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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 Schematic views of the pin-on-disk apparatus
6.2.1 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
S.No. Specimen
Name
Sliding Speed 2m/s Sliding Speed 4m/s
Initial
weight
(gm)
Final
weight
(gm)
Weight
loss
(gm)
Initial
weight
(gm)
Final
weight
(gm)
Weight
loss
(gm)
1 LM 25 8.27122 8.246 0.02522 8.27122 8.2422 0.02902
2 LM 25 + C 8.09076 8.073 0.01776 8.09076 8.067 0.02376
3 LM 25+C
+ 3%B4C 8.16358 8.1494 0.01418 8.16358 8.14182 0.02176
4 LM 25+C
+ 6%B4C 8.00555 7.9927 0.01285 8.00555 7.985 0.02055
5 LM 25+C
+ 9%B4C 8.35572 8.3444 0.01132 8.35572 8.33629 0.01943
Figure 6.3 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 vs wear rate (mm3/m)
Specimen Wear rate (mm3/m)
2 m/s 4 m/s
p 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 vs wear resistance (m/mm3)
SpecimenWear resistance (m/mm3)
2 m/s 4 m/s
p 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 vs specific wear rate (mm3/Nm)
Specimen Specific wear rate (mm3/Nm)
2 m/s 4 m/s
p 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 Typical SEM micro graph of Al/4 wt% C with 2 m/s
6.3.1 SEM Micro Graph of Al/4 wt% C/3, 6, 9 wt% B4C with
2 m/s
The worn surfaces of the composite AlMMC’s 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
(a) (b)
(c) (d)
Figure 6.9 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 Process parameters and levels
Level Load (N)Sliding Speed, S
(m/s)
Sliding Distance, D
(m)
1 20 2 1000
2 40 4 2000
3 60 6 3000
6.5 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
1 1 1 1
2 1 2 2
3 1 3 3
4 2 1 2
5 2 2 3
6 2 3 1
7 3 1 3
8 3 2 1
9 3 3 2
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 Responses table for S/N ratio for wear (Al – LM 25)
S.No. Load
(N)
Speed
(m/s)
Distance
(m)
Wear
(mm3/m) C.O.F
S/N
ratio
C.O.F
S/N
ratio
wear
rate
1 20 2 1000 0.006580 0.648 43.6355 3.76850
2 20 4 2000 0.005370 0.628 45.4005 4.04081
3 20 6 3000 0.003550 0.614 48.9954 4.23663
4 40 2 1000 0.010120 0.627 39.8964 4.05465
5 40 4 2000 0.007662 0.632 42.3132 3.98566
6 40 6 3000 0.006182 0.657 44.1774 3.64869
7 60 2 1000 0.013670 0.620 37.2846 4.15217
8 60 4 2000 0.012960 0.632 37.7479 3.98566
9 60 6 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)
1 46.01 40.27 40.27
2 42.13 41.82 41.82
3 37.96 44.00 44.00
Delta 8.05 3.73 3.73
Rank 1 2 3
Table 6.10 Main effects for plot for S/N ratios - coefficient of friction
Level Load (N) Speed (m/s) Distance (m)
1 4.015 3.992 3.992
2 3.896 4.004 4.004
3 4.106 4.022 4.022
Delta 0.210 0.030 0.030
Rank 1 2 3
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)
S.No. Load (N)
Speed(m/s)
Distance(m)
Wear(mm3/m) C.O.F
S/N Ratio c.o.f
S/N Ratio Wear Rate
1 20 2 1000 0.01702 0.527 35.3808 5.56379
2 20 4 2000 0.01638 0.513 35.7137 5.79765
3 20 6 3000 0.01618 0.502 35.8204 5.98593
4 40 2 1000 0.05016 0.583 25.9928 4.68663
5 40 4 2000 0.04988 0.564 26.0415 4.97442
6 40 6 3000 0.04762 0.573 26.4442 4.83691
