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Wear Analysis of Brass, Aluminium and Mild Steel by using Pin-on-disc Method

Conference Paper · March 2016

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 ISBN: 978-93-84935-85-6

Wear Analysis of Brass, Aluminium and Mild

Steel by using Pin-on-disc Method
Ramakant Rana1, Mitul Batra2, Vipin Kumar Sharma3, Aditya Sahni4
1,2,3,4
Mechanical and Automation Engineering department
Maharaja Agrasen Institute of Technology, Delhi, India
1
7ramakant@gmail.com; 2mitulbatra@gmail.com
3
mait.vipin@gmail.com, 4adityasahni2894@gmail.com

Abstract: Steel alloys have extensive application in today’s • Abrasive wear

technological industries. The range of physical properties
that can be imparted to them is remarkable. Wear tests were
conducted using a pin-on-disc wear test rig as per ASTM
specification G99. Experiments have been carried out to
study the wear of various material with respect to Steel, while
the operational parameters were normal load and sliding
velocity of pin w.r.t. rotating disk at room temperature.
Based on the experiments it is found that wear rate is
strongly dependent on applied load, sliding speed and
material.
Keywords: Wear Rate, Sliding Speed, Pin-On-Disc, Taguchi
I. INTRODUCTION
Mild steel is the most common form of steel and its price is
relatively low. The properties provided by this material are
acceptable for many applications. Mild steel has a relatively
low tensile strength, but it is cheap and malleable; surface
hardness can be increased through carburizing. It is often used
when large quantities of steel are needed.
The consequences of wear are many, Wear usually cost
money, in the form of energy loss and material loss, as well as
in the social system using the mechanical devices:
A. Wear can decrease national productivity
B. Wear can affect national security
C. Wear can affect quality of life
D. Wear causes accident.
The progressive loss of material due to abrasive action of hard
particles presented between the counter surfaces is defined as
abrasive wear. When a hard rough surface slides across a
softer surface the abrasive wear occurs. ASTM (American
Society for Testing and Materials) defined abrasive wear as
the loss of material due to hard particles or hard protuberances
that are forced against and move along a solid surface [2].
Three commonly identified mechanisms of abrasive wear of
coatings are:
1. Plowing
2. Cutting
3. Fragmentation
• Surface fatigue wear
When the wear particles are detached by cyclic crack growth
of micro cracks on the surface the fatigue wear is produced. It
is extremely important to improve the resistance of the
material against fracture in aerospace applications.
• Fretting wear
The repeated cyclical rubbing between disc and another
surface, which is known as fretting, over a period of time
which will remove material from one or both surfaces in
contact is known as Fretting wear. It is typically found
occurring in bearings, although most bearings have their
surfaces hardened to resist the problem [3].

A. Types of wear • Erosive wear

• Adhesive wear
The transfer of material from one surface to another
throughout the relative motion by a process of solid-phase
welding is defined as Adhesive wear or it can be defined as
the transfer of material from one surface to another as a result
of localized bonding between contacting surfaces. Particles
that are removed from one surface are either permanently or
temporarily attached to the other surface [1].
Erosive wear of the etched disc is caused by the impact of
particles of solid or liquid against the surface of coating [4].
The impacting particles gradually remove material from the
surface through repeated deformations and cutting actions. It
is a widely encountered mechanism in industry.
II. EXPERIMENTAL SETUP
Set up used in the study of wear test is capable of creating
reproducible abrasive wear situation accessing the abrasive
wear resistance of the prepared samples. It consists of a pin on

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3rd International Conference on Manufacturing Excellence – MANFEX 2016

disc, loading panel and controller. The entire test was carried
out using a “pin on disk” machine with normal condition. The
condition has 40-50% relative humidity and a temperature of
32-35OC.A high precision weighing machine (accuracy
0.001gm.) has been used to weigh the pin specimen before and
after the tests. in the due course of the experiment. The mass
loss was measured on weigh balance (accuracy 0.001gm.) and
after that wear rate has been calculated by using the given
formula:
K = V w/ t (1)
The specimen was held steady and stationary within a holder
of the apparatus and the required normal load was applied
through lever mechanism as can be seen in the figure 1. The
sliding distance was kept at 1.0 km for all tests various levels
of the load speed and pin material were listed in table 1.
At the end of each set of experiment the mass loss of the pin
specimen was measured by a high precision weighing machine
and time taken to the mass loss was recorded with the help of
a precise stopwatch as shown in table 2 [9].

