Friction and Lubrication in Mechanical Design Episode 1 Part 1 ppsx

Plastics Products Design Handbook, Part A: Materials and Components; Part B: Processes and Design for Processes, edited by Edward Miller 9.. Computer-Aided Graphics and Design: Second E

FRICTION RND

MKHRNICRL D€SIGN

MECHANICAL ENGINEERING

A Series of Textbooks and Reference Books

Editor

L L Faulkner

Columbus Division, Battelle Memorial Institute

and Department of Mechanical Engineering

The Ohio State University Colurnbus, Ohio

1 Spring Designer's Handbook, Harold Carlson

2 Computer-Aided Graphics and Design, Daniel L Ryan

3 lubrication Fundamentals, J George Wills

4 Solar Engineering for Domestic Buildings, William A Himmelman

5 Applied Engineering Mechanics: Statics and Dynamics, G Boothroyd and

C Poli

6 Centrifugal Pump Clinic, lgor J Karassik

7 Computer-Aided Kinetics for Machine Design, Daniel L Ryan

8 Plastics Products Design Handbook, Part A: Materials and Components; Part B: Processes and Design for Processes, edited by Edward Miller

9 Turbomachinery: Basic Theory and Applications, Earl Logan, Jr

10 Vibrations of Shells and Plates, Werner Soedel

1 1 Flat and Corrugated Diaphragm Design Handbook, Mario Di Giovanni

1 2 Practical Stress Analysis in Enginee~ng Design, Alexander Blake

13 An Introduction to the Design and Behavior of Bolted Joints, John H

Bickford

14 Optimal Engineeing Dmgn: pn'nc@les and Applications, James N Siddall

1 5 Spring Manufacturing Handbook, Harold Carlson

1 6 Industrial Noise Control: Fundamentals and Applications, edited by Lewis

H Bell

17 Gears and Their Vibration: A Basic Approach to Understanding Gear

Noise, J Derek Smith

18 Chains for Power Transmission and Material Handling: Design and Appli-

cations Handbook, American Chain Association

19 Corrosion and Corrosion Protection Handbook, edited by Philip A Schweitzer

20 Gear Drive Systems: Design and Application, Peter Lynwander

2 1 Controlhg In-Plant Airborne Contaminants: Systems Design and Calcula- tions, John D Constance

