84

CHAPTER 6
WEAR TESTING MEASUREMENT

Wear is a process of removal of material from one or both of

two solid surfaces in solid state contact. As the wear is a surface removal
phenomenon and occurs mostly at outer surfaces, it is more appropriate and
economical to make surface modification of existing alloys than using the
wear resistant alloys.
6.1

EXPERIMENTAL PROCEDURE OF WEAR TEST

Dry sliding wear tests for different number of specimens was

conducted by using a pin-on-disc machine (Model: Wear & Friction

Monitor TR-20) supplied by DUCOM is shown in Figure 6.1.

Figure 6.1

Wear testing machine

85
The pin was held against the counter face of a rotating disc
(EN31 steel disc) with wear track diameter 60 mm. The pin was loaded
against the disc through a dead weight loading system. The wear test for all
specimens was conducted under the normal loads of 20N, 40N and a
sliding velocity of 2 and 4 m/s.
Wear tests were carried out for a total sliding distance of
approximately 3000 m under similar conditions as discussed above.
The pin samples were 30 mm in length and 12 mm in diameter. The
surfaces of the pin samples were slides using emery paper (80 grit size)
prior to test in order to ensure effective contact of fresh and flat surface
with the steel disc. The samples and wear track were cleaned with acetone
and weighed (up to an accuracy of 0.0001 gm using microbalance) prior to
and after each test. The wear rate was calculated from the height loss
technique and expressed in terms of wear volume loss per unit sliding
distance.
In this experiment, the test was conducted with the following
parameters:
1.

Load

2.

Speed

3.

Distance
In the present experiment the parameters such as speed, time

and load are kept constant throughout for all the experiments.
These parameters are given in Table 6.1.

86
Table 6.1

Parameter taken constant during sliding wear test

Pin material

Al, Al/C, Al/C/3B4C, Al/C/6B4C, Al/C/9B4C

Disc material

EN 31 steel

Pin dimension

Cylinder with diameter 12 mm height 30 mm

Sliding speed (m/s)

2, 4

Normal load

20, 40

Sliding distance (m) 3000

6.2

PIN-ON-DISC TEST
In this study, Pin-on-Disc testing method was used for

tribological characterization. The test procedure is as follows:

Initially, pin surface was made flat such that it will support the
load over its entire cross-section called first stage. This was
achieved by the surfaces of the pin sample ground using emery
paper (80 grit size) prior to testing
Run-in-wear was performed in the next stage/ second stage.
This stage avoids initial turbulent period associated with friction
and wear curves
Final stage/ third stage is the actual testing called constant/
steady state wear. This stage is the dynamic competition
between material transfer processes (transfer of material from
pin onto the disc and formation of wear debris and their
subsequent removal). Before the test, both the pin and disc were
cleaned with ethanol soaked cotton (Surappa et al 2007)

87
Before the start of each experiment, precautionary steps were
taken to make sure that the load was applied in normal direction. Figure 6.2
represents a schematic view of Pin-on-Disc setup.

Figure 6.2
6.2.1

Schematic views of the pin-on-disk apparatus

Weight Loss
The alloy and composite samples are cleaned thoroughly with

acetone. Each sample is then weighed using a digital balance having an

accuracy of 0.1 mg. After that, the sample is mounted on the pin holder
of the tribometer ready for wear test. For all experiments, the sliding
speeds are adjusted to 2 and 4 m/s.
The specific wear rates of the materials were obtained by
W= w

where W denotes specific wear rates in mm3/N-

w is the

weight loss measured in grams,

density of the worn material in g/mm3 and F is the applied load in N.
Weight loss of the alloy and composite samples in grams is shown in
Table 6.2.

88
Table 6.2

Data of cumulative wear loss of alloy and composites

Weight loss of alloy and composite
Sliding Speed 2m/s

S.No.

