01 Tribology

CETIM, 2016
EUROTRANS Gear Training

TRIBOLOGY
Page 1

Quality and Failure
CETIM, 2016

TRIBOLOGY
Page 2
TRIBOLOGY FOR GEAR APPLICATIONS

Basic notions of tribology
Lubrication and lubricants
Operation of parallel axes gears
Tribology of gear mesh
Lubrication for gear transmissions
TESTING & MONITORING
Overview of the test methods and means
Monitoring of in-service reducers and gear assemblies
Monitoring of gear assemblies: lubricant analysis
Appearance and failure of gear teeth in operation
-1,52E-04
-1,76E-04
-2,00E-04
-5,60E-05
-1,04E-04
-8,00E-06
1,60E-05
-3,20E-05
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Tribology for gear applications
1,60E-04
1,36E-04
3,60E-05
7,20E-05
1,08E-04
Z(m)
1,44E-04
1,80E-04
0,00E+00-5,00E+07
1,00E+08-1,50E+08
5,00E+07-1,00E+08
2,50E+08-3,00E+08
2,00E+08-2,50E+08
1,50E+08-2,00E+08
3,50E+08-4,00E+08
3,00E+08-3,50E+08

TRIBOLOGY
Page 4
CETIM, 2016
Robert SHANDRO
1,84E-04
Michel OCTRUE
6,40E-05
MEC Dpt.
CETIM Senlis
8,80E-05
MEC Dpt.
CETIM Senlis
1,12E-04
Tl. : + 33 (0) 3 44 67 32 14
Fax : + 33 (0) 3 44 67 34 25
Courriel : robert.shandro@cetim.fr
4,00E+08
3,00E+08
3,50E+08
2,50E+08
Qeq (N/m2) 2,00E+08
1,50E+08
1,00E+08
5,00E+07
0,00E+00
-8,00E-05
X(m)
4,00E-05
Tl. : + 33 (0) 3 44 67 33 94
Fax : + 33 (0) 3 44 67 34 25
Courriel : michel.octrue@cetim.fr
Tribology Laboratory
Aid to design
Programs and data banks:
ESDU, TRIBOLOG, ACTIS
Aid to R&D
Standard and Simulation tests
Tribometers:
TGV, Pin-test, Plint TE-77
Aid to maintenance
Wear mechanisms analysis:
Observations by microscope
EDS analysis
Laser profile-meter
-1,28E-04
Tribology
What is Tribology ?
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TRIBOLOGY
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Tribology comes from the Greek word,

"tribos", meaning "rubbing" or "to rub", and
from the suffix, "ology" means "the study of".
Consequently, Tribology is the study of
rubbing, or "the study of things that rub"
Tribology
Individual Components
Assemblies or Products
Manufacturing Processes
Construction/Exploration
Natural Phenomena
Applications and Fields which Include

Modern Tribology
Tribology
Gears
Engines
Bearings
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TRIBOLOGY
Page 7
Brakes
Water Erosion
Pocket watch
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TBM
Wind Erosion
Tribology
Turning
Excavator

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Grinding
Tribology
Every Application has:
Surfaces in Contact,
and
in Relative Motion
(e.g. sliding, rolling, impacting)
Tribology
Science and technology to study
interactions of two surfaces in contact.
This includes the fields of :
Friction
Wear
Lubrication
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Tribology
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Economic importance
Possible saving: 26 billions Euro per year for
French industries
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Excavation costs
Tunnel diameter
Tunnel length
15 M
40 M
10 m
1 km

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TBM cost
30-45
k
Scientific aspects
Science in evolution
Science of multidiscipline
Wear is expensive
60 k/meter
One working day

(excavating or
not)
Scientific aspects
Friction
The First Recorded Tribologist
pouring lubricant (water?) in front
of the sledge in the transport of
the statue (2400 B.C)
Low relief at Kouyunjik, Assyrie, 700 BC
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Friction
Classic notions:
(Leonardo da Vinci, Amontons, Coulomb)
Friction force is proportional to load
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Friction coefficient is independent of contact area

