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Tribology for Scientists and Engineers pp 43–91Cite as

Friction and Wear

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Abstract

Friction is a universal phenomenon which is observed in a great variety of sliding and rolling situations. The study of friction and wear has long been of enormous practical importance, since the functioning of many mechanical, electromechanical, and biological systems depends on the appropriate friction and wear values. In recent decades, this field has received increasing attention as it has become evident that the consumption of resources resulting from high friction and wear is greater than 6 % of the Gross National Product of the USA. In this chapter, various theories, mechanisms, and factors affecting of friction and wear were discussed.

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Author information

Authors and Affiliations

  1. College of Engineering & Applied Science, University of Wisconsin-Milwaukee, Milwaukee, WI, 53201, USA

    Pradeep L. Menezes, Michael Nosonovsky & Michael R. Lovell

  2. Department of Mechanical Engineering, Indian Institute of Science, Bangalore, Karnataka, 560012, India

    Satish V. Kailas

Authors
  1. Pradeep L. Menezes
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  2. Michael Nosonovsky
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  3. Satish V. Kailas
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  4. Michael R. Lovell
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Corresponding author

Correspondence to Pradeep L. Menezes .

Editor information

Editors and Affiliations

  1. Department of Industrial Engineering, University of Wisconsin, Milwaukee, Wisconsin, USA

    Pradeep L. Menezes

  2. Department of Mechanical Engineering, University of Wisconsin, Milwaukee, Wisconsin, USA

    Michael Nosonovsky

  3. Department of Marine Engineering, Texas A&M University, Galveston, Texas, USA

    Sudeep P. Ingole

  4. Department of Mechanical Engineering, Indian Institute of Science, Bangalore, India

    Satish V. Kailas

  5. Department of Industrial Engineering, University of Wisconsin, Milwaukee, Wisconsin, USA

    Michael R. Lovell

Appendices

Questions

  1. 1.

    Explain friction mechanisms. Calculate the friction coefficient when conical asperities slid against softer materials.

  2. 2.

    State empirical laws of friction. State and explain the adhesion theory of friction with suitable diagrams.

  3. 3.

    What are the factors affecting friction? Explain.

  4. 4.

    How does the crystal structure influence friction? Why do FCC metals have more friction than HCP metals?

  5. 5.

    Define wear. How do you measure wear?

  6. 6.

    Describe various wear mechanisms in detail.

  7. 7.

    What is adhesive wear? Derive Archard theory of adhesive wear.

  8. 8.

    What is abrasive wear? Derive the quantitative expression for abrasive wear.

  9. 9.

    Explain various subsurface zones that are formed during sliding.

  10. 10.

    What are the factors affecting wear process?

  11. 11.

    Explain the following:

  12. (a)

    Static and kinetic friction

  13. (b)

    Steady-state and stick–slip friction

  14. (c)

    Coefficient of friction and angle of friction

  15. (d)

    Real area and apparent area

  16. (e)

    Adhesion friction and plowing friction

  17. (f)

    Erosive wear and corrosive wear

  18. (g)

    Two-body wear and three-body wear

  19. (h)

    Fretting wear and fatigue wear

Problems

  1. 1.

    A steel ball is slid against an aluminum flat surface at two different normal loads. At low normal load, the coefficient of friction is 0.40 and the groove width is 0.4 mm. At high load, the coefficient of friction is 0.6 and the groove width is 0.8 mm. Calculate the adhesive component of friction. Given: μtotal = μadhesion + μplowing.

  2. 2.

    A hard steel ball of 3 mm diameter slid against a soft aluminum surface, produces a groove of 1.5 mm width. Calculate the adhesive component of friction when coefficient of friction is recorded 0.4. Given: μtotal = μadhesion + μplowing.

  3. 3.

    A steel surface with conical asperities of an average semi-angle of 60° slides against a soft aluminum surface of hardness, H = 100 MPa under a constant normal load of 20 N. Calculate the volume of aluminum displaced in unit slid distance.

  4. 4.

    A rigid cutter was used to cut a medium carbon steel bar of 5 mm diameter. The hardness of the carbon steel is 2 GPa. The width of cut is 0.5 mm. It took 5 min to cut and the energy expended was 50 W (Nm/s). The coefficient of friction between the cutter and the steel bar is 0.3. Calculate the wear coefficient of the steel bar during the cutting process.

Solutions

  1. 1.

    Given: μ total = μ adhesion + μ plowing

    For a ball on flat surface, the above equation can be rewritten as

    $$ {\mu}_{total}={\mu_a}_{dhesion}+\frac{4r}{3\pi R} $$
    (1)

    where 2r is the groove width and R is the radius of the steel ball.

    At low load, (1) can be written as

    $$ 0.4={\mu_a}_{dhesion}+\frac{4\times 0.2}{3\pi R} $$
    (2)

    At high load, (1) becomes

    $$ 0.6={\mu_a}_{dhesion}+\frac{4\times 0.4}{3\pi R} $$
    (3)

    Solving (2) and (3), we get μ adhesion = 0.2.

  2. 2.

    Given: μ total = μ adhesion + μ plowing

    For a ball on flat surface, the above equation can be rewritten as

    $$ {\mu}_{total}={\mu_a}_{dhesion}+\frac{4r}{3\pi R} $$
    (1)

    Here r = 0.75 mm and R = 1.5 mm.

    Solving (1), \( 0.4={\mu_a}_{dhesion}+\frac{4\times 0.75}{3\pi \times 1.5} \)

    we get μ adhesion = 0.18.

  3. 3.

    Total volume of material displaced in unit sliding distance is given by

    $$ Q=\frac{2}{\pi}\frac{W}{H} \tan \theta. $$

    Substituting values, we get

    $$ Q=\frac{2}{\pi}\times \frac{20}{100\times {10}^6} \tan 30=7.35\times {10}^{-8}. $$
  4. 4.

    We know that the total wear volume is given by

    $$ Q=K\frac{W}{H}\kern1em or\kern1em K=\frac{ QH}{W}. $$

    Wear volume of steel bar

    $$ \begin{array}{l}Q=\frac{\pi {d}^2}{4}\times w\\ {}\end{array} $$

    where w is the width of cut. Solving the parameters, we get

    $$ Q=\frac{\pi \times {0.005}^2}{4}\times 0.5\times {10}^{-3}=9.8\times {10}^{-9} $$

    Work done is given by

    $$ F= Energy\times time $$
    $$ F=50\times 5\times 60=15000 $$
    $$ \begin{array}{l}W=\frac{F}{\mu }=\frac{15000}{0.3}=50000\\ {}\end{array} $$
    $$ K=\frac{ QH}{W}=\frac{9.8\times {10}^{-9}\times 2\times {10}^9}{50000}=3.9\times {10}^{-4} $$

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Menezes, P.L., Nosonovsky, M., Kailas, S.V., Lovell, M.R. (2013). Friction and Wear. In: Menezes, P., Nosonovsky, M., Ingole, S., Kailas, S., Lovell, M. (eds) Tribology for Scientists and Engineers. Springer, New York, NY. https://doi.org/10.1007/978-1-4614-1945-7_2

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