Tribology Lab (MEL456)
2014
Experiment No.1
AIM: To evaluate the effect of polishing a sample with different grit size emery papers on the surface
roughness.
MATERIAL USED: Mild Steel, Aluminium, Emery paper
PARAMETERS: 1. Cut-off length
2. Evaluation length
3. Velocity
THEORY:
Surface deviations: departures from nominal surface in form of waviness, roughness, flaws, lay, and
profile
Waviness: surface irregularities that deviate from mean surface in form of waves
Waviness height: peak-to-valley distance in inches or millimeters
Waviness width: distance between successive waviness peaks or valleys in inches or millimeters
Roughness: relatively finely spaced irregularities superimposed on waviness pattern
Caused by cutting tool or abrasive grain action
Irregularities narrower than waviness pattern
Roughness height: Ra deviation measured normal to centerline in microinches or m
Roughness width: distance between successive roughness peaks parallel to nominal surface in inches
or millimeters
Profile: contour of specified section through a surface
Roughness width cutoff: greatest spacing of repetitive surface irregularities included in measurement
of roughness height
Must be greater than roughness width
SMMEE, IIT ROPAR
Page1
Tribology Lab (MEL456
MEL456)
2014
Flaws: irregularities such as scratches, holes, cracks, ridges, or hollows that do no
not follow regular
pattern
Lay: direction of predominant surface pattern caused by machining process
MEASUREMENT: Surface finish can be measured in two ways, contact and non--contact methods.
Contact methods involve dragging of a measurement stylus across the surface, the instruments are
called profilometers.
The most common method is to use diamond stylus profilometer. The surface is run perpendicular to
the lay of the surface. The probe usually traces along the straight line on a flat surface or in circul
circular
arc around a cylindrical surface. The length of the path it traces is called measurement length.
The wavelength of the lowest frequency filter that will be used to analyse the data is usually defined
as the sampling length.
SMMEE, IIT ROPAR
Page2
Tribology Lab (MEL456)
2014
The disadvantage of the profilometer is that it is not accurate when the size of the features of the
surface is close to the same size of the stylus. Another disadvantage is that profilometers have
difficulty detecting flaws of the same general size as the roughness of the surface.
Using a stylus profilometer provides a raw profile of surface roughness which will combine all
waviness, form profile and actual roughness profile. There will be very high frequencies in raw profile
due to presence of vibrations or debris on the surface.
These high frequencies are removed using form removal method, using another wave with a straight
line profile or polynomial profile.
Removing the waviness using filter cut-off frequency. This is all accomplished using digital filters.
Observations
Ra = Average Surface Roughness
Rz = Maximum Surface Roughness
Rq = R.M.S Surface Roughness
Take the readings of average roughness, maximum surface roughness and r.m.s surface roughness
for different samples on different grade Emery papers.
Sample no.
Ra
Rasd
Sample no.
Ra
Rasd
SMMEE, IIT ROPAR
Emery Paper Grade: .
Rq
Rqsd
Rz
Rzsd
Emery Paper Grade: .
Rq
Rqsd
Rz
Rzsd
Page3
Tribology Lab (MEL456)
Sample no.
Ra
Rasd
2014
Emery Paper Grade: .
Rq
Rqsd
Rz
Rzsd
Note: All measurements of roughness parameters are in micro-meter (m).
Results: Write the observed effect of polishing grade paper on surface roughness during the
experiment.
Either arithmetic average roughness height (Ra)
root mean square (Rq)
SMMEE, IIT ROPAR
Page4
Tribology Lab (MEL456)
2014
Experiment No.2
AIM: The study of deformation and evolution of stylus drag coefficient in case of bulk materials
during progressive load scratch test
MATERIAL USED: Aluminium, cast iron and copper
Machine Used: Scratch Tester (Make: Ducom, Model: TR-101) (Load range: upto 200N), software:
winducom
PARAMETERS:
1. Scratch speed
2. Scratch length
3. Loading rate
4. Surface roughness
THEORY:
Scratch hardness, abrasion resistance and wear of bulk materials can also be evaluated using
scratch test. The mechanical properties extracted during scratch test involve indentation of the
material moving relative to the indenter.
