Dynamic evolution of interface roughness during friction and wear processes

K.J Kubiak,L Dubar,A Dubois,T.G Mathia,M Bigerelle

doi:10.1002/sca.21082

Abstract

Dynamic evolution of surface roughness and influence of initial roughness (S(a) = 0.282-6.73 µm) during friction and wear processes has been analyzed experimentally. The mirror polished and rough surfaces (28 samples in total) have been prepared by surface polishing on Ti-6Al-4V and AISI 1045 samples. Friction and wear have been tested in classical sphere/plane configuration using linear reciprocating tribometer with very small displacement from 130 to 200 µm. After an initial period of rapid degradation, dynamic evolution of surface roughness converges to certain level specific to a given tribosystem. However, roughness at such dynamic interface is still increasing and analysis of initial roughness influence revealed that to certain extent, a rheology effect of interface can be observed and dynamic evolution of roughness will depend on initial condition and history of interface roughness evolution. Multiscale analysis shows that morphology created in wear process is composed from nano, micro, and macro scale roughness. Therefore, mechanical parts working under very severe contact conditions, like rotor/blade contact, screws, clutch, etc. with poor initial surface finishing are susceptible to have much shorter lifetime than a quality finished parts.

Highlights

Initial surface roughness can have significant influence on friction and wear processes in tribological contacts under fretting conditions (Kubiak and Mathia, 2009; Sokoloff et al, 2012; Stahlmann et al, 2012)
Dynamic evolution of surface morphology has been evaluated by analysis of surface profiles after tests with
Analysis of dynamic evolution of roughness during friction process shows that the degradation of material in abrasive wear process rapidly change the roughness in tribological contact

Summary

Introduction

Initial surface roughness can have significant influence on friction and wear processes in tribological contacts under fretting conditions (Kubiak and Mathia, 2009; Sokoloff et al, 2012; Stahlmann et al, 2012). Damage induced by fretting is considered as a plague for modern industry and can be found in many engineering applications (Fu et al, 1998) for example in transport industry, electrical contacts, bridge cable lines, rotor/blade contact of jet engine, and in dental implants and brackets (Rapiejko et al, 2009), hip and knee prosthesis. Degradation of such contact is a dynamic process and conditions at interface are constantly changing (Jerier and Molinari, 2012). In this article we will focus on initial roughness and its influence on friction and wear process dynamics

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Conclusion