Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes

only to
students enrolled in courses for which the textbook, Fundamentals of Machine Component Design by Robert C. Juvinall and Kurt M. Marshek
has been adopted. Any other reproduction or translation of this work beyond that permitted by Sections 107 or 108 of the 1976 United States
Copyright Act without the permission of the copyright owner is unlawful.
SOLUTION (9.1)
Known: Iron anodes were used on the surface of a copper sheathed ocean vessel to
protect from corrosion.
Find: Explain why iron anodes on a copper surface exposed to ocean water would be
effective against corrosion.
Analysis:
Positioning a non-corrosion resistant steel in contact with a large copper surface that is
exposed to ocean water (salt solution) allows the steel to corrode before and in place of
the copper. Steel is “active” or more anodic as shown on Table 9.1 in position 17
compared to copper which sits towards the “noble” cathodic protected position 8. The
steel will corrode and become depleted at which time the steel anodes can be replaced
which will spare the copper sheathing.
Comments:
The size of the steel anodes would have to be determined in order to balance design and
maintenance costs. It would also be prudent to run large scale and long-term tests in
order to devise an appropriate maintenance and replacement schedule for the anodes in
addition to determining their proper and/or adequate placement.

9-1
SOLUTION (9.2)
Known: Aluminum plates are fastened together with brass rivets. The aluminum plates
have a total exposed area of 1.5 ft2 and the rivets have a total exposed area of 2.5 in.2.
The environment involves moisture and some salt.
Find:
(a) Determine which metal will corrode.
(b) If twice as many rivets are used, what effect would this have on the total rate of
corrosion?
Schematic and Given Data:

Brass rivets
Total exposed
area = 2.5 sq.
in.

Aluminum plates
Total exposed
area = 1.5 sq. ft

Electrolytic environment Area Ratio = Asheet/Arivet = 86.4

Assumptions:
1. Good electrical contact exists between the brass rivets and the aluminum plates.
2. Salt is present in the environment.
3. The compatibility chart, Table 9.1, applies to this case.
Analysis:
(a) Since aluminum #16 is more anodic than brass #8, the aluminum plate will corrode
(but slowly, because of the area effect). ■
(b) Doubling the number of brass rivets would about double the corrosion rate of the
aluminum plates, because the current density at each brass rivet would remain
about the same, thereby doubling the current density of the aluminum plates. ■
Comment: (1) The corrosion rate would be higher if the rivets were aluminum and the
plates were brass. (2) An "important factor in galvanic corrosion is the area effect, or
the ratio of the cathodic to anodic areas. An unfavorable area ratio consists of a large
cathode and a small anode. For a given current flow, the current density is greater for
a small electrode than for a larger one. The greater the current density at an anodic
9-2
area the greater the corrosion rate. Corrosion of the anodic area may be 100 or 1000
times greater than if the anode and the cathodic area were equal in size." See
Corrosion Engineering, Third Edition, Mars G. Fontana, McGraw-Hill, New York,
1986.

9-3
SOLUTION (9.3)
Known: Square metal plates having a total exposed area of 10.75 ft2 are fastened
together with rivets having a total exposed area of 15.5 in.2. The environment involves
moisture and some salt. Consider two cases: (1) iron plates with nickel-copper alloy
rivets, and (2) nickel-copper alloy plates with iron rivets.
Find:
(a) For each case, determine which metal will corrode?
(b) How do the rates of corrosion compare for the two cases?
(c) If half as many rivets were used, what influence would this have on the total rate
of corrosion?
Schematic and Given Data:

Metal rivets
Total exposed
area = 15.5 sq.
in.

Metal plates
Total exposed
area = 10.75 sq. ft

Electrolytic environment Area Ratio = Asheet/Arivet = 100

Assumptions:
1. Good electrical contact exists between the rivets and the plates.
2. Salt is present in the environment.
3. The compatibility chart, Table 9.1, applies to this case.
Analysis:
(a) The iron #17 is more active (anodic) than the nickel-copper alloy #6 and would
corrode in both cases (1) and (2). ■
(b) Because the current density is about 100 times greater at the rivet surface than at
the plate surface due to area effect, the corrosion rate is highest if the rivets are
iron. ■
(c) Halving the number of iron rivets would minimally affect corrosion rate of an
individual rivet because the current at each rivet would remain about the same.
Halving the number of nickel-copper alloy rivets would about halve the corrosion

9-4
 rate of iron plates, again because the current density at each rivet would remain
about the same, thereby halving the current density of the iron plates. ■
Comment: An "important factor in galvanic corrosion is the area effect, or the ratio of
the cathodic to anodic areas. An unfavorable area ratio consists of a large cathode and
a small anode. For a given current flow, the current density is greater for a small
electrode than for a larger one. The greater the current density at an anodic area the
greater the corrosion rate. Corrosion of the anodic area may be 100 or 1000 times
greater than if the anode and the cathodic area were equal in size." See Corrosion
Engineering, Third Edition, Mars G. Fontana, McGraw-Hill, New York, 1986.

9-5
SOLUTION (9.4)
Known: Lead sheet is pop riveted with bronze fasteners. The ratio of the areas is
known. The environment is seawater.
Find:
(a) Determine which metal will corrode.
(b) Determine the influence of using half as many fasteners on the total rate of
corrosion.
(c) Suggest ways to reduce corrosion.
Schematic and Given Data:

Bronze
fasteners

Lead sheet

Total exposed
area of sheet is 100
times that of fasteners

Seawater Area Ratio = A lead /Abronze = 100

Assumptions:
1. Good electrical contact exists between the fasteners and the lead sheets.
2. Salt is present in the environment.
3. The compatibility chart, Table 9.1, applies to this case.

Analysis:
(a) Since lead #15 is more anodic than bronze #8, the lead will corrode. However,
two factors cause the corrosion to be relatively slow. First, the area ratio slows the
rate, and second, lead passivates well, forming a protective coating.
(b) Halving the number of bronze fasteners would about halve the corrosion rate of the
lead sheets, because the current density at each bronze fastener would remain
about the same, thereby halving the current density of the lead sheets.
(c) Reduce the corrosion by (1) eliminating the electrolytic salt ions in the
environment, (2) insulating the fasteners from the lead sheets, and (3) choosing a
less anodic material for the sheets.

9-6
SOLUTION (9.5)
Known: Galvanized steel sheet metal of known area is riveted with copper rivets of
known area. The entire assembly is immersed in salt water.
Find:
(a) Determine which metal will corrode.
(b) Determine the influence of using half as many rivets on the total rate of corrosion.
(c) Suggest ways to reduce corrosion.
Schematic and Given Data:

Copper rivets
Total exposed
area = 2 in. 2

Galvanized steel
sheets
Total exposed
area = 1.2 ft 2

Electrolytic environment Area Ratio = A sheet/Arivet = 86.4

Assumptions:
1. Good electrical contact exists between the rivets and the galvanized metal sheets.
2. Salt is present in the environment.
3. The compatibility chart, Table 9.1, applies to this case.
Analysis:
(a) Since the galvanized metal #19 is more anodic than the copper #8, it will corrode
(slowly, because of the area effect).
(b) Halving the number of copper rivets would about halve the corrosion rate of the
galvanized steel sheets, because the current density at each copper rivet would
remain about the same, thereby halving the current density of the galvanized metal.
(c) Reduce the corrosion by eliminating the electrolytic salt ions in the environment.
Comment: It is impossible to reduce the corrosion rate by using a sacrificial anode,
since the galvanized steel is so anodic. Only magnesium is more active than galvanized
metal but magnesium will react with air immediately.

