Materials Today: Proceedings xxx (xxxx) xxx
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Materials Today: Proceedings
journal homepage: www.elsevier.com/locate/matpr
Analysis of the wear properties of through hardened AISI-4140 alloy
steel using Taguchi technique
Ranbir Singh Rooprai a,⇑, Harvinder Singh a, Talvinder Singh a, Yogesh Kumar Singla b
a
b
Chitkara University Institute of Engineering and Technology, Chitkara University, Punjab, 140401, India
Case Western University, Cleveland, Ohio, 44106, USA
a r t i c l e
i n f o
Article history:
Received 8 March 2021
Received in revised form 6 April 2021
Accepted 15 April 2021
Available online xxxx
Keywords:
AISI 4140
API GL-4
EN 31
ANOVA
a b s t r a c t
Alloy Steel AISI 4140 has applications in various fields like automotive, aerospace, manufacturing
industries. In the sliding pairs wear is the main cause for energy loss, that may reduce the efficiency of
the mechanical systems. The study reveals the optimization of tribological properties of AISI 4140 under
lubricated condition using Taguchi approach. Pin on disk wear test is perform to find the out the effect of
sliding speed, load and distance on properties of AISI 4140 steel. The wear study was done for different
loads, in order to make the comparison. ANOVA is used in this experimental work.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Functional Material, Manufacturing and Performances.
1. Introduction
Among the specifications for wear resistance for alloy steel
gears, one of the main reliability indices can be considered. In addition to the direct loss of material leading to functional failure. Surface wear induces the vibration and sound of the equipment
important as the excitement of gear mesh is very responsive to
its surface geometry [1]. The characteristics of any material depend
upon the various conditions where it used to perform operations.
Vibration and unnecessary foreign/pollution particles often contribute to associated with a low excess loads on the contact profile
or even during the operation of machining in points of contact for
high-speed and heavy-duty equipment [2–4]. Various types of
wear were arising during the interacting of surfaces of two or more
components of any machine. Abrasion, skidding and contact tiredness can lead to more frequent and complex surface and subsurface damage to wear behaviour under extreme loads. Scuffing
also induced where the load and sliding speed makes impulsive
impact of the surface of the material during operation. For several
years, better gear wear has been standard practice for resist some
sort of surface modification technologies [5–7]. Friction is the
motion resistance encountered when a solid is experienced over
another body slides. Different types of friction were arising while
performing the operation due to various conditions falls in it. The
⇑ Corresponding author.
E-mail address: ranbi.rooprai@chitkara.edu.in (R.S. Rooprai).
force of resistance, parallel to the direction the ’friction force’ is
known as movement. Wear is known to all, and we certainly all
believe we understand what wear means. Nevertheless, the concept of wear is difficult to formulate precisely and entirely [8].
There’s also no way to eliminate friction completely from movements. It is very hard to overcome the effect of induced friction
while performing operations. Oiling is the best method to reduce
the friction of moving parts. For reducing wear, an oil layer is put
between the contact surfaces of moving parts [9]. Using the lubricants, wear and friction can be easily reduced. It is very effective
method to reduce the effect of wear and friction while performing
operation. While choosing the type of lubricant used in operation,
we have to be very careful. As if we do some mistake while selecting of lubricants it may affect the characteristics of the material
and increase the wear and friction as well [10]. In order to minimize the friction and wear of materials, wearing behaviour by tribometer is needed. By calculating weight loss using digital
balances, wear rate of the material can be determined. Tribometer
is a setup where pin on disk or ball on disk test were easily performed with accuracy. Dry or lubricant type wear test were conducted by the best use of the tribometer apparatus. A wear and
frictional force setup were attached with the tribometer apparatus.
With the help of this setup, we are able to calculate the SWR and
COF easily. The tribometer allows tribological behaviour to be
studied under varying contact pressure, sliding speed, time and
lubrications [11,12]. AISI 4140 has various applications in the field
of aerospace, automobiles and manufacturing industries. As for
https://doi.org/10.1016/j.matpr.2021.04.196
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Functional Material, Manufacturing and Performances.