Scratch test can be done by moving the sample relative to the indenter tip. In the test
method, a diamond stylus of defined geometry (Rockwell C, a conical diamond indenter with an
included angle of 120 and a spherical tip radius of 200 m) is drawn across the flat polished surface
of a test specimen at a constant speed and a defined normal force (constant or progressively
increasing) for a defined distance. At the same time the lateral force needed to move the sample is
typically measured. The ratio of the lateral force to the normal force is defined as the stylus drag
coefficient.
Further, the results obtained from the scratch test depend on a number of parameters like
scratch speed, scratch length, loading rate, surface roughness and material properties. These factors
also influence the evolution of stylus drag coefficient during scratch test.
SMMEE, IIT ROPAR
Page5
Tribology Lab (MEL456)
2014
Measurement Principle
Sample under test is firmly held in a vice or chuck which is mounted on motorized translator
table. A stylus is pressed on surface with a controlled normal load (Fn). Servo control of Fn ensures
that it is precisely maintained at the desired level despite of surface waviness. Tangential force (Ft) at
the contact is measured while stylus scratches the surface. The ratio () of Ft and Fn is merely the
stylus drag coefficient. Energy required to damage the surface contributes an additional component
to Ft over friction, which increases this ratio.
Table and Observations:
Sample Material: _______
Scratch No. : _______
Loading rate: _____N/mm
Scratch speed: _______ (Constant)
Normal Force
(Fn)
Sample Material: _______
SMMEE, IIT ROPAR
Lateral Force
Stylus drag coefficient
(Ft)
(= Ft/ Fn)
Scratch No. : _______
Loading rate: _____N/mm
Page6
Tribology Lab (MEL456)
2014
Scratch speed: _______ (Constant)
Normal Force
(Fn)
Sample Material: _______
Lateral Force
Stylus drag coefficient
(Ft)
(= Ft/ Fn)
Scratch No. : _______
Loading rate: _____N/mm
Scratch speed: _______ (Constant)
Normal Force
(Fn)
Lateral Force
Stylus drag coefficient
(Ft)
(= Ft/ Fn)
Check the profile of the scratch using optical microscope, and paste the micrographs.
Graph:
Plot the graph between stylus drag coefficient and applied normal load (progressive)
corresponding to each loading rate and each different material.
Results:
Comment upon the variation in stylus drag coefficient with different loading rate for different
materials. Also comment on profile of the scratch using optical microscope.
SMMEE, IIT ROPAR
Page7
Tribology Lab (MEL456)
2014
Experiment No. 3
AIM: To study the effect of load on dry adhesive wear test (pin-on-disk test)
MATERIAL USED: mild steel, stainless steel disk
Machine Used: Universal Tribometer (Make: CETR, Model:)
PARAMETERS:
1. Disk speed: 1m/s
2. Effective radius (contact point of specimen): 20 mm
3. RPM: 477 (N = (60 v)/(D)
4. Vertical Load: 1Kgf and 2Kgf
THEORY:
In material science, 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.
Adhesive wear can be found between surfaces during frictional contact and generally refers
to unwanted displacement and attachment of wear debris and material compounds from one
surface to another. Two separate mechanisms operate between the surfaces.
Generally, adhesive wear occurs when two bodies slide over or are pressed into each other,
which promote material transfer. This can be described as plastic deformation of very small
fragments within the surface layers. The asperities or microscopic high points or surface
roughness found on each surface, define the severity on how fragments of oxides are pulled off and
adds to the other surface, partly due to strong adhesive forces between atoms but also due to
accumulation of energy in the plastic zone between the asperities during relative motion.
For our experiment, we are using pin on disk arrangement where pin highly finished surface
test specimen and disk of stainless steel which rotates and generates a relative motion.
SMMEE, IIT ROPAR
Page8
Tribology Lab (MEL456
MEL456)
2014
Schematic view of Pin-on-disk
Measurements:
Measure the initial weight of the test sample (pin) after proper cleaning with acetone in the
weighing balance. Hold the sample under test (pin) firmly in the holder and make close contact of the
pin with the disk. Initially set the trac
trackk diameter of the pin and fix the initial parameters such as disk
velocity, applied load on the pin,, time interval of 100 s.
s. Then calculate the rpm of the disk using the
formula
V = ( D N)/60
Where D track diameter of the pin
N no. of rpm of the disk
Enter the preset values of parameters in the software and then
then run the experiment
experiment. Take the weight
change of the pin after a run of 100 sec..
sec.
