EMM4303
Tribology
Tribology Test Methods
Overview of Tribology
Our focus for this course
Overview of Tribology
Classification of Tribology Tests
Tribometer
First tribometer sketch by Leonardo da Vinci (1452-1519)
Test Methods
Factors Important in a Tribological Test (generally known as Friction test, Wear test):
One must consider the following factors:
▪ The measuring device should simulate the tribosystem as closely as possible
▪ The geometry of the test specimens should resemble the system of interest
▪ Conditions (contact pressure, speed, temperature, humidity, etc) of the test must
resemble the ones encountered in the system of interest
▪ Samples should be cleaned and prepared for the test consistently
▪ The surface roughness of the test samples should be the same as in the evaluated
tribosystem
▪ How to prepare samples for friction test
Friction forces often depend significantly on the surface characteristics of the tested
samples. Thus, the surface finish of the test specimens must be representative.
Technique used to clean the surfaces prior to the test may influence the results. For
instance, using solvents like acetone and ethanol for cleaning the metallic surfaces.
Tribology Test Standards
➢ Material and lubricant related test
ASTM G-99 Pin on disk test
ASTM D2670, D3233 Pin and Vee Block Tester
ASTM D2266, DIN 51350/5, IP 239 Four ball wear tests
ASTM D2266, D3702, D4172 Multi-specimen tester
ASTM A514 Pin on drum wear tester
ASTM G77 Block On Ring Test
ASTM G98 Galling resistance test of materials
ASTM G133 Reciprocating Ball-on-Flat Sliding Wear
ASTM G83-96 Wear test using cross cylinder apparatus
ASTM D5707 Measuring Friction and Wear Properties of Lubricating Grease using SRV Test
ASTM D5706 Determining Extreme Pressure Properties of Lubricating Greases using SRV test
Friction Tests of Piston Ring and Cylinder Liner Materials Under Lubricated
ASTM G181-11
Conditions
[Link]
Tribology Test Standards
➢ Grease related test
ASTM D2596, DIN 51350/4 Four ball weld tests
ASTM D1831 Roll stability tests for greases
DIN 51813 Solid matter content in lubricating greases
ASTM D4170 Fretting Test for lubricant greases
ASTM D2509 – D2782 Timken Test for grease
➢ Erosion related test
ASTM G76 Air Jet Erosion Tester
ASTM G-73 Liquid impingement erosion test
ASTM G134 Cavitating liquid jet erosion test
ASTM G32 Cavitation Erosion Using Vibratory
➢ Corrosion related test
ASTM G119 Test for studying wear and corrosion synergy
[Link]
Laboratory Tribometer
Classification of Tribology Tests
Tribology Test Methods
Laboratory tribometer: Pin-on-disk (POD)
• ASTM G99 compliant
Tribology Test Methods
Laboratory tribometer: Pin-on-disk (POD)
• ASTM G99 compliant
Tribology Test Methods
Laboratory tribometer: Pin-on-disk (POD)
• ASTM G99 compliant
Ff = Friction Force (N)
µ = Coefficient of friction (No units)
FN = Normal Force* (N)
* The normal force FN is usually the same as the pin weight, except for when something
is pulling up or pushing down on the test pin even though it is on a flat surface.
Tribology Test Methods
Laboratory tribometer: Ball-on-ring (BOR)
• ASTM G77 compliant
Tribology Test Methods
Laboratory tribometer: Ball-on-ring (BOR)
• ASTM G77 compliant
Tribology Test Methods
Laboratory tribometer: Ball-on-ring (BOR)
• ASTM G77 compliant
Seyfert C. (2014)
Tribology Test Methods
Laboratory tribometer: Four-ball tribometer
• ASTM G77 compliant
Tribology Test Methods
Laboratory tribometer: Four-ball tribometer
• ASTM G77 compliant
What is the difference?
