Wear Mechanism

SHIVAJI CHOUDHURY
Wear

 Wear is the undesirable removal of

solids from a sliding or rolling
component.
Wear analysis

 In analyzing a wear problem in a machine,

it is necessary to determine the kind of
wear that occurred.
 Analysis requires microscopic examination
of the worn area and a close look at the
used lubricant.
 Wear is generally proportional to the
applied load and the amount of sliding.
Types of wear :
 1.Adhesive Wear  7.Electro-Corrosive
 2.Abrasive Wear wear
 3.Erosion Wear  8.Fretting wear
 4.Polishing Wear  9.Electrical
 5.Contact fatigue discharge wear
 6.Corrosive wear  10.Cavitation
damage
 11.False brinelling
1.Adhesive Wear
Adhesive Wear — the removal of material due to
adhesion between surfaces.
1. – Mild adhesion — is the removal of surface films,
such as oxides, at a low rate.
2. – Severe adhesion — the removal of metal due to
tearing, breaking, and melting of metallic junctions.
This leads to scuffing or galling of the surfaces and
even seizure.
1.1.Adhesive Wear -Prevention
 MECHANICAL LUBRICANT
1. Reduce load, speed 1. Use more viscous
and temperature oil to separate
2. Improve oil cooling surfaces
3. Use compatible 2. Use "extreme
metals pressure" (anti-
4. Apply surface scuff) additives
coatings such as such as a sulfur-
phosphating phosphorous or
borate compounds
 2.Abrasive Wear
• Abrasive Wear — the cutting of furrows on a
surface by hard particles, (for example, sand
particles between contact surfaces, or hard
asperities on an opposing surface).
 Cause: Hard particles contaminating oil Hard
metal with rough surface against soft. metal
2.1.Abrasive Wear-Prevention
 MECHANICAL  LUBRICANT
1. Remove abrasive by 1. Use oil free of
improved air and oil
filtering, clean oil abrasive particles
handling practices, 2. Use more viscous
improved seals, flushing
and frequent oil changes
oil
2. Minimize shot peening,
beading, or sand blasting
of surfaces because
abrasives cannot be
completely removed
3. Increase hardness of
metal surfaces
3.Erosion Wear

 • Erosive Wear — the cutting of

furrows on a surface by hard particles
contained in a fluid traveling at high
velocity.
3.1.Erosion Wear -Prevention
 MECHANICAL  LUBRICANT
1. Remove abrasive by 1. Use oil free of abrasive
improved air and oil Particles
filtering, clean oil
2. Use more viscous oil
handling practices,
improved seals, flushing
and frequent oil changes
2. Reduce impact angle to
less than 15 degrees
3. Increase hardness of
metal surfaces
4.Polishing Wear
 • Polishing Wear — the continuous removal
of surface films, laid down via a chemical
reaction from an additive in oil or by very
fine hard particles in the lubricant, and so
on.
 Polishing wear is characterized by very
shiny, very smooth, mirror like metal
surfaces. Fine abrasives wear away the
surface films as they form and reform.
4.1.Polishing Wear -Prevention
 MECHANICAL  LUBRICANT
1. none 1. Choose less
chemically active
additive
2. Remove corrosive
contaminant
3. Remove abrasive
5.Contact fatigue

 • Contact Fatigue — the cracking,

pitting, and spalling of a surface in
sequence due to cyclic stresses in a
contact.
 Contact fatigue is most common in
rolling element bearings, gear teeth,
and cams.
5.1.Contact fatigue- Prevention
 MECHANICAL  LUBRICANT
1. Reduce contact 1. Use clean, dry oil.
pressures and 2. Use more viscous
frequency of cyclic oil
stress. 3. Use oil with
2. Use high quality higher-pressure
vacuum melted viscosity coefficient
steels.
3. Use less abusive
surface finish
6.Corrosive wear
 • Corrosive Wear — the removal of corrosion
products from a surface by motion, such as the
rubbing off of rust.
 cause :water contamination most common
cause
6.1.Corrosive wear-Prevention
 MECHANICAL  LUBRICANT
1. Use more corrosion 1. Remove corrosive
resistant metal material such as
(not stainless) too chemically
2. Reduce operating active additive and
temperature contaminates
3. Eliminate corrosive 2. Use improved
material corrosion inhibitor
3. Use fresh oil
7.Electro-Corrosive wear

 • Electro-Corrosive Wear — the

removal of metal by dissolution in a
corrosive liquid with the aid of electric
currents.
 One source of currents is streaming
potential from high velocity fluids.
 The oil serves as the electrolyte.
7.1.Electro-Corrosive wear-
prevention
 MECHANICAL  LUBRICANT
1. Decrease liquid 1. Decrease or
velocity and increase electrical
velocity gradients conductivity of
2. Use corrosion- lubricants or
resistant metals hydraulic fluids
3. Eliminate stray
currents
8.Fretting wear

 • Fretting Wear — localized wear of

lubricated surfaces due to
reciprocating sliding of extremely low
amplitude because of vibration.
8.1.Fretting wear -Prevention
 MECHANICAL  LUBRICANT
1. Reduce or stop 1. Use oil of lower
vibration by tighter viscosity
fit or higher load . 2. Relubricate
2. Improve lubrication frequently
between surfaces by 3. Use oxidation
rougher (then inhibitors in oil
honed) surface finish
9.Electrical discharge wear

 • Electrical Discharge Wear — the

removal of molten metal from
surfaces due to electrical sparks
between them.
 High static voltages are sometimes
generated by large rotating
machinery and these are relieved by
sparking to regions of lower potential.
9.1.Electrical discharge wear-
Prevention
 MECHANICAL  LUBRICANT
1. Improve electrical 1. Use of oil of higher
insulation of bearings electrical conductivity
2. Degauss magnetic
rotating parts
3. Install brushes on
shaft
4. Improve machine
grounding
10.Cavitation damage

 • Cavitation Damage — the removal of

material due to cracking and pitting caused
by high energy implosions of vacuous
cavities in a cavitating liquid.
 Liquids cavitate when suddenly subjected
to low pressures.
 Removal of metal by vapor cavity implosion
in a cavitating liquid.
10.1.Cavitation damage-Prevention
 MECHANICAL  LUBRICANT
1. Use hard, tough 1. Avoid low vapor
metals, such as tool pressure, aerated, wet
steel oils
2. Reduce vibration, flow 2. Use noncorrosive oils
velocities and
pressures
3. Avoid restriction and
obstructions to liquid
flow
11.False Brinelling
 • False Brinelling — localized wear in
lubricated rolling element bearings
due to slight rocking motion of rollers
against raceways.
11.1.False Brinelling- Prevention
 MECHANICAL  LUBRICANT
1. Reduce or 1. Change viscosity
eliminate impact
2. Rotate bearings
occasionally
Microscopic Observation
(Wear debris analysis)
 (a) Rubbing wear,
 (b) cutting wear,
 (c) fatigue wear,
 (d) scuffing wear,
 (e) corrosive wear,
 (f) abrasive wear.
Bearing damage classifications:
ISO 15243
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