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है”ह”ह

IS 10636-3 (1983): Methods for Measurement of Abrasive WearProperties of Metallic Material, Part 3: Test Methods forLow Stress Abrasion [MTD 3: Mechanical Testing of Metals]

IS : 10636 ( Part 3 ) - 1983

Indian Standard METHODS FOR

MEASUREMENT OF ABRASIVE WEAR

PROPERTIES OF METALLlC MATERIAL

PART 3 TEST METHODS FOR LOW STRESS ABRASION

Methods of Physical Tests Sectional Committee, SMDC 3

Ch&mnn Representing I

SHRI P. K. CHAK~AVARTY The Tata Iron & Steel Co Ltd, Jamshedput

Members

SHEI R. K. ABROL Bharat Steel Tubes Ltd, Ganaur SHRI KANWALJIT SINQH ARORA ( Alt.matc)

SHRI SUJIT KUMAB BASU M. N. Dastur & Co (P) Ltd, Calcutta SERI S. Smr GUPTA (Alternate )

DR A. CHAKRABORTY Usha Martin Black (Wire Ropes) Ltd, Calcutta Srrm H. MAHESWARY ( Alternate )

SERI K. K. CHERIAN Indian Aluminium Co Ltd, Calcutta SHRI PAI~KAJ DE ( Alternate )

SEaI 0. P. CHnoa Associated Instrument Manufacturers’ ( India 1 Private Ltd, New Delhi

SHRI V. N. NANDA ( Alternate ) DR R. P. DAMBAL Indian Telephone Industries Ltd, Bangalore

SHRI N. NA~ARAJ ( Alternute ) SHRI M. K. DAS GUPTA National Physical Laboratory ( CS IR ), New Delhi DEPUTY DIRECTOR ( MET )-2, Ministry of Railwavs

RDSO, LUOKNOW‘ ’ . ASSISTANT RESIDENT OFFICEB/

MET-~, RDSO, LUCKNOW ( Alternate ) SHRI D. DUTTA The Indian Tube Co Ltd, Jamshedpur

SHRI C. B. LUNAWAT ( Alternate) SHRI J. C. ERRY Steel Authority of India Ltd, ( Bokaro Steel

Plant) Bokaro SHBI K. G. GARQ Directorate General of Technical Development

and Production ( Air ), New Delhi SHRI P. RAQHOTHAMA Rro ( Alternate)

SERI A. G~oea National Test House, Calcutta SHRI D. S. MAJTJMDAR (Alternate)

( Continued on pdgd 2 )

0 Copyright 1983 INDIAN STANDARDS INSTITUTION

This publication is protected under the Indian Co@right Act ( XIV of 1957) and reproduction in whole or in part by any means except with written permission ofthe nublisher shall be deemed to be an infringement of copvrixht under the said Act.

IS : 10636 ( Part 3) - 1983

Membrrr Reprsnnting

SHBI S. A. HAQUB SHRI A. S. WUU ( Altamatr )

Tata Iron and Steel Co Ltd, Jamahedpur

SEIBI S. B. IDNANI SHRI G. S. SOBR ( Altrrnata )

Blue Star Limited, Bombay

SHRI S. V. KULXABXI Fuel Instruments & Engineers Pvt Ltd,

SHBI J. V. KUL~CARNI ( Altcrnatr ) Ichalkaranji

SERI S. KUMAR Mining Allied Machinery Corporation Ltd.

SHBI K. S. LAKSEIMINAUAYAN Durgapur

SHRI R. D. SHABMA ( Aftmate) Avery India Ltd, Calcutta

SHRI S. R. MAJUMDAB Ministry of Defence ( DGI ) SHRI A. K. CHAKBQBOBTY I Altcmatc \

SHBI R. A. PADMANABHAN

SHRI M. PRASAD

* C&al Mechanical Engineering Research Institute (CSIR 1, Durgapur

Steel SHRI N. GOPALAK~~IBHNA ( Altrrnats )

Authority of India Ltd, Ranchi

. SHRI S. RADHAKRISENAN

DR V. SBINIVAS~J ( Ahnutr ) SHRI R. N. SAHA

SEBI S. K. PANDEY ( Affernatc ) SHRI D. N. SARKAB

SHEI A. R. BA~U ( Altmatc) SH~I F. C. SHABXA Srirt~ K. Swmrappm SH~I H. K. TANEJA

