And SURFACE WEAR AND SURFACE FATIGUE

Terminology

Abrasive wear
One hard and sharp material sliding or rubbing against a
material that is softermaterial removal

Adhesive wear
Two materials in contact that transfer material from one to
the other; removed material adheres to mating surfaces

Surface Wear Surface Fatigue
Two surfaces contacting one another under pure rolling, or
rolling with a small amount of sliding in contact.


Examples of abrasive wear

1. polishing
2. tumbling
3. grinding

Examples of adhesive wear

1. scoring
2. cold welding

Examples of surface wear

1. ball and roller bearings
2. spur and helical gears
3. cams and roller followers



We will concentrate on surface fatigue, which requires that the
two contacting machine components are in pure rolling or rolling
with a small amount of sliding.

The challenge to the engineer in determining how surface fatigue
may impact a design, is to find a way to approximate the size and
shape of the contact area.

For example, a ball rolling along a horizontal plane, theoretically
contacts the plane at a single point. However, we know that this
cannot be true. For one thing, point loads do not really exist
they are just idealizations the engineer uses in appropriate
analysis. However, even if there were point loads, the material
from which the ball is made could not withstand the infinite
stress created by a point load and an infinitely small area.

To find the stress imposed by contact, we will need the
customary parameters: force and area. For the general case of
contact, the geometry of the contacting area is elliptical and the
pressure distribution over this area is considered a semi-
ellipsoid:


Contact pressure is a maximum at the center, and zero on the
edges of the ellipsoid. The total contact force at the center of
the ellipsoid is its volume:
max
3
2
abp F
contact
=

Maximum pressure, therefore, is:

ab
F
p
2
3
max
=

Average pressure, is the contact load, F, divided by the area.

.
2
3
max avg
p p
ab
F
p
average
=
=

To determine the contact area, we need to define geometry
constants that are dependent on radii of curvature of the
contacting bodies.



2
1
2 2 1 1
2
2 2
2
1 1
2 2 1 1
2 cos
'
1 1
'
1 1
2
'
1 1
'
1 1
2
1
'
1 1
'
1 1
2
1
(
(

|
|
.
|

\
|

|
|
.
|

\
|
+
|
|
.
|

\
|
+
|
|
.
|

\
|
=
|
|
.
|

\
|
+ + + =

R R R R R R R R
B
R R R R
A

is the angle between planes containing R
1
and R
2
.


Material constants must also be determined for bodies A and B.


Now the patch dimensions, a, and b, are found as follows:

( )
( )
3
2 1
3
2 1
4
3
4
3
A
m m F
k b
A
m m F
k a
b
a
+
=
+
=

k
a
and k
b
are found depending on the value of:

= cos
-1
(B/A) (SEE PAGE 476, NORTON)

The pressure distribution can now be determined from:

2 2
1 max
|
.
|

\
|

|
.
|

\
|
=
b
y
a
x
p p

At the contact surface the maximum normal stresses occur
along the centerline of the ellipsoid and are as follows:

max
max
max
) 2 1 ( 1 2
) 2 1 ( 1 2
p
p
b a
a
p
b a
b
z
y
x
=
(

+
+ =
(

+
+ =

For two cylinders in contact:

The contact patch half width:

1 2
2 m m F
a
A l
+
=
|
|
.
|

\
|
+ =
2 1
1 1
2
1
R R
A

Maximum load is determined to be:
max
2
alp F

=


Average pressure is:

avg
p
al
F
=
2


Pressure distribution is:
2
max
1
x
p p
a
| |
=
|
\ .


Maximum applied stresses:

max
max
2 p
p
y
z x


=
= =


For two spheres in contact:

The contact patch half width:

1 2
3
.375
m m
a F
A
+
=
|
|
.
|

\
|
+ =
2 1
1 1
2
1
R R
A

The maximum pressure is:

max
2
3
2
F
p
a
=

The pressure distribution is:

2 2
max 1
x y
p p
a a
| | | |
=
| |
\ . \ .

Stresses:

( )
3
max 3
2 2 2
3
max
2 2 2 2
1
(1 2 ) 2(1 )
2
z
x y
z
p
a z
p z z
a z a z

(
(
= +
(
+
(

(
| | | |
( = = + + +
| |
( + +
\ . \ .

IN CLASS ASSIGNMENT:

FIND THE PEAK PRESSURE BETWEEN A FLAT CAST IRON
SURFACE AND A 100 mm DIAMETER STEEL WHEEL, 5 mm WIDE
AND CARRYING A LOAD OF 500 N. THE CAST IRON HAS AN
ULTIMATE COMPRESSIVE STRENGTH, S
UC
, OF 750 M Pa AND ITS
YIELD STRESS S
y
, IS 350 M Pa. FIND THE FACTOR OF SAFETY.

YOUNGS MODULUS OF ELASTICITY FOR THE STEEL, E
S
, IS 207
G Pa AND THE POISSONS RATIO, , IS 0.29

YOUNGS MODULUS OF ELASTICITY FOR THE CAST IRON, E
CI
, IS
105 G Pa AND THE POISSONS RATIO, , IS 0.21