9-7
SOLUTION (9.6D)
Known: The web site http://www.corrosion-doctors.org provides information about
corrosion.
Find: Search http://www.corrosion-doctors.org, and under the “Information
Modules” section choose “Corrosion Environments and Applications”. Select one of
the listed topics and write a summary of the information covered. Include if costs are
addressed, types of materials affected, what type of corrosion can be expected, and how
to deter the effects of corrosion.
Analysis: Under the module “Corrosion in Buildings”, problem areas in heating, water
supply and sewage disposal systems are addressed. This module mainly concentrates
on corrosion caused by water, focused on the problem of hot water. For example, water
contains dissolved oxygen and dissolved salts, which can lead to a corrosion problem.
The costs associated with corrosion is not mentioned, however, it does note that to
extend the service life of a hot water tank, the operating temperature should be as low
as feasible (no more than 150° F). The article also notes that a wise precaution is to
avoid the use of different metals to eliminate galvanic corrosion. Corrosion inhibitors
such as phosphates or silicates can be used in association with the heating system piping
to minimize corrosion on the waterside. Also, when inhibitors cannot be added to the
water, the scale found naturally in the water usually reduces corrosion because it can act
as a protective coating.

9-8
SOLUTION (9.7D)
Known: The web sites http://www.corrosionsource.com and http://www.corrosion-
doctors.org both provide information about corrosion.
Find: (a) List types of corrosion phenomena that can be identified by visual
observation. (b) List methods of controlling corrosion.
Analysis:
(a) Corrosion mechanism/remedial action based on visual observations:
1. General attack
2. Attack in joints, seams or seal surfaces
3. Localized attack on metal surface
4. Directional surface indications
5. Cracking or brittleness
6. Different metals or parts in contact
7. Formation of internal blisters or cracks
8. Attack on wear or load bearing surface
9. Joining of dissimilar metals
10. Attack around weldment
11. Coating or lining failure
12. Elastomer/Plastic degradation
(b) Suggestions for corrosion control:
1. Cathodic Protection
2. Inhibition
3. Coatings & Linings
4. Electroplating
Methods to protect a metallic system against corrosion:
1. Thermodynamic protection
2. Kinetic protection
3. Barrier protection
4. Structural design
5. Environmental control
6. Metallurgical design

9-9
SOLUTION (9.8)
Known: AISI 301 stainless steel plates having a known total exposed area are fastened
together with chromium plated steel cap screws having a known total exposed area.
The environment involves moisture, and possibly some salt.
Find:
(a) Determine which metal will corrode.
(b) Determine the influence of using half as many bolts on the total rate of corrosion.
(c) Suggest ways to reduce corrosion.
Schematic and Given Data:

Chromium plated steel

cap screws
Total exposed
area = 110 cm 2

301 Stainless steel

plates
Total exposed
area = 1.5 m 2

Electrolytic environment

Assumptions:
1. Good electrical contact exists between the screws and the plates.
2. Salt is present in the environment.
3. The compatibility chart, Table 9.1, applies to this case.
Analysis:
(a) Since chromium #12 is more anodic than 301 stainless steel #7, the chromium-
plated screws will corrode. Corrosion will be quite severe due to the 136:1
(1/0.011 : 1/1.5) area ratio, and once the chromium plating is penetrated, the
underlying steel is even more anodic (if AISI 410, 416, 420, steel is used).
(b) By using half of the number of chromium plated steel cap screw would minimally
affect the corrosion rate of an individual cap screw because the current density at
each cap screw would remain about the same. (Halving the number of cap screws
would halve the current; therefore, the corrosion rate would be the same.)
(c) The corrosion can be reduced by (1) eliminating the electrolytic salt ions in the
environment, (2) insulating the screws from the plate (bushing, etc.), (3) choosing
a less anodic material for the screws (preferably higher than 301 stainless), and (4)
isolating the plates from the environment by painting, etc.
Comments*:
1. An important axiom related to coatings is as follows: "If one of two dissimilar
metals in contact is to be coated, the more noble (cathodic) or more corrosion-
resistant metal should be coated."
9-10
2. An "important factor in galvanic corrosion is the area effect, or the ratio of the
cathodic to anodic areas. An unfavorable area ratio consists of a large cathode
and a small anode. For a given current flow, the current density is greater for a
small electrode than for a larger one. The greater the current density at an anodic
area the greater the corrosion rate. Corrosion of the anodic area may be 100 or
1000 times greater than if the anode and the cathodic area were equal in size."
*See Corrosion Engineering, Third Edition, Mars G. Fontana, McGraw-Hill, New
York, 1986.

SOLUTION (9.9)
Known: AISI 301 stainless steel plates having a known total exposed area are fastened
together with titanium cap screws having a known total exposed area. The environment
involves moisture, and possibly some salt.
Find:
(a) Determine which metal will corrode.
(b) Determine the influence of using half as many bolts on the total rate of corrosion.
(c) Suggest ways to reduce corrosion.
Schematic and Given Data:

Titanium cap screws

Total exposed
area = 110 cm 2

301 stainless
Steel plates
Total exposed
area = 1.5 m 2

Electrolytic environment

Assumptions:
1. Good electrical contact exists between the screws and the plates.
2. Salt is present in the environment.
3. The compatibility chart, Table 9.1, applies to this case.
Analysis:
(a) Since 301 stainless steel #7 is more anodic than the titanium #4, the stainless steel
plates will corrode. However, corrosion will not be very severe, since the current
density in the plate is only 1/136 as much as in the titanium screws.
(b) Halving the number of titanium cap screws would about halve the corrosion rate of
the stainless steel plates, because the current density at each titanium cap screw

9-11
 would remain about the same, thereby halving the current density of the stainless
steel plates.
(c) Reduce the corrosion by (1) eliminating the electrolytic salt ions in the
environment, (2) insulating the screws from the plate, and (3) choosing a less
anodic material for the plate.
Comment: An "important factor in galvanic corrosion is the area effect, or the ratio of
the cathodic to anodic areas. An unfavorable area ratio consists of a large cathode and
a small anode. For a given current flow, the current density is greater for a small
electrode than for a larger one. The greater the current density at an anodic area the
greater the corrosion rate. Corrosion of the anodic area may be 100 or 1000 times
greater than if the anode and the cathodic area were equal in size." See Corrosion
Engineering, Third Edition, Mars G. Fontana, McGraw-Hill, New York, 1986.