Tribology Test Methods
Laboratory tribometer: Four-ball tribometer
• ASTM G77 compliant Worn Surface of Steel Ball
Test Lubricants
M.F. Abdollah (2021)
Tribology Test Methods
Laboratory tribometer: Four-ball tribometer
• ASTM G77 compliant
Seyfert C. (2014)
Stribeck’s Curve
Laboratory tribometer: Friction coefficient µ
• Derive friction equation and plot the graph below
𝜂𝒱 𝜂𝒱
@
𝐹𝑁 𝑝
Minimum Film Thickness
Laboratory tribometer: Minimum film thickness hmin
• Derive necessary equation and plot the graph below
𝜂𝒱 𝜂𝒱
@
𝐹𝑁 𝑝
Stribeck’s Curve
Laboratory tribometer: Friction coefficient µ & Minimum film thickness hmin
M.F. Abdollah (2021)
Minimum Film Thickness
Laboratory tribometer: Minimum film thickness hmin
• Lubricant film strength Ls
• Maximum Pressure Pmax as in Hertz contact theory
M.F. Abdollah (2021)
Minimum Film Thickness
Laboratory tribometer: Minimum film thickness hmin
• Minimum film thickness hmin as in Hamrock and Dowson model
M.F. Abdollah (2021)
Film Thickness Parameter
Laboratory tribometer: Dimensionless film parameter ʎ
• When one knows the minimum film thickness hmin of a contact, it should be at least confronted to
the roughness of the mating solids.
• The value of dimensionless film parameter ʎ is an indicator of the lubrication regime as in Hamrock:
[Link]
Overview of Film Thickness
The presence of a liquid film that separated your vehicle or body from the ground, literally lifting up your
mass and reducing dramatically the friction that usually allows you to control your vehicle or body. This film
separation is the result of hydrodynamic pressure* and can occur between two rigid bodies; it
is hydrodynamic lubrication (HL). However, the lubricated systems mentioned earlier (your car tyres and your
foot/sole) have something in common: they deform under load and when this deformation has a similar order
or magnitude to the film thickness, it is called elastohydrodynamic lubrication (EHL) and it also results in a film
separation between bodies. This full separation even under load is often something looked after to design
almost wear-less systems with reduced friction.
Diagram of steel-steel oil lubricated contact
(left), wheel on road aquaplaning (centre)
and human foot slipping on a wet smooth
floor (right) – liquid film thickness are
oversized for clarity purposes.
[Link]
Model/Bench Test
for Tribology
Classification of Tribology Tests
Tribology Test Methods
Bench / Model test: Journal Bearing TM282 Journal Bearing Friction Test
Tribology Test Methods
Bench / Model test: Journal Bearing
At Rest Start up During Operation
Tribology Test Methods
Bench / Model test: Journal Bearing
• Wear caused either by inadequate lubrication, wear debris or vibration
(a) (b) (c)
Solid contact with the Material transformation A completely worn off
shaft results in a polished (dark areas) due to bearing surface exposes the
shiny smooth surface intense wear subjacent lining material
Philipp Bergmann, 2018
Stribeck’s Curve
Bench / Model test: Friction coefficient µ
• Derive friction equation and plot the graph below
𝜂𝒱 𝜂𝒱
@
𝐹𝑁 𝑝
Stribeck’s Curve
How to categorize “Hydrodynamic” for Lubrication in Journal Bearings?
Minimum Film Thickness
Bench / Model test: Minimum film thickness hmin
• Derive necessary equation and plot the graph below
𝜂𝒱 𝜂𝒱
@
𝐹𝑁 𝑝
Friction
Bench / Model test: Frictional moment Mf
Moment of friction
Forces on the shaft
Friction
Bench / Model test: Frictional moment Mf
Forces on the shaft
Friction
Bench / Model test: Friction force Ff
Forces on the shaft
Friction
Bench / Model test: Friction coefficient µ
Forces on the shaft
Tribology Test Methods for High Contact Pressure
Bench / Model test: Metal Forming
Peter Groche, 2018
Tribology Test Methods for High Contact Pressure
Bench / Model test: Metal Forming
Peter Groche, 2018
Bench Test
emulates
Real Tribological Conditions
Classification of Tribology Tests
Tribology test Methods
Sliding length 0 - 300 mm
Sliding speed
0 - 100 mm/s
• Tribo-tester for metal forming (mm/s)
Load, Axis 1 (kN) 0 - 100 kN
Universal Sheet Tribo-tester Load, Axis 2 (kN) 0 - 50 kN
Hydraulic Clamping system
