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Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.
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Source: STANDARD HANDBOOK OF MACHINE DESIGN
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WEAR
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Professor of Mechanical Engineering Department of Mechanical Engineering and Applied Mechanics The University of Michigan Ann Arbor, Michigan
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34.1 GENERAL PRINCIPLES IN DESIGN FOR WEAR RESISTANCE / 34.1 34.2 STEPS IN DESIGN FOR WEAR LIFE WITHOUT SELECTING MATERIALS / 34.4 34.3 WEAR EQUATIONS / 34.6 34.4 STEPS IN SELECTING MATERIALS FOR WEAR RESISTANCE / 34.7 34.5 MATERIAL-SELECTION PROCEDURE / 34.14 REFERENCES / 34.18 BIBLIOGRAPHY / 34.18
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There is no shorthand method of designing machinery for a specified wear life. Thus a step-by-step method is given for designers to follow. The method begins with an examination of worn parts of the type to be improved. The next step is an estimate of stresses, temperatures, and likely conditions of operation of the redesigned machinery. Material testing for wear resistance is discussed, and finally, a procedure is given for selecting materials for wear resistance.
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34.1 GENERAL PRINCIPLES IN DESIGN FOR WEAR RESISTANCE
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The wear life of mechanical components is affected by nearly as many variables as human life. Wearing surfaces are composed of substrate material, oxide, absorbed gas, and dirt. They respond to their environment, method of manufacture, and conditions of operation. They suffer acute and/or progressive degeneration, and they can often be partially rehabilitated by either a change in operating conditions or some intrusive action. The range of wearing components and devices is endless, including animal teeth and joints, cams, piston rings, tires, roads, brakes, dirt seals, liquid seals, gas seals, belts, floors, shoes, fabrics, electrical contacts, disks and tapes, tape heads, printer heads, tractor tracks, cannon barrels, rolling mills, dies, sheet products, forgings, ore crushers, conveyors, nuclear machinery, home appliances, sleeve bearings, rollingelement bearings, door hinges, zippers, drills, saws, razor blades, pump impellers, valve seats, pipe bends, stirring paddles, plastic molding screws and dies, and erasers. There is not a single universal approach to designing all these components for an acceptable wear life, but there are some rational design steps for some. There are no
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34.1 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.
WEAR 34.2
PERFORMANCE OF ENGINEERING MATERIALS
equations, handbooks, or material lists of broad use, but there are guidelines for some cases. Several will be given in this section. 34.1.1 Types, Appearances, and Mechanisms of Wear Wear is a loss or redistribution of surface material from its intended location by definition of the ASTM. Using this definition, we could develop a simple explanation for wear as occurring either by chemical reaction (that is, corrosion), by melting, or by mechanical straining. Thus to resist wear, a material should be selected to resist the preceding individual causes of wear or else the environment should be changed to reduce surface stress, temperature, or corrosiveness. The preceding three natural processes are too broad to be useful for material selection in light of the known properties of materials. A more detailed list of material properties appropriate to the topic of wear is given in Table 34.1. The preceding methods of material removal are usually not classified among the mechanisms of wear. Usually a mechanism is defined as a fundamental cause.Thus a fundamental argument might be that wear would not occur if there were no contact. If this were so, then mere contact could be called a mechanism of wear. However, if we define a mechanism as that which is capable of explanation by the laws of physics, chemistry, and derivative sciences, then mere contact becomes a statement of the condition in which surfaces exist and not a mechanism. But if stresses, lattice order, hydrogen-ion concentration, fugacity, or index of refraction were known, and if the effect of these variables on the wear rate were known, then a mechanism of wear has been given. Most terms used to describe wear therefore do not suggest a mechanism. Rather, most terms describe the condition under which wearing occurs or they describe the appearance of a worn surface. Terms of the former type include dry wear, metal-to-metal wear, hot wear, frictional wear, mechanical wear, and impact wear. Closer observation may elicit descriptions such as erosion, smooth
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