SOLUTION (9.10)
Known: Metal plates having a known total exposed area are fastened together with
rivets having a known total exposed area. The environment involves moisture, and
possibly some salt. Consider two cases: (1) steel plates with copper rivets and (2)
copper plates with steel rivets.
Find:
(a) For each case, determine which metal will corrode.
(b) Compare the rates of corrosion for the two cases.
(c) Determine the influence of using twice as many rivets on the total rate of
corrosion.
Schematic and Given Data:

Rivets
Total Exposed
Area = 100 cm 2

Metal Plates
Total Exposed
Area = 1 m 2

Assumption: The steel is an ordinary non-corrosion-resistant steel.

Analysis:
(a) Assuming an ordinary non-corrosion-resistant steel, the steel would be the more
9-12
 active (anodic) and would corrode in both cases (1) and (2).
(b) Because the current density is 100 times greater at the rivet surface than at the
plate surface due to area effect, the corrosion rate is highest if the rivets are steel.
(c) Doubling the number of steel rivets would minimally affect corrosion rate of an
individual rivet because the current at each rivet would remain about the same.
Doubling the number of copper rivets would about double the corrosion rate of
steel plates, again because the current density at each rivet would remain about the
same, thereby doubling the current density of the plates.
Comment: An "important factor in galvanic corrosion is the area effect, or the ratio of
the cathodic to anodic areas. An unfavorable area ratio consists of a large cathode and
a small anode. For a given current flow, the current density is greater for a small
electrode than for a larger one. The greater the current density at an anodic area the
greater the corrosion rate. Corrosion of the anodic area may be 100 or 1000 times
greater than if the anode and the cathodic area were equal in size." See Corrosion
Engineering, Third Edition, Mars G. Fontana, McGraw-Hill, New York, 1986.

SOLUTION (9.11D)
Known: Some plumbing codes require that an electrical insulator be used when copper
tubing is connected to steel pipe.
Find: With the aid of a simple sketch, explain the rationale behind this requirement.
Schematic and Given Data:

Teflon

Steel Copper

+ -+
+ +
+ +

Assumption: The steel is non-corrosion-resistant type.

Analysis: The purpose would be to provide an electrical insulator to break the galvanic
circuit, similar to Fig. 9.7, as shown above.

9-13
SOLUTION (9.12D)
Known: A pickup truck tailgate cable having a breaking strength of 4,000 lb is
fabricated from 7x19 braided carbon steel wire. To prevent corrosion, the 5 mm-
diameter steel wire cable is galvanized and covered with a weather resistant heat shrink
tube made of crosslinked polyolefin. The ends of the tailgate cable are sealed with
epoxy during manufacturing. Because of the tailgate cables geometry and specific end
fixtures, the cable bends and twists when the pickup truck tailgate is raised and lowered.
The twisting and bending opens and closes the 7 cable wire bundles all located within
the polyolefin tube.
Find: List and then comment on the possible reasons why the galvanized cables might
corrode and break within a few years of initial use and describe what could be done to
improve the design (see Figure P9.11D).
Schematic and Given Data:
Polyolefin tube
Wire

Assumptions:
1. The environment involves moisture and some salt.
2. The polyolefin tube and the epoxy seal will not prevent moisture and some salt
from entering the 7x19 braided carbon steel wire.
3. The compatibility chart, Table 9.1, applies to this case.
Analysis: Reasons that would cause the galvanized cables to corrode and break
prematurely would most probably include some combination of the following:

1. Fatigue-corrosion of the cable.

2. Poor zinc coating (galvanizing) of the cable.
3. Insufficient amount and/or distribution of the zinc coating.
4. Water entering the steel wire cable
9-14
5. Failure of the polyolefin cover to prevent entry of water
6. Water creating crevice “crack” between the wires created by electrolyte
heterogeneity created by sealing off atmospheric oxygen from the center of the
water drop, making it unlike the oxygen-rich electrolyte near the edge. Corrosion
occurs at the oxygen-starved interior – see textbook Figure 9.6.
7. The epoxy may seal the ends of the cable not allowing oxygen to enter and water to
drain.
8. Poor design choice in using ordinary steel. Most tailgate cable manufacturers use
braided stainless steel wire.
9. A rough wire surface was created (a) during manufacture of the wire, (b) from zinc
coating, (c) from rubbing between wires, and/or (d) from bending and/or twisting
of the wires.
10. The twisting of the wire bundles causes the bundles to open allowing water to (a)
enter between wires, (b) travel into the cable core, and (c) into those areas where no
zinc coating is present.
Comment: It is possible to avoid corrosion by using stainless steel wires but the initial
cost of the cable would be higher.

SOLUTION (9.13D)
Known: Corrosion of the internal steel surfaces of the crankcase of a particular engine
is a problem. Someone suggests replacing the steel oil drain plug with one made of
magnesium. You recommend retaining the steel plug, but that one end of a small
magnesium rod be embedded in the inside surface of the plug.
Find: Explain your recommendation.
Schematic and Given Data:

Drain Plug
(steel) Oil

Insert Rod
(magnesium)

Crankcase
(steel)
"Best Design"

Analysis: Corrosion of the (sacrificial) magnesium plug would occur at the threads,
causing it to loosen and leak. Corrosion of the exposed surfaces of the plug with
magnesium insert would not affect plug sealing.
9-15
SOLUTION (9.14D)
Known: Design details are to be illustrated that will reduce corrosion.
Find: Illustrate design details to reduce: (a) atmospheric corrosion, (b) concentration
cell corrosion, and (c) galvanic corrosion.
Analysis:
1. The illustrations are left to the student to draw.
2. The article, Recommended Design Details to Reduce Corrosion, by Fred M.
Reinhart appearing in Product Engineering Design Manual, edited by Douglas C.
Greenwood, McGraw-Hill, 1959, p. 294-295, illustrates and describes
recommended design details to reduce corrosion.
3. The descriptions are as follows:
A. Atmospheric Corrosion
1. Structural members should be arranged so that moisture of liquids will
not collect. Inverting angles and channels prevents this condition.
Drilling holes is another method to insure proper drainage.
2. Rounded corners and smooth contours should be used whenever possible
to prevent the accumulation of moisture, liquids and solid matter. Using
corrosion resistant materials is often found to be more economical due to
greater service life.
3. Butt-welded joints are less likely to corrode and should be used. If lap
joints are required, all crevices should be filled with a non-absorbing
caulking compound or welded to prevent retention of liquids in crevices.
4. Storage tanks and other containers should be supported on legs to allow
a free circulation of air underneath. This prevents the possibility of any
condensation and collection of moisture under the tank.
B. Concentration Cell Corrosion
1. All liquid containers should be designed with smooth and rounded
corners. Sharp corners, stagnant areas and other such conditions are
favorable to the accumulation of precipitates, solids and scale, which
promote concentration-cell attack. Sloping bottoms should be used with
valves arranged for complete drainage.
2. All baffles and internal stiffeners in tanks should have openings arranged
to avoid liquid pockets and permit the free drainage of fluids.
3. In the design of liquid passages, all pipes and connections should be
constructed to insure uniform flow, with a minimum turbulence and air
entrainment. This also reduces settling of solids.
4. Cathodic protection of containers with corrosive liquids can be done by
immersing a rod of a more anodic material inside. This reverses the
galvanic current and the container becomes cathodic and is less likely to
corrode. Magnesium and zinc rods are often used.
C. Galvanic Corrosion
1. In joints and connections, the proportions of dissimilar metals should be
chosen so the anodic or less noble metal has the greater exposed area. If
fastenings such as bolts and rivets are required, they should be made of
the more noble or cathodic type material.
2. When possible the connection of dissimilar metals should be separated
by an insulating material to reduce or prevent the current flow in the