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Friction coefficient is independent of sliding speed
Friction
Conceptual Definition of Friction
Microscopic forces of
mechanical Deformation
Friction is the resistance to

relative motion between two
bodies in contact.
Microscopic forces of
molecular Adhesion.
Mechanisms of friction
(Bowden & Tabor)
F
F(friction) = S(shearing)+ P(ploughing)
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Surface roughness destruction
= adhesion + deformation
Physi & chem linkage
(H: hardness, yield strength)
(A: real area, S: shear strength)
adhesion
F ad = A.S
P = A.H
ad = F ad/P = S/H = 0.2
2a
deformation
F def = H.a.x = H.x2.tan
def
= 2/.cot = 0.1 ( > 80)
P = H..a2/2 = 0.5*H..x2(tan )2
Friction is NOT a Material Property
Friction is a System Property
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When assessing a systems tribology need, we must consider:

Materials, Coating, Lubricant
Contact Area, Geometry, Stress
Surface Roughnesses
Sliding Speed
Sliding Mode (unidirectional, reciprocating,
multidirectional)
Duty Cycle (continuous contact, intermittent contact)
Environment (Temperature, Humidity),
Atmosphere (air, exhaust gases, vacuum)
Pb / Pb : 1,5
Cu / Cu : 0,7 - 1,4
Al / Al : 0,8 - 1,2
Ag / Ag : 0,8 - 1
Cr / Steel : 0,5
Pb / Steel : 1,2
Cu / Steel : 0,8
Al / Steel : 0,5
Ag / Steel : 0,5
Examples of static friction

coefficient
Cr / Cr: 0,4
Load
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Friction force
Compression strength
Causes of the high values:

1. Work hardening
2. Junction growth
= to / po
Three body friction model
Third body
Shear strength
Friction
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F = A (adhesion) + D (deformation) + C (third body)
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Deformation
Influence of surface roughness

on Friction coefficient
Adhesion
Roughness
0,5
Influence de Ra sur (PEHD1000/F16-ph)
2,5
Rugosit moyenne Ra (m)
Hob
frais
Mach.
rectif
Grind
3,5
Polished
polie
Sand
sabl
Balst 22
Ra Roughness influence on
1,5
Ra Mean Roughness (m)
Balst 4
Sand 4
sabl

0,7
0,6
0,5
0,4
0,3
0,2
0,1
5
4,5
4
3,5
3
2,5
2
1,5
1
0,5
0
0
Hob
frais
Mach.
rectif
Grind
Sand
sabl
2
Balst 2
Sand
sabl
Balst 4 4
polie
Polished
0,5
1,5
2,5
Rugosit
moyenne Ra
(m)
Ra Mean
Roughness
(m)
3,5
Influence de Ra surinfluence
U (PEHD1000/F16-ph)
Ra Roughness
on wear rate U
MeanCoefficient
coefficient
of friction (COF)
de frottement moyen
Wear rate
pin
U (m/min)
Taux for
d'usure
du pion
(m/min)
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4,5
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4,5
Wear modes
Adhesion (galling, scuffing, scoring)
Abrasion (polishing, ridging, scoring)
Erosion (cavitation)
Fretting (corrosion fretting)
Surface fatigue (pitting, scabbing, shelling,
spalling)
Corrosion (scaling, burning and rusting)
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TRIBOLOGY
Page 28
8%
6%
Wear modes in Cetim
8%
14%
17%
(Data from 560 cases in 1996, DMA, CETIM)
9%
6%
Wear modes in the world
9%
17%
Donnes mondiales
29%
18%
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Fretting
Grippage
Adhsion
Abrasion
rosion
Fatigue de contact
Autres (cavitation)
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Abrasion
Adhsion
Erosion
Fretting
Chimique
59%
P
2
1
X 700
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TRIBOLOGY
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CETIM, 2016
No transfer
Transfer from 2 to 1
Transfer from 1 to 2
Adhesion: mechanisms
Junctions between asperities

Material transfer
Surface damage
F
1
Adhesion
Pharmaceutical application
Adhesion on 316 L SS
Adhesion
Automobile application
x 2000, 15 KV
Adhesion
Automobile application
10 m
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Adhesion
Adhesion
Gear box
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Scuffing, Galling and Scoring

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Scuffing: Localized damage caused by the occurrence of

solid-phase welding between sliding surfaces, without
local surface melting.
Only solid surface welding in UK
Solid welding and following abrasion like scoring in USA
Galling = severe scuffing, Scuffing = mild galling
White: not compatible