Sliding Speed 4m/s

Specimen

Initial

Final

Weight

Initial

Final

Weight

Name

weight

weight

loss

weight

weight

loss

(gm)

(gm)

(gm)

(gm)

(gm)

(gm)

LM 25

8.27122

8.246

0.02522 8.27122

8.2422 0.02902

LM 25 + C 8.09076

8.073

0.01776 8.09076

8.067

LM 25+C
+ 3%B4C

LM 25+C
+ 6%B4C

LM 25+C
+ 9%B4C

Figure 6.3

0.02376

8.16358 8.1494 0.01418 8.16358 8.14182 0.02176

8.00555 7.9927 0.01285 8.00555

7.985

0.02055

8.35572 8.3444 0.01132 8.35572 8.33629 0.01943

Weight loss of alloy and composite with 2 m/s

89

Figure 6.4

Weight loss of alloy and composite with 4 m/s

Figures 6.3 and 6.4 show the cumulative weight loss of the alloy
specimen after addition of graphite and boron carbide produced with the
help of stir casting technique. After addition of reinforced material the
sliding wear decreases significantly or says that weight loss is decreasing
as the graphite and boron carbide addition is increasing as compared to
matrix metal.
6.2.2

Wear Calculation
1.

Area
Cross sectional Area,

2.

Volume loss
Volume loss = Cross sectional Area x Height loss

3.

Wear rate
Wear rate = Volume loss / Sliding distance

90
4.

Wear resistance
Wear resistance = 1/ Wear rate

5.

Specific wear rate

Specific wear rate = Wear rate/load

6.2.3

Graphs
Table 6.3

Specimen

Specimen vs wear rate (mm3/m)

Wear rate (mm3/m)
2 m/s

4 m/s

6.58676928

40.49484735

g4

1.70248684

20.06797604

b3

1.27498018

17.07768475

b6

1.13700184

14.43573299

b9

0.90552998

8.4144354

Figure 6.5

Specimen vs wear rate (mm3/m) with 2 and 4 m/s

91
LM-25 and composites reinforced with boron carbide and
graphite particles of size ranges (200 meshes) at a load of 20, 40 N and
total time is 5 minutes. It can be attributed to the increase in hardness of the
material due to the presence of hard ceramic particles. Material removal in
a ductile material such as aluminium alloy matrix is due to the indentation
and ploughing action of the sliding disc which is made from hard steel
material (EN31 steel disc). Incorporation of hard graphite and B4C
particles in the Al alloy LM25 restricts such ploughing action of hard steel
counterpart and improves the wear resistance. Comparing the wear
properties of composites reinforced with graphite and B4C particles, it is
observed that despite their higher hardness, composites reinforced with
graphite and B4C particles show improved wear resistance as compared to
Al 6061 composites reinforced with SiC particles (Sanjeev Das et al 2006).
Table 6.4

Specimen

Specimen vs wear resistance (m/mm3)

Wear resistance (m/mm3)
2 m/s

4 m/s

0.151819497

0.0246945

g4

0.587376053

0.049830636

b3

0.784325918

0.058555947

b6

0.879506053

0.069272548

b9

1.104325668

0.118843387

92

Figure 6.6

Specimen vs wear resistance (m/mm3) with 2 and 4 m/s

Figure 6.6 shows the wear resistance as a function of time for

the LM25 and composites reinforced with boron carbide and graphite
particles of size ranges (200 meshes) at a load of 20, 40 N and total time is
5 minutes. It is observed that wear resistance of LM25 increased.
Table 6.5

Specimen

Specimen vs specific wear rate (mm3/Nm)

Specific wear rate (mm3/Nm)
2 m/s

4 m/s

0.329338464

2.024742368

g4

0.085124342

1.003398802

b3

0.063749009

0.853884238

b6

0.056850092

0.72178665

b9

0.045276499

0.42072177

93

Figure 6.7

Specimen vs specific wear rate (mm3/Nm) with 2 and 4

m/s
Figure 6.7 shows the specific wear rate as a function of time for

the LM25 and composites reinforced with boron carbide and graphite
particles of size ranges (200 mesh) at a load of 20, 40 N and total time is
5 minutes. It is observed that specific wear rate of LM25 decreased.
6.3

SEM MICRO GRAPH OF AL/4 WT% C WITH 2 M/S

The worn surface of the Al/4% graphite composite is shown in

Figure 6.8. It clearly exhibits the presence of deep permanent grooves and
fracture of the oxide layer, which may have caused the increase of wear
loss. However, the worn surfaces of the two composites exhibit finer
grooves and slight plastic deformation at the edges of the grooves.
The surface also appears to be smooth because of the graphite
reinforcement content.