Here, K: is the wear rate(gram/sec), Vw: is the mass loss TABLE 2: Observations for different set of input factors
(grams), t= time (sec)

Weight of Pin
(gram)
Material

Speed

Time
Load

Before

After
Brass 2 kg 1000 7.5091 7.5064 954.8
Brass 5 kg 1300 7.5064 7.2764 367.23
Brass 8 kg 1600 7.2764 6.6820 198.91
Mild Steel 2 kg 1300 2.7015 2.6796 183.62
Fig. 1. Wear and Friction Monitor Used for the Wear Tests Mild Steel 5 kg 1600 2.6796 2.6587 119.35
III. EXPERIMENTAL SETUP Mild Steel 8 kg 1000 2.6587 2.5088 159.13
Aluminium 2 kg 1600 6.9543 6.9488 99.46
Experiments were performed using a design matrix generated
with the help of taguchi technique. Three different materials Aluminium 5 kg 1000 6.9488 6.9324 190.96
were chosen as pin material which were tested at three Aluminium 8 kg 1300 6.9324 6.6323 183.62
different levels of speed and loads. Hardened tool steel was
taken as the plate material. Pin samples and disc has been
cleaned properly before and after each test to prevent any form
of corrosion on the surface.

TABLE 1: Various levels for input factors

Material Load Speed

Brass 2 kg 1000
Brass 5 kg 1300
Brass 8 kg 1600
Aluminium 2 kg 1300
Aluminium 5 kg 1600
Aluminium 8 kg 1000
Mild Steel 2 kg 1600
Mild Steel 5 kg 1000
Mild Steel 8 kg 1300 Fig. 2. Variation of Wear Rate with Pin Material, Load and
Speed.

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 Wear Analysis of Brass, Aluminium and Mild Steel by using Pin-on-disc Method

IV. RESULT AND DISCUSSION

It is clear from the figure 2 that Mild Steel has less wear rate
as compared to brass and mild steel as it developed a
protective layer in atmospheric conditions [6, 7]. The wear
rate increases with the increase in disc speed and load but the
variation with load is more sudden. The major amount of wear
occurs due to sticking of the material due to the heat generated
at the frictional contact [5, 8].

TABLE 3: Response Table for Wear Rate

Level Material Load Speed

1 0.001206 0.000059 0.000344
2 0.000412 0.000296 0.000793
3 0.000592 0.001855 0.001073
Delta 0.000794 0.001796 0.000729
Fig. 3. Normal probability plot for Wear Rate data Rank 2 1 3

Table 3 shows the responses of Wear Rate along with the

ranks of the process parameters and Table 2 shows the
Taguchi L9 Orthogonal Array (OA) used in the
experimentation [9].

Figure 3 shows the Normal probability plot for Wear Rate data
and the Figure 4 shows the Interaction Plot for Wear Rate. The
results in Figure 3 and Figure 4 revealed that the residuals
generally fall on a straight line implying that the errors are
normal. Figure 3 also revealed that they have a pattern and all
the values are in an unusual structure. This implies that the
range proposed in the Design of Experiment is adequate and
there is no reason to suspect any violation of the independence
assumption [7].

Figure 6 shows the Scatter-Plot of Wear Rate vs Pin Material,

Load and Speed. Figure 6 depicted that Wear Rate was least
with the Mild Steel in as comparison to the Brass and
Aluminium. It also depicted that the wear rate increases with
Fig. 4. Interaction Plot for Wear Rate the increase in Load and Speed.

V. CONCLUSION
The material undergoes heavy wear due to sticking of the
surfaces as a result of heat generated from friction. The
amount of wear increases as the normal load and disc speed
increases and test pin and the disc exhibits high amount of
chatter due to sticking of surfaces.

In this paper, application of Taguchi optimization on the Wear

between various material and Steel is carried out. Taguchi
Optimization Technique has been applied for optimizing the
Wear Rate to investigate the influence of parameters like Load
Fig. 5. Scatter-Plot of Wear Rate vs Pin
and Speed. The results are as follows:
Material, Load and Speed

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3rd International Conference on Manufacturing Excellence – MANFEX 2016
1) For the Wear Rate, the Load and the Pin Materialare the
main influencing factors on the Wear, followed by the speed
of the disc.
2) Interaction plots are useful in determining the optimum
condition to obtain particular values of Wear Rate.
3) Verification experiments carried out show that the
optimized values can be used for obtaining the wear within
6% error as can be seen in Normal probability plot for Wear
Rate data (Figure 3).
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Fatigue behavior of powder metallurgy high speed steels, fatigue
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Mater. Sci. Engg. a Structure Mater, 387–389, 2004, 501–4.
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