INDEX
1. Introduction
6. Verification Tests
a. Best and worst cases b. Reproducibility and Repeatability
1. Introduction
Reproducibility and repeatability are still problems to solve in tribological science, specifically in coefficient of friction (COF) and wear results obtained from tribotesters.
Tests
Those results evidence a lack of test parameters controlling in order to achieve a good reproducibility and repeatability of coefficient of friction values. 3
COF
1. Introduction
There are plenty of papers and reports that shown how different are the tribological test conditions in terms of standardization and scatter results of coefficient of friction in dry conditions.
Coefficient of Friction
Bibliographic Entry Technical Physics .USA. Wiley Encarta Encyclopedia 2004 CRC Handbook of Physical Quantities College Physics- 4th Edition. USA: McGraw-Hill Determining the Coefficient of Friction Succeed in Physical Science.
Materials
Steel on Steel Steel on Steel (dry) Steel on Steel Steel on Steel (dry)
0.6
0.57
0.74 0.15
0.6
0.09
0.4
Despite of that, the existing literature concerning coefficient of friction values does not specify enough information in order to trust in the presented results.
4
Thesis:
The coefficient of dry friction is influenced by materials but it is also affected by operating conditions such as load, velocity, temperature, as well as the geometry and configuration of the friction elements and the surrounding atmosphere.
Purpose of Work:
To acknowledge the influence of operating conditions (controlled and uncontrolled inputs) and test equipment on the coefficient of friction values and suggest improvements for the tribotest methods.
Define a test method for a operating conditions (controlled inputs) in order to reduce scatter of coefficient of friction on ball-on-disk tribological tests.
Examination of typical model friction couple: ball-on-disk, taking into account usually controlled and uncontrolled inputs of a tribotesting system.
Controlled Input
Humidity Load
Speed
Sliding distance
Materials
Sliding track radius
Ball Diameter
Load direction
10mm.
T-10 and T-11 vertical and horizontal for T-10.
35
0.1
50
80 35
10
15 10
0.2
0.3 0.3
G1
Steel disk and ceramic ball (S/C).
50
80 35
15
5 15
0.1
0.2 0.2
50
80
5
10
0.3
0.1
G2
MATERIALS
Additional one test of each was performed in order to measure acceleration of vibration. Humidity (%) Load (N) 10 Velocity (m/s) 0.1 0.2 0.3 5
G3
50
10
15
0.2
10
11
T-10 Vertical
T-11 Vertical
2
LOAD
LOAD
LOAD
Contact point
Transducer
12
13
Coefficient of Friction
1.00 0.80
0.60
0.40
0.277
0.20
0.123
0.204
0.00
Tests
S/S 0.540 S/C 0.713 P/C 0.657
14
Material Combination
Scatter of COF
0.8
0.7 0.6 0.5 0.4 0.3 0.2 0.1 0
COF
Wear
COF and wear values obtained from tests made by the author (group 1). 15
Wear (mm3)
0.6 0.5
0.4
0.3 0.2 0.1 0
35%H 50%H 80%H 80%H 35%H 50%H 50%H 80%H 35%H 35%H 50%H 80%H 80%H 35%H 50%H 50%H 80%H 35%H 35%H 50%H 80%H 80%H 35%H 50%H 50%H 80%H 35%H steel / steel steel / ceramic T10 Horizontal coating / ceramic steel / steel steel / ceramic T10 Vertical coating / ceramic steel / steel steel / ceramic T11 Vertical coating / ceramic
VARIABLES
Ap-p (g)
COF
16
Coefficient of Friction
160
0.7
17
120.0
0.5
80.0 0.4 60.0 0.3 40.0 0.2 0.1 0
20.0
0.0
T10H
T10V
T11V
T10H
T10V
T11V
T10H
T10V
T11V
Coated/Ceramic (P/C)
Steel/Ceramic (S/C)
Steel/Steel (S/S)
Ap-p (g)
COF
18
Coefficient of Friction
100.0
Coefficient of Friction
1.00 0.80
0.60
0.40
0.277
0.20
0.123
0.204
0.00
Tests
S/S 0.540 S/C 0.713 P/C 0.657
19
Material Combination
Scatter of COF
5. Taguchi Analysis
The Approach - The Taguchi Method is based on orthogonal array (OA) experiments. - The OA produces a set of well-balanced (minimum experimental runs) tests. - Taguchis method uses the statistical measure of performance called Signal-to-Noise ratios (S/N), which are functions of desired output that serve as objective functions for optimizations. S/N = Eta = -10 * log10 [(1/n) * (yi2)] - The ratio depends on the quality of the product/process to be optimized. The three categories of S/N ratios are: Lower-the-better Higher-the better Nominal-the-best - The parameter level combination that maximizes the appropriate S/N ratio is the optimal setting. 20
5. Taguchi Analysis
The Method
1. Selection of the factors that are affecting the results. 2. Selection of the appropriate levels that each factor may hold within the tests (3 levels each). 3. Selection of the orthogonal array determine the number of tests to run. to
Tribotester
Material
S/S
H%
35
N
5
m/s
0,1
50
80
10
15 10
0,2
0,3 0,3
Tribotester T10H
Material S/C
H% 50
80 35
35
N m/s 15 0,1
5 5 0,2 0,1
S/S
P/C
50
50
35
10
5
15
0,2
0,3
0,2
4. Conduction of the tests design (27 test instead of 229 test), Almost 9 time less effort.
5. Analyzing the results . 6. Prediction of the optimum performance and influence of factors. 7. Verification tests of the experimental.
