“Advancements in Dual Condition Pin-on-Disc Wear Testing Machine Development”

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“Advancements in Dual Condition Pin-on-Disc Wear Testing Machine Development”

ABSTRACT:

Surface wear analysis of engineering materials was conducted using a Pin-on disc wear testing machine. Wear is a complex and dynamic process influenced not only by surface and material properties but also by operating conditions. Surface wear can lead to increased maintenance or manufacturing costs. To address this, a dual condition Pin-on-disc wear testing machine was developed, allowing assessment of dry and lubricated surface contacts of engineering materials.

The study focused on investigating the surface wear of Aluminium 6061, Bronze, and Brass pins. Performance tests were carried out under varying loads, time, and speeds. Pin wear rate, wear resistance, and specific wear rate were determined for each pin type. The tests were performed at constant sliding speeds of 0.158m/s and 0.1975m/s, and forces of 5N, 8N, and 10N, respectively. After each test, the pins were removed, and their final volume was measured.

Results showed that the 4mm diameter Aluminium 6061 pin exhibited the highest wear rate of 0.2129 mm3/m under dry surface conditions, at a speed of 0.158m/s, and with an applied force of 8N, compared to the 6mm diameter pin used. In contrast, the Bronze pin had the lowest wear rate of 0.0394mm3/m at a constant speed of 0.158m/s, with a pin diameter of 6mm, and under an applied force of 5N. Under lubricated conditions, the wear rate per second for the 6mm diameter pins was 20.5μm3/m, 8.2μm3/m, and 11μm3/m for Aluminium 6061, Bronze, and Brass, respectively. The use of lubrication reduced wear by 54%. Furthermore, Bronze exhibited a 59.32% lower wear rate per second compared to Aluminium 6061 and Brass in the pin-on disc setup.

Based on the results, the wear resistance was found to follow the order of Bronze > Brass > Aluminium 6061 pin. The specific wear rate for the 6mm diameter pins under lubricated conditions was lowest at a sliding speed of 0.158m/s and a sliding distance of 568.8m. The specific wear rate values for Brass, Aluminium 6061, and Bronze pins were 0.3172 × 10−3mm3/Nm, 0.5901 × 10−3mm3/Nm, and 0.2428 × 10−3mm3/Nm, respectively.

In conclusion, engineering surfaces with good lubrication and increased contact surface area exhibit reduced wear rates. This study contributes to the development of indigenous technology in Machine Design and Tribology.

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