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\
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=
E
WR
A
re
2 1
1 1 1
R R R
+ =
2
2
2
1
2
1
*
1 1 1
E E E
+
=
1857-1894
Heinrich Hertz
19
Sliding Friction Physics Real Contact
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4
3
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E
WR
A
re
In words
Smaller Asperity Radii Smaller real area
Larger Elastic Modulus Smaller real area
GPa E
steel
200
1 GPa = 1x 10
9
N/M
2
= 1.45 x 10
5
psi
GPa E
lead
15
GPa E
SiC
500
GPa E
rubber
001 . 0
20
Sliding Friction Physics Real Contact
Greenwood & Williamson - 1966
W
A
a
Apparent Area
A
a
W
Asperities of same radii
Asperities of random distribution of heights (e.g. Gaussian, exponential etc..)
Asperities separated no interaction
Exponential Distribution success!!
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R
E
W
A
re
W - force applied
E
*
- composite Elastic Modulus
R summit radius of curvature
is the standard deviation of the peak heights
21
Sliding Friction Physics Real Contact
Greenwood Williamson - 1966
W
A
a
W
Recall:
F
fe
= A
re
s (s is shear strength of junctions)
Substituting for A
re
F
fe
~ W
F
fe
has no dependence on Apparent Area
Consistent with Amonton
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W
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A
a
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Dry Friction Physics Real Contact
Greenwood Williamson - 1966
In Words
Larger the applied force larger real area of contact (friction )
Larger Elastic Modulus smaller area of contact (friction)
Larger Summit Radii larger area of contact (friction)
Larger the roughness smaller area of contact (friction)
*
F
fe
= A
re
s
Friction ~ shear strength of the real regions of contact
* elastic domain
23
Sliding Friction Physics Real Contact
Greenwood Williamson 1966
1) Only Exponential law gives Laws of Friction results
2) Other frictional mechanisms (e.g. plowing) not considered
3) Asperity on asperity/ resolution - reality
4) Assumes elastic contact only next step is plasticity
Laws of friction follows since all surfaces have texture
The mean asperity real contact area is independent of applied force -Exp dist onlyR
The mean asperity real pressure very weak dependence on applied force -Exp dist onlyE
*
(/R)
1/2
The number of contacts are proportional to applied force -Exp Dist only W/(E
*
(
3
R)
1/2
)
Good News
Bad News
24
Sliding Friction Physics Elastic and Plastic
Greenwood & Williamson 1966
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R
E
W
A
re
A
rp
= W/H
Pure Elastic
Pure Plastic
Plastic deformation will begin when the pressure at the asperity is greater than H.
Calculate for various distribution (e.g. Exp) the probability of plastic deformation
...) , ( W f
A
A
re
rp
=
2
1
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R H
E
Plasticity Index
(very weak dependence on W)
H- hardness of lowest hardness surface at interface
25
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R
E
W
A
re
A
rp
= W/H
1.0
0.6
Sliding Friction Physics Elastic and Plastic
Greenwood Williamson 1966
<0.6 elastic regime Larger A
r
higher friction (Too Smooth)
>1.0 plastic regime, lower Ar,but..
deformation, wear etc. eventually back to elastic regime or
.scoring scuffing galling failure etc..
26
Sliding Friction Physics Elastic and Plastic
Greenwood Williamson 1966
2
1
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R H
E
160 nm
R 10 um
100 nm
R 70 um
Likely - Elastic Deformation
Likely - Plastic Deformation
27
Sliding Friction Physics Reset Real Area of Contact
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R
E
W
A
re
A
rp
= W/H
Elastic Mode
Plastic Mode 2
1
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R H
E
Plasticity Index - Predicts Elastic or Plastic
Friction relates to the Adhesion between surfaces at the real area of contact.
Adhesion chemical bonds, mechanical, etctotally different/new field
F
fp
= A
rp
s (s is shear strength of junctions)
Recall (pure plastic): A
rp
= W/H so F
fp
= W(s/H)
ap
=s/H
F
fe
= A
re
s (s is shear strength of junctions)
Recall (pure elastic):
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ae
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Dry Friction Physics Elastic and Plastic - Models
AF- Abbot Firestone 1933 Pure Plastic (Truncation Model)
GW Greenwood and Williamson 1966- Elastic only spherical contacts etc.
CEB Cheng, Etsion, Bogy 1987 Elastic/Plastic
KE Kogut and Etsion 2004 - Elastic/Plastic and tangential loading effects
J amari and Schipper 2006 Elastic/Plastic Ellipsoids asperities
J . J amari and D.J . Schipper, An elastic-plastic contact model of ellipsoid bodies, Tribology Letters, Vol. 21 No. 3 march 2006.
F=external Load
P=Aspertiy Contact Force
Fs=Total Adhesive Force
Qmax-Static Friction Force
29
Friction Physics Rough Surface Contacts
C.Y. Poon and R. S. Sayles, The Classification of rough surface contacts in relation to tribology, J . Phys D: Appl.