Black: compatible
Ti Cu Au Ag Al Zn Mg Cd Sn Pb In

TRIBOLOGY
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CETIM, 2016
Scoring: The formation of severe scratches (grooves) in

the direction of sliding.
It may be caused both by adhesion or abrasion
Sometimes : Scoring = scuffing in USA
Scuffing should be avoided whenever possible.
W Mo Cr Co Ni Fe Nb Pt Zr
Tribological compatibility
of metals
In
Pb
Sn
Cd
Mg
Zn
Al
Ag
Au
Cu
Ti
Zr
Pt
Nb
Fe
Ni
Co
Cr
Mo
W
Load
Galling test ASTM G98
Pin in rotation
Matriau
Mobile
Material
Mobile
410
416*
430
440 C
304
316
17-4 PH
Duret
Brinell
BHN
Brinell
352
342
159
560
140
150
415
28
90
21
145
165
290
14
410 416
21
28
21
21
14
14
21
350
300
250
200
150
31
50
100
21
145
14
75
21
255
21
/3
16
31
/3
04
31
/4
316
14
14
165 290
14
14
21 250
14
14
14
14
14
14
430 440C 304

21
21
14
14
14
14
21
40
C
31
/4
16
31
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H
4P
7-

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/1
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17-4PH
(630)
21
14
21
21
14
14
14
Threshold galling stress of stainless steels (MPa)
Threshold galling stress (MPa)
PART 1
MATERIAL
Waukesha 88
Nitronic 32
Nitronic 50
Nitronic 60
Stellite 6B
Tribaloy 700
Brinell
Hardness
141
141
141
141
141
235
401
401
235
401
205
205
321
205
205
205
205
205
215
205
205
205
205
205
205
205
415
415
415
415
415
47 HRC
47 HRC
PART 1
MATERIAL
AISI 303
AISI 201
AISI 316
SAE 17-4 PH
20 Cr-80Ni
SAE 17-4 PH
Nitronic 32
Nitronic 32
SAE 17-4 PH
AISI 304
AISI 304
Nitronic 50
Nitronic 50
Nitronic 32
Nitronic 32
AISI 304
AISI 301
AISI 420
SAE 17-4 PH
SAE 17-4 PH
Nitronic 50
34CrNiMo6 (35 NCD 6)
AISI 660, SAE A286
20 Cr -80Ni
TA6V (Ti-6Al-4V)
Stellite 6B
AISI 304
AISI 316
Stellite 6B
Tribaloy 400
Tribaloy 700
Tribaloy 400
Tribaloy 400
Abrasion
Brinell
Hardness
180
202
200
405
180
380
401
401
140
140
205
205
321
401
235
140
169
472
313
332
205
448
270
180
332
415
140
140
415
54 HRC
47 HRC
54 HRC
47 HRC
Scuffing
contact
pressure
in MPa
350+
350+
350+
350+
350+
75
235
235
50
90
14
14
14
90
55
28
350+
350+
350+
350+
350+
350+
350+
250
350+
350+
240
25
350+
350+
350+
350+
185
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Threshold galling stress

of alloys (MPa)
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Process in which hard particles or protuberances are forced

against and moving along a solid surface
Hard protuberance
Hard particle
Abrasion
Abrasion (vane pomp)
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The harder
material scratches
the softer material
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Abrasion (tunnel boring machine)
Abrasion (tunnel boring machine)
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Abrasion (tunnel boring machine: ring wear)
60
W
0 200 400 600 8001000
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Be
40
Mo
Mild Steels (0.4%C)
Ti
Cr
Pure metal
gg
g Cold forming metals
20 CoFe
Steels after heat treatment
Ni
Cu
g
Zn
Al
Cd Pb
Vickers hardness
0
Tool steels
Influence of hardness
Relative resistance
Abrasion test (ASTM G132)
Pin-test
Sand
Specimen
Abrasion test (ASTM G-65)
Elastomer
coating
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load
Erosion
Four types of erosions:
Impacts by solid particles moved by fluid
Wear by flow of a fluid
Cavitation
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Angle of incidence 90
Erosion by impact of droplets
Erosion by particles impacts

Angle of incidence zero
Laminar flow
Turbulent flow
Turbulence generated by surface

roughness
Erosion by fertilizers particles
Erosion by particles in ink
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Erosion
1,00
0,5
0,1
0,05
0,01
wear = K..m.V2/2H
K: coefficient
: density of material
m: mass of particles
V: speed
H: hardness
Al
Ni
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Hardness after annealing

Hardness after erosion
Al
Cu
500 1000
4000
Vickers Hardness
Ni
Cu
Sn
Pb

Pb
Cd
Cd
100
Erosion (mm3.g-1)
60
90
Incidence angle ()
Brittle
Materials
Tough Materials
30
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Metals after annealing