9-16
 galvanic circuit. Paint or plastic coatings serve to reduce the galvanic
current by increasing the circuit resistance.
3. Painted coatings should be applied with caution. Do not paint the less
noble material, otherwise greatly accelerated corrosion will occur at
imperfections in the coating. If possible exposed surfaces should be
painted. Commercial protectives are now available.
4. In designing equipment, keep different metals far apart in the solution;
this increases the resistance of the electrolytic path. Chemical inhibitors
are often added to corrosive solutions. Some bare zinc, magnesium or
steel in the liquid will counteract corrosion.
5. In joining dissimilar materials, well apart in the galvanic series, avoid
threaded connections since the threads deteriorate rapidly. Brazed joints
are preferred using a brazing allow more noble than at least one of the
metals that are being joined together.
6. At connections of dissimilar materials, consider using small replaceable
sections made of the less noble metal. These expendable parts should be
easy to replace and made oversize to increase their corrosive life.
Nonmetallic gaskets increase the circuit resistance.

SOLUTION (9.15D)
Known: A report on Mechanism Corrosion needs to be written.
Find: Write a report addressing six basic courses of corrosion, and explain what can be
done to minimize or eliminate each.
Analysis:
1. The article, The Six Types of Corrosion...a Preventative Guide, by Peter C. Noy
appearing in Product Engineering Design Manual, edited by Douglas C.
Greenwood, McGraw-Hill, 1959, p. 156-157, discusses six mechanisms of
corrosion.
2. The author describes the six basic causes:
• Direct Attack
• Complex Attack
• Galvanic Action
• Concentration Cell
• Dezincification
• Fatigue and Stress Corrosion
3. The article lists three basic recommendations:
• Have the design examined by a corrosion expert.
• Test the problem exhaustively. Here, keep as close to service conditions as
possible, and include the most severe conditions.
• Watch out for environmental surprises (for example, hot coffee dissolves nickel
plate a thousand times faster than well drinking water).
Comment: For each cause, the article presents specific design recommendations.

9-17
SOLUTION (9.16)
Known: A small pin is pressed against one side of a rotating disc as shown in Figure
P9.16.
Find: Describe how the friction coefficient between the pin and the disc can be
measured. List one use for such an apparatus.
Comments:
1. The friction coefficient is defined by f = Ff / N where N is the force along the
longitudinal axis of the pin and Ff is the friction force exerted on the side of the disc
in a direction opposite to the disc rotation at a location underneath the pin. The load
N would be the force on the pin. The friction force, Ff, could be measured by
calibrating a strain-gauged pin or pin holder.
2. Pin on disk testers are used to study the friction between materials – pins and discs
as well as the wear between pins and discs for the condition where the pin will
experience a significantly larger number of wear passes than the disk. Effects of
lubrication and various lubricants can also be studied.

SOLUTION (9.17)
Known: A thin-walled non-rotating cylinder is pressed in an axial direction end-wise
against the end of a thin walled rotating cylinder as shown in Figure P9.17. The axes of
both cylinders are collinear.
Find: Describe how the frictional torque and the specimen temperatures could be
measured. Give one use for such an apparatus.
Comments:
1. The frictional torque, Tfb would be measured by the torque to rotate the bottom
cylinder or by measuring the torque, Tft to hold the top cylinder in rotational
position. Under steady state conditions, Tft should be equal to Tfb.
2. The temperature would vary in the specimen most probably being highest at the
sliding contact surface. A non-contact temperature-measuring device could be used
for measuring temperature near the sliding surfaces. Alternatively, a thermocouple
could be inserted in the non-rotating specimen close to the contact surface.
3. This type of apparatus has been used to study the friction behavior of nylon on steel
at high sliding speeds at reported loads of 0 to 50 kg, speeds of 0.01 to 200 cm/sec
and temperatures of room ambient to 200°C, in air.
Reference: Watanabe, M., Karasawa, M. and Matsubara, K., “The Frictional Properties of
Nylon.” Wear, 12, pp. 185-191, (1968).

4. This type of device has also been used to study the influences of humidity on the
friction and life of a solid lubricant.
Reference: Pritchard, C. and Midgley, J.W. “The Effect of Humidity on the Friction and Life
of Unbonded Molybdenum Disulphide Films,” Wear, 13, (1969), pp. 39-50.

9-18
SOLUTION (9.18)
Known: A rotating cylinder is pressed against a second rotating cylinder as shown in
Figure P9.18. The axes of the cylinder are parallel and the cylinders rotate in opposite
directions.
Find: Describe how such a friction and/or wear apparatus might be used.
Comments:
1. This type of apparatus is used to study surface fatigue failure in gear teeth (that
because of conjugate action roll on one another). The apparatus is also used to
evaluate lubricants and additives use in gear reducers and in friction drives.
2. This apparatus is categorized as “disk on disk (edge loaded)” and includes devices
that have two disks rotating while contacting against each other on their outer
surfaces. The disks can operate at different speeds thus producing sliding at the
contact surface.

9-19
SOLUTION (9.19)
Known: A latching mechanism involves steel mating surfaces of known hardness
rubbing back and forth over a known distance. Lubrication is questionable. The latch
is operated an average of 30 times per day. The compressive load between the surfaces
is known.
Find: Estimate the volume of metal that will wear away from the softer steel member
during one year of use.
Schematic and Given Data:

30 cycles/day, everyday

100 N 100 N

Steel, 100 Bhn

Steel, 300 Bhn

30 mm
Latch Latch
Closed Open

Analysis:
1. Apply Eq. (9.1a), W = ( KH) FS, where
K = 5 ✕ 10-3 (estimated from Fig. 9.12 for identical metals, poorly lubricated).
H = (100 Bhn)(9.81 MPa/Bhn) = 981 MPa for the softer steel.
F = 100 N
S = (2 ✕ 30 mm/operation)(30 operations/day) ✕ (365 days/year) = 657,000
mm/year
5 ! 10-3
2. W= (100 N)(657,000 mm/year) = 334.9 mm3/year ■
981 MPa

9-20
SOLUTION (9.20)
Known: A latching mechanism involves steel mating surfaces of known hardness
rubbing back and forth over a known distance. Lubrication is questionable. The latch
is operated an average of 30 times per day. The compressive load between the surfaces
is known.
Find: Estimate the volume of metal that will wear away from the softer steel member
during one year of use.
Schematic and Given Data:

