ME 329 Chapter 5 Oct 28 2009

Chapter 5
Tribology and Engineering Materials
Engineering Materials: properties and selection, 9th ed.

Kenneth G. Budinski, Michael K. Budinski
Chapter Goals
Upon completion of this chapter, the student should:
have an understanding of tribology and its
importance
have a knowledge of the fundamentals of friction
have a knowledge of the type of wear that can
occur
have a review of the fundamentals of bearings and
l bi
lubricants
t

2010 Pearson Higher Education,

Upper Saddle River, NJ 07458. All Rights Reserved.
Introduction
Origin of the word tribology

Friction costs (10% of GDP)
Wear cost (5% of GDP)
S
Scope
off ttribology
ib l


5.2 Contact Mechanics
Real area of contact

Hertz stress equations
St
Stress
iin reall contacts
t t are diff
differentt ffrom th
the
apparent stress


5.2 Contact
Mechanics
Figure 51 Concept of real

and
d apparent area off contact


5.2 Contact Mechanics
Figure 52
5 2 When real surfaces contact
contact, the up
up-features
features of the
surfaces carry the load


5.2 Contact
Mechanics
Figure 53 Hertz
equation for the contact of
a sphere on a flat surface
under elastic conditions


5.3 Friction
Role
R
l off surface
f
roughness
h
Components of friction: F = Fa + Fp + Fs + Fn
Fa
Fp
Fs
Fn
= force to break adhered junctions

= force to plow and deform surface features
= force to shear films between surfaces
= force due to the nature of the sliding system
Different types of friction Sliding vs. Rolling friction

Measurement
Lubricated
b
d friction
f
Significance in wear of components
Use of published friction data in design


5.3 Friction
Figure 5
54
4 The force required to move surface A up the
rugosities on surface B


5.3 Friction
Figure
g
55 Types
yp of friction

10

5.3 Friction
Figure 56 The difference between the coefficient of friction

and the traction coefficient; they are mathematically similar
similar, but
differ in point of force application.

11

5.3 Friction
Pure rolling at a & b,

some sliding between
these regions
Figure 57 Pure rolling only occurs in areas a and b

12

5.3 Friction
Figure 58 Equations
for friction force

13

5.3 Friction Schematic equation only!

r = Fr /N * {(Ra / E h R )} Kr
r
Fr
N
Ra
E
h
R
Kr
= Rolling friction coefficient

= Force to produce rolling
= Normal force
= Surface roughness
= Elastic modulus
= surface hardness
= radius of rolling shape
= variable related to tribosystem
Figure 58 General concept - potential equation

for rolling friction coeff
coeff.

14

5.3 Friction - Measurement
Figure 59 Rolling friction test. Rolling resistance number is the

height of the hill divided by the distance travelled on rolling from
the top (car in neutral with engine running).

15

5.3 Friction
Figure 510 Types of

friction force recordings that
can be encountered

16

5.3 Friction
Figure 511 Average

friction coefficients for
various materials in
reciprocating motion of an
annular ring rider (0.1 on a
type 316 stainless steel
counterface at 50% relative
humidity (RH) at various
normal forces.
The stroke was 50 mm and
the frequency was 0
0.5
5 Hertz
Hertz.
The friction force was
averaged for eight cycles in
each test.

17

5.3 Friction
Figure 512 Stribeck curve showing how lubricated sliding

s stems can ha
systems
have
e ffriction
iction vary
a with
ith ope
operating
ating conditions and
lubricant properties

18

5.3 Friction
Figure 513 Types

of lubrication

19

5.4 Definition of Wear
Correlation between wear and friction

Difference between wear and erosion
T
Types
off wear
Types of erosion
Types of abrasion
Surface fatigue

20

Figure
g
514 Major
j categories
g
of wear and specific
p
types
yp of
wear in each category

21

Figure 515 Types of erosion

22

5.5 Erosion
Figure 516 (a) Schematic of solid particle erosion; (b) erosion of a

wearback from a pipe carrying fly ash. Note hole and wavy surface.

23

5.5 Erosion
Figure 517 (a) Schematic of slurry erosion; (b) pump impeller

showing
h i erosion
i damage
d
from
f
pumping
i a slurry
l
off silica
ili and
d water
t

24

5.5 Erosion
Figure 518 (a) Schematic of liquid impingement erosion;

(b) pipe elbow perforated by impingement from high-velocity fluid
in a pipeline

25

5.5 Erosion
Figure 519 (a) Schematic of cavitation; (b) cavitation on a

stainless steel tank. An ultrasonic agitation device was attached to
the other side of this section of the tank (diameter = 15 cm).

