THE COPPERBELT UNIVERSITY

SCHOOL OF ENGINEERING.
MECHANICAL DEPARTMENT

TRIBOLOGY

NAME : SIN NUMBERS

DICKSON SIMUTAMI 17110201
BENSON JOHN MWANSA 17111031
PROGRAM :MECHANICAL ENGINEERING (HONS)
COURSE CODE : EM 560.
YEAR OF STUDY : 5TH YEAR
LECTURER : MR SIYINGWA
ASSIGNMENT NO :2

DUE DATE : 4TH MARCH, 2022.

WEAR.
ABSTRACT.
Wear is the damaging, gradual removal or deformation of material at solid surfaces.
Causes of wear can be mechanical or chemical. The study of wear and related
processes is known as tribology. Abrasive wear alone has been estimated to cost 1–4%
of the gross national product of industrialized nations. This report focuses on types of
wear phenomena observed in the industries (such as abrasive wear, adhesive wear,
fretting wear, fatigue wear, erosive wear and corrosive wear) and their mechanisms.
Key words: wear ,damaging, removal
INTRODUCTION
Wear is the damaging, gradual removal or deformation of material at solid surfaces.
Causes of wear can be mechanical also called as erosion or chemical also called as
corrosion. Wear of metals occurs by plastic displacement of surface and near-surface
material and by detachment of particles that form wear debris. In material science,
wear is the erosion of material from a solid surface by the action of another solid. The
study of the process of wear is the part of the theory of tribology. Wear in machine
components, along with different cycles, for example, fatigue and creep, makes
surfaces deteriorate, in the end prompting material degradation or loss of applicability.
Subsequently, wear has enormous monetary significance as first mentioned in the Jost
Report. Abrasive wear alone has been assessed to cost 1–4% of the gross national
product of industrialized countries. Wear of metals happens by plastic dislodging of
surface and close to surface material and by separation of particles that produce wear
debris. The molecule size may change from millimeters to nanometers. This cycle may
happen by contact with different metals, nonmetallic solids, streaming fluids, solid
particles or fluid beads entrained in streaming gasses. The wear rate is influenced by
components, for example, sort of stacking (e.g., stationary and active), kind of
movement (e.g., gliding and continuing), surrounding temperature, and lubrication,
specifically by the cycle of deposition and deterioration of the boundary lubrication
layer. Contingent upon the tribosystem, diverse wear types and wear systems can be
watched.
Wear can also be defined as the removal of material from a solid surface as a result of
mechanical action exerted by another solid. Wear chiefly occurs as a progressive loss
of material resulting from the mechanical interaction of two sliding surfaces under
load. Wear is such a universal phenomenon that rarely do two solid bodies slide over
each other or even touch each other without a measurable material transfer or material
loss. Thus, coins become worn as a result of continued contact with fabrics and human
fingers; pencils become worn after sliding over paper; and rails become worn as a
result of the continued rolling of train wheels over them. Only living things (such as
bone joints) are in some sense immune to the permanent damage caused by wear,
since they have the property of regrowth and healing. There are four basic types of
wear, namely corrosive, adhesive, abrasive wear and surface fatigue wear.
ABRASIVE WEAR.
There are two common types: two-body and three-body abrasion. Two-body abrasion
refers to surfaces that slide across each other where the one (hard) material will dig in
and remove some of the other (soft) material. An example of two-body abrasion is
using a file to shape a workpiece. Three-body abrasion is where particles between the
two surfaces remove material from one or both surfaces. The tumbling process is an
example of this.
Tumbling involves using particles to sand and polish the surface of a part. The
particles that cause abrasion are often called contaminants. Contaminants are anything
that enters a system that creates abrasion. While lubrication is imperative, an active
lubrication system can introduce contaminants that cause abrasion. Filters remove
contaminants and are one of the reasons proper maintenance and replacement of filters
is important. However, the lubrication, or the additives in it, can react with the metal,
creating a thin monolayer of contaminants that also make proper lubrication selection
important to reduce wear to your equipment.

Abrasive wear can have benefits, such as water jetting. Water jetting has the ability to
cut through metal with relative ease. This can reduce property changes that can occur
with other processes that generate excessive heat while cutting.

Surface roughness is another important variable for wear. Two-body abrasion is

reduced by having smoother surface roughness. For example, a journal or sleeve
bearing made out of a softer material will slide against a harder drive shaft with little
to no abrasion due to the surface finish. Using materials with similar hardness is
generally not advised. The reason for the softer bearing material is to further reduce
wear. Contaminants can become embedded into the softer materials and stop three-
body abrasion from occurring. This technique might damage the bearing, but is
preferred as it is designed to be relatively easy and more cost-effective to replace than
a drive shaft. The rougher surfaces can increase the coefficient of friction and micro-
peaks can break off, contributing to contaminants that are related to abrasion.