94

(a)

(b)

(c)

(d)

Figure 6.8
6.3.1

Typical SEM micro graph of Al/4 wt% C with 2 m/s

SEM Micro Graph of Al/4 wt% C/3, 6, 9 wt% B4C with

2 m/s
The worn surfaces of the composite AlMMCs are shown in

Figures 6.9 to 6.11. Indistinct grooves and fine scratches were formed on
the worn surface. The wear mechanism are characterised by the formation
of the grooves, which are produced by the ploughing action of hard
asperities on the counter disc and hardened worn debris. Increase in boron
carbide would results in decrease in wear.

95

Figure 6.9

(a)

(b)

(c)

(d)

Typical SEM micro graph of Al/4 wt% C/ 3 wt % of B4C

with 2 m/s

(a)

(b)

96

(c)

(d)

Figure 6.10 Typical SEM micro graph of Al/4 wt% C/ 6 wt % of B4C

with 2 m/s

(a)

(b)

(c)

(d)

Figure 6.11 Typical SEM micro graph of Al/4 wt% C/ 9 wt % of B4C

with 2 m/s

97
6.3.2

SEM Micro Graph of Al/4 wt% C with 4 m/s

(a)

(b)

(c)

(d)

Figure 6.12 Typical SEM micro graph of Al/4 wt% C/ 3 with 4 m/s
The SEM image of aluminium composite was shown in
Figure 6.12. It shows that the worn surfaces of the two composites exhibit
finer grooves and slight plastic deformation at the edges of the grooves.
The surface also appears to be smooth because of the graphite
reinforcement content.

98
6.3.3

SEM Micro Graph of Al/4 wt% C/3, 6, 9 wt% B4C with

4 m/s

(a)

(b)

(c)

(d)

Figure 6.13 Typical SEM micro graph of Al/4 wt% C/ 3 wt % of B4C

with 4 m/s

(a)

(b)

99

(c)

(d)

Figure 6.14 Typical SEM micro graph of Al/4 wt% C/ 6 wt % of B4C

with 4 m/s
The SEM image of the aluminium composite is shown in
Figures 6.13 - 6.14. It provides that the presence of boron particle increases
the hardness and reduces the metal removal rate reduced to 7% when
compared to previous combination.

(a)

(b)

100

(c)

(d)

Figure 6.15 Typical SEM micro graph of Al/4 wt% C/ 9 wt % of B4C

with 4 m/s
At a sliding speed of 4 m/s, the wear rate shows a lowering
trend which indicates the less removal of material from the surface.
The micrograph shows the removal of material by delamination.
Apart from this, cracks are generated along with particle pull out at the
surface. Figure 6.15 shows the presence of a large number of grooves over
the entire surface.
6.4

WEAR BEHAVIOUR
The aim of the experimental plan is to find the important factors

and the combination of factors influencing the wear process to achieve the
minimum wear rate and COF. The experiments were developed based on
an OA, with the aim of relating the influence of sliding speed, applied load
and sliding distance. These design parameters are distinct and intrinsic
feature of the process that influence and determine the composite
performance. Taguchi recommends analyzing the S/N ratio using
conceptual approach that involves graphing the effects and visually
identifying the significant factors.

101
The above mentioned pin on disc test apparatus was used to
determine the sliding wear characteristics of the composite. Specimens of
size 12 mm diameter and 10 mm length were cut from the cast samples,
and then machined. The contact surface of the cast sample (pin) was made
flat so that it should be in contact with the rotating disk. During the test, the
pin was held pressed against a rotating EN31 carbon steel disc by applying
load that acts as a counterweight and balances the pin. The track diameter
was varied for each batch of experiments in the range of 50 mm to 100 mm
and the parameters such as the load, sliding speed and sliding distance was
varied in the range given in Table 6.6. An LVDT (load cell) on the lever
arm helps determine the wear at any point of time by monitoring the
movement of the arm. Once the surface in contact wears out, the load
pushes the arm to remain in contact with the disc. This movement of the
arm generates a signal which is used to determine the maximum wear and
the COF is monitored continuously as wear occurs and graphs between
COF and time was monitored for both of the specimens, i.e., aluminium
LM25, 4% of C, 3% of B4C, 6% of B4C, 9% of B4C.
Further, weight loss of each specimen was obtained by weighing
the specimen before and after the experiment by a single pan electronic
weighing machine with an accuracy of 0.0001g after thorough cleaning
with acetone solution.
The results for various combinations of parameters were
obtained by conducting the experiment as per the OA and shown in
Table 6.7. The measured results were analyzed using the commercial
software MINITAB 15 specifically used in DOE applications.

