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Sustainable Design Research Centre, Bournemouth University, Fern Barrow, Talbot Campus, Poole, Dorset BH12 5BB, UK
Royal National Lifeboat Institution, Poole, UK
a r t i c l e
i n f o
Article history:
Received 19 October 2010
Received in revised form 17 May 2011
Accepted 4 June 2011
Available online 7 July 2011
Keywords:
Pin-on-disc
Adhesive wear
Friction
Model
ECR
Conductance
a b s t r a c t
A friction model is developed by considering the Coulomb friction model, a probabilistic
approach of wear prediction, the kinematics of the pin-on-disc configuration and the elastic
theory of bending. The model estimates the magnitude and direction of the frictional force, the
pin torque, the probability of asperity contact and the real area of contact distinguishing
between the part due to elastic and plastic asperity contacts respectively. Therefore, the
proposed model is suitable for the prediction of adhesive wear. It can be applied to metal
contacts for conductance characterisation through the plastically deformed asperities which is
of great interest for electrical contact resistance studies.
2011 Elsevier Ltd. All rights reserved.
1. Introduction
The pin-on-disc conguration is a common test for the study of sliding wear. The pin on disc tester measures the friction and
sliding wear properties of dry or lubricated surfaces of a variety of bulk materials and coatings [1]. For polymer testing, special pin
on disc machines is used to report the wear rates produced using different pin-on-disc congurations [2]. Two basic pin-on-disc
congurations are typically found depending of the loading of the pin along its major axis, which can be either in a direction
normal (horizontal conguration) or parallel (vertical conguration) with the axis of rotation of the disc[2]. If the rotation of the
pin is controlled by an actuator two new categories appear horizontal conguration with imposed pin rotation and a vertical
conguration with imposed pin rotation respectively [3]. The interest of the former machines is that kinematically they are
generalisation versions of the usual pin-on-disc machine where the pin is xed. The kinematic study of this machine was reported
in Ref. [4] and it is the fundamental pillar to devise the probabilistic friction and adhesive wear prediction models for the pin-ondisc apparatus.
In sliding contacts, adhesive wear mechanisms always occur [5]. Friction causes the asperities on one surface to become cold
welded to the other surface. The volume of material transferred for adhesive wear is proportional to the real area of contact and the
sliding distance. Several probabilistic models based on the Archard Adhesive Wear Law [6] for dry and lubricated contacts are
found in the literature [7]. A complete review of the probabilistic approach for wear prediction in lubricated sliding contacts can be
found in Ref. [8].
An initial study to model the friction is shown in Ref. [4]. Several improvements with respect to the former model are achieved
by a frictional model based on the following assumptions:
The pin is an elastic deformable body.
The real area of contact changes with the ratio between the angular velocity of the pin and the angular velocity of the disc.
The real area of contact depends on the compression and bending stresses acting on the pin.
Corresponding author. Tel.: + 44 1202 965560; fax: + 44 1202 965314.
E-mail address: atperez@bournemouth.ac.uk (A. Torres Prez).
0094-114X/$ see front matter 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mechmachtheory.2011.06.002
1756
Where
R
r
d
p
Distance from the centre of the pin Op to the centre of the disc Od (m)
Distance of a point P on the pin from its centre Op (m)
Angular velocity of the disc about its centre, Od (rad/s).
Angular velocity of the pin about its centre, Op (rad/s).
Fig. 1. Velocity vectors at point P within the pin with imposed rotation p in the pin-on-disc conguration. The system of reference (X,Y) is xed to the disc.
1757
Ar
N N
A
z
Ap = r
=
A
A A
A
Where p is the local relation between the real contact area and the contact area. This p is a parameter that can be
experimentally obtained.
According to the adhesion model of friction, each differential of the contact area (dA) contributes to the force acting on the pin
by the contribution of the differential real contact area (pdA) and the interfacial shear stress, (). The sense of the friction force is
opposite to the resultant force acting on the pin, where is the angle of the resultant force acting on the pin [4]. The friction forces
are shown in Eq. (4).