pumping station (Axis 1)
Compression Tension
(Axis 2) (Axis 1)
M.H. Sulaiman (2019)
Tribology test Methods
• Tribo-tester for metal forming Sliding length 0 - 500 mm
Sliding speed (mm/s) 0 - 150 mm/s
Cycle time (spm) 0 - 95 spm
Universal Sheet Tribo-tester (UST2)
Load, Axis 1 (kN) 0 - 50 kN
Load, Axis 2 (kN) 0 - 50 kN
Load, Axis 3 (kN) 0 - 100 kN
Axis 3 PLC
Coil
Axis 1
Cutting station Carriage Tool Guiding and
lubrication
Axis 2
E. Ceron et. al (2014)
Tribology test Methods
Drawing with
• Tribo-tester for metal forming
tangential
compression
Bending-under-tension
Pin-on-disk
Universal Sheet Tribo-tester (UST2) Bending with
tangential
compression
Strip drawing
with flat dies
Axis 3 PLC
Coil
Strip
reduction
Axis 1 Draw bead
test
test
Carriage Tool Guiding and
Strip
Cutting station tension
test
lubrication Hemispherical stretching
Axis 2
E. Ceron et. al (2014)
Tribology test Methods
• Example 1: Industrial case involving sheet metal forming
Stainless steel bearing
plate for pump hydraulics
1. Deep 2. Reverse 3. Redrawing 4. Punching 5. Collar drawing
drawing drawing & ironing
Process route
Üstünyagiz, E. at. al (2018)
Tribology test Methods
• Example 1: Industrial case involving sheet metal forming
Strip reduction
Punch
Galling leading to scoring
of workpiece surface Blank
Die
Punch
Blank
Strip material: EN 1.4301
Lubricant: Rhenus 722086 Die
Üstünyagiz, E. at. al (2018)
Tribology test Methods
• Example 1: Industrial case involving sheet metal forming
Üstünyagiz, E. at. al (2018)
Tribology test Methods
• Example 2: Industrial case involving sheet metal forming
➢ On-line production testing of new tribo-systems is costly and unflexible.
➢ Off-line production gives much higher flexibility.
Bending Under Tension test simulates Deep Drawing
E. Ceron et. al (2014)
Tribology test Methods
• Example 2: Industrial case involving sheet metal forming
Fb
Tool pin can be
preheated to max.
80˚C
Ff
Friction measured directly by
piezo-electric torque
transducer
E. Ceron et. al (2014)
Tribology test Methods
• Example 2: Industrial case involving sheet metal forming
Off-line testing
➢ Breakdown of lubricant causes gradual build-up of workpiece material on the die shoulder
➢ Multiple tests (1500 strokes) are needed to check whether this occurs or not
E. Ceron et. al (2014)
Tribology test Methods
• Example 2: Industrial case involving sheet metal forming
E. Ceron et. al (2014)
Tribology test Methods
• Example 2: Industrial case involving sheet metal forming
Stainless steel EN 1.4301 Stainless steel LDX 2101
Lub: rhenus SU 116A Lub: rhenus SU 116A
30 10000 60 15000
25 50
8000
torque [Nm]
torque [Nm]
40 10000
force [N]
20
force [N]
6000
15 30
4000 20 5000
10
EN 1.4301
5 2000 10
EN 1.4162
0 0 0 0
0 500 1000 1500 0 10 20 30 40
stroke stroke
torque drawing force torque drawing force
Good Bad
performance performance
E. Ceron et. al (2014)
Tribology test Methods
• Example 3: Industrial case involving railroad braking systems
Dynamometer test
Harun Yanar et. al (2022)
Tribology test Methods
• Example 3: Industrial case involving railroad braking systems
Harun Yanar et. al (2022)
Tribology test Methods
• Example 3: Industrial case involving railroad braking systems
Harun Yanar et. al (2022)
Tribology test Methods
• Example 3: Industrial case involving railroad braking systems
8
7
3 5 6
2 4
1
5 6
7 8
1 2 3 4
Harun Yanar et. al (2022)
Field Test
Classification of Tribology Tests
Tribology test Methods
• Field test: Automotive braking systems
Test car specifications
Talib Ria Jaafar (2012)
Tribology test Methods
• Field test: Automotive braking systems
➢ Modified ECE R13 test procedure
Talib Ria Jaafar (2012)
Tribology test Methods
• Field test: Automotive braking systems
➢ Modified ECE R13 test procedure
Talib Ria Jaafar (2012)
Tribology test Methods
• Field test: Automotive braking systems
➢ Modified ECE R13 test procedure
Talib Ria Jaafar (2012)
Tribology test Methods
• Field test: Automotive braking systems
Fade test result Recovery test result
Pressure Pressure
Temperature Temperature
Talib Ria Jaafar (2012)
Quiz
QUIZ
• Classify the tribology test below
Thank You