102
Table 6.6

6.5

Process parameters and levels

Sliding Speed, S

Sliding Distance, D

(m/s)

(m)

20

1000

40

2000

60

3000

Level

Load (N)

PLAN OF EXPERIMENTS
The dry sliding wear test was performed with three parameters:

applied load, sliding speed and sliding distance and varying them for three
levels. According to the rule that DOF for an OA should be greater than or
equal to the sum of those wear parameters, a L9 OA which has 9 rows and
3 columns was selected as shown below:
Table 6.7

Orthogonal array L9 of Taguchi

Experimental No.

Column 1

Column 2

Column 3

103
The selection of OA depends on three items in order of priority,
viz., the number of factors and their interactions, number of levels of the
factors and the desired experimental resolution or cost limitations. A total
of 9 experiments were performed based on the run order generated by the
Taguchi model. The response of the model is wear rate and COF. In OA,
the first column is assigned to applied loads, second column is assigned to
sliding speed and third column is assigned to sliding distance and the
remaining columns are assigned to their interactions. The objective of the
model is to minimize the wear rate and COF. The Signal to Noise (S/N)
ratio, which condenses the multiple data points within a trial, depends on
the type of characteristic being evaluated. In this study, smaller the better
characteristic was chosen to analyze the dry sliding wear resistance.
The response table for signal to noise ratios show the average of selected
characteristics of each level of the factor. This table includes the ranks
based on the delta statistics, which compares the relative value of the
effects. S/N ratio is a response which consolidates repetitions and the effect
of noise levels into one data point. Analysis of variance of the S/N ratio is
performed to identify the statistically significant parameters.
6.6

RESULTS AND DISCUSSIONS

The aim of the experimental plan is to find the important factors

and the combination of factors influencing the wear process to achieve the
minimum wear rate and COF. The experiments were developed based on
an OA, with the aim of relating the influence of sliding speed, applied load
and sliding distance. These design parameters are distinct and intrinsic
feature of the process that influence and determine the composite
performance. Taguchi recommends analyzing the S/N ratio using
conceptual approach that involves graphing the effects and visually
identifying the significant factors.

104
6.6.1

Results of Statistical Analysis of Experiments

The results for various combinations of parameters were

obtained by conducting the experiment as per the OA. The measured

results were analyzed using the commercial software MINITAB 15
specifically used in DOE applications. Tables 6.8 to 6.22 shows the
experimental results average of two repetitions for wear rate and COF.
To measure the quality characteristics, the experimental values are
transformed into a signal to noise ratio. The influence of control parameters
such as load, sliding speed and sliding distance on wear rate and COF has
been analyzed using signal to noise response table.
The ranking of process parameters using signal to noise ratios
obtained for different parameter levels for wear rate and COF are given for
aluminium LM25, 4% of C, 3% of B4C, 6% of B4C, 9% of B4C.
The control factors are statistically significant in the Signal to Noise ratio
and it could be observed that the sliding distance is a dominant parameter
on the wear rate and COF followed by applying load and sliding speed.
The analysis of these experimental results using S/N ratios gives the
optimum conditions resulting in minimum wear rate and COF.
6.6.2

Analysis of Variance Results for Wear Test

The experimental results were analyzed with ANOVA, which is

used to investigate the influence of the considered wear parameters,

namely, applied load, sliding speed and sliding distance that significantly
affects the performance measures. By performing analysis of variance, it
can be decided which independent factor dominates over the other and the
percentage contribution of that particular independent variable. Aluminium
LM25, 4% of C, 3% of B4C, 6% of B4C and 9% of B4C of the ANOVA

105
results for wear rate and COF for three factors varied at three levels and
interactions of those factors. This analysis is carried out for a significance
= 0.05, i.e. for a confidence level of 95%. Sources with a P-value
less than 0.05 were considered to have a statistically significant
contribution to the performance measures.
Table 6.8

S.No.

