Analysis of Wear and Friction Characteristics of EN19,
EN47, and EN353 Materials.
S. Srikar a, GVR Seshagiri Rao b.
a
Student, Department of Mechanical Engineering, Institute of Aeronautical Engineering,
Hyderabad [Link], India.
b
Professor, Department of Mechanical Engineering, Institute of Aeronautical Engineering,
Hyderabad [Link], India.
srikarsudamsetti@[Link]
lakshmiseshu29@[Link]
Abstract
This experiment examines the wear-friction characteristics of several steel grades. In our
daily lives, wear and friction are major factors therefore, it is imperative that these features to
be studied. Here, we primarily compute the steel's wear rate and coefficient of friction of
EN19, EN47, and EN353. It has to comprehend the tribological characteristics of various
steel materials after this analysis. Modern technology is characterized by sophisticated
machinery employed in both daily life and industry. When there is relative motion between
two mating surfaces, wear is likely to happen. This causes the dimensions of the machine
component to be lost, which can lead to component failure. This results in machine failure
and dangerous impacts on surfaces. The load and velocity of the disc are changed to perform
the wear test. The test is carried out in a dry environment. This analysis demonstrates that the
wear rate rises after initially declining. When there is relative motion between mating
surfaces, the proper graph is generated, along with the coefficient of friction and friction
force. After computing of wear and friction analysis of EN19, EN47, and EN353 materials
with various parameters it has to be suggested better material for tribological applications.
Keywords: Tribological properties, Wear rate, of (Coefficient of friction).
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1. Introduction
In making use of steel components, we undergo many challenges; among all those wears
have the important factor. In general Wear is defined as the friction between moving
components which is an undesired phenomenon in that case. So, it is significant to study
these properties [1].
1.1. Tribology
Tribology is the study and technology of interacting surfaces in relative motion as well as
related fields and activities. The study and application of friction, wear, and lubrication
concepts are all included in tribology. Greek word "tribos," which meaning "rubbing,".
1.2. Friction
Friction is a form of resistance to motion. This resistance (force) is determined by various
parameters such as the material, geometries, and surface characteristics of the bodies in
contact, as well as the operating circumstances and environment.[2] To obtain the
maximum efficiency of a component or process, it is generally desired to reduce friction.
1.3. Wear
It is the removal of material in the form of small debris at the contacting surfaces. There are
many consequences of wear such as the increase in maintenance, machine break down
difficult to replace parts that are worn out.[4]
1.4. Types of wear
a) Adhesive Wear, b) Abrasive Wear, c) Fatigue Wear, and d) Erosive wear.
1. 4.1. Adhesive wear:
When two materials which are in contact undergoes relative motion the material that is
removed from either of the material moves and sticks to another one either permanently or
temporarily, this kind of wear is called adhesive wear.[5]
1.4.2. Abrasive wear:
Unlike the above mentioned one, the abrasive wear mainly depends upon the hardness and
material properties of the materials that are in contact.[6] Abrasive type of wear depends on
different types of factors, based on the way after the substance is removed, several abrasive
wear mechanisms are produces.
a) Ploughing wear.
b) Cutting wear.
c) Fragmentation.
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1.4.2. Fatigue wear:
Wear occurs due to the cyclic loading. The wear particles are removed due to the growth of
cyclic crack on the material surface.
1.4.4. Erosive wear:
This type of wear generally occurs when particles of solid or liquid gets in contact with the
surface. These particles generally remove in the form of repeated deformations.[7]
1.5. Lubricants &Lubrication
We come across the word lubricant, many times in our life. The main purpose of using a
lubricant is to reduce friction and to maintain a smooth process.[8] Apart from that it also
acts as a separating layer between then moving parts. Lubrication also helps us to reduce
material wear and to remove heat in machinery.[9] The type of lubricant depends on the
specific situation.
In this industrialized world we are surrounded by machinery around us from wall clock to
automobiles. This machinery has many small moving parts in them. In the beginning the
damage that is caused by these moving parts is not much high. But slowly this can damage
the entire component. Tribology is the study of “why these effects occur, and they can be
reduced”.[10] By having in depth knowledge in the field of tribology we can save huge
money by reducing energy losses, improving component life etc. The study of tribology
takes the reader into the field of material science to have a clear understanding at micro
level.[11]
2. Methodology
2.1. Pin-On-Disk (POD) Abrasion Testing
This kind of wear testing equipment is used to measure tribological characteristics like wear
and friction. The pin on disk test is the most appropriate of numerous tribometer types used to
measure materials for friction and wear (typically wear rates and wear resistance). The
method's popularity is due to its abundance of tribological contacts, which may be simply
represented by a pin on disk motion, and its relative simplicity. These contacts include
lubricated biological implant contacts, rail wheels, dry bolt screw connections, and rail
contact. Throughout the exam, several motion modes including unidirectional, fretting, and,
more recently, any other complicated motion patterns are frequently checked ASTM G99.