22 CAD/CAM Systems Planning and Implementation, Charles S Knox

23 Probabilistic Engineering Design: Princbles and Applications, Jarnes N

Siddall

24 Traction Drives: Selection and Application, Frederick W Heilich 111 and

Eugene E Shube

25 Finite Element Methods: An Introduction, Ronald L Huston and Chris E

Passerello

26 Mechanical Fastening of plastics: An Engineen'ng Handbook, Brayton Lin-

coln, Kenneth J Gomes, and James F Braden

27 Lubrication in Practice: Second Edition, edited by W S Robertson

28 Princ@les of Automated Drafting, Daniel L Ryan

29 Practical Seal Design, edited by Leonard J Martini

30 Engineering Documentation for CAD/CAM Applications, Charles S Knox

3 1 Design Dimensioning with Computer Graphics Applications, Jerome C

Lange

32 Mechanism Analysis: Simplified Graphical and Analytical Techniques, Lyn-

don 0 Barton

33 CAD/CAM Systems: Justification, Implementation, Productivity Measure-

ment, Edward J Preston, George W Crawford, and Mark E Coticchia

34 Steam Plant Calculations Manual, V Ganapathy

35 Design Assurance for Engineers and Managers, John A Burgess

36 Heat Transfer Fluids and Systems for Process and Energy Applications,

Jasbir Singh

37 Potential Flows: Computer Graphic Solutions, Robert H Kirchhoff

38 Computer-Aided Graphics and Design: Second Edition, Daniel L Ryan

39 Electronically Controlled Proportional Valves: Selection and Application ,

Michael J Tonyan, edited by Tobi Goldoftas

40 Pressure Gauge Handbook, AMETEK, U.S Gauge Division, edited by Phil-

ip W Harland

41 Fabric Filtration for Combustion Sources: Fundamentals and Basic Tech-

nology, R P Donovan

42 Design of Mechanical Joints, Alexander Blake

43 CAD/CAM Dictionary, Edward J Preston, George W Crawford, and

Mark E Coticchia

44 Machinery Adhesives for Locking, Retaining, and Sealing, Girard S Havi-

land

45 Couplings and Joints: Design, Selection, and Application, Jon R Mancuso

46 Shaft Alignment Handbook, John Piotrowski

47 BASIC Programs for Steam Plant Engineers: Boilers, Combustion, Fluid Flow, and Heat Transfer, V Ganapathy

48 Solving Mechanical Design Problems with Computer Graphics, Jerome C

Lange

49 Plastics Gearing: Selection and Application, Clifford E Adams

50 Clutches and Brakes: Design and Selection, William C Orthwein

5 1 Transducers in Mechanical and Electronic Design, Harry L Trietley

52 Metallurgical Applications of Shock- Wave and High-Strain-Rate Phenom-

ena, edited by Lawrence E Murr, Karl P Staudhammer, and Marc A Meyers

53 Magnesium Products Design, Robert S Busk

54 How to Integrate CAD/CAM Systems: Management and Technology, Wil-

liam D Engelke

55 Cam Design and Manufacture: Second Edition; with cam design software

for the IBM PC and compatibles, disk included, Preben W Jensen

56 Solid-state A C Motor Controls: Selection and Application, Sylvester Camp-

bell

57 Fundamentals of Robotics, David D Ardayfio

50 Belt Selection and Application for Engineers, edited by Wallace D Erick- son

59 Developing Three-Dimensional CAD Software with the IBM PC, C Stan

Wei

60 Organizing Data for CIM Applications, Charles S Knox, with contri-

butions by Thomas C Boos, Ross S Culverhouse, and Paul F Muchnicki

61 Computer-Aided Simulation in Railway Dynamics, by Rao V Dukkipati

and Joseph R Amyot

62 Fiber-Reinforced Composites: Materials, Manufacturing, and Design, P K

Mallick

63 Photoelectric Sensors and Controls Selection and Application, Scott M

Juds

64 Finite Element Analysis with Personal Computers, Edward R Champion,

Jr., and J Michael Ensminger

6 5 Ultrasonics: Fundamentals, Technology, Applications: Second Edition, Revised and Expanded, Dale Ensminger

66 Applied Finite Element Modeling: Practical Problem Solving for Engineers,

Jeffrey M Steele

67 Measurement and Instrumentation in Engineering: Princ@les and Basic

Laboratory Experiments, Francis S Tse and lvan E Morse

60 Centrifugal Pump Clinic: Second Edition, Revised and Expanded, lgor J Karassik

69 Practical Stress Analysis in Engineering Design: Second Edition, Revised and Expanded, Alexander Blake

70 An Introduction to the Design and Behavior of Bolted Joints: Second Edition, Revised and Expanded, John H Bickford

71 High Vacuum Technology: A Practical Guide, Marsbed H Hablanian

72 Pressure Sensors: Selection and Application, Duane Tandeske

73 Zinc Handbook: Properties, Processing, and Use in Design, Frank Porter

74 Thermal Fatigue of Metals, Andrzej Weronski and Tadeusz Hejwowski

75 Classical and Modern Mechanisms for Engineers and Inventors, Preben

W Jensen

76 Handbook o f Electronic Package Design, edited by Michael Pecht

77 Shock- Wave and High-Strain-Rate Phenomena in Materials, edited by

Marc A Meyers, Lawrence E Murr, and Karl P Staudhammer

70 Industrial Refrigeration: Princ@les, Design and Applications, P C Koelet

79 Applied Combustion, Eugene L Keating

80 Engine Oils and Automotive Lubrication, edited by Wilfried J Bartz

0 1 Mechanism Analysis: Simplified and Graphical Techniques, Second Edition, Revised and Expanded, Lyndon 0 Barton