7 60 2 1000 0.09863 0.543 20.1198 5.30400
8 60 4 2000 0.96540 0.532 0.3059 5.48177
9 60 6 3000 0.09321 0.521 20.6107 5.66325
109
Table 6.12 Responses table for S/N ratio of coefficient of friction
(Al - LM 25/4% C)
Level Load(N) Speed(m/s) Distance(m)
1 35.64 27.16 27.16
2 26.16 20.69 20.69
3 13.68 27.63 27.63
Delta 21.96 6.94 6.94
Rank 1 2 3
Table 6.13 Main effects for plot for S/N ratios - coefficient of friction
Level Load(N) Speed(m/s) Distance(m)
1 5.782 5.185 5.185
2 4.833 5.418 5.418
3 5.483 5.495 5.495
Delta 0.950 0.311 0.311
Rank 1 2 3
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.No. Load (N)
Speed(m/s)
Distance(m)
Wear(mm3/m)
C.O.F S/N
ratioC.O.F
S/N Ratio Wear Rate
1 20 2 1000 0.01279 0.571 37.8626 37.8626
2 20 4 2000 0.01209 0.563 38.3515 38.3515
3 20 6 3000 0.01194 0.554 38.4599 38.4599
4 40 2 1000 0.04269 0.586 27.3935 27.3935
5 40 4 2000 0.04154 0.574 27.6307 27.6307
6 40 6 3000 0.04021 0.536 27.9133 27.9133
7 60 2 1000 0.08263 0.526 21.6572 21.6572
8 60 4 2000 0.08154 0.516 21.7726 21.7726
9 60 6 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)
1 38.22 28.97 28.97
2 27.65 29.25 29.25
3 21.79 29.43 29.43
Delta 16.44 0.46 0.46
Rank 1 2 3
Table 6.16 Main effects for plot for S/N ratios - coefficient of friction
Level Load (N) Speed (m/s) Distance (m)
1 38.22 28.97 28.97
2 27.95 29.25 29.25
3 21.79 29.43 29.43
Delta 16.44 0.46 0.46
Rank 1 2 3
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)
S.No. Load(N)
Speed (m/s)
Distance(m)
Wear(mm3/m) C.O.F
S/N ratio
C.O.F
S/N ratio wear rate
1 20 2 1000 0.01370 0.623 37.2656 37.2656
2 20 4 2000 0.01049 0.614 39.5845 39.5845
3 20 6 3000 0.00989 0.609 40.0961 40.0961
4 40 2 1000 0.03608 0.632 28.8547 28.8547
5 40 4 2000 0.03421 0.618 29.3169 29.3169
6 40 6 3000 0.03102 0.602 30.1672 30.1672
7 60 2 1000 0.07082 0.625 22.9969 22.9969
8 60 4 2000 0.69830 0.617 3.1192 3.1192
9 60 6 3000 0.68730 0.631 3.2571 3.2571
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)
1 38.982 29.706 29.706
2 29.446 24.007 24.007
3 9.761 24.507 24.507
Delta 29.191 5.699 5.699
Rank 1 2 3
Table 6.19 Main effects for plot for S/N ratios - coefficient of friction
Level Load(N) Speed(m/s) Distance(m)
1 38.982 29.706 29.706
2 29.446 24.007 24.007
3 9.791 24.507 24.507
Delta 29.191 5.699 5.699
Rank 1 2 3
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.No. Load (N)
Speed(m/s)
Distance(m)
Wear(mm3/m) C.O.F
S/N Ratio C.O.F
S/N Ratio Wear Rate
1 20 2 1000 0.00905 0.544 40.8670 40.8670
2 20 4 2000 0.00896 0.536 40.9538 40.9538
3 20 6 3000 0.00884 0.526 41.0710 41.0710
4 40 2 1000 0.02103 0.588 33.5432 33.5432
5 40 4 2000 0.02094 0.564 33.5805 33.5805
6 40 6 3000 0.02086 0.553 33.6137 33.6137
7 60 2 1000 0.04302 0.579 27.3266 27.3266
8 60 4 2000 0.04104 0.553 27.7359 27.7359
9 60 6 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)
1 40.96 33.91 33.91
2 33.58 34.09 34.09
3 27.61 34.15 34.15
Delta 13.36 0.24 0.24
Rank 1 2 3
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)
1 40.96 33.91 33.91