SHRI V. N. PANDEY ( Alternate ) Da V. RAO

National Aeronautical Laboratory ( CSIR ), Bangalore

Directorate General of Supplies and Disposals, New Delhi

Ministry of Defence ( DGOF )

Directorate General of Civil Aviation, New Delhi Ministry of Defence ( R&D ) Indian Register of Shipping, Bombay

National _ Metallurgical Laboratory ( CSIR ),

DB D. J. CHAKBAVABTI ( Alternuts ) Jamshedpur

Sasr K. RAQEA~X.NDBAX, Director ( Strut & Met )

Director General, IS1 ( Ex-o&io Mmhr)

Smtar) Smu S. K. GUPTA

Deputy Director ( Metals), ISI

2

IS I 10636 ( Part 3 ) - 1983

Indian Standard METHODS FOR

MEASUREMENT OF ABRASIVE WEAR PROPERTIES OF METALLIC MATERIAL

PART 3 TEST METHODS FOR LOW STRESS ABRASION

0. FOREWORD

0.1 This Indian Standard was adopted by the Indian Standards Institution on 27 July 1983, after the draft finalized by the Methods of Physical Test Sectional Committee had been approved by the Structural and Metals Division Council.

0.2 Wear is a consequential removal of material from one or both of the surfaces in relative motion against each other. Several factors, such as mechanical, thermal and chemical ( corrosion ) are associated with the process of wear. However, in most of the industrial applications involving material handling, abrasive wear plays a dominant role. Abrasion is a wear by displacement of material from surfaces in relative motion, caused by the presence of hard protuberances or by the presence of hard particles, either between the surfaces or embedded in one of them. Abrasive wear may occur in dry state or in the presence of a liquid. Abrasive wear occurs when a relatively harder material moves across the wearing

a)

b)

c)

metal surface. This mode of-wear has three sub-groups:

Gouging Wear refers to the situation in which the metal is removed by a type of ‘ Machining ’ operation in which the hard material indents the metal and in moving along the surface, removes material in relatively larger pieces. This type of wear is often accompanied by heavy impact and common examples are seen in wear of crusher liners, earth-moving shovels and in heavy digging operations.

High Stress Abrasion is a term used where the wear is on a finer scale than the gouging abrasion but the stresses involved are sufficient to fracture the abrasive particles. A common example is the wear of ball and liners in ball mills.

Low Stress Abrasion occurs in a situation when the stresses involved are very low and the abrasive particles are fine and

3

IS : 10636 ( Part 3 ) - 1983

not fractured. A situation of this type is found to exist during dry sand running down a chute abrasive slurries moving inside a pipe and in ore classifiers, etc.

0.3 Extensive work has been done all over the world on the measurement of wear and several testing machines have been developed. However, none of these have been standardized which makes it difficult to compare results obtained in different laboratories even when the testing machines are almost similar. In the present standard an attempt has been made to present some of the methods which may be used as standard methods for the measurement of abrasion resistance of metals and alloys under different abrasive wear situation.

0.4 This standard is being issued in three parts covering different test methods for determination of wear. This part ( Part 3 ) deals with the test methods for low stress abrasion.

The other parts in the series are given below:

Part 1 Test method for gouging abrasion resistance (jaw crusher test )

Part 2 Test method for high stress abrasion

0.5 In reporting the result of a test made in accordance! ,with this standard, if the final value, observed or calculated, is to be rounded off, it shall be done in accordance with IS : 2 - 1960*.

1. SCOPE

1.1 This standard ( Part 3 ) prescribes the following two test methods for the measurement of low stress abrasion:

a) Rubber wheel abrasion machine method;

b) Rotating Pin Method.

Low stress abrasion occurs in a situation in which the stress imposed on the abrasive particles does not exceed the crushing strength of the particles. These tests may evaluate the resistance to low stress abrasion of different materials. These tests may also be used to study the effects of metallurgical factors on the resistance to low stress abrasion.

*Rules for rounding off numerical values ( revised).