30 cycles/day, everyday

100 N 100 N

Steel, 100 Bhn

Steel, 300 Bhn

20 mm
Latch Latch
Closed Open

Analysis:
1. Apply Eq. (9.1a), W = ( KH) FS, where
K = 5 ✕ 10-3 (estimated from Fig. 9.12 for identical metals, poorly lubricated).
H = (100 Bhn)(9.81 MPa/Bhn) = 981 MPa for the softer steel.
F = 100 N
S = (2 ✕ 20 mm/operation)(30 operations/day) ✕ (365 days/year) = 438,000
mm/year
5 ! 10-3
2. W= (100 N)(438,000 mm/year) = 223.3 mm3/year ■
981 MPa

9-21
SOLUTION (9.21)
Known: A latching mechanism involves steel mating surfaces of known hardness
rubbing back and forth over a known distance. Lubrication is questionable. The latch
is operated an average of 30 times per day. The compressive load between the surfaces
is known.
Find: Estimate the volume of metal that will wear away from the softer steel member
during one year of use.
Schematic and Given Data:

30 cycles/day, everyday

100 N 100 N

Steel, 300 Bhn

Steel, 300 Bhn

30 mm
Latch Latch
Closed Open

Analysis:
1. Apply Eq. (9.1a), W = ( KH) FS, where
K = 5 ✕ 10-3 (estimated from Fig. 9.12 for identical metals, poorly lubricated).
H = (300 Bhn)(9.81 MPa/Bhn) = 2948 MPa for the softer steel.
F = 100 N
S = (2 ✕ 30 mm/operation)(30 operations/day) ✕ (365 days/year) = 657,000
mm/year
-3
×
2. W = 5 10 (100 N)(657,000 mm/year) = 111.4 mm3/year
2948 MPa
Comments: The wear volume of the block is computed as Vb = abhb where:
1. For a rectangular (a ✕ b) steel block, the wear volume for the block is Vb = abhb
where hb is the linear block wear, and (ab) is the contact area of the block.
2. For a steel plate, the wear volume for the plate is Vp = 30bhp where (30b) is the
area of the wear "scar" and hp is the linear plate wear.
3. Since both mating surfaces have 300 Bhn hardness, W = Vb = Vp = abhb = 30bhp.
4. Therefore, hb = 30hp/a where a is the length of the block. ■

9-22
SOLUTION (9.22)
Known: A pin of known material rubs against a rotating disc of known material.
Find: The wear coefficient for the material of the pin and the disk.
Schematic and Given Data:

20 N Pin (Copper)
80 Vickers

r = 16 mm Disk (Al 2014-T6)

135 Bhn
n = 80 rpm
Volumetric wear loss after 2 hours:
Copper: WCu = 2.7 mm 3
Aluminum: WAl = 0.65 mm 3

Assumption: Abrasive wear occurs.

Analysis:
1. Solve Eq. (9.1a) for the wear coefficient, K:
K = WH/FS

2. Hardness of pin, HCu = (80 kg/mm2)(9.81 MPa 2 ) = 784.8 MPa.

kg/mm

Hardness of Disk, HAl = (135 kg/mm2)(9.81 MPa 2 ) = 1324.35 MPa.

kg/mm
3. Force of pin and disk: FCu = FAl = 20 N.

4. Rubbing Distance of pin and disk: SCu = SAl = S.

S = 2π(16 mm/rev)(80 rev/min)(60 min/hr)(2 hr) = 9.65 ✕ 105 mm.

5. Therefore,
(2. 7 mm3)(784. 8 MPa)
KCu = WCu HCu = = 1. 10 ! 10-4
FS 5
(20 N)(9. 65 ! 10 mm) ■
(0. 65 mm3)(1324. 35 MPa)
KAl = WAl HAl = = 4. 46 ! 10-5
FS 5
(20 N)(9. 65 ! 10 mm) ■

9-23
Comments:
1. Figure 9.11 shows us that aluminum and copper fall in the category of "compatible
metals": Solid Solubility Above 1%. Therefore, using Fig. 9.12 for this
combination indicated that the wear coefficient for the softer material (Cu) for
unlubricated surfaces will be in the range 5 ✕ 10-4 < KCu < 6 ✕ 10-3. Note that our
experimental results show that KCu is below this range. In general, the
experimental result is to be preferred over the tables.
2. The wear volume for the copper pin is Vp = πd2Δp/4. If the pin diameter d = 4
mm, then since Vp = 2.7 mm3, we have Δp = 0.215 mm. The wear volume for
the aluminum disk can be written as Vdisk = πDdΔdisk, where d = 4 mm, D = 32
mm, and Vdisk = 0.65 mm3 which results in Δdisk = 0.0016 mm. Note that the
wear depth in the disk is 1/134 of that of the pin linear wear.

SOLUTION (9.23)
Known: A pin of known material rubs against a rotating disc of known material.
Find: The wear coefficient for the material of the pin and the disk.
Schematic and Given Data:
20 N
Al
95 Bhn

r = 16 mm Steel
210 Bhn
n = 80 rpm
Volumetric wear loss after 2 hours:
Steel: WCu = 0.65 mm 3
Aluminum: WAl = 2.7 mm 3

Assumption: Abrasive wear occurs.

Analysis:
1. Solve Eq. (9.1a) for the wear coefficient, K: K = WH/FS
2. Evaluating the above equation for each material yields the following
(2. 7 mm3)(95 Bhn)(9. 81 MPa/Bhn)
KAl = = 1. 30 ! 10-4
5
(20 N)(9. 65 ! 10 mm) ■
(0. 65 mm3)(210 Bhn)(9. 81 MPa/Bhn)
KSteel = = 6. 94 ! 10-5
5
(20 N)(9. 65 ! 10 mm) ■

9-24
SOLUTION (9.24)
Known: A steel part rubs in a slot of a steel link without lubrication. The hardnesses,
length of travel, frequency of operation, and loading are all known.
Find: The volume of metal worn from the link in one year.
Schematic and Given Data:
2000 cycles/year

20 lb

Steel Part 550 Bhn

Steel Link 150 Bhn

Unlubricated Surface
3 in.

Assumptions:
1. Adhesive wear occurs, Eq. (9.1a) is valid.
2. The wear coefficient can be estimated from Fig. 9.12.
Analysis:
1. Apply Eq. (9.1a), W =
K
H()FS, where K = 4 ✕ 10-3 from Fig. 9.12 for unlubricated
identical metals.
H = (150 Bhn)(1.424 ksi/Bhn) = 213.6 ksi.
F = 20 lb = 0.02 klb.
S = (3 ✕ 2 in/cycle)(2000 cycles/year)(1 year) = 12,000 in.

