A mathematical model for erosive abrasive wear analysis by using abrasive size and material hardness

Purpose: Erosion and abrasion are the prominent wear mechanisms reducing the lifetime of machine components. Both wear mechanisms are playing a role meanwhile, generating a synergy, leading to a material removal on the target. The purpose of study is to create a mathematical expression for erosive abrasive wear. Design/methodology/approach: Many factors such as environmental cases and material character have an influence in erosive abrasive wear. In the work, changes in abrasive size and material hardness have been analyzed. As an abrasive particle, quartz sand has been used. All tests have been done in 20 wt.% slurry. Heat treatment has been applied to different steel specimens (steel grades C15, St 37 and Ck45) to change hardness value, which ranged from 185 to 880 Vickers hardness number. Findings: After the four-hour test, it is determined that by an increase in abrasive size and decrease in material hardness, wear rate increases. Worn surfaces of the targets have been examined to figure out the wear mechanisms at different conditions under scanning electron microscopy. The results indicate that by an increase in material hardness, the number and diameter of micro-craters on the worn surfaces decrease. The diameters of micro-craters have been about 3–8 µm in hard materials and about 120–140 µm in soft materials. Research limitations/implications: It is determined that by an increase in abrasive size and decrease in material hardness, wear rate increases. The results indicate that by an increase in material hardness, the number and diameter of micro-craters on the worn surfaces decrease. Practical implications: The study enables to indicate the dominant factor in worn steel used in mechanical components. Originality/value: After analyzing the test results, a novel mathematical expression, considering both abrasive size and material hardness, has been developed.