26

5.6 Types of Wear
Figure 5
520
20 (a) Adhesion of asperities in adhesive wear; (b)
metal-to-metal wear on gear teeth (no lubrication)

27

5.6 Types of Wear
Figure 521 (a) Schematic of formation of an excrescence in

galling; (b) galling damage on the polished conforming surfaces of
special nuts after one use

28

5.6 Types of Wear
Figure 522 (a) Schematic of oxidative wear; (b) oxidative

wear occurred from low-speed moving with a mating chain link
(dark area)

29

5.6 Types of Wear
Figure 523 (a) Schematic of asperity interaction in fretting wear;

(b) fretting damage on a splined shaft from relative motion of a
mating part

30

5.6 Types of Wear
Figure 524 (a) Schematic of low-stress abrasion; (b) low-stress

abrasion of a shaft from hard contaminants in a plastic bushing

31

5.6 Types of Wear
Figure 525 (a) Schematic of high-stress abrasion; (b) star

wheels on a refuse grinder that have been subjected to highstress abrasion
abrasion. Wheels are 2 in.
in (50 mm) thick.
thick

32

5.6 Types of Wear
Figure 526 (a) Schematic of gouging abrasion; (b) gouging

damage caused
ca sed b
by grinding
g inding of rocks
ocks

33

5.6 Types of Wear
Figure 5
527
27 (a) Schematic of pitting due to surface fatigue; (b)
pitting of a large roller thrust bearing race due to surface fatigue

34

5.6 Types of Wear
Figure 529 (a) Spalling of a coating from surface fatigue; (b)

spalling of plating due to surface fatigue (oscillatory movement
of about 5 mm)

35

5.6 Types of Wear
Figure 528 (a) Schematic of impact wear; (b) impact wear on

the striking
st iking face of a batte
battering
ing tool

36

5.6 Types of Wear
Figure 530 (a) Schematic of brinelling; (b) brinelling of a

bearing race by static overload

37

5.7 Bearings
Basic types
Plain bearings
R lli element
Rolling
l
t
Bearing life (L10)
Bearing precision
Bearing selection
Bearing
g materials (Design
(
g factors))

38

5.7 Bearings
Figure 531
Factors that
affect
ff
wear
and friction at
different
scales

39

5.7 Bearings
Figure 532
5 32 Fundamental
F ndamental catego
categories
ies of bea
bearings
ings

40

5.7 Bearings
Figure 533 Engineering materials used for bearings

41

5.7 Bearings
Figure 534 Examples of various types of ball bearings: (a) deep

groove single row (for radial loads,
groove,
loads limited axial); (b) angular
contact (takes radial load and axial loads in one direction); (c) split
inner ring (special applications); (d) self-aligning double row
(tolerates some misalignment); (e) ball thrust bearing (for axial
loads only)

42

5.7 Bearings
Figure 535 Examples of roller bearings: (a) cylindrical

(accommodates high radial load, no axial loads); (b) tapered
(accommodates radial and axial loads); (c) spherical
((accommodates misalignment);
g
); (d)
( ) needle (high
( g radial load
capacity for its size)

43

5.7 Bearings
Figure 536
Ball versus roller
bearing selection

44

5.8 Lubricants
Types
Mineral oils
F ll formulated
Fully
f
l t d oils
il
Greases
Solid film lubricants
Bio-based lubricants

45

5.8 Lubricants
Figure 537 Types of lubricants

46

5.8 Lubricants
Figure 538 Engineering materials used to combat abrasive wear

47

5.8 Lubricants
Figure 539
5 39 Materials
Mate ials used
sed fo
for non
non-abrasive
ab asi e wear
ea sit
situations
ations

48

5.8 Lubricants
Figure 540 Spalling of chromium plate on a hardened steel guidepost,

produced by surface fatigue from reciprocating ball contact

49

5.8 Lubricants
Figure
g
541 Part failure due to abrasive wear. Asbestos p
packing
g
ran against the stainless steel bushing (type 316).

50

5.8 Lubricants
Table 5
51
1 DN limits for greases and oils

51

5.8 Lubricants
Table 5
52
2 Solid
Solid-film
film lubricants

52

5.10 Preventing Wear Failures
Abrasion guidelines
Metal-to-metal guidelines
Oth guidelines
Other
id li

53

Summary
Table 5
53
3 Some standard tribotests

54

Global Considerations
New energy solutions will bring new tribology

challenges
Effect of bio-based fuels and lubes
Removal of anti-wear additives
Overall goal of reducing friction worldwide

55


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Chapter 5

Tribology and Engineering Materials

Engineering Materials: properties and selection, 9th ed.

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Origin of the word tribology

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

5.2 Contact Mechanics

Real area of contact

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Figure 51 Concept of real

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

5.2 Contact Mechanics

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

= force to break adhered junctions

Different types of friction Sliding vs. Rolling friction

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Figure 56 The difference between the coefficient of friction

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Pure rolling at a & b,

Figure 57 Pure rolling only occurs in areas a and b

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

5.3 Friction Schematic equation only!

= Rolling friction coefficient

Figure 58 General concept - potential equation

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

5.3 Friction - Measurement

Figure 59 Rolling friction test. Rolling resistance number is the

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Figure 510 Types of

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Figure 511 Average

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Figure 512 Stribeck curve showing how lubricated sliding

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

Figure 513 Types

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

5.4 Definition of Wear

Correlation between wear and friction

Engineering Materials: properties and selection, 9th ed.

2010 Pearson Higher Education,

5.4 Definition of Wear

Engineering Materials: properties and selection, 9th ed.