FRx = p cos dA = rp 2 p cosrddr
0 0
A
FRy = p sindA =
r
2
0p 0 p sinrddr
p d r cos
s
sin = q = s
2
u2 + s2
2d R2 + 2Rrd d p sin + d p r2
d R + d p r sin
u
cos = q
2
= s
2
u + s2
2d R2 + 2Rrd d p sin + d p r2
A
The previous expressions can be written in more elegant form using the parameter = p/d, Eq. (5).
r
p 2
R + 1r sinr
FRx = p q
drd
0 0
R2 + 2Rr1sin + 12 r2
p 2
1r cos
FRy = pq
2
drd
0 0
R + 2Rr1sin + 12 r2
The differential friction force which contributes to the differential friction torque is shown in Eq. (6):
d FR = dFRx x + dFRy y
d TF =
r d FR
p 2
R + 1r sinr sin
TF = pq
2
drd
0 0
R + 2Rr1sin + 12 r2
p 2
1r cos
pq
drd
2
0 0
R + 2Rr1sin + 12 r2
Assuming a uniform distribution of the real contact area, the y-component of the frictional force is 0. This conclusion can be
drawn visualising that the sum of all velocities along y direction is 0. This is because the eld of velocities along y is an odd
function in respect to the x component which fulls Eq. (9).
sx; y = sx; y
As a result, the y component of the force acting on the pin is 0 according to this model.
1758
The frictional torque is 0 for = 1 (The pin does not rotate in the pin on plate equivalent model)
Frictional torque is negative for b 1
Frictional torque is positive for N 1
The frictional torque T is proportional to the pin radius.
When b 0:
0.9
FRx/(rp2)
0.8
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
10
0.7
0.6
0.5
0.4
0.3
-2
10-2
100
101
10
103
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
rp/R
Fig. 2. Normalised x-component of the friction force (3D). [10 2,103],rp/R [0.009,0.9].
0.1
0.2
0.009
0.1
1759
1
0.9
0.8
FRx/(rp2)
0.7
0.6
0.5
rp/R=0.0090
0.4
rp/R=0.0454
r /R=0.1181
0.3
r /R=0.2454
p
0.2
rp/R=0.5000
rp/R=0.6272
0.1
r /R=0.7545
p
r /R=0.9000
p
0
10-2
10-1
100
101
102
103
Fig. 3. Normalised x-component of the friction force (2D). [10 2,103],rp/R [0.009,0.9].
2
2
-3
Normalised friction torque required to rotate the pin: TF /(rp) when p =1 (N/m ) and R=2510 (m)
x10-3
14
FRx/(rp2)
x10-3
12
14
12
10
8
6
4
2
0
-2
-4
10
8
6
4
2
0
103
102
101
100
10-1
10
-2
0.009 0.1
0.2
0.3
0.4
0.5
0.6
0.7
-2
0.8
-4
rp/R
Fig. 4. Normalised friction torque (3D). [10 2,103],rp/R [0.009,0.9].
2
2
-3
Normalised friction torque required to rotate the pin: T F /(rp) when p=1 (N/m ) and R=2510 (m)
0.015
r /R=0.0090
p
r /R=0.0454
p
0.01
rp/R=0.1181
rp/R=0.2454
rp/R=0.5000
r /R=0.6272
TF/(rp2)
0.005
rp/R=0.7545
rp/R=0.9000
-0.005
-0.01
10-2
10-1
100
101
102
103
1760
0.9
FRx/(rp2)
0.8
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.7
0.6
0.5
0.4
0.3
-2
-10
-10-1
-100
-101
-102
-103
0.9
0.8
0.7
0.6
0.5
0.4
0.2
0.3
0.1
0.2
0.009
0.1
rp/R
Fig. 6. Normalised x-component of the friction force (3D). [ 103,10 2],rp/R [0.009,0.9].
2
2
-3
Normalised friction force: F Rx /(rp) when p=1 (N/m ) and R=2510 (m)
1
0.9
0.8
FRx/(r2p)
0.7
0.6
0.5
r /R=0.0090
p
r /R=0.0454
p
0.4
r /R=0.1181
p
rp/R=0.2454
0.3
rp/R=0.5000
0.2
rp/R=0.6272
rp/R=0.7545
0.1
r /R=0.9000
p
0
-10-2
-10-1
-100
-101
-102
-103
Fig. 7. Normalised x-component of the friction force (2D). [ 103,10 2],rp/R [0.009,0.9].
2
2
-3
Normalised friction torque required to rotate the pin: T F /(rp) when p=1 (N/m ) and R=2510 (m)
x10-3
14
x10-3
12
14
TF/(rp2)
12
10
10
8
6
4
2
4
-103
-10
-101
-10
-10-1
-10-2
0.009
0.1
0.2
0.3
0.4
0.5
0.6
0.7
rp/R
Fig. 8. Normalised friction torque (3D). [ 103,10 2],rp/R [0.009,0.9].
