Analyzing frictional noise for wear monitoring under dry and lubrication condition: experimental modelling with pin-on-disc tribometer

Abstract

In industrial settings, the use of frictional noise to improve wear monitoring is highly promising. It enables the identification of changes in friction and wear conditions, the assessment of different phases of wear, and the examination of the impact of wear on machine performance. By analysing acoustic signatures, it is conceivable to continuously monitor the wear characteristics and surface conditions. This helps in predicting wear and detecting aberrant wear regimes in real-time. The data demonstrate that in dry conditions, the aluminum disc has higher coefficients of friction relative to cast iron and mild steel, likely due to the absence of graphite flakes in aluminum. Under lubricated conditions, a layer of lube significantly decreases the coefficient of friction, with no apparent deviations across the materials, demonstrating that complete lubrication avoids direct metal contact. In lubrication-starved applications, oily depictions nevertheless help minimize friction, though less efficiently than complete lubrication. In dry conditions, frictional sound levels for mild steel are higher due to direct surface hits, while lubrication reduces noise by eliminating metal-on-metal contact. As a result, monitoring noise levels is a helpful indicator of lubrication difficulties, aiding in maintenance and repairs.