4

IS : 10636 ( Part 3) - 1983

2. RUBBER WHEEL ABRASION MACHINE METHOD

2.1 Equipment - The equipment, namely a rubber wheel abrasion machine, essentially consists of a 200 mm diameter steel wheel with 12.7 x 12.7 mm synthetic rubber rim on its outer periphery. The wheel rotates through a silica sand slurry at a speed of 134 m/min. A stationary specimen of the test material attached to the end of a loading lever is pressed against the rotating rubber wheel with a force of 250 f 10 N. The hardness of the rubber in the rubber wheel should be around 75-80 Shore A ( see Fig. 1 ).

I

1. D. C. Motor 1 HP 1500 RMP 6. Specimen 2. Lever 7. Stand for Lever 3. Gear Box 200 Ratio 5 : 1 8. Cover for Container 4. Container 9. Steel Wheel 5. Rubber RIM

FIG. 1 SCHEMATIC ARRANGEMENT OF RUBBER WHEEL ABRASION TESTING MACHINE FOR Low STRESS ABRASION TEST

2.2 Test Specimen - The specimen is of size 6 mm x 25 mm x 55 mm with one face curved to the radius of the rubber wheel rim.

2.3 Test Procedure - The specimen is pressed against the rubber rim at specified load and the wheel is rotated for 5 000 revolutions. This is called the running in period. The specimen is then taken out, cleaned and weighed. It is then mounted against the rubber wheel again and the second run is completed for 5 000 revolutions. The weight loss in

5

IS:l&W(Part3)-1983

the second run is taken for comparison of the wear resistance. The sand slurry consists of water and sand in the ratio 2 : 3 by weight and the size of sand shall be - 355 + 250 Irm ( - 45 + 65 mesh ).

2.4 Presentation of Result

2.4.1 The result of the test is obtained in terms of weight loss in milligrammes which the specimen incurs during the second and subsequent stages of 5 000 revolutions. An average value from at least three tests is taken for comparison.

A similar run on hot rolled mild steel reference plate with hardness 140 f 10 HB shall be made and the results shall be expressed in terms of wear ratio.

2.4.2 If any one of the values of the set of three tests falls out side 20 percent of the mean values, a fresh set of three tests shall again be conducted.

3. ROTATING PIN METHOD

3.1 Equipment

3.1.1 As shown in Fig. 2 the equipment basically consists of a rotating platform being rotated by a vertical shaft passing centrally through a slurry tank. Provisions are made on this platform for mounting four rotating spindles equally placed along the periphery of the rotating platform. These spindles are rotated by a single motor mounted on the platform. All of these spindles have arrangements for holding specimen at their bottom end in such a way that they are submerged deep inside the slurry. Speed of the rotating platform can range from 20 to 30 rpm. The rotational speed of the spindles can vary up to 3 000 rev/min.

3.1.2 Slurry -The slurry consists of water and sand in the proportion water: Sand = 2 : 3 with sand of - 355 -!- 250 r.rm ( - 45 + 65 mesh ).

3.2 Test Specimen

3.2.1 The test specimen is in the form of a cylinder with its exposed part having a diameter of 15 or 25 mm and a length of 25 mm.

3.3 Test Procedure - Four test specimen of exact size and shape are mounted on the spindles. The platform as well as the spindles are rotated at fixed rpm. The loss in weight of the specimen after specified number of rotation of the spindles is determined. The weight loss of the specimen after 10 000 f 100 rpm of the spindles shall be taken as wear data for comparison.

6

,-

..1

*

-,,

.,

.

.

%, “

_. —— -------—---- —--

ROTATINGPLATFORM

-1

N–.—C_———.

-)=———---

ROTATING SPECIMEN .–:=—==—.=—.

(4 Nos. EQUALLYPLACED)

DRilN/lw

TS

CouAG

FIG. 2 SCHEMATXCARRANGEMENTOF MACHINE FOR Low STRESSABRASIONRESISTANCETEST

..

.

.

.I

,

IS : 10636 ( Part 3 ) - 1983

3.4 Presentation of Result -The results of the tests once obtained as a weight loss in milligram, an average value of the four specimen shall be reported as an average weight loss. No single value of the weight loss shall vary more than 20 percent from the average value. The result shall be presented as the ratio of wear of the reference hot rolled mild steel of hardness 140 f 10 HB, when tested under identical conditions and the material under test.

8