4 ! 10-3
2. W= (0.02 klb)(12000 in) = 4.494 ✕ 10-3 in3. ■
213. 6 ksi

Comments:
1. The wear volume for the steel link is computed as Vsl = LwΔsl, where L is the
stroke distance of the steel part, w is the width of contact, and Δsl is the linear link
wear. If w = 0.5, then since Vsl = 4.494 ✕ 10-3 in.3, we have Δsl = 3 ✕ 10-3 in.
2. The wear volume for the steel part is

4 ! 10-3
Vsp = (K/H)FS = (0. 02) (12000) = 1. 226 ! 10-3 in. 3, and it is
550 ! 1. 424
approximately Vsp = w2Δsp. With w = 0.5 in. and Vsp = 1.226 ✕ 10-3 in3, we have
Δsp = 4.904 ✕ 10-3 in. which is about 1.6 times of Δsl.
9-25
20 lb
Steel Part

2000 cycles/year
w w Contact Area

3 in.
Steel Link

9-26
SOLUTION (9.25)
Known: Figure P4.1 in Chapter 4 shows a 0.5 in.-diameter ball loaded in compression
by a 4000 lb force against the left end of a bar where the cross-section is 1 in. x 1 in.
The balls are hardened steel. The steel bar has a yield strength of 50 ksi.
Find: Determine the maximum contact stress that will result from the load of 4000 lb.
Schematic and Given Data: Please see Figure P4.1 from Chapter 4.
Assumptions:
1. Localized yielding of the contact surfaces does not occur.
2. The stress is distributed over the contact area.
3. Contact stresses do not cause failure or fracture of the surfaces.
Analysis:
1. Let body 1 be the steel ball (E1 = 30 x 106 psi):
R1 = 0.25 in.
E1 = 207 GPa (Appendix C-1)
v1 = 0.30 (Appendix C-1)

2. Let body 2 be the steel bar (E2 = 30 x 106 psi):

R2 = 0 in. for flat surface
E2 = 207 GPa (Appendix C-1)
v2 = 0.30 (Appendix C-1)
3. From Eq. 9.2
1 " v12 1 " v22 1 " (0.3)2 1 " (0.3)2
!= + = +
E1 E2 207 # 10 9 207 # 10 9
= 8.792 # 10 "12 m 2 / N

Δ = 60.67 x 10-9 in2/lb

4. From Eq. 9.3 the maximum contact pressure is

F(1 / R1 + 1 / R2 )2
p0 = 0.578 3
!2
4000 lb(1 / 0.25in + 0)2
= 0.578 3 = 10330 MPa
(8.792 " 10 #12 m 2 / N)2

po = 1,498,240 psi

The contact pressure (compressive stress) calculated is greater than the yield
strength. The maximum contact stress will therefore equal the yield strength of
50,000 psi. ■

9-27
Comments:
1. The contact stress calculation produces a value of almost 1.5 million psi. We can
therefore concluded that the ball will deform the steel bar surface until the contact
area increases enough to support the load.
2. Clearly, the assumption that localized yielding of the contact surface does not
occur is incorrect.
3. The maximum force that the ball can exert on the end of the steel bar (i.e., the
force that the bar will support) can be estimated from the equation
Fmax = Sy Aprojected = (50,000 psi)(0.1963 in2) = 9815 lb. ■
4. We are assuming an idealized stress-strain curve.

9-28
SOLUTION (9.26)
Known: Figure P4.2 in Chapter 4 shows a 0.25 in.-diameter ball loaded in compression
by a 1000 lb force against the left end of a bar where the cross-section is 1 in. x 1 in.
The balls are hardened steel and the steel bar has a yield strength of 50 ksi.
Find: Determine the maximum contact stress that will result from the load of 1000 lb.
Schematic and Given Data: Please see Figure P4.2 from Chapter 4.
Assumptions:
1. Localized yielding of the contact surfaces does not occur.
2. The stress is equally distributed over the contact area.
3. Contact stresses do not cause failure or fracture of the surfaces.
Analysis:
1. Let body 1 be the steel ball (E1 = 30 x 106 psi):
R1 = 0.125 in.
E1 = 207 GPa (Appendix C-1)
v1 = 0.30 (Appendix C-1)

2. Let body 2 be the steel bar (E2 = 30 x 106 psi):

R2 = 0 in. for flat surface
E2 = 207 GPa (Appendix C-1)
v2 = 0.30 (Appendix C-1)
3. From Eq. 9.2

1 " v12 1 " v22 1 " (0.3)2 1 " (0.3)2

!= + = +
E1 E2 207 # 10 9 207 # 10 9
= 8.792 # 10 "12 m 2 / N

Δ = 60.67 x 10-9 in2/lb

4. From Eq. 9.3 the maximum contact pressure is

F(1 / R1 + 1 / R2 )2
p0 = 0.578 3
!2
1000 lb(1 / 0.125in + 0)2
= 0.578 3 = 10330 MPa
(8.792 " 10 #12 m 2 / N)2

po = 1,498,240 psi

The contact pressure (compressive stress) calculated is greater than the yield stress.
The maximum contact stress will therefore equal the yield stress of 50,000 psi. ■
(We are assuming an idealized stress-strain curve.)

9-29
Comments:
1. The contact stress calculation produces a value of almost 1.5 million psi. Since the
yield stress of the steel bar is only 50,000 psi, the ball will deform the steel bar
surface until the contact area increases enough to support the load.
2. Clearly, the assumption that localized yielding of the contact surfaces does not occur
is incorrect.
3. The maximum force that the ball can exert on the end of the steel bar (i.e., the
force that the bar will support) can be estimated from the equation
Fmax = Sy Aprojected = (50,000 psi)(0.04909 in2) = 2454 lb. ■
4. We are assuming an idealized stress-strain curve.

9-30
SOLUTION (9.27)
Known: A hardened steel spherical ball of known diameter exerts a known load
against a hard-bronze bearing-alloy spherical seat of known diameter.
Find: Determine maximum contact stress.
Schematic and Given Data:

Hard-bronze
bearing alloy
spherical
seat
2000 N 10.2 mm
10 mm
Hardened
Steel Sphere

Assumptions:
1. The surfaces of the bodies are frictionless.
2. The bodies are isotropic and homogeneous.
3. The surfaces are smooth and continuous.
4. The radii of curvature R1 and R2 are large compared to the dimensions of the
contact area.
5. The compressive yield strength of the weaker material in not exceeded.
Analysis:
1. Let body 1 be the steel ball:
R1 = 5 mm
E1 = 207 GPa (Appendix C-1)
ν1 = 0.30 (Appendix C-1)
2. Let body 2 be the bronze socket:
R2 = -5.10 mm
E2 = 110 GPa (Appendix C-1)
ν2 = 0.33 (Appendix C-1)
3. From Eq. (9.2),

!2 ! 2 1 - (0. 3)2 1 - (0. 33)2

Δ= 1- 1 + 1- 2 = + = 1.250 ✕ 10-11
E1 E2 207 ! 10 9
110 ! 10 9

3 2
F(1/R 1 + 1/R 2)
4. From Eq. (9.3), po = 0.578 2
Δ
9-31
 3 2000(1/0. 005 + 1/-0. 00510)2
= 0.578 = 336 MPa ■
1. 25 ! 10-11 2

SOLUTION (9.28D)
Known: A hardened steel spherical ball of known diameter exerts a known load
against a hard-bronze bearing-alloy spherical seat of known diameter.
Find: Determine the maximum contact stress for loads from 1800 N to 2000 N.
Schematic and Given Data:

