Wear Analysis for Engineers
Raymond G. Bayer

Chapter 1   THE WEAR ANALYSIS METHOD
1.1 WEAR ANALYSIS OVERVIEW
1.2 THE WEAR ANALYSIS PROCESS
1.2.1 Examination
1.2.2 Characterization
1.2.3 Modeling and Evaluation
1.2.4 Testing
1.3 PROCESS IMPLEMENTATION
1.3.1 Problem-Solving Situation
1.3.2 Design Situation

Chapter 2   BASIC TRIBOLOGY
2.1 SYSTEM CONCEPT
2.2 WEAR MECHANISMS
2.2.1. Adhesive Mechanisms
2.2.2 Single-Cycle Deformation Mechanisms
2.2.3 Repeated-Cycle Deformation Mechanisms
2.2.4 Chemical Mechanisms
2.2.5 Thermal Mechanisms
2.2.6 Tribofilm Mechanisms
2.2.7 Coexistence and Interaction of Mechanisms
2.2.8 Mild and Severe Wear
2.3 FRICTION
2.4 LUBRICATION
2.5 WEAR SITUATIONS
2.5.1 Sliding
2.5.2 Rolling
2.5.3 Impact
2.5.4 Abrasive Situations
2.6 DESIGN FACTORS
2.6.1 Mechanical
2.6.2 Material
2.6.3 Lubrication
2.6.4 Environmental Considerations

Chapter 3   EXAMINATION METHODS
3.1 TRIBOSYSTEMS
3.1.1 Macrotribosystems
3.1.2 Microtribosystems
3.2 WEAR
3.2.1 Wear Scar Features
3.2.2 Examination Techniques
3.3 OPERATING AND DESIGN CONDITIONS
3.3.1 Analysis Without Worn Parts
3.3.2 Analysis With Worn Parts
3.4 SUPPLEMENTARY EXAMINATIONS AND COMPARISONS

Chapter 4   CHARACTERIZATION METHODS
4.1 OPERATIONAL CLASSIFICATION
4.2 MECHANISTIC CLASSIFICATION

Chapter 5   PHENOMENOLOGICAL CONSIDERATIONS
5.1 TRIBOLOGICAL TRENDS
5.2 PIVOTAL FEATURES
5.3 LUBRICATION
5.4 MATERIALS
5.5 DATABASE USE AND TESTING
5.6 WEAR SEVERITY

Chapter 6   ANALYTICAL METHODS
6.1 WEAR RELATIONSHIPS
6.1.1 Sliding
6.1.2 Rolling
6.1.3 Impact
6.1.4 Abrasion
6.2 DATA ANALYSIS
6.3 ALTERNATIVE MODELS

Chapter 7   SPECIAL CONSIDERATIONS
7.1 CONTACT CONDITIONS
7.2 FLUID LUBRICATION
7.3 COATINGS AND SURFACE TREATMENTS
7.4 JOURNAL BEARINGS
7.5 FRETTING
7.6 GALLING

Chapter 8   WEAR ANALYSIS EXAMPLES
8.1 DESIGN TRIAGE FOR SLIDING WEAR
8.2 ELECTRO-EROSION PRINT HEAD
8.3 FLUID TRANSFER SYSTEM LUGS
8.4 INJECTION VALVE
8.5 DISK DRIVE BEARING

Appendixes
A.I EQUATIONS FOR CONTACT STRESS AND AREA
A.II NOMINAL K-FACTORS AND FRICTION COEFFICIENTS
A.III ZERO-WEAR FACTORS AND COEFFICIENTS OF FRICTION FOR SLIDING
A.IV K-FACTORS AND P-V LIMITS FOR PLASTICS
A.V GALLING THRESHOLD STRESS

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