2 33.58 34.09 34.09
3 27.61 34.15 34.15
Delta 13.36 0.24 0.24
Rank 1 2 3
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 Seq SS Adj SS Adj MS F P
Main Effects 2 0.00009896 0.00009896 0.00004948 92.95 0.000
2-Way
Interactions1 0.00000016 0.00000016 0.00000016 0.29 0.611
Residual
Error 5 0.00000266 0.00000266 0.00000053
Total 8 0.00010177
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 Analysis of variance for C.O.F (coded units) with LM 25
Source DF Seq SS Adj SS Adj MS F PMain Effects
2 0.00007267 0.00007267 0.00003633 0.15 0.867
2-Way Interactions
1 0.00025600 0.00025600 0.00025600 1.03 0.356
Residual Error
5 0.00124133 0.00124133 0.00024827
Total 8 0.00157000
Table 6.25 Analysis of variance for wear (coded units) with LM25/C
Source DF Seq SS Adj SS Adj MS F P Main Effects
2 0.204498 0.204498 0.102249 0.93 0.454
2-Way Interactions
1 0.000005 0.000005 0.000005 0.00 0.995
Residual Error
5 0.550155 0.550155 0.110031
Total 8 0.754658
Table 6.26 Analysis of variance for C.O.F (coded units) LM25/C
Source DF Seq SS Adj SS Adj MS F P
Main Effects 2 0.00102750 0.00102750 0.00051375 0.49 0.640
2-Way
Interactions1 0.00000225 0.00000225 0.00000225 0.00 0.965
Residual
Error 5 0.00525981 0.00525981 0.00105196
Total 8 0.00628956
123
Table 6.27 Analysis of variance for wear (coded units) with
LM25/C/3B4C
Source DF Seq SS Adj SS Adj MS F P Main Effects 2 0.00717965 0.00717965 0.00358983 309.48 0.0002-Way Interactions
1 0.00000069 0.00000069 0.00000069 0.06 0.817
Residual Error
5 0.00005800 0.00005800 0.00001160
Total 8 0.00723834
Table 6.28 Analysis of variance for C.O.F (coded units) with
LM25/C/3B4C
Source DF Seq SS Adj SS Adj MS F PMain Effects 2 0.0017528 0.0017528 0.0008764 2.06 0.223 2-Way Interactions
1 0.0004622 0.0004622 0.0004622 1.09 0.345
Residual Error
5 0.0021278 0.00212780.0004256
Total 8
Table 6.29 Analysis of variance for wear (coded units) with
LM25/C/6B4C
Source DF Seq SS Adj SS Adj MS F P Main Effects 2 0.39871 0.39871 0.19935 5.18 0.0602-Way Interactions
1 0.09619 0.09619 0.09619 2.50 0.175
Residual Error
5 0.19241 0.19241 0.03848
Total 8 0.68731
124
Table 6.30 Analysis of variance for C.O.F (coded units) with LM25/C/6B4C
Source DF Seq SS Adj SS Adj MS F P Main Effects 2 0.0003622 0.0003622 0.00018108 2.81 0.152 2-Way Interactions
1 0.0001000 0.0001000 0.00010000 1.55 0.268
Residual Error
5 0.0003218 0.0003218 0.00006437
Total 8 0.0007840
Table 6.31 Analysis of variance for wear (coded units) with LM25/C/9B4C
Source DF Seq SS Adj SS Adj MS F P Main Effects
2 0.00160594 0.00160594 0.00080297 103.08 0.000
2-Way Interactions
1 0.00000089 0.00000089 0.00000089 0.11 0.749
Residual Error
5 0.00003895 0.00003895 0.00000779
Total 8 0.00164578
Table 6.32 Analysis of variance for C.O.F (coded units) with LM25/C/9B4C
Source DF Seq SS Adj SS Adj MS F P Main Effects
2 0.00211367 0.00211367 0.00105683 5.19 0.060
2-Way Interactions
1 0.00008100 0.00008100 0.00008100 0.40 0.556
Residual Error
5 0.00101733 0.00101733 0.00020347
Total 8 0.00321200