A wear testing machine is a laboratory device used to evaluate the performance of materials or coatings under friction and wear conditions. It is widely used in machinery, materials, automotive, aerospace, electronics, coatings, and other fields to study the wear resistance, coefficient of friction, and life prediction of materials. The following are general operating instructions for wear testing machines, applicable to common reciprocating, rotary, or pin-disc wear testing machines.

I. Preparation Before Use

1. Equipment Inspection

Ensure the power supply, control system, sensors, and mechanical components of the testing machine are in normal working order. Check for looseness, wear, or oil leaks. Confirm that the equipment is properly grounded and that safety devices are intact.

2. Sample Preparation

Prepare the test sample and the wear pair (such as pins, balls, discs, etc.) according to the testing standard. The sample surface should be clean and free of oil, oxide layer, or impurities. It can be wiped with alcohol or acetone and cleaned with an ultrasonic cleaner before drying. Record the sample material, dimensions, surface treatment method, and initial surface roughness.

3. Specimen Installation

Securely mount the main specimen (e.g., plate or block sample) in the sample stage or fixture, ensuring it will not loosen or shift during testing. Mount the grinding element (e.g., steel ball, cylindrical pin) on the loading arm or spindle, adjusting its position to ensure good contact and uniform force distribution.

II. Setting Test Parameters

According to the experimental purpose and relevant standards (e.g., GB/T, ASTM, ISO, etc.), set the following parameters in the control panel or accompanying software:

1. Load: Set the normal force applied to the specimen, in Newtons (N), such as 5N, 10N, 50N, etc. Select an appropriate load based on the material hardness.

2. Motion Mode: Select rotary, reciprocating sliding, or linear motion mode.

3. Speed ​​or Frequency: Set the spindle speed (e.g., 100 rpm) or reciprocating frequency (e.g., 5 Hz).

4. Stroke Distance: For reciprocating testing machines, set the sliding stroke length, such as 5 mm or 10 mm.

5. Test Time or Number of Cycles: Set the running time (e.g., 30 minutes) or the total number of friction cycles (e.g., 10.000 cycles).

6. Environmental Conditions: If a heating platform or environmental chamber is available, set the temperature (e.g., room temperature, 100℃, 200℃); if lubrication is required, add lubricating oil or grease.

III. Starting the Test

1. Start the equipment and confirm smooth operation without abnormal noise or vibration.

2. Observe the real-time display of friction force, friction coefficient, temperature, and other data on the control system.

3. The equipment automatically records the data and generates a friction coefficient-time curve or wear change curve.

IV. Post-Test Operation

1. Stop the Equipment

After the test, turn off the motor and control system, and unload the load.

2. Remove the Sample

Carefully disassemble the sample to avoid secondary damage. Use a soft cloth or tweezers to handle it and prevent scratching the worn surface.

3. Cleaning and Inspection

Clean the sample surface with alcohol or acetone to remove wear debris and residue. Observe the wear morphology using an optical microscope, laser confocal microscope, or surface profilometer; measure the width or depth of the wear scar; and calculate the wear volume or mass loss.

4. Data Processing

Calculate the average coefficient of friction.

Compare the wear resistance under different materials or processes.

Analyze the wear mechanism (e.g., adhesive wear, abrasive wear, fatigue wear, etc.).

5. Equipment Maintenance

Clean the testing machine's worktable, fixtures, and guide rails; add lubricating oil if necessary. Cover with a dust cover when not in use for extended periods.

V. Precautions

1. Overloading is strictly prohibited to avoid damage to the sensors or mechanical structure.

2. Samples must be securely installed to prevent loosening that could damage the equipment or distort data.

3. Take safety precautions during high-temperature or high-speed testing to prevent burns or mechanical injury.

4. Regularly calibrate the force sensor, displacement sensor, and temperature system to ensure testing accuracy.

5. Select appropriate wear pairs and testing methods for different materials and operating conditions to ensure comparability of results.

In summary:

The use of a wear testing machine must be strictly in accordance with the operating procedures. From sample preparation and parameter setting to data acquisition and analysis, each step affects the accuracy and reliability of the test results. Correct use of this equipment can effectively evaluate the wear resistance of materials, providing a scientific basis for product design, material selection, and quality control.