0.8
0.9
0.015
1761
2
2
-3
Normalised friction torque required to rotate the pin: TF /(rp) when p=1 (N/m ) and R=2510 (m)
r /R=0.0090
p
r /R=0.0454
p
r /R=0.1181
p
r /R=0.2454
p
r /R=0.5000
p
0.01
r /R=0.6272
p
TF/(rp2)
rp/R=0.7545
rp/R=0.9000
0.005
0
10-2
10-1
100
101
102
103
6
Experimental data LDPE
LDPE model fit
Experimental data PP
PP model fit
Experimental data PMMA
PMMA model fit
FRx(N)
4
3
2
1
0
10-2
10-1
100
R
Fig. 10. Friction force FRx.
101
1762
0.6
Experimental data LDPE
0.5
0.4
FRy(N)
0.3
0.2
0.1
0
10-2
10-1
100
101
100
101
R
Fig. 11. Friction force FRy.
1.2
x10-3
1.1
1
0.9
TF(Nm)
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
10-2
10-1
R
Fig. 12. Pin friction torque TF.
Table 1
Experimental data obtained from [4].
Experimental conditions
FRx (N)
FRy (N)
TF (Nm)
Experimental conditions
FRx (N)
FRy (N)
TF (Nm)
Experimental conditions
FRx (N)
FRy (N)
TF (Nm)
PP (polypropylene)
Normal load = 10 N, R = 2510 3(m), = 13106(N/m2)
1 = 0.08
2 = 0.8
3=2
2.4
1.2
1
0.02
0.15
0.20
5
5
510
2210
2910 5
LDPE (low density polyethylene)
Normal load = 10 N, R = 2510 3(m), = 8.1106(N/m2)
1 = 0.15
2 = 1.5
3 = 2.5
4.5
3
2.5
0.03
0.14
0.18
610 5
4710 5
5710 5
PMMA (polymethyl metacrylate)
Normal load = 10 N, R = 2510 3(m), = 1.95108(N/m2)
1 = 0.035
2 = 0.35
3=1
5.4
4.3
3.1
0.05
0.24
0.35
410 5
2710 5
3410 5
4=8
0.75
0.23
3810 5
Type of regression
'power2'
'pchipinterp'
'pchipinterp'
4=7
1.4
0.24
7710 5
Type of regression
'exp2'
'pchipinterp'
'smoothingspline'
4 = 3.5
1.8
0.46
3810 5
Type of regression
'exp2'
'pchipinterp'
'pchipinterp'
1763
8
Experimental data PP
Model prediction PP
Experimental data LDPE
Model prediction LDPE
Experimental data PMMA
Model prediction PMMA
7
6
FRx(N)
5
4
3
2
1
0
10-2
10-1
100
101
R
Fig. 13. Friction force FRx acting on the pin. Positive .
12
x 10-3
Model prediction PP
Model prediction LDPE
Model prediction PMMA
10
TF(Nm)
8
6
4
2
0
-2
10-2
10-1
100
101
R
Fig. 14. Friction torque acting on the pin. Positive .
Table 2
Best values of p in least mean square sense (LMSE) for [10].
Optimisation LMSE
PP
LDPE
PMMA
2.504210 3
9.084610 3
4.243510 4
elastic depending on the contact pressure. A suitable criterion to classify the type of contact area consists on selecting an elastic
asperity contact if the contact pressure is less than 0.6H, H is the hardness and plastic asperity contact otherwise [9].
The PAC and torque predictions for this model are shown in Figs. 17, 18 for positive values and Figs. 19,20 for negative
values respectively. The torque predictions have the same tendencies of the experimental data.
1764
8
Model prediction PP
Model prediction LDPE
Model prediction PMMA
Experimental data PP
Model prediction PP
Experimental data LDPE
7
6
FRx(N)
5
4
3
2
1
0
10-2
10-1
100
101
R
Fig. 15. Friction force FRx acting on the pin. Negative .
0.012
Model prediction PP
Model prediction LDPE
Model prediction PMMA
0.01
TF(Nm)
0.008
0.006
0.004
0.002
0
-10-2
-10-1
-100
-101
R
Fig. 16. Friction torque acting on the pin. Negative .