ADHESION WEAR.
Surface roughness also contributes to adhesion. For this type of wear a material’s
compatibility will be important. Compatibility does not mean materials that work well
together; rather, that the materials “like” each other, causing them to stick together.
This compatibility forms a bond causing parts to seize and even become cold-welded
together. There are a few general rules to follow for material selection to make sure
unwanted adhesive wear doesn’t occur. Materials that make contact with one another,
in general, should:

• Not dissolve in the other

• Not, in given environment and other conditions, form into an alloy

• Not be identical (e.g., an aluminum shaft with an aluminum bearing)

• Have at least one metal from the B-subgroup (e.g., elements to the right of Nickel,
Palladium, and Platinum on the periodic table).
Adhesion is possible to calculate. The adhesion and abrasive wear calculations share
the same formula; however, it can vary by as much as +/-20%. This inaccuracy is due
to constant changing surface conditions and lubrication during operation. It may be
better than no data, but designers need to be aware of the limitations and accuracy of
the formula. Trying to calculate or predict wear is made more difficult if components
have non-conforming geometries, such as when gear teeth and cams are involved.
These components can have difficulty staying properly lubricated. To reduce adhesive
wear, sometimes corrosive wear is purposely induced.

CORROSIVE WEAR.
Corrosive wear is material degradation wherein both wear and corrosion wear
mechanisms are present. The effects of both wear and corrosion can result in intense
damage or material losses. The effects can be more severe than when encountering
either of these two mechanisms alone. Typically, surface failure such as erosion and
abrasion results from the dynamic interaction between two surfaces. It is the kind of
damage resulting from the synergistic attack of both wear and corrosion when it takes
place within a corrosive setting. Having a clear understanding of the causes and nature
of corrosive wear is important in choosing and using components or parts.
Corrosive wear occurs whenever a gas or liquid chemically attacks a surface left
exposed by the sliding process. Normally, when a surface corrodes, the products of
corrosion (such as patina) tend to stay on the surface, thus slowing down further
corrosion. But, if continuous sliding takes place, the sliding action removes the surface
deposits that would otherwise protect against further corrosion, which thus takes place
more rapidly. A surface that has experienced corrosive wear generally has a matte,
relatively smooth appearance.
Chlorides, phosphates, or sulfides can be added to induce corrosion and reduce a more
destructive adhesive wear. Corrosive wear is more often thought of as something you
want to prevent. Rust, or oxidation, is the No. 1 form of corrosive wear. Lubrication,
material selection, surface finish, including coatings—like in abrasive and adhesive
wear—are the main factors to consider.
The majority of the materials presented are compatible metals that would be a poor
choice in applications where contact occurs. This chart is re-created from Robert L
Norton’s textbook, Machine Design.

Noble materials are noted as having non-corrosive properties. Gold specifically is used
in electronics as a coating due to its ability to resist corrosion. Noble materials are
often used sparingly or in minimal waste processes due to their cost. Other materials
are self-anodizing. Aluminum is known for reacting with oxygen to form a layer of
aluminum oxide that will prevent oxidation.
Iron and ferrous materials not only are prone to rust, but will flake off, exposing
another layer allowing the oxidation to continue the degradation process. In the case of
self-anodizing materials, slight abrasions or even stresses can cause crack propagation
or scrap off the aluminum oxide, allowing the corrosive wear to continue.
Stress affects corrosive wear. Stress corrosion and corrosion fatigue will significantly
accelerate corrosive wear. The difference between these types is the loading situation.
Static loads cause stress corrosion where more dynamic loading, such as cyclic loads
will cause corrosion fatigue.

SURFACE FATIGUE WEAR

Surface-fatigue wear is produced by repeated high stress attendant on a rolling motion,
such as that of metal wheels on tracks or a ball bearing rolling in a machine. The stress
causes subsurface cracks to form in either the moving or the stationary component. As
these cracks grow, large particles separate from the surface and pitting ensues.
Surface-fatigue wear is the most common form of wear affecting rolling elements such
as bearings or gears. For sliding surfaces, adhesive wear usually proceeds sufficiently
rapidly that there is no time for surface-fatigue wear to occur.
Though the wear process is generally thought of as harmful, and in most practical
situations is so, it has some practical uses as well. For example, many methods of
producing a surface on a manufactured object depend on abrasive wear, among them
filing, sanding, lapping, and polishing. Many writing instruments, principally the
pencil, crayon, and chalk, depend for their effect on adhesive wear. Another use is
seen in the wear of the incisor teeth of rodents. These teeth have a hard enamel
covering along the outer curved surface but only soft dentine on the inner surface.
Hence, abrasive and adhesive wear, which occurs more rapidly on the softer side, acts
to maintain a sharp cutting edge on the teeth.