Important Note to students

(Applies to all course material related to Tribology)

This material is only an excerpt of the class room lectures prepared as per the syllabus contents. It needs to be supplemented with material from text book and other sources. It is not comprehensive. You need to prepare additional notes wherever required. Evaluation questions may be expected from material not covered in the slides but discussed during the lectures. Few Figures/photos/Graphs etc. have been removed because of upload limit. To be used for internal circulation only.

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

Tribology Introduction

Tribology

Friction

Wear

Lubrication

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

PEOPLE

Leonardo da Vinci

Leonardo di ser Piero da Vinci (April 15, 1452 May 2, 1519) was an Italian Renaissance polymath: painter, sculptor, architect, musician, scientist, mathematician, engineer, inventor, anatomist, geologist, cartographer, botanist and writer. Leonardo has often been described as the archetype of the Renaissance Man, a man of "unquenchable curiosity" and "feverishly inventive imagination. Considered to be one of the greatest painters of all time and the most diversely talented person ever to have lived.

Guillaume Amontons
(1663 1705) Amontons' Laws of Friction were first recorded in books during the late 17th century.

Charles-Augustin de Coulomb
Charles-Augustin de Coulomb (14 June 1736 23 August 1806) was a French physicist. He is best known for developing Coulomb's law, the definition of the electrostatic force of attraction and repulsion. The SI unit of charge, the coulomb, was named after him.

BEAUCHAMP TOWER (1845-1904)

Towers Spherical engine was a unique contender in the rotary steam engine market His experiments led to the revelation of pressure development in a fluid film.
P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

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Source : http://www.wikipedia.org/

Why Tribology ?
Losses resulting from ignorance of Tribology amount to 4 % of the GDP of every country One third of worlds energy resources in present use appear as Friction in one form or other A saving of 1% of GDP can be realized by research and better tribological practices
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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

Surface Surface Characteristics

Geometric Characteristics

Physico-Chemical Characteristics

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

GEOMETRIC CHARACTERISTICS ERROR OF FORM + WAVINESS + ROUGHNESS

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

GEOMETRIC CHARACTERISTICS

Error of form : Any deviation from the intended surface profile. Caused due to the errors in the manufacturing process.

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

GEOMETRIC CHARACTERISTICS Waviness :Large waves generated on the surface due to machine tool vibrations Roughness :Features on the surface other than error of form and waviness.

Lay : - The direction of the predominant surface pattern. Flaw :- Any defect on the surface (Inclusions, voids, porosity, cracks, etc.)
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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

PHYSICO-CHEMICAL CHARACTERISTICS

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

PHYSICO-CHEMICAL CHARACTERISTICS Physisorbed Layer: Gases like Oxygen, Argon, Krypton, etc. and water vapor gets adsorbed to a clean surface Thickness of the layer- 0.3 nm No transfer of electrons Chemisorbed Layer: Electron sharing between the chemisorbed species and the solid surface-covalent bonds Energy required to remove these bonds are high Depends on the purity of the surface Layers are monomolecular
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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

PHYSICO-CHEMICAL CHARACTERISTICS Chemically reacted layer: Most of the metals react with oxygen Forms oxides on the surface Interaction continues till a thick layer is formed(10-100 nm)

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

PHYSICO-CHEMICAL CHARACTERISTICS Beilby Layer: Melting and surface flow during machining of molecular layers Generally amorphous or microcrystalline Layers get hardened due to the adjacent cold metal Thickness 1-100 nm Heavily deformed layer and Lightly deformed layer: Machining makes surfaces highly strained Smaller grains due to recrystallisation of the layers

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

ROUGHNESS MEASUREMENT
1. Contact type instruments (stylus measurements):Stylus measurements transform the vertical movements of the stylus to corresponding electrical signals. 2. Non-contact type of instruments :a. Pneumatic devices b. Optical devices c. Transmission electron microscopy d. Reflection electron microscopy
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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

ROUGHNESS PROFILE

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

ROUGHNESS MEASUREMENT
Methods 1. Mean or M-System:- The mean line is taken as the centroid of the profile. Areas above and below the line are equal. 2. Ten point average:The average heights/depths of five highest peaks and five lowest valleys is determined. 3. Method of least squares A reference line is fixed in such a way that the square root of sum of squares of the vertical deviations from this line is minimum
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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

SCHEMATIC OF A SURFACE PROFILE

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

ROUGHNESS PARAMETERS
Extreme value height descriptors
Rp Rv Rt Rz Rpm Distance between the highest asperity and mean line Distance between the lowest valley and mean line Distance between the highest asperity and lowest valley Difference between the averages of five highest asperities and five lowest valleys. Distance between the average of five highest peaks and mean line

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

ROUGHNESS PARAMETERS

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

ROUGHNESS PARAMETERS
1. Mean of a profile 2. Variance 3. Standard deviation 4. Skewness 5. Kurtossis
Roughness height distribution Surfaces with same Ra Value Bearing Area curve Bearing Ratio

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

ROUGHNESS HEIGHT DISTRIBUTIONS

Gaussian Distribution

Non-Gaussian Distribution

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

ROUGHNESS
Gaussian distribution:- The Gaussian (normal) distribution was
historically called the law of errors. It was used by Gauss to model errors in astronomical observations, which is why it is usually referred to as the Gaussian distribution. Gaussian probability distribution is perhaps the most used distribution in all of science. The probability density function for the Gaussian distribution with mean and standard deviation is given by the following formulas.

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

ROUGHNESS HEIGHT DISTRIBUTIONS

Non-Gaussian Distribution

Turning, shaping, EDM, Milling, Honing, Grinding, Abrasion processes

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

BEARING AREA CURVE

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

Contents
True area and Geometric area Conformal contact Non conformal contact Elastic Half space Hertzian contact Friction
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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

CONFORMAL CONTACT When two surfaces closely match together such a contact is called a conformal contact. NON-CONFORMAL CONTACT When the surfaces do not closely match together such a contact is called a non-conformal contact.

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

ELASTIC HALF SPACE In Non- conformal contacts the pressures at the contact spots are very high. Elastic contact theory. A semi-infinite elastic solid bounded a plane surface. Strains are small within the contact region.

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

HERTZ CONTACT THEORY(1882)

(1857 1894) German physicist

Assumptions 1. Surfaces are smooth, continuous and non-conforming 2. Strains are small 3. Each solid is an elastic half-space in the contact region 4. Surfaces are frictionless

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University

HERTZ CONTACT THEORY(1882) P

Contact area will be circular a Contact radius = a Ball radius = R Maximum contact pressure = Po
1 3

3PR a= * 4E
3P P0 = 2 2a

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P.M. Anil, Asst. Professor (S.G) SMBS, VIT University