Phys. 25 (1992) A249-A256
F
r
i
c
t
i
o
n
C
o
e
f
f
i
c
i
e
n
t
30
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1
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E
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A
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R
E
W
A
re
A
rp
= W/H
1.0
0.6
Unworn
high friction - deformation
Worn- run-in
Minimal friction
Very worn
high friction larger A
r
adhesion
Sliding Friction -- Engine- Valve Train Components
31
Sliding Friction
Transmission Components
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32
Sliding Friction Physics Plowing Term
) tan( 2
=
d
Assumes isotropic material
Gear Surface
6 deg
d
0.06
Bharat Bhushan, (2002), Introduction to Tribology, J ohn Wiley & Sons, New York
100:1 Vertical Magnification
33
Sliding Friction Physics Plowing Term
Plowing Term Not that big for typical machined surface textures
But! - debris and wear particlesanother story
Sand Particle (Ottawa 16)
Slope ~ 30 deg
d
0.36
Also --Sandpaper, brake pads etc
34
Sa: In spec
Sdq: Low
Sa: In spec
Sdq: High
Problem: Brake Rotor Sa inspec some work ..some have NVH issues
Solution: Quantify the surfaces Spec additional texture parameters q
Solution: Identify cause of texture variation..(materials? tools? setup?)
Glenn R. Weier, Kelsey Hayes 1995
Sliding Friction Physics Plowing Term
dydx
y
y x Z
Ly
x
y x Z
Lx
A
Sdq
2
) , (
0
2
) , (
0
1
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=
Sdq: Root-Mean Square Surface Slope
35
Sliding Friction Physics Surface Texture
Bottom Line What is the connection between Surface Texture and Friction?
1) Friction - adhesion at the real area of contact
2) Friction - the deformation of asperities
2) Friction - plowing of the harder asperities into the softer material
Other Texture Parameters can relate to the real area of contact/asperity slope
..this has been the source of confusion/speculation/empirical work
Surfaces are not a nice distribution of asperities of radius R
36
Kotwal, C.A. and Bhuhsan, B. (1996) Contact Analysis of Non-Gaussian Surface for
Minimum Static and Kinetic Friction and Wear Tribol. Trans. 39, 890-898
elastic limit
Sliding Friction Physics Surface Texture Parameters
Ssk
Sku
Sku=3.0
Ssk=0.0
Ssk<<0.0 Ssk>>0.0
Sku<3.0 Sku>3.0
37
Functional Bearing Area Parameters .. Spk, Sk Svk....
D C
B A
tp
=100% x (A +B +C +D )/L
Spk =Peak Height .. First Region of contact
Sk =Core Height... working Region ..Base
Svk =Valley Depth ... Lubricant Retention Region
tp
Peaks
Core
Valleys
100%
50%
0%
Min Ht
Max Ht
40%
Svk
Sk
Spk
Mr1 Mr2
mr
Friction Physics Surface Texture Parameters
Abbott and Firestone (1933)
38
Cylinder Bore Finishes and Their Effect on Oil Consumption
Stephen H. Hill,
SAE, 2001-01-3550
LD=Production Gasoline Auto Engines
Units in um unless specified
C
y
l
i
n
d
e
r
B
o
r
e
Best predictor of Oil Consumption, Vo,
Vo = Svk(100-Mr2)/200
Careful of Vo units etc.
39
Sliding Friction Physics Surface Texture Parameters
Functional Bearing Area Parameters .. Spk, Sk, Svk....
40
K
S
S
S
S S
S
S SI
z
a
sk
sm vk
pk
k
+
(
=
1
log
SI = Surface Index for TFM
SIW SI for Optical Profiler
SIT SI for Stylus Profiler
Largest SI Worst TFM
K for optical or stylus
Tribology Transactions, 51: 784-789, 2008
41
Effect of Roughness Parameter and Grinding Angle on Coefficient of
Friction When Sliding os Al-Mg Alloy over EN8 Steel
Pradeep L. Menezes Kishore and Satish V. Kailas,
ASME J ournal of Tribology, October 2006, Vol 128. p 697-704
The coefficient of friction and transfer layer formation were observed to depend
primarily on the direction of the grinding marks of the harder mating surface and
independent of the surface roughness of harder mating surface.
Direction of Motion
42
Modeling and Optimizing Honing Texture for Reduced Friction in Internal
Combustion Engines
J effrey J ocsak, Yong Li, Tian Tain and Victor K. Wong
SAE, 2006-01-0647
MIT-Ring-Pack Simulation Program
Reduce Cross Hatch Angle -reduces friction (less asperity contact/more hydrodynamic lift)
However, -Tradeoff- As reduce cross hatch angle increase risk of scuffing (TDC) / oil consumption
u
u
=
0 =
h
F
r
i
c
t
i
o
n
43
Cross Hatch Angle Analysis
Sliding Friction 3D Texture Directional Analysis
44
Conclusion Sliding Friction and Surface Texture
Friction relates to adhesion of surfaces at points of real contact
.Real area of contact relates to surface texture
Friction relates to deformation / plowing asperity shape/slope
Asperity Shape/Slope relates to surface texture
The challenge is choosing the right lateral/height resolution
for measurement and the appropriate texture parameters to
relate to friction and then to optimize for desired friction
What is clear, is that the study of surface roughness continues to get more
complicated and that we are a long way from understanding it.
J . A. Greenwood (1992)
I.L. Singer and H.M. Pollock (eds.) Fundamentals of Friction: Macroscopic and
Microscopic Processes 57-76 1992 Kluwer Academic Publishers, Netherlands.