Responses table for S/N ratio for wear (Al LM 25)

Load Speed Distance

(N)

(m/s)

(m)

Wear
(mm3/m)

S/N
C.O.F

ratio
C.O.F

S/N
ratio
wear
rate

20

1000

0.006580 0.648

43.6355 3.76850

20

2000

0.005370 0.628

45.4005 4.04081

20

3000

0.003550 0.614

48.9954 4.23663

40

1000

0.010120 0.627

39.8964 4.05465

40

2000

0.007662 0.632

42.3132 3.98566

40

3000

0.006182 0.657

44.1774 3.64869

60

1000

0.013670 0.620

37.2846 4.15217

60

2000

0.012960 0.632

37.7479 3.98566

60

3000

0.011430 0.618

38.8391 4.18023

106
Table 6.9

Responses table for S/N ratio of coefficient of friction (Al

LM 25)
Level

Load (N)

Speed (m/s)

Distance (m)

46.01

40.27

40.27

42.13

41.82

41.82

37.96

44.00

44.00

Delta

8.05

3.73

3.73

Rank

Table 6.10

Main effects for plot for S/N ratios - coefficient of friction

Level

Load (N)

Speed (m/s)

Distance (m)

4.015

3.992

3.992

3.896

4.004

4.004

4.106

4.022

4.022

Delta

0.210

0.030

0.030

Rank

Figure 6.16 Main effects for plot for S/N ratios - wear rate

107

Figure 6.17 Main effects for plot for S/N ratios - wear rate

Figure 6.18 Main effects for plot for S/N ratios - coefficient of friction

108

Figure 6.19 Main effects for plot for S/N ratios - coefficient of friction
Table 6.11

Responses table for S/N ratio for wear (Al-LM 25/4% C)

20

1000

0.01702

0.527

S/N
Ratio
Wear
Rate
35.3808 5.56379

20

2000

0.01638

0.513

35.7137 5.79765

20

3000

0.01618

0.502

35.8204 5.98593

40

1000

0.05016

0.583

25.9928 4.68663

40

2000

0.04988

0.564

26.0415 4.97442

40

3000

0.04762

0.573

26.4442 4.83691

60

1000

0.09863

0.543

20.1198 5.30400

60

2000

0.96540

0.532

0.3059

60

3000

0.09321

0.521

20.6107 5.66325

Load Speed Distance

Wear
S.No.
C.O.F
(N) (m/s)
(m)
(mm3/m)

S/N
Ratio
c.o.f

5.48177

109
Table 6.12

Responses table for S/N ratio of coefficient of friction

(Al - LM 25/4% C)

Table 6.13

Level

Load(N)

Speed(m/s)

Distance(m)

35.64

27.16

27.16

26.16

20.69

20.69

13.68

27.63

27.63

Delta

21.96

6.94

6.94

Rank

Main effects for plot for S/N ratios - coefficient of friction

Level

Load(N)

Speed(m/s)

Distance(m)

5.782

5.185

5.185

4.833

5.418

5.418

5.483

5.495

5.495

Delta

0.950

0.311

0.311

Rank

Figure 6.20 Main effects for plot for S/N ratios - wear rate

110

Figure 6.21 Main effects for plot for S/N ratios - wear rate

Figure 6.22 Main effects for plot for S/N ratios - coefficient of friction

111

Figure 6.23 Main effects for plot for S/N ratios - coefficient of friction
Table 6.14

Responses table for S/N ratio for wear (Al LM 25/4%

C/3% B4C

S/N
Wear C.O.F
Ratio
S.No. Load Speed Distance
(N) (m/s)
(m)
(mm3/m)
Wear
Rate
1
20
2
1000
0.01279 0.571 37.8626 37.8626
S/N
ratio
C.O.F

20

2000

0.01209

0.563

38.3515 38.3515

20

3000

0.01194

0.554

38.4599 38.4599

40

1000

0.04269

0.586

27.3935 27.3935

40

2000

0.04154

0.574

27.6307 27.6307

40

3000

0.04021

0.536

27.9133 27.9133

60

1000

0.08263

0.526

21.6572 21.6572

60

2000

0.08154

0.516

21.7726 21.7726

60

3000

0.08012

0.552

21.9252 21.9252

112
Table 6.15

Responses table for S/N ratio of coefficient of friction (Al

LM 25/4% C/3% B4C))

Level

Load (N)

Speed (m/s)

Distance (m)

38.22

28.97

28.97

27.65

29.25

29.25

21.79

29.43

29.43

Delta

16.44

0.46

0.46

Rank

Table 6.16

Main effects for plot for S/N ratios - coefficient of friction

Level

Load (N)

Speed (m/s)

Distance (m)