02 Fundamental Fluid Mechanics for the Practicing Engineer, James W

Murdock

03 fiber-Rein forced Composites: Materials, Manufacturing, and Design, Sec- ond Edition, Revised and Expanded, P K Mallick

Vibrations of Shells and Plates: Second Edition, Revised and Expanded,

Mechanical Wear Prediction and Prevention, Raymond G Bayer

Mechanical Po wer Transmission Components, edited by David W South

and Jon R Mancuso

Handbook of Turbomachinery, edited by Earl Logan, Jr

Engineering Documentation Control Practices and Procedures, Ray E

Computer-Aided Design o f Polymer-Matrix Composite Structures, edited

by Suong Van Hoa

Friction Science and Technology, Peter J Blau

Introduction to Plastics and Composites: Mechanical Properties and Engi- neering Applications, Edward Miller

Practical Fracture Mechanics in Design, Alexander Bla ke

Pump Characteristics and Applications, Michael W Volk

Optical Princr;Oles and Technology for Engineers, James E Stewart Optimizing the Shape of Mechanical Elements and Structures, A A

Seireg and Jorge Rodriguez

Kinematics and Dynamics of Machinery, Vladimlr Stejskal and Michael

Val4Sek

Shaft Seals for Dynamic Applications, Les Horve

Reliability-Based Mechanical Design, edited by Thomas A Cruse

Mechanical Fastening, Joining, and Assembly, James A Speck

Turbomachinery Fluid Dynamics and Heat Transfer, edited by Chunill Hah High- Vacuum Technology: A Practical Guide, Second Edition, Revised and Expanded, Marsbed H Hablanian

Geometric Dimensioning and Tolerancing: Workbook and Ans werbook,

Jarnes D Meadows

Handbook of Materials Selection for Engineering Applications, edited by

G T Murray

1 14 Handbook of Thermoplastic Ptping System Design, Thomas Sixsmith and

1 15 Practical Guide to Finite Elements: A Solid Mechanics Approach, Steven

1 16 Applied Computational Fluid Dynamics, edited by Vijay K Garg

1 1 7 Fluid Sealing Technology, Heinz K Muller and Bernard S Nau

1 1 8 Friction and Lubrication in Mechanical Design, A A Seireg

Reinhard Hanselka

M Lepi

Additional Volumes in Preparation

Machining of Ceramics and Composites, edited by Said Jahanmir, M

Ramulu, and Philip Koshy

Heat Exchange Design Handbook, T Kuppan

Couplings and Joints: Second Edition, Revised and Expanded, Jon R

Mancuso

Mechanical Engineering Software Spring Design with an IBM PC, AI Dietrich

Mechanical Design Failure Analysis: With Failure Analysis System Soft-

ware for the IBM PC, David G Ullman

Influence Functions and Matrices, Yuri A Melnikov

FRICT'ION R" LUBRIC~ION IN

M€CHANI(RL

D€SIGN

University of Wisconsin-Madison Madison, Wisconsin and University of Florida Gaines viiie, Florida

M A R C E L

MARCEL DEKKER, INC NEW YORK BASEL HONG KONG

a% D E K K E R

ISBN: 0-8247-9974-7

This book is printed on acid-free paper

Headquarters

Marcel Dekker, Inc

270 Madison Avenue, New York, NY 10016

Copyright 0 1998 by Marcel Dekker, Inc All Rights Reserved

Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or

by any information storage and retrieval system, without permission in writing from the publisher

Current printing (last digit):