Our first specimen is mild steel (Hardness
(Hardne = 130 Hv)
Initial weight of specimen =
Table and Observations:
Sample Material: _______
SMMEE, IIT ROPAR
Disk velocity. : 1m/s
RPM : 477
Page9
Tribology Lab (MEL456)
2014
Applied Load on pin: _____N
S. No.
Weight (g)
Coeff. of friction
Frictional force (F)
()
1
2
3
4
5
Sample Material: _______
Disk velocity. : 1m/s
RPM : 477
Applied Load on pin: _____N
S.No.
Initial
weight (g)
Final
weight (g)
Weight
loss (g)
Vol. loss
Commu.
(mm3) =( wt. Wear
loss)/(density (mm3)
of sample)
Wear rate
(mm3/min)
1
2
3
4
5
Graph:
Plot the graph between
1. Cumulative wear (mm3) and time (sec) corresponding to each load on pin.
2. Cumulative wear rate (mm3/min.) and time (sec) corresponding to each load on pin.
Results:
Comment upon the trend of variation in wear and wear rate with respect to time at different applied
loads on the pin.
SMMEE, IIT ROPAR
Page10
Tribology Lab (MEL456)
2014
Experiment No. 4
AIM: To study the effect of rotational speed of disk on dry adhesive wear (pin-on-disk test)
MATERIAL USED: mild steel, stainless steel disk
Machine Used: Universal Tribometer (Make: CETR, Model:)
PARAMETERS:
1. Vertical Load:
2. Effective radius (contact point of specimen)
3. Disk speed
4. RPM: (N = (60 v)/(D)
THEORY:
In material science, 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.
Adhesive wear can be found between surfaces during frictional contact and generally refers
to unwanted displacement and attachment of wear debris and material compounds from one
surface to another. Two separate mechanisms operate between the surfaces.
Generally, adhesive wear occurs when two bodies slide over or are pressed into each other,
which promote material transfer. This can be described as plastic deformation of very small
fragments within the surface layers. The asperities or microscopic high points or surface
roughness found on each surface, define the severity on how fragments of oxides are pulled off and
adds to the other surface, partly due to strong adhesive forces between atoms but also due to
accumulation of energy in the plastic zone between the asperities during relative motion.
For our experiment, we are using pin on disk arrangement where pin highly finished surface
test specimen and disk of stainless steel which rotates and generates a relative motion.
SMMEE, IIT ROPAR
Page11
Tribology Lab (MEL456
MEL456)
2014
Schematic view of Pin-on-disk
Measurements:
Measure the initial weight of the test sample (pin) after proper cleaning with acetone in the
weighing balance.. Hold the sample under test (pin) firmly in the holder and make close contact of the
pin with the disk. Initially set the track diameter of the pin and fix the initial parameters such as
applied load on the pin,, time interval of 100 s, disk velocity. Then calculate the rpm of the disk using
the formula
V = ( D N)/60
Where D track diameter of the pin
N no. of rpm of the disk
Enter the preset values of parameters in the software and then run the experiment. Take the weight
change of the pin after a run of 100 sec..
sec.
Our first specimen is mild steel (Hardness = 130 Hv)
Initial weight of specimen =
Table and Observations:
Sample Material: _______; Effective radius = 20 mm; Applied Load on pin: 1 KgF = 9.8 N
SMMEE, IIT ROPAR
Page12
Tribology Lab (MEL456)
Disk velocity. : 1m/s
S. No.
2014
RPM : 477
Weight (g)
Coeff. of friction
Frictional force (F)
()
1
2
3
4
5
Sample Material: _______; Effective radius = 20 mm; Applied Load on pin: 1 KgF = 9.8 N
Disk velocity. : 2 m/s
RPM : 954
S.No.
Final
weight (g)
Initial
weight (g)
Weight
loss (g)
Vol. loss
Commu.
