Wear Mechanism

SHIVAJI CHOUDHURY

Wear
Wear is the undesirable removal of
solids from a sliding or rolling
component.

Wear analysis
In analyzing a wear problem in a machine,
it is necessary to determine the kind of
wear that occurred.
Analysis requires microscopic examination
of the worn area and a close look at the
used lubricant.
Wear is generally proportional to the
applied load and the amount of sliding.

Types of wear :

1.Adhesive Wear
2.Abrasive Wear
3.Erosion Wear
4.Polishing Wear
5.Contact fatigue
6.Corrosive wear

7.Electro-Corrosive
wear
8.Fretting wear
9.Electrical
discharge wear
10.Cavitation
damage
11.False brinelling

1.Adhesive Wear
Adhesive Wear the removal of material due to
adhesion between surfaces.
1. Mild adhesion is the removal of surface films,
such as oxides, at a low rate.
2. Severe adhesion the removal of metal due to
tearing, breaking, and melting of metallic junctions.
This leads to scuffing or galling of the surfaces and
even seizure.

1.1.Adhesive Wear -Prevention

MECHANICAL
1. Reduce load, speed
and temperature
2. Improve oil cooling
3. Use compatible
metals
4. Apply surface
coatings such as
phosphating

LUBRICANT
1. Use more viscous
oil to separate
surfaces
2. Use "extreme
pressure" (antiscuff) additives
such as a sulfurphosphorous or
borate compounds

2.Abrasive Wear
Abrasive Wear the cutting of furrows on a
surface by hard particles, (for example, sand
particles between contact surfaces, or hard
asperities on an opposing surface).
Cause: Hard particles contaminating oil Hard
metal with rough surface against soft. metal

2.1.Abrasive Wear-Prevention
MECHANICAL
1. Remove abrasive by
improved air and oil
filtering, clean oil
handling practices,
improved seals, flushing
and frequent oil changes
2. Minimize shot peening,
beading, or sand blasting
of surfaces because
abrasives cannot be
completely removed
3. Increase hardness of
metal surfaces

LUBRICANT
1. Use oil free of
abrasive particles
2. Use more viscous
oil

3.Erosion Wear
Erosive Wear the cutting of
furrows on a surface by hard particles
contained in a fluid traveling at high
velocity.

3.1.Erosion Wear -Prevention

MECHANICAL
1. Remove abrasive by
improved air and oil
filtering, clean oil
handling practices,
improved seals, flushing
and frequent oil changes
2. Reduce impact angle to
less than 15 degrees
3. Increase hardness of
metal surfaces

LUBRICANT
1. Use oil free of abrasive
Particles
2. Use more viscous oil

4.Polishing Wear
Polishing Wear the continuous removal
of surface films, laid down via a chemical
reaction from an additive in oil or by very
fine hard particles in the lubricant, and so
on.
Polishing wear is characterized by very
shiny, very smooth, mirror like metal
surfaces. Fine abrasives wear away the
surface films as they form and reform.

4.1.Polishing Wear -Prevention

MECHANICAL
1. none

LUBRICANT
1. Choose less
chemically active
additive

2. Remove corrosive

contaminant
3. Remove abrasive

5.Contact fatigue
Contact Fatigue the cracking,
pitting, and spalling of a surface in
sequence due to cyclic stresses in a
contact.
Contact fatigue is most common in
rolling element bearings, gear teeth,
and cams.

5.1.Contact fatigue- Prevention

MECHANICAL
1. Reduce contact
pressures and
frequency of cyclic
stress.
2. Use high quality
vacuum melted
steels.
3. Use less abusive
surface finish

LUBRICANT
1. Use clean, dry oil.
2. Use more viscous
oil
3. Use oil with
higher-pressure
viscosity coefficient

6.Corrosive wear
Corrosive Wear the removal of corrosion
products from a surface by motion, such as the
rubbing off of rust.
cause :water contamination most common
cause

6.1.Corrosive wear-Prevention
MECHANICAL
1. Use more corrosion
resistant metal
(not stainless)
2. Reduce operating
temperature
3. Eliminate corrosive
material

LUBRICANT
1. Remove corrosive
material such as
too chemically
active additive and
contaminates
2. Use improved
corrosion inhibitor
3. Use fresh oil

7.Electro-Corrosive wear
Electro-Corrosive Wear the
removal of metal by dissolution in a
corrosive liquid with the aid of electric
currents.
One source of currents is streaming
potential from high velocity fluids.
The oil serves as the electrolyte.

7.1.Electro-Corrosive wearprevention
MECHANICAL
1. Decrease liquid
velocity and
velocity gradients
2. Use corrosionresistant metals
3. Eliminate stray
currents

LUBRICANT
1. Decrease or
increase electrical
conductivity of
lubricants or
hydraulic fluids

8.Fretting wear
Fretting Wear localized wear of
lubricated surfaces due to
reciprocating sliding of extremely low
amplitude because of vibration.

8.1.Fretting wear -Prevention

MECHANICAL

LUBRICANT

1. Reduce or stop
vibration by tighter
fit or higher load .
2. Improve lubrication
between surfaces by
rougher (then
honed) surface finish

1. Use oil of lower

viscosity
2. Relubricate
frequently
3. Use oxidation
inhibitors in oil

9.Electrical discharge wear

Electrical Discharge Wear the
removal of molten metal from
surfaces due to electrical sparks
between them.
High static voltages are sometimes
generated by large rotating
machinery and these are relieved by
sparking to regions of lower potential.

9.1.Electrical discharge wearPrevention

MECHANICAL
1. Improve electrical
insulation of bearings

2. Degauss magnetic
rotating parts
3. Install brushes on
shaft
4. Improve machine
grounding

LUBRICANT
1. Use of oil of higher
electrical conductivity

10.Cavitation damage
Cavitation Damage the removal of
material due to cracking and pitting caused
by high energy implosions of vacuous
cavities in a cavitating liquid.
Liquids cavitate when suddenly subjected
to low pressures.
Removal of metal by vapor cavity implosion
in a cavitating liquid.

10.1.Cavitation damage-Prevention
MECHANICAL
1. Use hard, tough
metals, such as tool
steel
2. Reduce vibration, flow
velocities and
pressures
3. Avoid restriction and
obstructions to liquid
flow

LUBRICANT
1. Avoid low vapor
pressure, aerated, wet
oils
2. Use noncorrosive oils

11.False Brinelling
False Brinelling localized wear in
lubricated rolling element bearings
due to slight rocking motion of rollers
against raceways.

11.1.False Brinelling- Prevention

MECHANICAL
1. Reduce or
eliminate impact
2. Rotate bearings
occasionally

LUBRICANT
1. Change viscosity

Microscopic Observation
(Wear debris analysis)
(a) Rubbing wear,
(b) cutting wear,
(c) fatigue wear,
(d) scuffing wear,
(e) corrosive
wear,
(f) abrasive wear.

Bearing damage classifications:

ISO 15243

Thanking you