The pin-on-disc test rig gets its name from the fact that a pin is pressed up against a revolving
disc. Using a loading lever with a weighted pan which allows it to add dead weights as
needed load is imparted to the specimen (pin).[12] Abrasive wear occurs between the moving
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parts because of the pin being forced up against the disc when the pressure is applied. With
the aid of sensors, the wear and frictional force are determined. The data is then sent to the
system, which already has software installed.[13] This allows us to acquire the graphs of the
wear rate and coefficient of friction. The program itself allows for a comparison of the
generated graphs.
Figure.1: Pin/Ball on Disc Tester
Figure.2: Pin on Disc Parts
[1] LVDT sensor measures the wear generated.
[2] Load cell measures the frictional force.
[3] Proximity sensor senses the speed of the disc.
Test circumstances and important parameters for the pin-on-disk wear test rig is that it works
by pressing two surfaces against one another to set up a rubbing experiment. Nonetheless, it
seems that a variety of factors might affect the test outcomes, thus the specific test design
must closely resemble the real tribological interaction that is being studied. When creating a
pin-on-disk wear test, the following elements need to be considered.
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2.1. PROCEDURE
Pin shape: The pin can be of either of the shapes that are suitable for the test, i.e., it can be a
cylindrical pin with hemisphere head or a pin with ball a send.
2.1.1. Pin Alignment: This part of the experiment plays important role, because if we do not
set the pin correctly, misalignment can take place and because of that non uniform loading
will act on the pin, hence it directly shows effect on the test results.
2.1.2. Pin material: The material selected for the pin is very important. It needs to be
considered that typically, the behavior of tribological properties of the same material is
different by their use i.e. if that material is used for the pin or the material is used for the
plate. It is practically true for the contact between soft and hard materials. This discrepancy
results from the wear primarily occurring on softer materials. If the ball on the disc case is
considered, a softer ball will wear down more quickly and generate a flat-on-flat contact with
a pressure profile that differs greatly from the first one. If the disk is softer, plowing wear
will happen and a groove will form on the disk.
2.1.3. Pin location: Generally, in this experiment the pin is pressed against the rotating disc.
As a result of the abrasion the material on the softer material is removed and fells down
because of gravity.
Table 1: Machine specifications.
Machine Specifications
Specimen pin size Ø6mm, Ø8mm, Ø10mm, Ø12mm
Wear disc size Ø160mm x 8mm thick
Wear track diameter Ø60- Ø80mm
Disc speed 500-1000 rpm
Normal load 10N-100N
Frictional force 0N-50N
Wear 0µ-1500µ
2.2. Material selection
The selection of material that is to be studied plays a pivotal role in the entire process. The
materials that are to be studied are EN47, EN19 and EN353. These materials have
applications such as gears, camshafts, crankshafts and piston pins.
5
2.2.1. EN47 Material
Table: 2 Chemical Composition of EN47
Element Minimum Maximum
Carbon 0.45 0.55%
Manganese 0.5 0.80%`
Silicon 0.15 0.35%
Nickel 0.30 0.50%
Molybdenum 0.15 0.25%
Chromium 0.9 1.2%
Sulphur 0.04 0.06%
Phosphorous 0.04 0.06%
Table:3 Mechanical Properties
Tensile strength, Mpa 800
Yield Strength, Mpa 590
Elongation 14%
Hardness HRc 30-35
2.2.2. EN19Material
Table:4 Chemical Composition of EN19
Element Minimum Maximum
Carbon 0.35 0.45%
Manganese 0.5 0.80%`
Silicon 0.15 0.30%
Molybdenum 0.2 0.4%
Chromium 0.9 1.5%
Sulphur 0.04 0.05%
Phosphorous 0.04 0.06%
Table:5 Mechanical Properties
6
Tensile strength, Mpa 665
Yield Strength, Mpa 415
Elongation 22%
Hardness HRc 28-34
2.2.3. EN353 Material
Table:6 Chemical Composition EN353.
