Document Type


Date of Award


Degree Name

Master of Science in Mechanical Engineering - (M.S.)


Mechanical and Industrial Engineering

First Advisor

Roman Dubrovsky

Second Advisor

Rong-Yaw Chen

Third Advisor

Avraham Harnoy


In this work a modification of a wear testing machine has been done by designing a new loading mechanism and redesigning different components for a new roller-on-roller wear testing machine. A new loading mechanism containing gearbox frame and load cell assembly have been designed, manufactured and assembled. A pusher of the pushing mechanism is redesigned for better durability. Existing bearing support was redesigned and replaced. All new units of the wear testing machine were lined up and assembled with the machine. Finite element stress analysis for designed frame in the load mechanism was performed by using the Integrate Design Engineering Assistant System, known as I-Deas, and ANSYS.

More than 30 AISI D2 and H13 tool steel specimens treated by plasma ion nitriding and/or magnetic treatment were tested on a computer controlled wear testing machine. The operational surface roughness has been investigated during all stages of wear. It was found that plasma ion nitriding surface treatment improves the wear resistance of the tool steel dramatically. The higher the nitrogen concentration is used the better the improvement is. Specimens treated with higher nitrogen concentration provide better wear resistance. Surface treated by a combination of processes: ion nitriding and magnetization improve wear resistance. Magnetic treatment applied before ion nitriding provides better influence on durability. Magnetic treatment performed with higher number of cycles provides better wear resistance.



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