Tribology

(MDP 413)
Fourth Year,
Mechanical Engineering Dept.,
Faculty of Engineering,
Fayoum University

Dr. Ahmed Salah Abou Taleb

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 Wear
In materials science, wear is erosion or sideways
displacement of material from its "derivative" and
original position on a solid surface performed by the
action of another surface

Wear is related to interactions between surfaces and

more specifically the removal and deformation of
material on a surface as a result of mechanical action of
the opposite surface.

The definition of wear may include loss of dimension

(material) from plastic deformation if it is originated at
the interface between two sliding surfaces.
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 Wear
Occurrence of wear depends on:
• Geometry of the surface

• Applied load

• The rolling and sliding velocities

• Environmental conditions

• Mechanical, Thermal, Chemical and Metallurgical properties

• Physical, Thermal and Chemical properties of the lubricant

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Types of Wear

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 Mechanical Wear
I- Adhesive Wear (Shear):
It means damage of surfaces resulting from rubbing
(sliding) of two metallic bodies under load without
deliberate presence of an abrasive agent.

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 Mechanical Wear
I- Adhesive Wear (Shear):
Sut Metal 1 > Sut Metal 2 > Sut Junction 1
Shear of Junction
Steel & Tin bronze (min. wear) J
Cold weld

Sut Metal 1 > Sut Junction > Sut Metal 2 2

Wear in metal 2
Steel & lead bronze

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 Mechanical Wear
I- Adhesive Wear (Shear):
Sut Junction > Sut Metal 1 > Sut Metal 2 1
Wear in metal 2 bigger than wear in
metal 1
J
Cold weld
Steel & Copper

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Sut Junction = Sut Metal 1 = Sut Metal 2

Severe wear (random failure)

So one should use different material to control the wear in the

proper surface.
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 Mechanical Wear
I- Adhesive Wear (Shear):
Adhesive Wear Calculations for a semi spherical particles:
𝑛
2 3
1 4 3
𝑞 𝑤𝑒𝑎𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 = = 𝜋𝑎 𝑛
2 3𝜋𝑎𝑖
3
1
2 3
𝜋𝑎 𝑛 𝜋𝑎 2𝑛
𝑄 𝑤𝑒𝑎𝑟𝑣𝑜𝑙𝑢𝑚𝑒/𝑢𝑛𝑖𝑡 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 3 =
2𝑎 3
𝑊
𝐻 𝐻𝑎𝑟𝑑𝑛𝑒𝑠𝑠 =
𝜋𝑎2 𝑛
1𝑊
𝑄 =
3 𝐻
𝑘 𝑊
𝑄 𝑤𝑒𝑎𝑟𝑣𝑜𝑙𝑢𝑚𝑒/𝑢𝑛𝑖𝑡 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 =
3 𝐻
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 Mechanical Wear
II- Abrasive Wear:
• Abrasive wear occurs when a harder material is
rubbing against a softer material
• It’s characterized by damage to a surface by a harder
material.
Two Surface Wear

Three surface wear

A- Introduced between
surfaces (sand, dirt, ……).
B- Formed during wear
process (chip, oxides, …).
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 Mechanical Wear
II- Abrasive Wear:
Types of abrasive wear

Gouging abrasion
• Large particles
• High compression loads

High stress or grinding abrasion

• Smaller particles
• High compression load

Low stress or scratching abrasion

• No compression load
• Scratching abrasion while material is sliding
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 Mechanical Wear
II- Abrasive Wear:
𝑊𝑣
Q= 𝐾
3σ𝑠
Where; Q = wear volume, v = sliding velocity, W = applied load,
σs = surface strength, K = wear coefficient

Abrasive Wear Calculations for a triangle scratch:

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𝑞 𝑤𝑒𝑎𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 = 2𝑎𝑕 . 𝐿
2
𝑄 𝑤𝑒𝑎𝑟𝑣𝑜𝑙𝑢𝑚𝑒/𝑡𝑟𝑎𝑣𝑒𝑙 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 𝑎𝑕 𝑛 = 𝑛 𝑎2 cot 𝛽
2 𝑊 𝑊
𝑄 = cot 𝛽 𝐻 𝐻𝑎𝑟𝑑𝑛𝑒𝑠𝑠 =
𝜋 𝐻 𝜋𝑎2 𝑛
𝑘 𝑊
𝑄 𝑤𝑒𝑎𝑟𝑣𝑜𝑙𝑢𝑚𝑒/𝑢𝑛𝑖𝑡 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 =
3 𝐻 11
 Mechanical Wear
II- Abrasive Wear:
Abrasive Wear Calculations for a triangle scratch:
𝑘 𝑊 𝑘 𝑊
𝑞 (𝑟𝑎𝑡𝑒 𝑜𝑓 𝑤𝑒𝑎𝑟) = 𝐿= 𝑣
3 𝐻 3 𝐻
𝑞 𝑘 𝑃
𝐷 (𝑟𝑎𝑡𝑒 𝑜𝑓 𝑐𝑕𝑎𝑛𝑔𝑒 𝑖𝑛 𝑑𝑖𝑚𝑒𝑛𝑠𝑖𝑜𝑛) = = 𝑣
𝐴 3 𝐻
Example: Bearing need to figure out the change in clearance.