Element Minimum Maximum
Carbon, C 0.1 0.20%
Manganese, Mn 0.50 1.00%
Silicon, Si 0.10 0.35%
Nickel, Ni 1.00 1.50%
Molybdenum 0.08 0.15%
Chromium, Cr 0.75 1.25%
Sulphur, S 0.00 0.040%
Phosphorous, P 0.00 0.040%
Table:7 Mechanical Properties of EN353.
Tensile strength, Mpa 680
Yield Strength, Mpa 440
Elongation 22
Hardness HRc 48
2.3. Sample Preparation
The specimen (pin) for the test is made with the help of the dimensions of the standard
specimen that is provided with the test rig.
The dimensions are:
Total length of specimen=32mm
Radius of curvature of sample head (hemi sphere) =5.13mm Depth of sample head=4mm
Diameter of sample=10mm
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Figure.3: Sample specimen
The specimen prepared on the CNC lathe machine. Three samples for each material are
made. First raw material of cylindrical shape is turned down to 11mm diameter. Again,
the sample is fixed in the spindle; the contour turning is done for 4mm length with
5.13mm radius of curvature and 10mm diameter. The rest is turned down to 10mm
diameter.
2.4. Working procedure on pin on disc
2.4.1. Machine setup
1. Check all the power connections and switch on the power supply.
2. Turn on the MCB on the test rig and on the controller unit.
3. Move the sliding block under the loading lever, press the start button on the controller,
by revolving the rpm knob set the rpm to required value and press stop button on
controller.
4. Clean the disc with the help of acetone. Fix the specimen in the hardened jaws with the
help of Allen keys and adjust the heigh of the specimen as well.
5. Adjust the wear track diameter (WTD) by losing the studs on the lower end, and then fix
it.
6. Apply the required load on weight pan with the help of dead weights.
7. Set the time duration of the test on the controller unit.
2.5 Test Parameters
Table: 8 Test conditions followed
Parameter EN19 EN353 EN47
Load (N) 20 30 50
Speed 1000 1000 1000
(RPM)
WTD (mm) 80 80 80
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Figure.4: Pin on disc Test Rig
Figure.5: Experimentation
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3. Results and Discussions
Figure6: Pin/Ball on disc tester readings.
Figure 7: Testing on pin/ball on disc test rig.
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3.1. EN47 wear and friction.
Referring to Figure. 8, it is concluded that the wear and frictional force of EN47 material at
50N load and 1000rpm ranges between 0µm and 1220µm, and the friction force is in between
19N and 26N. From the graph, it is observed that wear is high at the start, and it gradually
becomes constant. As for frictional force, there is not much variation from the starting to the
end, which results in uniform frictional force.
Figure8: Graph of EN47 at 50N, 1000rpm and 80WTD.
3.2. EN19wear and friction.
The wear is gradually increasing and the rate of wear ranges from 0µm to 950µm at a load of
20N and 1000rpm, whereas the frictional force ranges from 8N to 12N. From the below
mentioned graph it is observed that the wear rate is gradually increasing, and the friction
force is constant throughout the experimentation for EN19 specimen.
Figure9: Graph of EN19 at 20N, 1000rpm and 80WTD.
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3.3. EN353wear and friction.
At a load of 30N and 1000rpm the wear rate is increased at the beginning, but as the time
passes it came to constant, and as of coefficient of friction, it is mostly uniform throughout
the experiment. The wear rate ranges from 0µm to 1000µm, and the frictional force is at an
average of 12N for the EN353 sample.
Figure 10: Graph of EN353 at 30N, 1000rpm and 80 WTD.
4. Conclusion
Tribological properties like wear and frictional force are studied for EN47, EN353 and EN19
under dry conditions against EN31 disc at different loads, speed and wear track Diameter on
the pin on disc tribometer, respective COF and WR (wear rate) graphs are taken, and
conclusions were made.
From the above-mentioned graphs, we can understand two things majorly
1. When the test begins the coefficient of friction (COF) raises rapidly and gradually comes
to a point and then do not change vigorously.
2. The wear rate keeps on increasing as the test proceeds and after some time it do not
fluctuate beyond a certain range.
For the performed experiments the most suitable material among the three materials is EN19
because it has the least wear rate and frictional force under the test condition. Initially the
EN47 material wear is high but gradually it became constant and EN19 material wear is
uniform throughout the testing as observed from its graph. EN353 material also showed
similar results like uniform wear curve as EN19 but the rate of wear and frictional force is
more for EN353 compared to EN19.
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Experimental validation of fatigue life for thread rolling form tool material, IOP
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