38.22

28.97

28.97

27.95

29.25

29.25

21.79

29.43

29.43

Delta

16.44

0.46

0.46

Rank

Figure 6.24 Main effects for plot for S/N ratios - wear rate

113

Figure 6.25 Main effects for plot for S/N ratios - wear rate

Figure 6.26 Main effects for plot for S/N ratios coefficient of friction

114

Figure 6.27 Main effects for plot for S/N ratios - coefficient of friction
Table 6.17

Responses table for S/N ratio for wear (Al - LM 25/ 4%

C/ 6%B4 MMC)

20

1000

0.01370

0.623

S/N
S/N ratio
ratio
wear
C.O.F
rate
37.2656 37.2656

20

2000

0.01049

0.614

39.5845

39.5845

20

3000

0.00989

0.609

40.0961

40.0961

40

1000

0.03608

0.632

28.8547

28.8547

40

2000

0.03421

0.618

29.3169

29.3169

40

3000

0.03102

0.602

30.1672

30.1672

60

1000

0.07082

0.625

22.9969

22.9969

60

2000

0.69830

0.617

3.1192

3.1192

60

3000

0.68730

0.631

3.2571

3.2571

S.No.

Load Speed Distance Wear

C.O.F
(N) (m/s)
(m)
(mm3/m)

115
Table 6.18

Responses table for S/N ratio of coefficient of friction

(Al - LM 25/ 4% C/ 6%B4 MMC)

Level

Load(N)

Speed(m/s)

Distance(m)

38.982

29.706

29.706

29.446

24.007

24.007

9.761

24.507

24.507

Delta

29.191

5.699

5.699

Rank

Table 6.19

Main effects for plot for S/N ratios - coefficient of friction

Level

Load(N)

Speed(m/s)

Distance(m)

38.982

29.706

29.706

29.446

24.007

24.007

9.791

24.507

24.507

Delta

29.191

5.699

5.699

Rank

Figure 6.28 Main effects for plot for S/N ratios - wear rate

116

Figure 6.29 Main effects for plot for S/N ratios - wear rate

Figure 6.30 Main effects for plot for S/N ratios - coefficient of friction

117

Figure 6.31 Main effects for plot for S/N ratios - coefficient of friction
Table 6.20

Responses table for S/N ratio for wear (Al - LM 25/ 4% C

and 9% B4 MMC)

S/N
Load Speed Distance
Wear
Ratio
S.No.
C.O.F
(N) (m/s)
(m)
(mm3/m)
Wear
Rate
1
20
2
1000
0.00905 0.544 40.8670 40.8670
S/N
Ratio
C.O.F

20

2000

0.00896

0.536

40.9538 40.9538

20

3000

0.00884

0.526

41.0710 41.0710

40

1000

0.02103

0.588

33.5432 33.5432

40

2000

0.02094

0.564

33.5805 33.5805

40

3000

0.02086

0.553

33.6137 33.6137

60

1000

0.04302

0.579

27.3266 27.3266

60

2000

0.04104

0.553

27.7359 27.7359

60

3000

0.04092

0.543

27.7613 27.7613

118
Table 6.21

Responses table for S/N ratio of coefficient of friction (Al

LM 25/ 4% C and 9% B4 MMC)
Level

Load(N)

Speed(m/s)

Distance(m)

40.96

33.91

33.91

33.58

34.09

34.09

27.61

34.15

34.15

Delta

13.36

0.24

0.24

Rank

Figure 6.32 Main effects for plot for S/N ratios - wear rate

119
Table 6.22

Main effects for plot for S/N ratios - coefficient of friction

Level

Load(N)

Speed(m/s)

Distance(m)

40.96

33.91

33.91

33.58

34.09

34.09

27.61

34.15

34.15

Delta

13.36

0.24

0.24

Rank

Figure 6.33 Main effects for plot for S/N ratios - wear rate

120

Figure 6.34 Main effects for plot for S/N ratios coefficient of friction

Figure 6.35 Main effects for plot for S/N ratios coefficient of friction

121
The interaction terms have little or no effect on the coefficient
of friction & the pooled errors accounts only 0.5% & 1.4%. From the
analysis of variance & S/N ratio, it is inferred that the sliding distance has
the highest contribution on wear rate & COF followed by load & sliding
speed.
6.7

