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Zhiwei Yu, Xiaolei Xu, Xiaoyan Guo
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N.P. Barykin, F.A. Sadykov, I.R. Aslanian
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Book Chapter
Friction and Wear Testing
Available to PurchaseSeries: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006911
EISBN: 978-1-62708-395-9
... Abstract Tribology is the study of contacting materials in relative motion and more specifically the study of friction, wear, and lubrication. This article discusses the classification and the mechanisms of friction, wear, and lubrication of polymers. It describes the tribological applications...
Abstract
Tribology is the study of contacting materials in relative motion and more specifically the study of friction, wear, and lubrication. This article discusses the classification and the mechanisms of friction, wear, and lubrication of polymers. It describes the tribological applications of polymers and the tribometers and instrumentation used to measure the tribological properties of polymers. The article discusses the processes involved in calculating the wear rate of polymers and the methods of characterization of the sliding interface. It provides information on the pressure and velocity limit of polymer composites and polymer testing best practices.
Book Chapter
Failure of a Nylon Driving Gear
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0092102
EISBN: 978-1-62708-234-1
... (frictional wear). No recommendations were made. Gears Lubrication Nylon (Other, miscellaneous, or unspecified) wear Figure 1 shows pitting on the tooth flank of a nylon oil-lubricated driving gear. The pitting produced numerous surface microcracks in association with large-scale fragmentation...
Abstract
A nylon oil-lubricated driving gear showed pitting upon visual inspection. The pitting produced numerous surface microcracks. Further investigation (visual inspection and 37x images) supported the conclusion that failure occurred in association with large-scale fragmentation (frictional wear). No recommendations were made.
Book Chapter
Friction and Wear in a 24-Unit Speed-Increaser Gearbox
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0009190
EISBN: 978-1-62708-225-9
... the consideration and control of many interrelated factors. Bending fatigue Gear boxes Helical gears Lubrication Scuffing Carburized steel Fatigue fracture Abrasive wear In an industrial application, 24 speed-increaser gearboxes were used to transmit 258 kW (346 hp) and increase speed from 55...
Abstract
In an industrial application, 24 speed-increaser gearboxes were used to transmit 258 kW (346 hp) and increase speed from 55 to 375 rev/min. The gears were parallel shaft, single helical, carburized, and ground. The splash lubrication system used a mineral oil without antiscuff additives with ISO 100 viscosity. After about 250 h of operation, two gearboxes failed by bending fatigue. Investigation showed the primary failure mode was scuffing, and the earlier bending fatigue failures were caused by dynamic loads generated by the worn gear teeth. Testing of a prototype gearbox showed that the failure resulted from several interrelated factors: the lubricant viscosity was too low causing high temperatures; no antiscuff additives were used; a gearbox designed as a speed reducer was used as a speed increaser (the designer selected a long-addendum tooth for the pinion); the gear teeth were not provided with a coating or plating to ease running-in; and the gears were not run-in properly under reduced loads. The case suggests that such gear failures can be avoided if designers and operators recognize that the lubricant is an important component of a gearbox and appreciate that gear design requires the consideration and control of many interrelated factors.
Book Chapter
Failure Investigation of a Locomotive Turbocharger Main Shaft and Bearing Sleeve
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001846
EISBN: 978-1-62708-241-9
...-cycle rotation-bending fatigue. The bearing sleeve failed as a result of abrasive and adhesive wear. Detailed metallurgical analysis indicated that the sleeve and its respective journal had been subjected to abnormally high temperatures, increasing the amount of friction between the sleeve, bearing bush...
Abstract
The main shaft in a locomotive turbocharger fractured along with an associated bearing sleeve. Visual and fractographic examination revealed that the shaft fractured at a sharp-edged groove between two journals of different cross-sectional area. The dominant failure mechanism was low-cycle rotation-bending fatigue. The bearing sleeve failed as a result of abrasive and adhesive wear. Detailed metallurgical analysis indicated that the sleeve and its respective journal had been subjected to abnormally high temperatures, increasing the amount of friction between the sleeve, bearing bush, and journal surface. The excessive heat also softened the induction-hardened case on the journal surface, decreasing its fatigue strength. Fatigue crack initiation occurred at the root fillet of the groove because of stress concentration.
Book Chapter
Failure of a Rubber Office-Chair Roller
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c0048536
EISBN: 978-1-62708-222-8
... mode of loading. Nevertheless, the fracture surface of the failure-causing crack suggested a tensile-stress component was involved in driving failure. Frictional wear Microcracking Rubber Brittle fracture A brittlelike crack propagation caused failure in a rubber office-chair roller...