Hard-bronze
bearing alloy
spherical
seat
1800 N
to 10.2 mm
2000 N 10 mm
Hardened
Steel Sphere

Assumptions:
1. The surfaces of the bodies are frictionless.
2. The bodies are isotropic and homogeneous.
3. The surfaces are smooth and continuous.
4. The radii of curvature R1 and R2 are large compared to the dimensions of the
contact area.
5. The compressive yield strength of the weaker material in not exceeded.
Analysis:
1. Let body 1 be the steel ball:
R1 = 5 mm
E1 = 207 GPa (Appendix C-1)
ν1 = 0.30 (Appendix C-1)

2. Let body 2 be the bronze socket:

R2 = -5.10 mm
E2 = 110 GPa (Appendix C-1)
ν2 = 0.33 (Appendix C-1)

3. From Eq. (9.2),

9-32
 2 2
1 - ν1 1 - ν2 1 - (0. 3)2 1 - (0. 33)2
Δ= + = + = 1.250 ✕ 10-11
E1 E2 207 ! 10 9 110 ! 10 9

3 2
F(1/R 1 + 1/R 2)
4. From Eq. (9.3), po = 0.578 2
Δ
3 2
1800(1/0. 005 + 1/-0. 00510)
= 0. 578 2 = 324 MPa
(1. 25 × 10 )
-11
■
Comments:
3
1. Inspection of Eq. (9.3), shows that po ~ F .
3
324 1800
2. For F = 1900 N, p = 3 , and po = 330 MPa.
o 1900
3
324 1800
3. For F = 2000 N, p = 3 , and po = 336 MPa.
o 2000
4. The maximum contact stress is plotted for normal loads from 1800 N to 2000 N.

336
po, maximum contact
stress (MPa)

330

324
1800 1900 2000
F, normal load (N)
Maximum contact stress
vs. normal load

5. For the analysis to be valid, the values of po should not exceed the yield strength of
the ball or socket joint materials selected.

9-33
SOLUTION (9.29)
Known: The arm for a Geneva indexing mechanism supports a rolling cylindrical
hardened steel pin that fits into the Geneva wheel slots. The pin is to have the same
length and diameter. The material properties of the wheel are known. A design contact
stress and design overload torque are given.
Find: Determine the smallest acceptable pin diameter.
Schematic and Given Data:

Geneva Wheel slot,

cast iron (E = 140 GPa,
! = 0.25)

Pin, hardened steel,

rolling cylinder

100 mm
radius

Design contact stress,

700 MPa

Design overload torque,

60 N.m

Assumptions:
1. The surfaces of the bodies are frictionless.
2. The bodies are isotropic and homogeneous.
3. The surfaces are smooth and continuous.
4. The radii of curvature R1 and R2 are large compared to the dimensions of the
contact area.
5. The compressive yield strength of the weaker material in not exceeded.

9-34
Analysis:
1. Design force, F = 60 N.m/0.100 m = 600 N
2. Let body 1 be the pin:
R1 = R
E1 = 207 GPa (Appendix C-1)
ν1 = 0.30 (Appendix C-1)
3. Let body 2 be the slot:
R2 = ∞
E2 = 140 GPa
ν2 = 0.25
po = 700 MPa
L = 2R
4. From Eq. (9.2)
2 2
1 − ν1 1 − ν2
Δ= +
E1 E2

1 ! (0. 30)2 1 ! (0. 25)2

= + = 1.109 ✕ 10-11
207 " 10 9 140 " 10 9

5. From Eq. (9.5),

F(1/R 1 + 1/R 2)
po = 0.564
LΔ

600(1/R + 1/!)
700 ✕ 106 = 0.564
2R(1. 109 " 10-11)

700 ! 106 600

R=
0. 564 2(1. 109 ! 10-11)

R = 0.0042 m

Therefore, minimum pin diameter = 8.4 mm ■

9-35
SOLUTION (9.30)
Known: Two mating steel spur gears are 20 mm wide, and the tooth profiles have radii
of curvature at the line of contact of 10 mm and 15 mm. A force of 250 N is
transmitted between them.
Find:
(a) Compute the maximum contact pressure and the width of contact.
(b) Determine the value and depth below the surface for the maximum shear stress.
Schematic and Given Data:

Line of
10 mm
Contact

15 mm

Gear width, 20 mm
Gear transmitted force, 250 N

Assumptions:
1. The teeth are frictionless and smooth.
2. The teeth remain elastic.
3. The gears are isotropic and homogeneous.
4. The contact is not conformal.
Analysis:
1. L = 20 mm, F = 250 N
R1 = 10 mm, R2 = 15 mm
ν = 0.30, E = 2.07 ✕ 105 MPa
[Note: Use N, mm, and MPa for units throughout.]
2. From Eq. (9.2),
2 2
1 − ν1 1 − ν2
Δ= +
E1 E2

1 ! (0. 3)2
= (2) = 8.792 ✕ 10-6
2. 07 " 105

9-36
3. From Eq. (9.5),

F(1/R 1 + 1/R 2)
po = 0.564
LΔ

250(1/10 + 1/15)
= 0.564 = 275 MPa ■
20(8. 792 ! 10-6)
4. From Eq. (9.6),

FΔ
b = 1.13
L(1/R 1 + 1/R 2)

250(8. 792 ! 10-6)

= 1.13 = 0.029 mm
20(1/15 + 1/10)
Therefore, 2b = 0.058 mm ■
5. From Fig. 9.15, τmax ≈ 0.3po = 82.5 MPa ■
at a distance of 0.8b = 0.023 mm, below the surface. ■

SOLUTION (9.31)
Known: A steel gear tooth of known dimensions presses against a cast iron gear tooth
of known dimensions with a known force.
Find:
(a) Compute the maximum contact pressure and the width of contact.
(b) Determine the value and depth below the surface for the maximum shear stress.
Schematic and Given Data:

10 mm Line of
Contact

15 mm

Gear width, 20 mm
Gear transmitted force, 250 N

9-37
Assumptions:
1. The teeth are frictionless and smooth.
2. The teeth remain elastic.
3. The gears are isotropic and homogeneous.
4. The contact is not conformal.
Analysis:
1. L = 20 mm, F = 250 N
Let body 1 be the steel pinion:
R1 = 10 mm, E1 = 207 GPa, ν1 = 0.30 (Appendix C-1).
Let body 2 be the cast iron gear:
R2 = 15 mm, E2 = 103 GPa, ν2 = 0.26 (Appendix C-1).
[Note: Use N, mm, and MPa for units throughout.]
2. From Eq. (9.2),
2 2
1 − ν1 1 − ν2
Δ= +
E1 E2

1 ! (0. 3)2 1 ! (0. 26)2

= + = 1. 345 " 10-11 Pa-1
207 " 10 9 103 " 10 9

3. From Eq. (9.5),

F(1/R 1 + 1/R 2)
po = 0.564
LΔ

250(1/0. 01 + 1/0. 015)

= 0.564 = 222 MPa ■
0. 02(1. 345 ! 10-11)
4. From Eq. (9.6),

FΔ
b = 1.13
L(1/R 1 + 1/R 2)