A non uniform distribution of contact stress leads to a non uniform distribution of probability of asperity contacts within the contact
area. Therefore, this new distribution can produce a friction force in the direction of y-axis different to 0. The contact pressure is
obtained using the theory of elastic bending [10]. A bar under a bending couple has the stresses shown in Eq. (10).
z =
E
x y = x = xy = xz = yz = 0
R
10
where R is the radius of curvature and E is the Young's modulus. The value of z is a plane that contains the y axis.
The moment created by the distribution of z is given by Eq. (11).
My = z xdA
11
Table 3
Best values of p in least mean square sense (LMSE) for [ 10,10 2].
Optimisation LMSE
p
PP
2.681310
LDPE
PMMA
9.088110 3
4.416410 4
1765
0.012
0.01
0.008
0.006
PAC
TF(Nm)
0.004
Model prediction PP
Model prediction LDPE
Model prediction PMMA
PAC (p) --> PP
0.002
0
10-2
10-1
0
101
100
R
Fig. 17. Probability of asperity contact (PAC) is a function of . Obtained from the experimental x-component of the friction force acting on the pin. Positive values.
The determination of k1 is shown in Eq. (12). Fig. 22 helps to visualise the equivalent force system.
M = 0
h
k 2
k 2 rp
k 4
2
= z xdA = 1 x dA = 1 r cos rdrd = 1 rp
2
rp
rp 0 0
rp 4
12
+ FR
Although the contact pressure in contact theory is normally expressed as positive, in elasticity a compressive stress is expressed
as negative. In this study the contact pressure is positive.
Using the Principle of Superposition it is possible to divide the stress distribution in two different problems: the compression
and the bending, Fig. 21.
As a result, the contact pressure can be expressed as shown in Eq. (13):
z = k0 +
k1
rp
13
14
14
x 10-3
12
Model prediction PP
Model prediction LDPE
Model prediction PMMA
10
8
TF(Nm)
k0 =
6
4
2
0
-2
10-2
10-1
100
101
R
Fig. 18. Friction torque predictions if the PAC varies with . Positive values.
1766
0.015
Model prediction PP
Model prediction LDPE
Model prediction PMMA
PAC (p) --> PP
PAC (p) --> LDPE
PAC (p) --> PMMA
0.01
0.005
PAC
FRx(N)
0
10-2
10-1
0
101
100
R
Fig. 19. Probability of asperity contact (PAC) is a function of . Obtained from the experimental x-component of the friction force acting on the pin. Negative
values.
0.014
Model prediction PP
Model prediction LDPE
Model prediction PMMA
0.012
TF(Nm)
0.01
0.008
0.006
0.004
0.002
0
-10-2
-10-1
-100
-101
R
Fig. 20. Friction torque predictions if the PAC varies with . Negative values.
Fig. 21. Elastic model of the pin to obtain contact pressure. Principle of Superposition. L is the applied load.
1767
where L is the load, h is the height of the pin and FR is the resultant friction force.
It is possible to calculate a limit of height or a limit of friction force to ensure the whole pin surface is making contact with the
disc. This limitation is expressed in Eq. (15).
0k0 +
k1
x
rp
15
The condition of contacting surfaces separation occurs in the point where x is equal to the pin radius (rp), Eq. (16).
k0 k1
L
2F h Lrp
FR h
R3
2
r2p
rp
16
This limitation implies a pin can be separated from the disc if its height or the friction force is high enough.
The stress distribution on the counterface of the pin can be generalised for a resultant friction force that it is not parallel to the x-axis.
R is the angle between the x-axis and the resultant of the experimental friction force, hence the contact stress distribution is:
z = k0 +
k1
rp
cosR r
17
The friction forces and friction pin torque for this new model can be expressed as shown in Eq. (18):
r
p 2
R + 1r sinr
FRx = PACq
drd
2
0 0
R + 2Rr1sin + 12 r2
p 2
1r cos
FRy = PACq
2
drd
0 0
R + 2Rr1sin + 12 r2
p 2
R + 1r sinr sin
TF = PACq
2
drd
0 0
R + 2Rr1sin + 12 r2
18
p 2
1r cos
PACq
drd
2
0 0
R + 2Rr1sin + 12 r2
Fy
Fx
The probability of asperity contact for this model is shown in Eq. (19).
R = arctg
8
>
>
>
>
>
>
>
!
