axis

Prepared By: Er. Chacko Preno Koshy          
69
S5 ‐ ME ‐ A ‐ SAINTGITS

Stress and pressure distribution

Prepared By: Er. Chacko Preno Koshy          
70
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 35
13‐Sep‐2017

Example
 2 steel rollers are in contact as shown. Given; W = 5 [N], RA = 10
× 10-3 [m], RB = 15 × 10-3 [m], E = 2.1 × 1011 [Pa], ν = 0.3, l = 10
× 10-3 [m]. Compute maximum contact pressure and width of
contact. How deep below the surface does the maximum shear
stress occur and what is its value.
Solution
• Determine R, E*, P, a, po, τmax., z
• R = 5.99 × 10-3 m
• E* = 1.15 × 1011 Pa
• P = W/l = 500 N/m
• a = 5.75 × 10-6 m
• po = 55.4 MPa
• τmax = 16.8 MPa
• z = 4.4 × 10-6 m Prepared By: Er. Chacko Preno Koshy          
71
S5 ‐ ME ‐ A ‐ SAINTGITS

BEARINGS
 A bearing is a mechanical element that permits relative motion between two
components or parts, such as the shaft and housing, with minimum friction.

 Objective of bearing is to provide relative positioning and rotational freedom


while transmitting a load between two parts.

 Bearings permit smooth, low-friction movement between two surfaces. The


movement can be either rotary (a shaft rotating within a mount) or linear (one
surface moving along another).

 Bearings can employ either a sliding or a rolling action. Bearings based on


rolling action are called rolling-element bearings. Those based on sliding
action are called plain bearings.

 In rolling contact bearings as the name implies the friction is of rolling type.
 It is much smaller than the sliding type.
Prepared By: Er. Chacko Preno Koshy          
72
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 36
13‐Sep‐2017

Types of Bearings
Broadly, bearings can be classified into

Sliding bearing and


Here load is transferred through a thin
film of lubricant (oil).

Rolling element bearing


Here load is transferred through rolling
elements such as balls, straight and
tapered cylinders and spherical rollers.

Prepared By: Er. Chacko Preno Koshy          
73
S5 ‐ ME ‐ A ‐ SAINTGITS

Types of Bearings – General Classification

Prepared By: Er. Chacko Preno Koshy          
74
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 37
13‐Sep‐2017

Comparison between types of Bearings

Refer any standard textbook and/or google yourself

Prepared By: Er. Chacko Preno Koshy          
75
S5 ‐ ME ‐ A ‐ SAINTGITS

Prepared by Er. Chacko Preno Koshy 38

You might also like