1. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 4, July - August (2013) © IAEME
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EFFECT OF ORIENTATION AND APPLIED LOAD ON ABRASIVE WEAR
PROPERTY OF ALUMUNIUM ALLOY –AL6061
Mohd Shadab Khan1
, Dr. Zahir Hasan2
1
Jr. Associate Professor, Department of Mechanical Engineering, Integral University,
Kursi Raod, Lucknow - 226026, U.P. India
2
Professor & Principal, Jahagirabad Institute of Technology, Jahangirabad,
Barabanki – 225203, U.P. India
ABSTRACT
Wear is a continuous process in which material is degraded with every cycle. Scientists are
busy in improving the wear resistance. Approximately 75% failure in components or machine parts
is due to wear. The present paper investigates experimentally the effect of orientation and normal
load on Aluminium alloy and calculating weight loss due to wear. To do so, a multi-orientational
pin-on-disc apparatus was designed and fabricated. Experiments were carried out under normal load
05-20 N, speed 2000 rpm. Results show that the with increasing load weight loss increases at all
angular positions. The loss in weight is maximum at zero degree (horizontal position) and minimum
at ninety degree (vertical position) for a particular load. Maximum wear occur when the test
specimen is held at 0o
angle minimum wear occur when the specimen is held at 90o
angle for given
applied load The circumferential distance travel is constant for all positions and for all load but still
mass loss varies.
Keywords: Abrasive Wear, Alumunium, Grinding Disc, Mass Loss, Orientation.
1. INTRODUCTION
Wear is a continuous process in which material is degraded at every cycle. Kloss et al.
emphasized the various tools such as wear measuring equipments, mathematical modeling, tribo
meters and simulations are used for measuring wear resistance and wear rate over many decades. It
was observed by several authors [1-11] that the variation of friction and wear rate depends on
interfacial conditions such as normal load, geometry, relative surface motion, sliding speed, surface
roughness of the rubbing surfaces, type of material, system rigidity, temperature, stick slip, relative
humidity, lubrication and vibration. Among these factors sliding speed and normal load are the two
major factors whose play significant role for the variation of friction and wear rate. As reviewed by
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2. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 4, July - August (2013) © IAEME
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Becker, et al.[12] , the three important wear mechanisms mentioned over the years are: corrosion,
abrasion, and adhesion. Researchers are also suggested some parameters hardness, fatigue or tensile
strength producing effect in wear rate. Hardness does give any indication of the wear resistance of a
material; however studies have demonstrated that the addition of certain alloying elements increases
the wear resistance but not the hardness. Al 6061 is widely used in numerous engineering
applications including transport and construction where, superior mechanical properties such as
tensile strength and hardness are essentially required. Typical mechanical properties for Al 6061 are
presented in Table 4.1.
The objective of this work is to design a new type of pin on disc setup which can check wear
rate or loss of weight of the selected specimen at different orientation and at different loads.
2. MATERIALS AND METHODS
In order to carry out the experimental work the following procedure is adopted.
(i) Design of setup (ii) Materials Selection (iii) Wear Behavior
2.1 Design of setup
In view of the objective a set-up was needed to be designed which can calculate wear rate at
different angular positions (0o
, 30o
,45o
,60o
,90o
)of work piece. The designed setup is shown in the
fig.2.1
Fig.2.1. Design of setup
The set up has following different parts (1) Controller (2)D.C. Motor (3) Flange
Coupling(4)Bearing(5)Main Frame (6)Frame(Angular)(7)Acrylic Sheet(8)Grinding Wheel
(9)Specimen(10)Screw Jack(11)Load Cell
2.2 Selection of Material
For the present investigation Al-alloy 6061 type Aluminium alloy has been selected. Table
2.1 shows the Chemical Composition of the Al6061 alloy
10
1
2
4
7
9
84 1135 6
39
0o
60o
30o
90o

3. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 4, July - August (2013) © IAEME
82
Table 2.1- Properties of Al6061
2.2.1 Specimen Preparation
The specimen for wear studies was cut from the Al alloy plate. The specimen cross section
used was 1 cm x 1cm with a thickness of 4.5 cm. The top and bottom specimen surfaces were made
planer by polishing against emery papers of appropriate grits. For the preparation of the surface to be
used for wear studies, the final grit size of the emery paper was the same as the one to be used for the
wear studies.
2.3 Wear characterization
The following method was adopted for wear characterization
2.3.1 Selection of Applied Load and the Position of the Specimen
The following loads were selected for present objective
(i) 5 N (ii) 10 N (iii) 15 N (iv) 20 N
For each load the position of the specimen was kept at 0o
, 30o
, 45o
, 60o
and 90o
respectively.
2.3.2 Selection of Grinding Wheel
The type of grinding wheel used for certain application, greatly influence the quality of the surface
produced. Therefore, for different types of materials, different types of abrasive wheels can be used.
Thus for Aluminium the grade of grinding disc taken is C46-K6V.
2.3.3 Speed of Grinding Wheel
The speed of grinding disc is kept at constant value of 2000 rpm
2.3.4 Test Procedure
Before the test the weight of the test specimen was taken accurately using an electronic
balance with an accuracy of 0.001 g. The maximum weighing capacity of the electronic balance was
320 g. After a travel time of 05 minutes against the grinding disc, the sample was taken out carefully
so that the debris’s were removed from the valleys of the specimen and exact wear materials can be
measured. Once again weight was taken carefully using the above balance and the difference in
weight was noted. This was continued for five times with same specimen and same position. After
that next specimen was taken for next test condition i.e. 30o
angle and 5 N applied load and so on.
The tests were conducted for five different orientations namely 0o
, 30o
, 45o
, 60o
and 90o
. Thus a total
of 25 reading is taken for one particular load. This is continued for load of 10N, 15N, 20N
respectively. The cumulative effect of weight loss was taken for calculating the wear mass.
3. RESULTS
The effect of load on the specimen is shown in fig. 3.1 to 3.5 at various angular positions
namely 00
, 300
, 450
,600
and 900
respectively. The mass loss of the materials is presented for loads
5N, 10N, 15N, 20N. The effect of orientation on the specimen is shown in fig. 3.6 to 3.9. Grade of
grinding disc taken is C46-K6V for Alumunium material.
Elements Cu Mn Mg Si Fe Cr Ti Zn Density MOE PR
Wt % 0.15-0.40 0.15 0.8-1.2 0.4-0.8 0.7 0.04-0.35 0.15 0.25 2.7 g/cm3
70-80 GPa 0.33

4. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 4, July - August (2013) © IAEME
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3.1 Effect of Load at Different Orientations
• From graph 3.1 it is observed that the wear mass increases from 0.801 gm to 1.012 gm as the
applied load on the specimen increases from 5N to 20N when orientation of the specimen is
0o
.
• From graph 3.2 it is observed that the curve follows the same pattern as in graph 3.1.The
wear mass increases from 0.753 gm to 0.926 gm as the applied load on the specimen
increases from 5N to 20N when orientation of the specimen is 30o
• From graph 3.3 it is observed that the wear mass increases from 0.710 gm to 0.905 gm as the
applied load on the specimen increases from 5N to 20N when orientation of the specimen is
45o
.
• From graph 3.4 it is observed that the wear mass increases from 0.629 gm to 0.882 gm as the
applied load on the specimen increases from 5N to 20N when orientation of the specimen is
60o
.
• From graph 3.5 it is observed that the wear mass increases from 0.376 gm to 0.630 gm as the
applied load on the specimen increases from 5N to 20N when orientation of the specimen is
90o
.[13]
Fig 3. 1 - Effect of load at 00
orientation Fig 3.2 - Effect of load at 30o
orientation
Fig 3.3 - Effect of load at 450 orientation Fig 3.4 - Effect of load at 600 orientation
0.710
0.820 0.856 0.905
0.000
0.200
0.400
0.600
0.800
1.000
5N 10N 15N 20N
MassLoss(gm)
Applied Load(N)
0.629
0.740 0.781
0.882
0.000
0.200
0.400
0.600
0.800
1.000
5N 10N 15N 20N
MassLoss(gm)
Aplied Load (N)
0.801
0.917 0.940
1.012
0.000
0.200
0.400
0.600
0.800
1.000
1.200
5N 10N 15N 20N
MassLoss(gm)
Applied Load(N)
0.753
0.851 0.8890.926
0.000
0.100
0.200
0.300
0.400
0.500
0.600
0.700
0.800
0.900
1.000
5N 10N 15N 20N
MassLoss(gm)
Applied Load(N)

5. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 4, July - August (2013) © IAEME
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Fig 3.5 - Effect of load at 900 orientation
3.2 Effect of Orientation at Different Load
The following observations were made:
• From graph 3.6 it is observed that as the orientation of the specimen changes from 0o
to 90o,
the wear mass decreases from 0.801gm to 0.376 gm when applied load is 5N.
• From graph 3.7 it is observed that the wear mass follows the same pattern as in graph 3.6.The
wear mass decreases from 0.917gm to 0.439gm as the orientation changes from 0o
to 90o
when applied load is 10N.
• Similarly from graph 3.8 and 3.9 it is observed that the wear mass decreases from 0.940 gm
to 0.605 gm and from 1.012gm to 0.630 gm respectively as the orientation of the specimen
changes from 0o
to 90o
when applied loads are 15N and 20N respectively.
Fig.3.6 - Effect of orientation angle at 5N Fig 3.7 - Effect of orientation angle at 10N
0.376
0.439
0.605 0.63
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0 5 10 15 20 25
Massloss(gm)
Applied Load(N)
0.801
0.753
0.710
0.629
0.376
0.000
0.100
0.200
0.300
0.400
0.500
0.600
0.700
0.800
0.900
0 30 45 60 90
Wear(mg)
Orientation Angle(Degree)
0.917
0.851 0.820
0.740
0.439
0.000
0.200
0.400
0.600
0.800
1.000
0 30 45 60 90
Wear(mg)
Orientation Angle (Degree)