(mm3) =( wt. Wear
loss)/(density (mm3)
of sample)
Wear rate
(mm3/min)
1
2
3
4
5
Graph:
Plot the graph between
1. Cumulative wear (mm3) and time (sec) corresponding to each load on pin.
2. Cumulative wear rate (mm3/min.) and time (sec) corresponding to each load on pin.
Results:
Comment upon the trend of variation in wear and wear rate with respect to time at different applied
loads on the pin.
SMMEE, IIT ROPAR
Page13
Tribology Lab (MEL456)
2014
Experiment No. 5
AIM: To study the effect of load on adhesive wear under lubricating conditions (pin-on-disk test)
MATERIAL USED: mild steel, stainless steel disk, lubricating oil
Machine Used: Universal Tribometer (Make: CETR, Model:)
PARAMETERS:
1. Disk speed: 1m/s
2. Effective radius (contact point of specimen): 20 mm
3. RPM: 477 (N = (60 v)/(D)
4. Vertical Load: 1Kgf and 2Kgf
THEORY:
In material science, 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.
Adhesive wear can be found between surfaces during frictional contact and generally refers
to unwanted displacement and attachment of wear debris and material compounds from one
surface to another. Two separate mechanisms operate between the surfaces.
Generally, adhesive wear occurs when two bodies slide over or are pressed into each other,
which promote material transfer. This can be described as plastic deformation of very small
fragments within the surface layers. The asperities or microscopic high points or surface
roughness found on each surface, define the severity on how fragments of oxides are pulled off and
adds to the other surface, partly due to strong adhesive forces between atoms but also due to
accumulation of energy in the plastic zone between the asperities during relative motion.
For our experiment, we are using pin on disk arrangement where pin highly finished surface
test specimen and disk of stainless steel which rotates and generates a relative motion.
SMMEE, IIT ROPAR
Page14
Tribology Lab (MEL456
MEL456)
2014
Schematic view of Pin
Pin-on-disk under lubricating conditions
Measurements:
Measure the initial weight of the test sample (pin) after proper cleaning with acetone in the
weighing balance. Hold the sample under test (pin) firmly in the holder and make close contact of the
pin with the disk with lubrication layer in between.
between. Initially set the track diameter of the pin and fix
the initial parameters such as disk velocity, applied load on the pin,
pin, time interval of 100 ss. Then
calculate the rpm of the disk using the formula
V = ( D N)/60
Where D track diameter of the pin
N no. of rpm of the disk
Enter the preset values of parameters in the software and then run the experiment. Take the weight
change of the pin after a run of 100 sec..
sec.
Our first specimen is mild steel (Hardness
(Hardne = 130 Hv)
Initial weight of specimen =
SMMEE, IIT ROPAR
Page15
Tribology Lab (MEL456)
2014
Table and Observations:
Sample Material: _______
Disk velocity. : 1m/s
RPM : 477
Applied Load on pin: _____N
S. No.
Weight (g)
Coeff. of friction
Frictional force (F)
()
1
2
3
4
5
Sample Material: _______
Disk velocity. : 1m/s
RPM : 477
Applied Load on pin: _____N
S.No.
Initial
weight (g)
Final
weight (g)
Weight
loss (g)
Commu.
Vol. loss
(mm3) =( wt. Wear
loss)/(density (mm3)
of sample)
Wear rate
(mm3/min)
1
2
3
4
5
Density of mild steel = 7.85 g/cm3
Graph:
Plot the graph between
1. Cumulative wear (mm3) and time (sec) corresponding to each load on pin.
2. Cumulative wear rate (mm3/min.) and time (sec) corresponding to each load on pin.
SMMEE, IIT ROPAR
Page16
Tribology Lab (MEL456)
2014
Results:
Comment upon the trend of variation in wear and wear rate with respect to time at different applied
loads on the pin and also compare the results with dry adhesion wear (Experiment 3) for each test
sample.
Also monitor the wear behavior of the specimen using SEM analysis and try to find out the effect of
variation in applied load on wear and possible mechanism of wear.
SMMEE, IIT ROPAR
Page17
Tribology Lab (MEL456)
2014
Experiment No. 6
AIM: To study the effect of rotational speed of disk on th adhesive wear of specimen (pin-on-disk
test) under lubricating conditions
MATERIAL USED: mild steel, stainless steel disk, lubbricant
Machine Used: Universal Tribometer (Make: CETR, Model:)
PARAMETERS:
1. Vertical Load:
2. Effective radius (contact point of specimen)
3. Disk speed
4. RPM: (N = (60 v)/(D) 477 rpm and 954 rpm
THEORY:
In material science, 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.