Abstract
A brittle-like crack propagation caused failure in a rubber office-chair roller. A crack initiated from the inside of the roller and propagated in a discontinuous brittle-like fashion, as indicated from the evolution of concentric fracture striations. Compressive fatigue was a dominant mode of loading. Nevertheless, the fracture surface of the failure-causing crack suggested a tensile-stress component was involved in driving failure.
Book Chapter
Fracture and Wear Failure of a Locomotive Turbocharger-Bearing Sleeve
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001847
EISBN: 978-1-62708-241-9
... underneath. This led to further wear and an increase in friction between the sleeve and bearing bush. Fatigue crack initiation occurred at the root fillet because of stress concentration and large frictional forces. Insufficient nitriding depth facilitated the propagation of fatigue cracks. bearing...
Abstract
An investigation was conducted to determine what caused a bearing sleeve in a locomotive turbocharger to fail. The sleeve, which is made of nitrided 38CrMoAl steel, fractured at the transition fillet between the cylinder and plate. Visual examination revealed significant wear on the external surface of the cylinder, with multiple origin fatigue fracture appearing to be the dominant fracture mechanism. Metallurgical examination indicated that the nitrided layer was not as deep as it was supposed to be and had worn away on the outer surface of the sleeve, exposing the soft matrix underneath. This led to further wear and an increase in friction between the sleeve and bearing bush. Fatigue crack initiation occurred at the root fillet because of stress concentration and large frictional forces. Insufficient nitriding depth facilitated the propagation of fatigue cracks.
Image
Classification of the processes of friction leading to wear for elastomers ...
Available to PurchasePublished: 01 January 2002
Fig. 6 Classification of the processes of friction leading to wear for elastomers (adapted after Moore, Ref 23 ). The diagram clarifies the role of friction in determining the wear mechanism for elastomeric polymers.
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Image
Published: 01 January 2002
Fig. 11 Influence of fillers on friction and wear behavior of PEEK composites; L , Normal load, 196 N; speed 0.445 m/s; counterface plain carbon steel ring. (a) nanometer-sized SiC in PEEK; (b), and (c) PTFE in PEEK and PEEK + SiC (3.3 vol% constant) composites. Source: Ref 40
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Image
(a) Influence of PTFE on friction and wear performance of PEEK composites a...
Available to PurchasePublished: 01 January 2002
Fig. 12 (a) Influence of PTFE on friction and wear performance of PEEK composites and the optimum range of PTFE amount for best combination of μ and K 0 . (b) Linear correlation and synergistic effect as a result of two opposite trends. K 0,M and K 0,L represent specific wear rates
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Image
Specific wear rate and friction coefficient of unidirectional composites (s...
Available to PurchasePublished: 01 January 2002
Fig. 17 Specific wear rate and friction coefficient of unidirectional composites (see Table 4 ) in three orientations ( P , 1.5 N/mm 2 ; V , 0.83 m/s; distance slid, 16 km).
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Image
Effect of atmospheric pressure on the friction and wear of a carbon steel c...
Available to PurchasePublished: 01 January 2002
Image
Comparison between (a) Archard approach and (b) friction energy wear approa...
Available to PurchasePublished: 15 January 2021
Fig. 13 Comparison between (a) Archard approach and (b) friction energy wear approach to quantify the wear evolution of a sintered steel displaying a significant fluctuation of the friction coefficient, depending on the loading condition. Adapted from Ref 42
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Image
Effect of atmospheric pressure on the friction and wear of a carbon steel c...
Available to PurchasePublished: 15 January 2021
Fig. 33 Effect of atmospheric pressure on the friction and wear of a carbon steel cylinder. Adapted from Ref 107
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Image
Classification of the processes of friction leading to wear for elastomers....
Available to PurchasePublished: 15 May 2022
Fig. 5 Classification of the processes of friction leading to wear for elastomers. The diagram clarifies the role of friction in determining the wear mechanism for elastomeric polymers. Adapted from Ref 22
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Book Chapter
Wear and Failure of Babbit Bushes in Steam Turbine Sliding Bearings
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c9001533
EISBN: 978-1-62708-225-9
... consists of a number of parallel wear furrows, which are characteristic of metal wear. 1 , 2 The presence of large reoriented areas that can in the process of friction form cracks and crumble is remarkable. Individual cracks were observed to be located across the friction furrows of a worn-out surface...
Abstract
An investigation of wear and failure of babbitt bushes was completed in this study. The results showed that wear at dry sliding of babbitt obtained by plasma spraying was less than that of babbitt in the as-cast state and after a deformation heat treatment. The failure of babbitt bushes was caused by a simultaneous and interrelated exhibition of fatigue and wear processes that depend considerably on cohesion strength between the bush and the bearing base and accumulation of defects on the contact surface between the bush and the shaft.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003571
EISBN: 978-1-62708-180-1
... sliding pair, except in few instances, usually produces undesirable high friction and high wear conditions due to enhanced adhesion between the polymer. Also, poor conductivity of the polymers results in elevated temperature at the polymer/polymer interface, leading to melting and rapid wear. Therefore...