ANOVA

Table 6.23

Analysis of variance for wear (coded units) with LM 25

Source

DF

Main Effects

0.00009896 0.00009896 0.00004948 92.95 0.000

0.00000016 0.00000016 0.00000016

0.00000266 0.00000266 0.00000053

0.00010177

2-Way
Interactions
Residual
Error
Total

Seq SS

Adj SS

Adj MS

0.29

0.611

It can be observed that for AMMCs that the sliding distance has
the highest influence on wear rate. Hence sliding distance is an important
control factor to be taken into consideration during the wear process
followed by applied loads and sliding speed respectively, it can observe
that the load has the highest contribution, followed by sliding distance and
sliding speed for Al LM25 with reinforcement combination of MMCs.
The interaction terms have little or no effect on COF & the
pooled errors accounts. From the analysis of variance and S/N ratio, it is
inferred that the sliding distance has the highest contribution on wear rate
& COF followed by load & sliding speed. These values are shown in the
Tables 6.23 to 6.32.

122
Table 6.24
Source
Main
Effects

Analysis of variance for C.O.F (coded units) with LM 25

DF

Seq SS

Adj SS

Adj MS

0.00007267 0.00007267 0.00003633 0.15

0.867

0.00025600 0.00025600 0.00025600 1.03

0.356

Residual
Error

0.00124133 0.00124133 0.00024827

Total

0.00157000

2-Way
Interactions

Table 6.25
Source

Analysis of variance for wear (coded units) with LM25/C

DF

Main
Effects

Seq SS

Adj SS

Adj MS

0.204498 0.204498 0.102249

0.93

0.454

0.000005 0.000005 0.000005

0.00

0.995

Residual
Error

0.550155 0.550155 0.110031

Total

0.754658

2-Way
Interactions

Table 6.26

Analysis of variance for C.O.F (coded units) LM25/C

Source

DF

Main Effects

0.00102750 0.00102750 0.00051375 0.49

0.640

0.00000225 0.00000225 0.00000225 0.00

0.965

0.00525981 0.00525981 0.00105196

0.00628956

2-Way
Interactions
Residual
Error
Total

Seq SS

Adj SS

Adj MS

123
Table 6.27

Analysis of variance for wear (coded units) with

LM25/C/3B4C

Source

DF Seq SS

Adj SS

Adj MS

Main Effects 2

0.00717965 0.00717965 0.00358983 309.48 0.000

2-Way
Interactions

0.00000069 0.00000069 0.00000069

Residual
Error

0.00005800 0.00005800 0.00001160

Total

0.00723834

Table 6.28

0.06

0.817

Analysis of variance for C.O.F (coded units) with

LM25/C/3B4C

Source

DF

Main Effects

0.0017528 0.0017528 0.0008764

2.06

0.223

0.0004622 0.0004622 0.0004622

1.09

0.345

Residual
Error

0.0021278 0.0021278

Total

2-Way
Interactions

Table 6.29

Seq SS

Adj SS

Adj MS

0.0004256

Analysis of variance for wear (coded units) with

LM25/C/6B4C

Source

DF

Seq SS

Adj SS

Adj MS

Main Effects

0.39871

0.39871

0.19935

5.18

0.060

2-Way
Interactions

0.09619

0.09619

0.09619

2.50

0.175

Residual
Error

0.19241

0.19241

0.03848

Total

0.68731

124
Table 6.30

Analysis of variance for C.O.F (coded units) with

LM25/C/6B4C

Source

DF

Main Effects

2-Way
Interactions

0.0003622 0.0003622 0.00018108

2.81

0.152

0.0001000 0.0001000 0.00010000

1.55

0.268

Residual
Error

0.0003218 0.0003218 0.00006437

Total

0.0007840

Table 6.31

Source
Main

Seq SS

Adj SS

Adj MS

Analysis of variance for wear (coded units) with

LM25/C/9B4C
DF

Seq SS

Adj SS

Adj MS

0.00160594 0.00160594 0.00080297 103.08

0.000

2-Way
Interactions

0.00000089 0.00000089 0.00000089

0.749

Residual
Error

0.00003895 0.00003895 0.00000779

Total

0.00164578

Effects

Table 6.32

0.11

Analysis of variance for C.O.F (coded units) with

LM25/C/9B4C

Source

DF

Seq SS

Adj SS

Adj MS

Main
Effects

0.00211367 0.00211367 0.00105683 5.19

0.060

2-Way
Interactions

0.00008100 0.00008100 0.00008100 0.40

0.556

Residual
Error

0.00101733 0.00101733 0.00020347

Total

0.00321200