Adhesive wear can be found between surfaces during frictional contact and generally refers
to unwanted displacement and attachment of wear debris and material compounds from one
surface to another. Two separate mechanisms operate between the surfaces.
Generally, adhesive wear occurs when two bodies slide over or are pressed into each other,
which promote material transfer. This can be described as plastic deformation of very small
fragments within the surface layers. The asperities or microscopic high points or surface
roughness found on each surface, define the severity on how fragments of oxides are pulled off and
adds to the other surface, partly due to strong adhesive forces between atoms but also due to
accumulation of energy in the plastic zone between the asperities during relative motion.
For our experiment, we are using pin on disk arrangement with lubricant, where pin highly
finished surface test specimen and disk of stainless steel which rotates and generates a relative
motion.
SMMEE, IIT ROPAR
Page18
Tribology Lab (MEL456
MEL456)
2014
Schematic view of Pin
Pin-on-disk under lubricating condition
Measurements:
Measure the initial weight of the test sample (pin) after proper cleaning with acetone in the
weighing balance. Hold the sample under test (pin) firmly in the
the holder and make close contact of the
pin with the disk with lubricant layer in between.
between. Initially set the track diameter of the pin and fix the
initial parameters such as applied load on the pin
pin, time interval of 100 s, disk velocity. Then calculate
the rpm of the disk using the formula
V = ( D N)/60
Where D track diameter of the pin
N no. of rpm of the disk
Enter the preset values of parameters in the software and then run the experiment. Take the weight
change of the pin after a run of 100 sec..
sec.
Our
ur first specimen is mild steel (Hardness = 130 Hv)
Initial weight of specimen =
SMMEE, IIT ROPAR
Page19
Tribology Lab (MEL456)
2014
Table and Observations:
Sample Material: _______; Effective radius = 20 mm; Applied Load on pin: 1 KgF = 9.8 N
Disk velocity. : 1m/s
S. No.
RPM : 477
Weight (g)
Coeff. of friction
Frictional force (F)
()
1
2
3
4
5
Sample Material: _______; Effective radius = 20 mm; Applied Load on pin: 1 KgF = 9.8 N
Disk velocity. : 2 m/s
RPM : 954
S.No.
Final
weight (g)
Initial
weight (g)
Weight
loss (g)
Commu.
Vol. loss
(mm3) =( wt. Wear
loss)/(density (mm3)
of sample)
Wear rate
(mm3/min)
1
2
3
4
5
Density of mild steel = 7.85 g/cm3
Graph:
Plot the graph between
1. Cumulative wear (mm3) and time (sec) corresponding to each load on pin.
2. Cumulative wear rate (mm3/min.) and time (sec) corresponding to each load on pin.
SMMEE, IIT ROPAR
Page20
Tribology Lab (MEL456)
2014
Results:
Comment upon the trend of variation in wear and wear rate with respect to time at different applied
loads on the pin under lubricating conditions and also compare the results with dry adhesion wear
(Experiment 4) for each test sample.
Also monitor the wear behavior of the specimen using SEM analysis and try to find out the effect of
variation in rotation speed under fixed applied load on wear and possible mechanism of wear.
SMMEE, IIT ROPAR
Page21
Tribology Lab (MEL456)
2014
Experiment No. 7
AIM: To study the slurry-erosion wear of ductile and brittle materials.
MATERIAL USED: Aluminium specimen, Cast iron specimen, sand particles < 300 m
Machine Used: Universal: Slurry Erosion Test Rig (In-house fabricated)
PARAMETERS:
1. Jet Velocity: 25 m/s. Nozzle diameter = 4 mm
2. Stand-off distance = 150 mm
3. Impingement angle = 90 and 30
4. Slurry concentration 3000 PPM
THEORY:
Erosion is the progressive loss of original material from a solid surface due to mechanical
interaction between surface and a fluid, a multi component fluid, or impinging liquid and/or solid
particles/ or both (ASTM-Standard (G40) 2013).
