Don’t Lose Your Shirt

Where wear happens to ware

Lecture 2

Benjamin D. Leonard, Ph.D.

 Introduction
●
What is it?
●
Theory
–
Macro
–
Micro
●
Testing
●
Prevention
 Objectives
●
Understand wear mechanisms
●
Know why wear laws are complex
and the most common equation
●
Have guidelines for selecting a
wear test
●
Have framework for reducing wear
What is Wear?

Energy Lost

Noise Heat

Friction
Wear

Plastic Deformation
 Studying Wear

Micro / Mechanisms Macro / Systems

●
Why? ●
How much?
●
Microscopic surface ●
Measure wear loss
inspection
●
Equation or diagram to
●
Guidelines for wear
predict wear
reduction
 Wear Mechanisms/Modes
Mechanism Why? Prevention
● Reduce hardness
Abrasive Wear Hard cuts soft differential
● Reduce cutting objects
● Dissimilar materials
Adhesive Wear Asperity cold welding ● Harden surface
Rubbing in corrosive ● Remove corrosive media
Corrosion Wear
environment ● Decrease rubbing
● Surface hardening
Repeated rolling or
Surface Fatigue Wear ● Eliminate material
impact
impurities
Abrasive Wear
Adhesive Wear

8
 Corrosive Wear

3/2/17
Surface Fatigue Wear
 Stages in System Life
1)Running-In
(Initial period)
2)Steady wear
(normal working
period)
3)Severe Wear
(quickly wear out)

Wear Process Curves

 Meng Studies Wear Models
Wear Modeling: Evaluation and Categorization of Wear Models
Ph. D. Thesis, University of Michigan, 1994
●
No perfect models
Stage Years
–
Accurate
–
Quantitative Empirical 1950-1970
–
Universal Mechanism Proposal 1970-1980
●
Trends Interdisciplinary 1980-1992+
–
“Macro” to “Micro” Category No. of Equations
–
Understand then subdivide
system Erosion 28
–
Interdisciplinary Sliding 154
 Wear Law!
Plug and Chug?
Not so Fast
Find The Which
Parameters! Equation?

Is Equation
Valid?
Operating
Conditions? Stage
of Life!
 Archard Wear Equation
K K
W F S W  F  v
H H
K K
 pS   p  v
H H
Forms of the Archard Wear Equation

■ F Normal force (N)

■ H Hardness (N/m2)
■ K Wear coefficient (dimensionless)
●
Archard (1953)
p Pressure (N/m2)
Based on Holm (1946)
■
●

■ S Sliding distance (m)

■ v Velocity (m/2) ●
Pre-Meng dissertation
■ W Wear volume (m3)
■ δ Wear Depth (previous slide)
■ (.) Signifies time derivative ●
Based on asperity contacts
 Pick Your Poison: Test
Selection
Why Test? Model in
Conjunction?

Coupon
Standard
VS
VS
Component
Custom

Machine Condition
VS
Rig Capabilities Match System
Wear Mode?
 Crunching the Numbers
1. Study at wear scars 2. Check friction

3. Uncertainty 4. Check Literature (Early)

 Common Tests
Industry Specific

Pin-On-Disk
Four Ball Test

Quick and Dirty

●
Hardness
●
Friction
Block-On-Ring
 Stopping Wear
System & Loading

Material
&
Surface
Environment

Interface
Prevention through System
and Environment
P*V
Eliminate abrasive Reduce Pressure x Velocity
third body particles

Improve environment: corrosion,

Modify or eliminate
temperature, solvent...
troublesome interfaces
 Prevention Through
Material Modification
Surface Texture
Solid Lubricant Modification Hard Coating

Heat Treatment
 Prevention at the Interface
Lubricant Family Example
Gas Air
Liquid Oil
Semisolid Grease
Solid PTFE

Keeping the Surfaces Separated

Stribeck Curve
 Memory Bytes
●
Wear modes describe how wear takes place
and how it can be stopped
●
Wear equations can be used to predict wear
but have many limitations
●
Know what you want from a wear test and
think it through before starting
●
Wear can be reduced or eliminated through
redesign, material modification or lubrication
Questions