Abstract
Plastics or polymers are used in a variety of engineering and nonengineering applications where they are subjected to surface damage and wear. This article discusses the classification of polymer wear mechanisms based on the methodologies of defining the types of wear. The first classification is based on the two-term model that divides wear mechanisms into interfacial and bulk or cohesive. The second is based on the perceived wear mechanism. The third classification is specific to polymers and draws the distinction based on mechanical properties of polymers. In this classification, wear study is separated as elastomers, thermosets, glassy thermoplastics, and semicrystalline thermoplastics. The article describes the effects of environment and lubricant on the wear failures of polymers. It presents a case study on nylon as a tribological material. The article explains the wear failure of an antifriction bearing, a nylon driving gear, and a polyoxymethylene gear wheel.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006789
EISBN: 978-1-62708-295-2
... in designing as well as in failure analysis for explaining the possible reasons of a given wear failure and thus adopting the most suitable countermeasures. It is also fundamental in basic research to help focus toward the goals, such as the reduction of wear rate or the optimization of friction. Wear...
Abstract
This article considers the main characteristics of wear mechanisms and how they can be identified. Some identification examples are reported, with the warning that this task can be difficult because of the presence of disturbing factors such as contaminants or possible additional damage of the worn products after the tribological process. Then, the article describes some examples of wear processes, considering possible transitions and/or interactions of the mechanism of fretting wear, rolling-sliding wear, abrasive wear, and solid-particle erosion wear. The role of tribological parameters on the material response is presented using the wear map concept, which is very useful and informative in several respects. The article concludes with guidelines for the selection of suitable surface treatments to avoid wear failures.
Series: ASM Handbook
Volume: 11B
Publisher: ASM International
Published: 15 May 2022
DOI: 10.31399/asm.hb.v11B.a0006850
EISBN: 978-1-62708-395-9
... in tribological applications are subjected to sliding against hard surfaces such as metals. A polymer–polymer sliding pair, except in few instances, usually produces undesirable high friction and high wear conditions due to enhanced adhesion between the polymers. Also, poor conductivity of the polymers results...
Abstract
This article presents the mechanisms of polymer wear and quantifies wear in terms of wear rate (rate of removal of the material). Interfacial and bulk wear are discussed as well as a discussion on the wear study of "elastomers," "thermosets," "glassy thermoplastics," and "semicrystalline thermoplastics." The article also discusses the effects of environment and lubricant on the wear failures of polymers. It presents a case study on considering nylon as a tribological material and failure examples, explaining wear resistance of polyurethane elastomeric coatings and failure of an acetal gear wheel.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006791
EISBN: 978-1-62708-295-2
... Abstract Friction and wear are important when considering the operation and efficiency of components and mechanical systems. Among the different types and mechanisms of wear, adhesive wear is very serious. Adhesion results in a high coefficient of friction as well as in serious damage...
Abstract
Friction and wear are important when considering the operation and efficiency of components and mechanical systems. Among the different types and mechanisms of wear, adhesive wear is very serious. Adhesion results in a high coefficient of friction as well as in serious damage to the contacting surfaces. In extreme cases, it may lead to complete prevention of sliding; as such, adhesive wear represents one of the fundamental causes of failure for most metal sliding contacts, accounting for approximately 70% of typical component failures. This article discusses the mechanism and failure modes of adhesive wear including scoring, scuffing, seizure, and galling, and describes the processes involved in classic laboratory-type and standardized tests for the evaluation of adhesive wear. It includes information on standardized galling tests, twist compression, slider-on-flat-surface, load-scanning, and scratch tests. After a discussion on gear scuffing, information on the material-dependent adhesive wear and factors preventing adhesive wear is provided.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006829
EISBN: 978-1-62708-295-2
... loop, the friction energy, E d (J) (i.e., friction work), inputted in the interface can be estimated. Both E d (J) and δ S variables can be considered to quantify the wear rate. Fretting Sliding Condition Most of the research work and industrial feedback emphasize that fretting damage...
Abstract
Fretting is a wear phenomenon that occurs between two mating surfaces; initially, it is adhesive in nature, and vibration or small-amplitude oscillation is an essential causative factor. Fretting generates wear debris, which oxidizes, leading to a corrosion-like morphology. This article focuses on fretting wear related to debris formation and ejection. It reviews the general characteristics of fretting wear, with an emphasis on steel. The review covers fretting wear in mechanical components, various parameters that affect fretting; quantification of wear induced by fretting; and the experimental results, map approach, measurement, mechanism, and prevention of fretting wear. This review is followed by several examples of failures related to fretting wear.
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