The phenomenon of loss of material from the surface of the components due to impact of
water and sand particles generally entrained in river waters is known as slurry erosion (SE). The
presence of sand/silt particles in the river waters that runs through the turbines causes significant
degradation of turbine blades and hence affects the performance of these hydroturbines.
The impacting particles gradually remove material from the surface through repeated
deformations and cutting action under the operating parameters. Slurry-erosive wear rate also depends
on the impingement angle, erodent wt.%, stand-off distance, jet velocity. Material that shows highest
erosion rate at low angles (15-30) is said to exhibit ductile mode of erosion. On the other hand, if
maximum erosion rate is observed at 90 angle, material loss is said to have taken place through brittle
erosion mode.
SMMEE, IIT ROPAR
Page22
Tribology Lab (MEL456)
2014
Schematic of slurry erosion test rig used for experimentation
Measurements:
Measure the initial weight of the test sample after proper cleaning with acetone in the
weighing balance. Hold the sample under test firmly in the holder of the slurry-erosion test rig and
start the pump after maintaining erodent % (0.3%) and pre-setting other parameters mentioned
above.
Take out the sample from the holder and measure the weight after each run after cleaning it
properly with acetone. Record the change weight after each run.
Table and Observations:
Table 1
Initial mass of specimen =
Sample Material: Aluminium (ductile); Jet velocity = 25 m/s; Stand-off distance: 150 mm;
Impingement angle = 90
Run
mass of
sample
(gm)
mass loss
(gm)
Volume Loss
(cm3) = mass
loss/density
Cumulative
vol. Loss (cm3)
Wear rate
(mm3/min.)
1
2
3
SMMEE, IIT ROPAR
Page23
Tribology Lab (MEL456)
2014
4
5
6
7
8
Density of Al = 2.7 g/cm3
Table 2
Initial mass of C.I. specimen =
Sample Material: Cast Iron (Brittle); Jet velocity = 25 m/s; Stand-off distance: 150 mm; Impingement
angle = 90
Run
mass of
sample
(gm)
mass loss
(gm)
Volume Loss
(cm3) = mass
loss/density
Cumulative
vol. Loss (cm3)
Wear rate
(mm3/min.)
1
2
3
4
5
6
7
8
Density of C.I. = 7.3 g/cm3
SMMEE, IIT ROPAR
Page24
Tribology Lab (MEL456)
2014
Table 3
Initial mass of specimen =
Sample Material: Aluminium (ductile); Jet velocity = 25 m/s; Stand-off distance: 150 mm;
Impingement angle = 30
Run
mass of
sample
(gm)
mass loss
(gm)
Volume Loss
(cm3) = mass
loss/density
Cumulative
vol. Loss (cm3)
Wear rate
(mm3/min.)
1
2
3
4
5
6
7
8
Density of Al = 2.7 g/cm3
Table 4
Initial mass of C.I. specimen =
Sample Material: Cast Iron (Brittle); Jet velocity = 25 m/s; Stand-off distance: 150 mm; Impingement
angle = 30
Run
mass of
sample
(gm)
mass loss
(gm)
Volume Loss
(cm3) = mass
loss/density
Cumulative
vol. Loss (cm3)
Wear rate
(mm3/min.)
1
2
3
4
5
SMMEE, IIT ROPAR
Page25
Tribology Lab (MEL456)
2014
6
7
8
Density of C.I. = 7.3 g/cm3
Graph:
Plot the graph between
1. Cumulative wear rate (mm3/min.) and time or run (sec) for both specimens (ductile and
brittle) at 90 impingement angle
2. Cumulative wear rate (mm3/min.) and time or run (sec) for both specimens (ductile and
brittle) at 30 impingement angle
3. Also plot Cumulative wear rate (mm3/min.) and time or run (sec) for Al and CI at two
impingement angles (90 and 30) separately.
Results:
Comment upon the trend of variation in wear rate with respect to time for ductile and brittle
materials and also discuss the effect of different impingement angles on the slurry-erosion
wear behavior of two different materials.
Also monitor the wear mechanism of the specimen using SEM analysis and try to find out the
effect of impingement angles on wear and possible mechanism of wear.
SMMEE, IIT ROPAR
Page26