250(1. 345 ! 10-11)

= 1.13 = 3.59 ✕ 10-5 m
0. 02(1/0. 01 + 1/0. 015)
Therefore, 2b = 7.18 ✕ 10-5 m ■

5. From Fig. 9.15, τmax ≈ 0.3po = 0.3(222) = 66.6 MPa ■

at a distance of 0.8b = 3.59 ✕ 10-5 m, below the surface. ■

9-38
SOLUTION (9.32)
Known: Two cylindrical rollers of known dimensions press against one another with
known force.
Find:
(a) The maximum contact pressure.
(b) The width of contact.
(c) The maximum subsurface shear stress.
Schematic and Given Data:

Width = 1.0 in

50 lb 50 lb
0.5 in
1.5 in

Material = steel
E = 30 x 10 6 Psi
! = 0.3

Assumptions:
1. The bodies are isotropic and homogeneous.
2. The contact is not conformal.
3. The materials remain elastic.
Analysis:
1. Use Eq. (9.2) to find Δ, where the bodies have identical E and υ-- we have
2
2
1-" 1 - (0.3)
!=2 =2 6 = 6.07 ✕ 10-8 in2/lb
E 30!10 psi

2. Use Eq. (9.5) to find the maximum contact pressure:

F(1/R 1 + 1/R 2)
po = 0.564
LΔ
50 lb(1/0. 5 in + 1/1. 5 in)
= 0.564 = 26,433 psi. ■
(1. 0 in)(6. 07 ! 10-8 in2/lb)
9-39
3. Use Eq. (9.6) to find b:

FΔ
b = 1.13
L(1/R 1 + 1/R 2)

50 lb(6. 07 ! 10-8 in2/lb)

= 1.13 = 1.206 ✕ 10-3 in. ■
(1. 0 in)(1/0. 5 in + 1/1. 5 in)

Therefore, the contact width is 2b = 2.41 ✕ 10-3 in.

4. From Fig. 9.15, τmax ≈ 0.3po = 0.3(26433 lb) = 7930 psi. ■

9-40
SOLUTION (9.33)
Known: Power is transmitted between two steel rollers pressed together. The
maximum contact pressure and the width of contact are known. There is slight
slippage, and the coefficient of friction is known.
Find:
(a) Determine the maximum completely reversed shear stress, τyz, and its location on
either side of the load line.
(b) Determine the maximum value of reversed tensile stress developed at the surface.
(c) Determine the maximum value of shear stress developed at the surface.
(d) Explain briefly the kinds of surface deterioration that might occur.
Schematic and Given Data:

!
b po = 2 GPa
2b = 1 mm
f = 0.3
!

Assumptions:
1. Both objects remain elastic.
2. The materials are isotropic and homogeneous.
3. The contact is not conformal.
Analysis:
1. From Fig. 9.17, τyz has a maximum value of ± 0.23po or ± 0.46 GPa,
existing at a distance of 0.9b, or 0.45 mm on either side of the load line. ■
2. From Fig. 9.18, σyt has a maximum value of 2fpo = 2(0.3)(2 GPa) = 1.2 GPa ■
3. τyzt is the only shear stress at the surface. From Fig. 9.18, τyzt has a maximum
value of fpo or (0.3)(2 GPa) = 0.6 GPa ■

9-41
SOLUTION (9.34)
Known: A roller of known dimensions rolls within a ring of known dimensions, and is
pressed against the ring with a known force.
Find:
(a) The maximum contact pressure.
(b) The width of the contact zone.
Schematic and Given Data:

150 N/mm
Roller, R1 = 7.5 mm
Length = 20 mm

Ring, R 2 = 37.5 mm

Material = Steel
E = 207 x 10 9 Pa
! = 0.3

Assumptions:
1. The surfaces are frictionless and smooth.
2. Both objects remain elastic.
3. The materials are isotropic and homogeneous.
4. The contact is not conformal.
Analysis:
1. Use Eq. (9.2) to find Δ:

2
1-"
!=2
E

1 - (0. 3)2
=2 = 8.79 ✕ 10-12 Pa-1
9
207!10 Pa

2. Use Eq. (9.5) to find the maximum contact pressure:

F(1/R 1 + 1/R 2)
po = 0.564
LΔ
9-42
 F = (150 N/mm)(20 mm) = 3000 N

R2 = -37.5 mm = -0.0375 m

3000 N(1/0. 0075 m + 1/-0. 0375 m)

po = 0.564 -12 -1
= 7.61 ✕ 108 Pa. ■
(0. 02 m)(8. 79 ! 10 Pa )

3. Use Eq. (9.6) to find b:

FΔ
b = 1.13
L(1/R 1 + 1/R 2)

(3000 N)(8. 79 ! 10-12 Pa-1)

= 1.13 = 1.26 ✕ 10-4 m.
(0. 02 m)(1/0. 0075 m + 1/-0. 0375 m)

Therefore, the contact width is 2b = 2.51 ✕ 10-4 m. ■

Comment: Care must be taken on this problem because the maximum stress of 110 ksi
(7.61 ✕ 108 Pa) is sufficient to yield many steels, invalidating assumption (b).

9-43
SOLUTION (9.35)
Known: Two cylindrical rollers, one with a 25-mm diameter and the other with a
75-mm diameter, press against one another with a force of 200 N. The steel rollers are
25-mm wide. The axes of the cylinders are parallel.
Find:
(a) The maximum contact pressure.
(b) The width of contact.
(c) The area of contact.
(d) The maximum subsurface shear stress.
Schematic and Given Data:

Width = 25 mm

200 N 200 N
37.5 mm
12.5 mm

Material = steel
E = 207 GPa
! = 0.3

Assumptions:
1. The bodies are isotropic and homogeneous.
2. The contact is not conformal.
3. The materials remain elastic.
Analysis:
1. Use Eq. (9.2) to find Δ:

2
1-"
!=2 , since the bodies are identical.
E
2
1 - (0.3) = 8.79 ✕ 10-12 m2/N
=2 9
207!10 Pa
2. Use Eq. (9.5) to find the maximum contact pressure:
9-44
 F(1/R 1 + 1/R 2)
po = 0.564
LΔ

200 N(1/0.0125 m + 1/0.375 m)

= 0.564 -12 = 175.7 MPa ■
(0.025 m)(8.79 ! 10 m 2/N)
3. Use Eq. (9.6) to find b:

FΔ
b = 1.13
L(1/R 1 + 1/R 2)
-12
b = 1.13 200 N(8.79 ! 10 m 2/N) = 2.901 ✕ 10-5 m ■
(0.025 m)(1/0.0125 m + 1/0.0375 m)

Therefore, the contact width is 2b = 5.802 ✕ 10-5 m ■

4. The contact area, A = (2b)(w) = (5.802 ✕ 10-5 m)(25 mm)

A = 1.450 ✕ 10-6 m2

5. From Fig. 9.15, τmax ≈ 0.3po = 0.3(175.7 MPa) = 52.71 MPa ■

9-45