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 Mechanical Wear
III- Fatigue Wear:
A particle of surface material suddenly separates from the
surface as a result of repeated stresses (actual surface contact
is not necessary) under lubricated contacts.

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 Mechanical Wear
III- Fatigue Wear:
Rolling fatigue Abrasive wear – one surface must be rougher
and harder than the other one (rolling bearing).

Sliding fatigue A wear particle is produced when an asperity

has experienced a sufficient number of contact
and deformations to produce fatigue failure
(crank shaft).
Crack fatigue In case of induced fatigue crack, fluid may
entrape in the crack and under load experiences
high hydrostatic pressure sufficient enough to
separate a particle of the surface

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 Mechanical Wear
IV- Erosion Wear:
The impingement of solid particles, or small drops of liquid or gas
on the solid surface cause wear what is known as erosion of
materials and components.

Pressure generated due to change in

velocity
P = 𝞓V 𝐸𝞺
P = Impact pressure
E = Modulus of elasticity of impacted
material
𝞺 = Density of the fluid
V = Velocity

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 Mechanical Wear
IV- Erosion Wear:
It is a type of wear that arises due to absorbing energy.
Solid particle erosion Cleaning casted products,
300 in ductile material & 900 in brittle.
Fluid erosion Bar lev Line.

Spark erosion Spark cutting M/Cs.

Cavitation erosion Higher pressure zone.

Journal bearing.
Fretting wear Is a fatigue wear with presence of vibration

Scuffing No lubrication, temperature increase, plastic

deformation occurs. Gears. 16
 Mechanical Wear
Chemical Wear:
Environmental conditions produce a reaction product on
one or both of rubbing surface and this chemical product
is subsequently removed by the rubbing action.

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 Mechanical Wear
Methods for control of the wear:
• Lubrication technology
• Materials substitution
• Load reduction
• Removal of impact conditions

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 Mechanical Wear
Design Against Wear:
PV Value
𝑃𝑜𝑤𝑒𝑟 𝑙𝑜𝑠𝑡 𝑑𝑢𝑒 𝑡𝑜 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 = 𝐹𝑣 = 𝜇𝑊𝑣
𝑊
𝑃𝑜𝑤𝑒𝑟 𝑙𝑜𝑠𝑡 𝑑𝑢𝑒 𝑡𝑜 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛/𝑢𝑛𝑖𝑡 𝑎𝑟𝑒𝑎 = 𝜇 𝑣 = 𝜇𝑃𝑣
𝐴
𝑘 𝑊
𝑄 𝑤𝑒𝑎𝑟𝑣𝑜𝑙𝑢𝑚𝑒 = .𝐿
3 𝐻
𝑑𝑄 𝑘 𝑊
𝑄 𝑤𝑒𝑎𝑟 𝑟𝑎𝑡𝑒 = = .𝑣
𝑑𝑡 3 𝐻
𝑄 𝑘 𝑊 𝑘
𝐷 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑐𝑕𝑎𝑛𝑔𝑒 𝑖𝑛 𝑑𝑖𝑚𝑒𝑛𝑠𝑖𝑜𝑛 = = 𝑣= 𝑃𝑣
𝐴 3𝐻 𝐴 3𝐻

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 Mechanical Wear
Design Against Wear:
Pass of Contact
It is the unit of sliding in which sliding has been experienced over a
distance equals to the width of the apparent contact in the
direction of sliding
𝑓𝑜𝑙𝑙𝑜𝑤𝑒𝑟 𝐶𝑖𝑟𝑐𝑢𝑚.
𝑁𝑜. 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 =
𝐶𝑎𝑚 𝐶𝑖𝑟𝑐𝑢𝑖𝑚
𝜋𝐷
=
𝐿
𝜏𝑚𝑎𝑥 < 𝜏𝑦

ϒ = 0.2- 0.54 for 2000 Pass

For M passes:
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𝑀𝜏𝑚𝑎𝑥 9 < 2000 𝛾𝜏𝑦 20
 Mechanical Wear
Problem:
For an eccentric cam and follower find out the selected material is
safe or not for 106 cam revolution.
τ (max.) = 7.95 *103 psi, τ(yield follower) = 150 *103 psi,
τ(yield cam) = 40 *103 psi, cam dia. = 4” and follower thick. = 0.002”
Solution:
Cam Follower
M (No. of Passes) 106 106 (π*4/0.002)= 6.28*109
τ(yield ) 40 *103 150 *103
τ (max.) 7.95 *103 7.95 *103

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