Enhanced Wear Volume Analysis Using Three-Dimensional Profilometry for Four-Ball Tribometer Setups

Abstract Accurately assessing wear volume is critical for advancing material development, improving manufacturing practices, and extending the lifespan of mechanical components. In four-ball tribometer tests, traditional methods typically estimate wear volume based on wear scar diameters, a two-dimensional approach. While some studies have modeled wear craters as three-dimensional features, these models are limited by their reliance on ball material and wear scar diameter, without considering the lubricant's influence. Additionally, such methods are prone to inaccuracies due to the irregular geometry of wear scars and the comparable scale of the calculated wear volume's height to surface roughness. These limitations highlight the need for precise methods to calculate wear volumes that go beyond conventional geometrical approximations. This research presents an advanced approach utilizing three-dimensional (3D) profilometry to achieve precise wear volume calculations. By analyzing the depth and contours of wear scars, the actual wear volume is determined by subtracting the deformed scar volume from the original, undeformed ball volume. The proposed methodology also incorporates an analysis of uncertainties, offering a robust framework for more reliable wear quantification. Experimental findings confirm the effectiveness of this technique, highlighting its improved accuracy and consistency over conventional diameter-based methods.