>
>
>
k1
>
>
p
k
+
r
cos
>
0
R
>
>
rp
<
PAC
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
:
!
k
if k0 + 1 r cosR 0
rp
r 0; rp 0; 2
The main improvements of this model in respect to the previous one are the predictions of:
The y component of the friction force.
The contact stress distribution within the pin.
19
1768
6
Model prediction PP
Model prediction LDPE
Model prediction PMMA
Max.PAC --> PP
Max.PAC --> LDPE
Max.PAC --> PMMA
0.025
0.02
3
0.015
2
PAC
FRx(N)
0.03
0.01
0.005
0
10-2
10-1
0
101
100
R
Fig. 23. Maximum value of the probability of asperity contact (PAC) is a function of . Obtained from the experimental x-component of the friction force acting on
the pin. Positive values.
q
1 + 3 2 L ke Ae + kp Ap
20
Where
the predicted volume of adhesive wear.
the coefcient of friction.
the fractional lm defect.
the sliding distance.
is the wear coefcient for non welded junctions
1.2
1
0.8
0.6
FRy(N)
L
ke
Model prediction PP
Model prediction LDPE
Model prediction PMMA
Experimental data PP
Model prediction PP
Experimental data LDPE
0.4
0.2
0
-0.2
-0.4
10-2
10-1
100
101
R
Fig. 24. Predictions of the y-component of the frictional force. Positive values.
16
1769
x 10-3
14
Model prediction PP
Model prediction LDPE
Model prediction PMMA
12
FRy(N)
10
8
6
4
2
0
-2
10-2
10-1
100
101
R
Fig. 25. Friction torque predictions of the proposed model. Positive values.
kp
Ae
Ap
Another application of the proposed model is the study of the electrical contact resistance (ECR). This is of special interest for
the assessment of the boundary layer formation under mixed and boundary lubrication regimes. The study can be carried out
assuming only the plastic asperity contacts are the main contributors for the nal conductance [9] as shown in Eq. (21).
Gp =
Ap
21
Where
0.03
0.025
3
0.015
2
0.01
0
-10-2
PAC
FRx(N)
0.02
0.005
-10-1
-100
0
-101
R
Fig. 26. Maximum value of the probability of asperity contact (PAC) is a function of . Obtained from the experimental x-component of the friction force acting on
the pin. Negative values.
1770
1.4
1.2
Model prediction PP
Model prediction LDPE
Model prediction PMMA
Max.PAC --> PP
Max.PAC --> LDPE
Max.PAC --> PMMA
FRy(N)
1
0.8
0.6
0.4
0.2
0
-10-2
-10-1
-100
-101
R
Fig. 27. Predictions of the y-component of the frictional force. Negative values.
values are shown in Figs. 2628. The model predicts a y-component different than 0 but there is certain disagreement with the
experimental data.
The PAC values within the pin are shown in Fig. 29 for Polypropylene (PP) and positive values.
The proposed model results are in better agreement with the experimental data than the predictions of the previous models.
The combination of a variable PAC within the area of contact for different experimental conditions (d, p, rp, R, h, R) makes this
model a useful tool for the evaluation of adhesive wear models.
9. Conclusions
A new model has been developed using the kinematics of the pin-on-disc apparatus, the use of the probabilistic approach for
wear prediction and elastic bending theory which improves the previous study [4]. This new model predicts the different
components of the resultant force acting on the pin, the pin torque, the stress distribution along the contact area, the probability of
asperity contact and the real area of contact distinguishing between elastic and plastic area of contact. The proposed model is of
interest in electrical contact resistance (ECR) studies because it can predict the conductance using the predicted real contact area
due to plastic asperity contacts.
This model will be used in future work to assess the asperity contact theory and adhesion models since it predicts the pressure
distribution and the plastic and elastic real area distribution within the contact.
0.012
Model prediction PP
Model prediction LDPE
Model prediction PMMA
0.01
TF(Nm)
0.008
0.006
0.004
0.002
0
-10-2
-10-1
-100
-101
R
Fig. 28. Friction torque predictions of the proposed model. Negative values.
1771
1772
V
Op
p
u,
s
d
Od
R
r
rp
A
dA
Ar
p
FR
dFR
TF
dTF
PAC
H
M
k0, k1
L
h
FR
V
L
ke
kp
Ae
Ap
Gp
Acknowledgements
The authors wish to thank the Engineering and Physical Sciences Research Council (EPSRC) and the Royal National Lifeboat
Institution (RNLI) for funding this work.
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