80 80
35 35
15 10
5 10
0,3 0,1
0,1 0,3
S/C S/S
50
80
50
15
15
10
0,1
0,3
0,2
80 35
S/C
50 35
10
5
5
5 5
0,2 0,3
0,1 0,2
15 15
P/C
P/C
50
35
80
15
0,3
0,2
0,2
80 50
35 50 80 35
10 5
10 15 10 15
0,1 0,3
0,1 0,2 0,3 0,3 0,1
S/S
T11V
The greatest advantage of this method is the optimization of0,2 80 5 35 time and efforts in conducting experiments. 15 21 0,2 P/C
50 5 0,3
S/C
50
Tribotester
Kind of motion
T-10
Sliding
S/S: 35%, S/C: 50% and P/C: 80% S/S, S/C and P/C: 10 N S/S: 0.2 m/s, S/C: 0.1 m/s and P/C: 0.1 m/s 1,000 meters Non lubricated Vertical Ball-on-disk, 10 mm ball Ceramic (Al203) or steel 0.045 m 58 to 63 HRC Keep levels between 4.8g and 10g (Acceleration = Ap-p) 22
RH
P v D1 D SC G M Ra H Vibr
6. Verification Tests
Best case
Coefficient of Friction
1,2
Worst case
1,2
WORST CASE OF COEFFICIENT OF FRICTION P/C, 50%H, 5N, 0,3 m/s, T11V
Test 1
Test 2
Coefficient fo Friction
1
0,8 0,6 0,4 Series1 Series2
0,8
0,6
Test 3 Test 4
Test 5
Series3
0,4 0,2
0,2
0
TIME
0
TIME
23
6. Verification Tests
Optical Microscopy Image, 10X
Best case
3D Profilometer Image
m 7 6.5 6 5.5 5 4.5 4 3.5 3
Coefficient of Friction
1,2
1
0,8 0,6 0,4
Series1 Series2
2D Profilometer Image
Dlugosc = 2.09 mm Pt = 4.39 m Skala = 5 m
Series3
0,2
m 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 0 0.1 0.2 0.3 0.4 0.5 0.6
TIME
0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 mm
24
6. Verification Tests
Optical Microscopy Image, 10X
Worst case
3D Profilometer Image
m 7 6.5 6 5.5 5 4.5 4 3.5 3
1,2
WORST CASE OF COEFFICIENT OF FRICTION P/C, 50%H, 5N, 0,3 m/s, T11V
Coefficient fo Friction
2.5 2
1.5 1 0.5 0
Test 1
Test 2
0,8
0,6
2D Profilometer Image Atomic Force Microscopy Image 50m x 50m
Test 3 Test 4
Test 5
0,4 0,2 0
m 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 mm Dlugosc = 2.09 mm Pt = 2.35 m Skala = 5 m
TIME
25
6. Verification Tests
Reproducibility and Repeatability
Source of Data ASTM G-99 DIN 50324 and ASTM G-99 Preliminary tests made by this author Best cases of the optimization process made by the author Worst cases of the optimizacion process made by the autor COF Scatter 0,19 0,11 0,11 0,04 0,07 Improvement % 41% 78% 62%
In all cases, including the worst scenario, the results of repeatability were much better in all results made by the author
ND = No data Reproducibility
Repeatability
26
6. Verification Tests
Scatter of COF
1.100
0.867 0.071
27
Having a standardized method (using Taguchi approach), good quality of input variables control and good quality of tribotester equipment, its possible to achieve low scatter and then, get a considerable improving in repeatability and reproducibility values of coefficient of friction.
29
Future Work
The proposed new approach for tribotesting make it possible to compare tribocharacteristics on a friction pair between different research centers in frame of a round robin using different tribotesters as well.
There is now a big opportunity to accomplish the VAMAS TWA # 1 objective and improve the reproducibility and comparability of wear tests by developing internationally agreed test methodologies for characterisation of wear behaviour of advanced materials.
30
8. Acknowledges
Thanks to all colleagues from the Tribology department of the Institute for Sustainable Technologies - National Research Institute (ITeE-PIB) for all your technical support, advices and facilities. Thanks to the Scientific Board of Krakow University of Technology for your recommendations and support during this time.
31
Influence of Test Equipment and Working Conditions on the Coefficient of Friction Values
PhD DISSERTATION Demfilo Maldonado Corts MSc Eng
University of Monterrey (UDEM) Mechanical Engineering Faculty San Pedro Garza Garca, Mxico
32
33