6. International Journal of Mechanical Engineering and Technology (IJMET),
6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 4, July
Fig 3.8 - Effect of Orientation angle at 15N
4.0 DISCUSSION
As the position changes from 0 degree to 90 degree, the
particle changes, this changes the motion of
applicable done. The variation of wear mass shown in the above graph
changes from zero degree to 90 degree wear mass
forces. The fig. 4.1 shows orientation at o degree. It can be concluded
At 0 Degree
• It can seen from the FBD that weight of debri
to each other. The debri do not trap in between specimen and abrasive disc
of wt. of debri-particle and centrifugal force, the debri
• It becomes two body abrasions
• The Alumunium alloy (Al6061) gets fresh abrasive surface
decreases.
Fig 4.1
Debri-particle
0.940
0.889 0.856
0.000
0.200
0.400
0.600
0.800
1.000
0 30 45 60
Wear(mg)
Orientation Angle (Degree)
International Journal of Mechanical Engineering and Technology (IJMET),
6359(Online) Volume 4, Issue 4, July - August (2013) © IAEME
85
mg
Orientation angle at 15N Fig 3.9 - Effect of orientation angle at 20N
As the position changes from 0 degree to 90 degree, the forces applicable on the debri
this changes the motion of debri-particle. Therefore a complete analysis of forces
The variation of wear mass shown in the above graph shows
ro degree to 90 degree wear mass decreases due to the changes in orientation of
forces. The fig. 4.1 shows orientation at o degree. It can be concluded that:
It can seen from the FBD that weight of debri-particle (mg) and centrifugal force (mrw
debri do not trap in between specimen and abrasive disc
and centrifugal force, the debri-particle of specimen falls.
abrasions against general perception.
The Alumunium alloy (Al6061) gets fresh abrasive surface, due to this wear
Fig 4.1 – Specimen at 0o
(Horizontal)
Applied
Load
Abrasive Disc
0.781
0.605
60 90
Orientation Angle (Degree)
1.01
0.93 0.91
0.00
0.20
0.40
0.60
0.80
1.00
1.20
0 30 45
Wear(mg)
Orientation Angle (Degree)
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
August (2013) © IAEME
Effect of orientation angle at 20N
forces applicable on the debri-
Therefore a complete analysis of forces
shows that as position
decreases due to the changes in orientation of
particle (mg) and centrifugal force (mrw2
) add
debri do not trap in between specimen and abrasive disc. Due to addition
of specimen falls.
this wear resistance
0.91 0.88
0.63
60 90
Orientation Angle (Degree)

7. International Journal of Mechanical Engineering and Technology (IJMET),
6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 4, July
At 90 Degree
• In this case the set-up rotates to 90 degree.
particle and centrifugal force (mrw
• Since debri traps in between specimen and abrasive disc
abrasions due to this Al6061 do not get fresh abrasive surface.
• This Change in nature of forces increases the wear
Fig 4.2
5.0 CONCLUSION
On the basis of experimental work the following
(i) With increasing load wear (
agreement with M. A. Chowdhury
(ii) The loss in mass is maximum at zero degree (horizontal position
(iii) The loss in mass is minimum at ninety degree (vertical position) for a particular load.
(iv) Maximum wear occur when the test specimen is held at 0
(v) Minimum wear occur when the specimen is held at 90
(vi) The circumferential distance travel is constant for all positions
weight loss varies.
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International Journal of Mechanical Engineering and Technology (IJMET),
6359(Online) Volume 4, Issue 4, July - August (2013) © IAEME
86
up rotates to 90 degree. The load on the specimen adds to weight
particle and centrifugal force (mrw2
) and weight (mg) are perpendicular. to each other
ween specimen and abrasive disc hence it becomes three body
Al6061 do not get fresh abrasive surface.
This Change in nature of forces increases the wear resistance.
Fig 4.2 – Specimen at 90o
(Vertical)
On the basis of experimental work the following conclusion can be drawn:
wear (mass loss) increases at all angular positions this is in
agreement with M. A. Chowdhury, M. K. Khalil, D. M. Nuruzzaman, M. L. Rahaman [14]
The loss in mass is maximum at zero degree (horizontal position) for a particular load
The loss in mass is minimum at ninety degree (vertical position) for a particular load.
Maximum wear occur when the test specimen is held at 0o
angle
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angle for given applied load
he circumferential distance travel is constant for all positions and for
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
August (2013) © IAEME
The load on the specimen adds to weight of debri-
) and weight (mg) are perpendicular. to each other
hence it becomes three body
increases at all angular positions this is in
, M. K. Khalil, D. M. Nuruzzaman, M. L. Rahaman [14]
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