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Unit 1-Tribology

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13 views25 pages

Unit 1-Tribology

Uploaded by

SHYAM SUNDAR
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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TRIBOLOGY

Unit-1

1
CONTENTS
• Introduction
• Industrial significance of tribology
• Service life
• Role of elastic deformation
• Plasticity index
• Practical objectives of tribology
• Physio-chemical characteristics of solid surfaces
• Analysis of surface roughness
• Lubrication to reduce friction

2
Introduction to Tribology

• 'Tribology' - derived from the Greek word 'tribos’


(rubbing or sliding)

• It is the science and technology of interacting surfaces in relative motion and


of related subjects and practices.

• Focuses on friction, wear and lubrication of interacting surfaces in relative


motion.

• Tribological knowledge helps to improve service life, safety and reliability of


interacting machine components; and yields substantial economic benefits
3
Industrial significance of Tribology

• Crucial to modern machinery which uses sliding and rolling surfaces.

• The purpose of studying tribology is to minimize or eliminate losses


resulting from friction and wear at all levels of technology where the
rubbing of surfaces is involved.

• Tribology leads to greater plant efficiency, better performance, fewer


breakdowns and significant savings.

4
Industrial significance of Tribology
Example 1 : Seal

• Carbon graphite seal is employed


to avoid leakage of steam from
rotary joints of paper industry.
• Failure of this component occurs
due to adhesive wear which
causes uneven surface that leads
to reduction in mechanical contact
area.
• For same imposed load, reduction in mechanical contacts, increases the level of
stress and hence chances of failure

5
Industrial significance of Tribology
Example 2: Cam

• Cams are used to transmit


rotary motion in reciprocating
motion.
• Subjected to jerks while
sliding, which form some pits
on the cam surface reducing
mechanical performance.
• Understanding the mechanism
of pit formation helps to estimate the life of component and find methods to
reduce such pitting failures.
6
Industrial significance of Tribology
Example 3: Multi-row Roller Bearing

• Cracking of outer ring of roller


bearing is shown in Fig.
• Such failure occurs due to faulty
manufacturing and wrong
assembly.
• Tribological relations help
estimating increase in contact
stresses due to misalignment of shaft and improper mounting of bearing surfaces.
Hence an approximation on reduction in service life can be estimated.

7
Service Life

Motion under load induces stress:

- Elastic bending of asperities


- Breakage of asperities
- Plastic deformation of soft surface

8
Role of elastic deformation

Composite Young’s modulus


Hardness
Plasticity index Surface roughness
Spacing between any
two peaks

In general engineering applications, high Young’s modulus is preferred but


not in tribological applications.
Young's modulus is a measure of the stiffness of a solid material
stiffness versus

Strength: The amount of force it can withstand and still recover its original shape
Hardness: Defines the relative resistance that its surface imposes against the
penetration of a harder body
Toughness: The amount of energy that a material can absorb before fracturing.
9
Ways to keep plasticity index low

Introduce third body between interacting surfaces

- Elastically deformed substance fills irregular surfaces

- Fatigue failure occur after certain cycles


10
Practical Objectives of tribology

11
Physico-Chemical characteristics of solid surfaces

12
Deformed layer
• The strained layer is called the deformed layer (or work hardened layer) and
is an integral part of material itself in the surface region

• The amount of the deformed material present and the degree of deformation
that occurs are functions of two factors
• The amount of work or energy that is put into the deformation process
• Nature of the material

• The deformed layer can also be produced during friction process

• The thickness of the lightly deformed layer and heavily deformed layers
typically range from 1-10 μm and 10-100 μm, respectively

13
Beilby Layer
• Beilby layer in metals and alloys is produced by melting and surface flow
during machining of molecular layers.
• Subsequently hardened by quenching as they are deposited on a cool
underlying material.
• The layer has an amorphous or microcrystalline structure
• The thickness typically range 1-10μm
Chemically reacted Layer
• In many non-metals, the oxide and other chemically reacted layers may also
be present.
• Thickness of this layer depends on reactivity to environment, reaction
temperature and time.
• The thickness typically range 10-100nm.

14
Adsorbed layers
• Most of the adsorbed layers may be formed from environment both on metallic and
non metallic surfaces.
• The most common constituent of adsorbate layers are molecules of water vapour,
oxygen or hydro-carbons
Physisorbed Layer
• The physisorption process involves weak Van der waals forces
• No exchange of electrons takes place between the molecules of adsorbent and
adsorbate
• This layer can be mono molecular or poly molecular.
Chemisorbed layer
• In chemisorbtion, in contrast to physisorbtion, sharing of electrons or interchange
between chemisorbed species and the solid takes place.
• This layer is limited to mono molecular.

15
Analysis of Surface Roughness

Surface texture is the repetitive or random deviation from the nominal


surface that forms the three-dimensional topography of the surface.
• Real surfaces are difficult to define
• A number of techniques and parameters have been developed to
characterize surface topography.
• The most widely used surface descriptors are the statistical surface
parameters.
• A new development in this area involves surface characterization by
fractals.
• Surface texture includes: Roughness (nano- and micro roughness),
Waviness (macro roughness), Lay and Flaws

16
17
• Surface roughness is defined by short wavelength vertical deviations from
nominal surface.
• Larger the deviations, rougher the surface.
• Three different length: Sampling length, evaluation length and traversing length.

18
Characterization of Surface Topography by Statistical Parameters

• In order to describe the surface, at least two parameters are needed,


• height parameter -describing the variation in height
• spatial parameter -describing how height varies in the plane of the surface
• Height parameter is described by parameters such as the centre-line-
average or roughness average (CLA or 'Ra'), root mean square roughness
(RMS or 'Rq'), mean value of the maximum peak-to-valley height ('Rtm'), ten-
point height ('Rz') and many others.
• In engineering practice, however, the most commonly used parameter is the
roughness average.

19
20
Spatial Parameter

• Surfaces shown in the figure have the same


height parameters, but their spatial
arrangements are different.

• To describe spatial arrangement of a surface


the auto covariance function (ACVF) or its
normalized form the autocorrelation function
(ACF), the structure function (SF) or the power
spectral density function (PSDF) are commonly
used. Various surface profiles having the same
Ra value

21
22
Lubrication to reduce friction
Dimensionless film hmin - Separation between the two surfaces
Parameter Rrms, a - rms value of surface a
(Specific film thickness) Rrms, b - rm s value of surface b

• Boundary lubrication, Λ<1


• Hydrodynamic lubrication, Λ>5
• Mixed lubrication, 1<Λ<3
• Elastohydrodynamic 3 < Λ< 5

23
Economic benefits
Benefits in increase in storage Improves reliability through reduction in links
density in compact disk (reduction in friction loss)

Benefits in reducing the energy loss


in IC Engines

24
Economic benefits

•In 2014, Total automobile around the world Gross National Product in India increased
crosses 100 Crores. to 1,40,000 INR Billion in 2020
•2% saving in BHP leads to phenomenal 1% saving through tribological knowledge
energy savings. could save 1,40,000 Crores. 25

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