Metals hardening by heat treatment
Metals after work hardening
25
W
20
Ta
Mo
15
Tool
steel
Ni
Acier

Cu
10
Steel 1045
Ag Fe
5 Al
Cd Mg
Vickers hardness
Bi Sn
0
200
400
600
800
Erosion wear
Influence of incidence angle
Erosion resistance (g.mm-3)
Erosion test
Test results
(sand, 350
500m, 45,
66m/s,
Sderberg)
Test of erosion
10
20
erosion rate (mg/h)
30
(water, 20kHz, 50m, CETIM)

TA6V
304
XC68
XC45
CuZn30
Al6016
40
50
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60
Cavitation
Bubbles collapse mechanisms
When the oil is submitted to

alternative low and hight
pressure, air and water vapor
bubbles appears due to a
partial vacuum condition.
Cavitation: Simulation by computer

Overpressure
on bubble
"Micro-jet"
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In over pressure condition, a "Micro-jet" form, creating cavities and

wear particles. In a turbulent flow condition, wear particles will erode
the bearing antifriction layer.
Cavitation: Plane bearing
Area of repeated micro-jets

impacts and erosion areas
Cavitation: Details
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Cavitation: Details cross section
Cavitation:Hydrodynamic bearing
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Cavitation: Details
Fretting
Small amplitude of movement (< 50 m)
High cycles
Load
Generation of debris (often these oxidize, so

sometimes called fretting corrosion
debris
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load
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Cracking or pitting

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Fretting:Bearing of subway escalator
Surface fatigue
Spalling or pitting
Surface fatigue:Contact stress

analysis
Surface fatigue: Cam of engine
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Surface fatigue: Rail

Micro-pitting
Spalling, Pitting, Scabbing

and Shelling
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Spalling: Separation of particles form a surface in the form

of flakes or chips (rolling elements bearing, gear teeth),
more extensive than pitting.
Pitting: Formation of small holes .
Scabbing: Formation of bulge in the surface, or spalling in
fracture mechanics.
Shelling: Spalling used in railway.
Corrosion wear
Corrosion or erosion?
Corrosion wear
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Case of a jib crane
Pin surface analysis
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MoS2 + H2O MoOS2 + H2

2 MoS2 + 7 O2 + H2O 2 MoO2,SO2 + 2 H2SO4
Scaling, Burning and Rusting

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Scaling: The formation of a thick oxide on the surface of

heated metal.

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Burning: In sliding contacts, the oxidation of a surface due

to local heating in an oxidizing environment.
Rusting: The formation hydrated oxides
Advanced tribological
analysis methods
Third body theory by M. Godet
Three phases of wear:
Detachment of particles
Third body life at the interface

Disposal of third body
Third body theory
Normalized speed
Sliding speed (m/s)
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Rolling
Fracture
Shearing
Elastic def
Mechanisms
Wear map of steel (by Lim and Ashby)
Normalized pressure
Wear map of alumina ceramics

(by Xu)
System analysis by Czhicos
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Response
Coefficient of friction
Tribological
system
Movement type
Noise, vibrations
Parameters
Load
Surface damages
Wear rate
Temperature
Interface
(fluid,
debris)
Speed
Temperature
Time

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CETIM, 2016

EUROTRANS Gear Training

EUROTRANS Gear Training

EUROTRANS Gear Training

TRIBOLOGY FOR GEAR APPLICATIONS

EUROTRANS Gear Training

Tribology for gear applications

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Qeq (N/m2) 2,00E+08

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EUROTRANS Gear Training

Tribology comes from the Greek word,

Applications and Fields which Include

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One working day

Low relief at Kouyunjik, Assyrie, 700 BC

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Friction force is proportional to load

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Friction coefficient is independent of contact area

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Friction coefficient is independent of sliding speed

Friction is the resistance to

F(friction) = S(shearing)+ P(ploughing)

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Surface roughness destruction

(H: hardness, yield strength)

(A: real area, S: shear strength)

ad = F ad/P = S/H = 0.2

= 2/.cot = 0.1 ( > 80)

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When assessing a systems tribology need, we must consider:

Examples of static friction

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Causes of the high values:

Three body friction model

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F = A (adhesion) + D (deformation) + C (third body)

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Influence of surface roughness

Influence de Ra sur (PEHD1000/F16-ph)

Rugosit moyenne Ra (m)

Ra Mean Roughness (m)

Influence of surface roughness

Influence of surface roughness

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Influence of surface roughness

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Wear modes in Cetim

Wear modes in the world

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