Please cite this article as: Ranbir Singh Rooprai, H. Singh, T. Singh et al., Analysis of the wear properties of through hardened AISI-4140 alloy steel using
Taguchi technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2021.04.196
Ranbir Singh Rooprai, H. Singh, T. Singh et al.
Materials Today: Proceedings xxx (xxxx) xxx
Table 1
AISI 4140 chemical composition.
Element
C
Si
Mn
S
P
Cr
Mo
Wt(%)
0.382
0.230
0.930
0.006
0.005
0.900
0.218
this experimental study we are using this material because it also
uses in the gear box material of the food processing unit. This
material has very high strength and ductile properties so as it
can use in the gear box of the many manufacturing machine setups. A Pin on disk wear test perform for finding out the specific
wear rate and coefficient of friction. Material pin-on-disk tests
are regulated by the ASTM standard. Taguchi design technique
were used for experimental work in this study. The grey relational
grade and ANOVA were used to determine the best test conditions
[13,14]. The response table of means are used in this experimental
study to describing the optimum results. Various parameters are
well described with the help of Analysis of variance. Result of Pvalue for sliding distance is adjudged as the most favorable parameter. The effect of sliding speed, sliding distance and different loads
on wear rate and C.O.F were also determined by this pin on disk
test [17].
2. Materials and methods
For doing the experimental study AISI 4140 alloy steel were
used as specimens as it has application in gearbox of food processing unit. Mn and Cr has main component of this alloy steel for providing it high strength and toughness. Specimen having length of
40 mm and diameter of 10 mm. Due to ease of alignment of such
pins are used with spherical heads for proper area of contact with
rotating disk. Different heat treatment processes are done on specimens to attain the hardness of 40 HRC. It can be checked by using
Rockwell hardness machine which is available in-house lab. Diamond ball intender is used to check the hardness of pins with
applied load of 150 kg. This ball intender is very important and
best for use to check the hardness of the specimens with definite
load present in it. Chemical composition of material AISI 4140 is
display in the following Table 1.
The disk is used for this wear test is having hardness of 62 HRC.
The rotating disk and the specimen are contact perpendicular to
each other and experiment were conduct with this. The material
of disk is EN 31. API GL-4 gear oil is used as lubricant for this wear
test. It having good quality of viscosity as it acts as non-circulating
oil it can change after six months, so as to give better output in gear
box application in food processing unit.
Fig. 1. Pin on disk wear test setup.
sliding distance and different loads are the process parameters
used in this study. L9 orthogonal array is used to describe the
whole experimental work. ANOVA is also used for determining
the optimum results. Fig. 1 represents the setup of pin on disk.
Total 9 experiment were done for finding optimal value of SWR
and COF.
The specimen is stable and disk is rotating while a natural force
is exerted by a mechanism of the lever. Three Sliding speed of 1,
1.5, 2 m/s under three different normal loading of 50, 100, 150 N
and sliding distance of 500, 1000, 1500 m are used for doing experimental work. The specimens are weighed on Denver electronic
machine. It has least count of 0.01 mg. Acetone is used to wash
the specimens for cleaning them. The difference between initial
and final value of weight loss along with friction is calculated for
finding wear.
3. Experimental design
The research experimental work done on the ASTM G-99-17
standard under lubricated conditions. The observed data is
recorded which is described in Table 2. The observed data table
is describing the output of SWR and COF along with GRG with
input parameters sliding speed, sliding distance and load. In this
work study the pin is held vertically i.e., perpendicular to the
2.1. Wear test
Pin on wear test is perform in order to find out the SWR and C.O.
F by using standard ASTM G-99-17 [15,16]. While performing wear
test pin is held perpendicular to the rotating disk. Sliding speed,
Table 2
Experimental observed data.