1 0 9 8 7 6 5 4 3 2 1

PRINTED IN THE UNITED STATES OF AMERICA

Preface

The awareness of friction and attempts to reduce or use it are as old as human history Scientific study of the friction phenomenon dates back to the eighteenth century and has received special attention in modern times since

it is one of the most critical factors in all machinery The increasing empha- sis on material and energy conservation in recent years has added new urgency to the development of practical predictive techniques and informa- tion that can be used, in the design stage, for controlling friction and wear Advances in this field continue to contribute to improved energy efficiency, increased useful life of machines, and reduced maintenance costs

This book treats friction, lubrication, and wear as empirical phenomena and relies heavily on the experimental studies by the author and his coworkers to develop practical tools for design Empirical dimensionless relationships are presented, whenever possible, that can be readily applied

to a variety of situations confronting the design engineer without the need for extensive theoretical analysis or computation

The material in the book has been used for many years in an interdisci- plinary course on this subject taught at the University of Wisconsin- Madison, and can be used as a text for senior, graduate, or professional development courses It can also be used as a reference book for practical design engineers because the many empirical equations and design graphs can provide a fundamental parametric understanding to guide their design decisions

Chapter 1 gives a brief review of the history of this subject and sets the stage for the topics presented in the book Chapters 2, 3, and 4 summarize

111

iv Preface

the relevant relationships necessary for the analysis of contact mechanics in smooth and rough surfaces, as well as the evaluation of the distribution of the frictional resistance over the contacting surfaces due to the application

of tangential loads and twisting moments

Chapter 5 presents an overview of the mechanism of the transfer of

frictional heat between rubbing surfaces and gives equations for estimating the heat partition and the maximum temperature in the contact zone

Chapter 6 deals with the broad aspects of fluid film lubrication with

emphasis on the thermal aspects of the problem It introduces the concept

of thermal expansion across the film and provides a method for calculating the pressure that can be generated between parallel surfaces as a result of

the thermal gradients in the film Chapter 7 discusses the problem of

friction and lubrication in rolling/sliding contacts and gives empirical equations for calculating the coefficient of friction from the condition of pure rolling to high slide-to-roll ratios The effect of surface layers is taken

into consideration in the analysis Chapter 8 gives an overview of the

different wear mechanisms and includes equations to help the designer avoid unacceptable wear damage under different operating and environ-

mental conditions Chapter 9 presents selected case illustrations and cor-

responding empirical equations relating the factors influencing surface durability in important tribological systems such as gears, bearings, brakes, fluid jet cutting, soil cutting, one-dimensional clutches, and animal joints

Chapter 10 discusses the frictional resistance in micromechanisms Friction is considered a major factor in their implementation and successful operation Chapter 11 illustrates the role of friction in the generation of noise in mechanical systems, and Chapter 12 gives an introduction to sur- face coating technology, an area of growing interest to tribologists

Finally, Chapter 13 discusses in some detail a number of experimental techniques developed by the author and his coworkers that can be useful in the study of friction, lubrication, wear, surface temperature, and thermally induced surface damage

I am indebted to my former students, whose thesis research constitutes

the bulk of the material in this book Dr T F Conry for his contribution to Chapter 2; Dr D Choi to Chapter 3; Dr M Rashid to Chapter 5; Drs H Ezzat, S Dandage, and N Z Wang to Chapter 6; Dr Y Lin to Chapter 7;

Dr T F Conry, Mr T Lin, Mr A Suzuki, Dr A Elbella, Dr S Yu, Dr

A Kotb, Mr M Gerath, and Dr C T Chang to Chapter 9; Dr R Ghodssi

to Chapter 10; Drs S A Aziz and M Othman to Chapter 11; Dr K

Stanfill, Mr M Unee, and Mr T Hartzell to Chapter 12; and Professor

E J Weiter, Dr N Z Wang, Dr E Hsue, and Mr C Wang to Chapter 13

Preface V

Grateful acknowledgment is also due to Ms Mary Poupore, who efficiently took charge of typing the text, and to Mr Joe Lacey, who took upon himself the enormous task of digitizing the numerous illustra- tions in this book

A A Seireg