Wear Analysis for Engineers
Raymond G. Bayer

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360 pp.

ISBN: 0-9664286-5-X

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Like other types of analysis commonly used in engineering, wear analysis is fundamentally the use of equations and models to evaluate wear behavior. However, for it to be effective, wear analysis must incorporate certain elements and considerations beyond the evaluation of equations. In this book I describe a wear analysis methodology that incorporates these elements and considerations. While wear behavior is complex, useful wear analyses often are not. Generally, the complexity and rigor of the analysis depend primarily on the engineering needs and secondarily on the wear situation. It has been my experience that simple and basic wear analyses, conducted in the proper manner, are often adequate in many engineering situations. Integral and fundamental to the wear analysis approach is the treatment of wear and wear behavior as a system property. As a consequence wear analysis is not limited to the evaluation of the  effects of materials on wear behavior. Wear analysis often enables the identification of nonmaterial solutions or nonmaterial elements in a solution to wear problems. For example, changes in or recommendations for contact geometry, roughness, tolerance, and so on are often the results of a wear analysis.

The wear analysis process and the trends in tribological behavior described in this book are based on experienced gathered over 40 years of utilizing this method to resolve and avoid wear problems in a wide range of machines. Based on personal experience, this wear analysis method has been successfully applied to wear situations as diverse as those in modules containing computer chips to wear problems in engines and agricultural equipment. It has been used for devices sensitive to small amounts of wear but expected to withstand hundreds of millions of operations, as well as mechanisms less sensitive to wear or expected to withstand only a few hundred or so operations. Some of these applications are described in Chapter 8, as well as in my previous book, Mechanical Wear Prediction and Prevention (Marcel Dekker).

This book is intended to explain the wear analysis method and its implementation and to provide sufficient information for the performance of most wear analyses. It is intended primarily for engineers. The wear analysis process and the implementation of its various elements are described in the first chapter. Case study examples of wear analyses are presented in the final chapter. Basic information generally needed for the proper conduction of a wear analysis is provided in the intervening chapters. Chapter 2 contains a summary of general tribological behavior and generic descriptions of the significant phenomena involved. The general influence of operational conditions and design parameters on wear behavior and phenomena are also described in this chapter. Chapter 3 covers methods used in the examination phase of a wear analysis. Chapter 4 treats two methods of classification of wear situations that are useful in conducting wear analyses, particularly in identifying significant parameters and relevant models. General analytical relationships for wear and wear models, which are applicable to most wear situations, are discussed in Chapter 6. Chapters 5 and 7 contain a variety of additional information that is often significant in the conduction of a wear analysis. Chapter 5 focuses on phenomenological aspects. Chapter 7 focuses on specific wear situations that are frequently encountered in practice, such as galling and fretting.

Several appendixes are provided to facilitate the application of the wear analysis method. Appendix I contains contact stress equations for various geometries. The remaining appendices contain tables of experimental wear coefficients gathered from various sources.

The detail of tribological information provided in this book is intended to be adequate for typical wear analysis. There are situations where more detailed or more extensive information is required for the analysis. Numerous references are provided for this purpose. I have found the following to be good sources of additional information for wear analysis. Handbook of Tribology, B. Bhushan & B.K. Gupta, McGraw-Hill, is a good source of material data; Friction, Wear, and Lubrication Technology, Vol. 18, ASM Handbook, P. Blau Ed., ASM International, is a good source for data and for a description of tribological behavior in different applications. Mechanical Wear Prediction and Prevention, R. G. Bayer, Marcel Dekker, is a good source for general tribology, detailed cases studies, testing, and modeling.

I am grateful to all of those organizations (cited by Reference number in the figure legends and table footnotes) that granted permission for reproduction of numerous figures and tables.

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