S.N.
Sliding Speed (m/s)
Sliding Distance (m)
Load (N)
SWR (mm3/Nm)
COF
GRG
1
2
3
4
5
6
7
8
9
1.0
1.0
1.0
1.5
1.5
1.5
2.0
2.0
2.0
500
1000
1500
500
1000
1500
500
1000
1500
50
100
150
100
150
50
150
50
100
3.31
3.29
3.27
3.06
3.04
3.42
2.82
3.17
3.14
0.421
0.496
0.511
0.482
0.538
0.512
0.547
0.522
0.574
0.690
0.447
0.430
0.556
0.486
0.395
0.689
0.446
0.409
2
Materials Today: Proceedings xxx (xxxx) xxx
Ranbir Singh Rooprai, H. Singh, T. Singh et al.
Table 3
Response table of means.
Level
Sliding Speed (m/s)
Sliding Distance (m)
Load (N)
1
2
3
Delta
Rank
0.5223
0.4790
0.5146
0.0433
3
0.6449
0.4599
0.4111
0.2338
1
0.5104
0.4706
0.5349
0.0643
2
Fig. 2. Graph of Main effects plot for means.
Table 4
Analysis of variance (ANOVA).
Source
DF
Adj SS
Adj MS
F-Value
P-Value
Sliding Speed (m/s)
Sliding Distance (m)
Load (N)
Error
Total
2
2
2
2
8
0.003194
0.091266
0.006319
0.004001
0.104780
0.001597
0.045633
0.003159
0.002000
0.80
22.81
1.58
0.556
0.042
0.388
Various parameters are well described with the help of Analysis
of variance (ANOVA). Here P- value 0.042 for sliding distance is
adjudged as the most favourable parameter. Table 4 is of ANOVA.
circular disk to perform experiments. The spherical head pin is
used in this experimental work. It prevents or minimizes the damage of material when locating by drop down method. Lubrication
of material is playing a vital role in preventing material for wear
or friction. Gear oil API-GL4 is using in this experimental study
to see the effect of it on wear at different conditions. SWR is the
dependent on the load applied so it is very crucial to see what
result they come out from this experimental work. A setup is
attached with wear testing machine to give us the values of frictional force and wear. So, from this we can calculate the values
of SWR and COF for describing our results as outputs.
5. Conclusion
The main conclusions that could be drawn from the present
study are as follows:
Sliding distance is the most significant factor for the combination of outcomes i.e., wear and coefficient of friction.
The optimal values for the selected parameters are sliding speed
as 1 m/s, sliding distance 500 m and load 150 N.
The optimum value obtained for SWR and COF are 2.82 mm3/
Nm and 0.421.
P- value 0.042 for sliding distance is adjudged as the most
favourable parameter.
The effect of the chosen parameters in a sequential order is as
sliding distance followed by load and then sliding speed.
For the future scope, we could estimate the wear rate also
instead of wear and temperature generated during the process.
4. Results
In the results section, we describe the effects of the parameters
that we take in this work study on SWR. Here is the response table
for means outcome with all three parameters describing their level
and delta rank in it. Sliding distance effects most the combination
of wear and coefficient of friction (Table 3).
The main effect plots of means for GRG has been shown in Fig. 2.
From this plot, we are able to conclude the optimal combination of
parameters which could be written as sliding speed-1, sliding
distance-1 and load-3.
3
Ranbir Singh Rooprai, H. Singh, T. Singh et al.
Materials Today: Proceedings xxx (xxxx) xxx
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CRediT authorship contribution statement
Ranbir Singh Rooprai: Conceptualization, Methodology, Software, Validation. Harvinder Singh: Visualization, Investigation.
Talvinder Singh: Data curation, Writing - original draft. Yogesh
Kumar Singla: Supervision, Writing - review & editing.
Declaration of Competing Interest
The authors declare that they have no known competing financial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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