Search results for: Chase type friction tester

Authors: Mingjiang Dai, Qian Shi, Fang Hu, Songsheng Lin, Huijun Hou, Chunbei Wei

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A diamond-like carbon (DLC) is considered as a promising protective film since its high hardness and excellent tribological properties. However, DLC films are very sensitive to the environmental condition, its friction coefficient could dramatic change in high humidity, therefore, limited their further application in aerospace, the watch industry, and micro/nano-electromechanical systems. Therefore, most studies focus on the low friction coefficient of DLC films at a high humid environment. However, this is out of satisfied in practical application. An important thing was ignored is that the DLC coated components are usually used in the diversed environment, which means its friction coefficient may evidently change in different humid condition. As a result, the invalidation of DLC coated components or even sometimes disaster occurred. For example, DLC coated minisize gears were used in the watch industry, and the customer may frequently transform their locations with different weather and humidity even in one day. If friction coefficient is not stable in dry and high moisture conditions, the watch will be inaccurate. Thus, it is necessary to investigate the stable tribological behavior of DLC films in various environments. In this study, a-C:H:Si films were deposited by multi-function magnetron sputtering system, containing one ion source device and a pair of SiC dual mid-frequent targets and two direct current Ti/C targets. Hydrogenated carbon layers were manufactured by sputtering the graphite target in argon and methane gasses. The silicon was doped in DLC coatings by sputtering silicon carbide targets and the doping content were adjusted by mid-frequent sputtering current. The microstructure of the film was characterized by Raman spectrometry, X-ray photoelectron spectroscopy, and transmission electron microscopy while its friction behavior under different humidity conditions was studied using a ball-on-disc tribometer. The a-C:H films with Si content from 0 to 17at.% were obtained and the influence of Si content on the structure and tribological properties under the relative humidity of 50% and 85% were investigated. Results show that the a-C:H:Si film has typical diamond-like characteristics, in which Si mainly existed in the form of Si, SiC, and SiO2. As expected, the friction coefficient of a-C:H films can be effectively changed after Si doping, from 0.302 to 0.176 in RH 50%. The further test shows that the friction coefficient value of a-C:H:Si film in RH 85% is first increase and then decrease as a function of Si content. We found that the a-C:H:Si films with a Si content of 3.75 at.% show a stable friction coefficient of 0.13 in different humidity environment. It is suggestion that the sp3/sp2 ratio of a-C:H films with 3.75 at.% Si was higher than others, which tend to form the silica-gel-like sacrificial layers during friction tests. Therefore, the films deliver stable low friction coefficient under controlled RH value of 50 and 85%.

Keywords: diamond-like carbon, Si doping, moisture environment, table low friction coefficient

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Authors: A. Jourani, C. Trevisiol, S. Bouvier

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The aim of this work is to study the coupled effect of microstructure and surface roughness on friction coefficient, wear resistance and wear mechanisms. Friction tests on 35NCD16 steel are performed under different normal loads (50-110 N) on a pin-on-plane configuration at cyclic sliding with abrasive silicon carbide grains ranging from 35 µm to 200 µm. To vary hardness and microstructure, the specimens are subjected to water quenching and tempering at various temperatures from 200°C to 600°C. The evolution of microstructures and wear mechanisms of worn surfaces are analyzed using scanning electron microscopy (SEM). For a given microstructure and hardness, the friction coefficient decreases with increasing of normal load and decreasing of the abrasive particle size. The wear rate increase with increasing of normal load and abrasive particle size. The results also reveal that there is a critical hardness Hcᵣᵢₜᵢcₐₗ around 430 Hv which maximizes the friction coefficient and wear rate. This corresponds to a microstructure transition from martensite laths to carbides and equiaxed grains, for a tempering around 400°C. Above Hcᵣᵢₜᵢcₐₗ the friction coefficient and the amount of material loss decrease with an increase of hardness and martensite volume fraction. This study also shows that the debris size and the space between the abrasive particles decrease with a reduction in the particle size. The coarsest abrasive grains lost their cutting edges, accompanied by particle damage and empty space due to the particle detachment from the resin matrix. The compact packing nature of finer abrasive papers implicates lower particle detachment and facilitates the clogging and the transition from abrasive to adhesive wear.

Keywords: martensite, microstructure, friction, wear, surface roughness

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Authors: Jacob Hatherell, Jason Matthews, Arnaud Marmier

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Anvil Staking is a cold-forming process that is used in the assembly of plain spherical bearings into a rod-end housing. This process ensures that the bearing outer lip conforms to the chamfer in the matching rod end to produce a lightweight mechanical joint with sufficient strength to meet the pushout load requirement of the assembly. Finite Element (FE) analysis is being used extensively to predict the behaviour of metal flow in cold forming processes to support industrial manufacturing and product development. On-going research aims to validate FE models across a wide range of bearing and rod-end geometries by systematically isolating and understanding the uncertainties caused by variations in, material properties, load-dependent friction coefficients and strain rate sensitivity. The improved confidence in these models aims to eliminate the costly and time-consuming process of experimental trials in the introduction of new bearing designs. Previous literature has shown that friction coefficients do not remain constant during cold forming operations, however, the understanding of this phenomenon varies significantly and is rarely implemented in FE models. In this paper, a new approach to evaluate the normal contact pressure versus friction coefficient relationship is outlined using friction calibration charts generated via iterative FE models and ring compression tests. When compared to previous research, this new approach greatly improves the prediction of forming geometry and the forming load during the staking operation. This paper also aims to standardise the FE approach to modelling ring compression test and determining the friction calibration charts.

Keywords: anvil staking, finite element analysis, friction coefficient, spherical plain bearing, ring compression tests

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Authors: Sori Won, Bosung Seo, Kwangsuk Park, Seok Hong Min, Tae Kwon Ha

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With the increased needs for lightweight materials in automobile industry, the usage of aluminum alloys becomes prevailed as components and car bodies due to their comparative specific strength. These parts composed of different aluminum alloys should be connected each other, where welding technologies are commonly applied. Among various welding methods, friction welding method as a solid state welding gets to be popular in joining aluminum alloys as it does not produce a defect such as blowhole that is often formed during typical welding processes. Once two metals are joined, corrosion would become an issue due to different electrochemical potentials. In this study, we investigated variations of corrosion properties when Duralumin and AA6063 were joined by friction welding. From the polarization test, it was found that the potential of the welded was placed between those of two original metals, which could be explained by a concept of mixed potential. Pitting is a common form as a result of the corrosion of aluminum alloys when they are exposed to 3.5 wt% NaCl solution. However, when two different aluminum alloys (Duralumin and AA6063) were joined, pitting corrosion occurred severely and uniformly in Duralumin while there were a few pits around precipitates in AA6063, indicating that AA6063 was cathodically protected.

Keywords: corrosion properties, friction welding, dissimilar Al alloys, polarization test

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Authors: Nurzaki Ikhsan, Ahmad Saifizul Abdullah, Rahizar Ramli

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One of the functions of the commercial heavy vehicle is to safely and efficiently transport goods and people. Due to its size and carrying capacity, it is important to study the vehicle dynamic stability during cornering. Study has shown that there are a number of overloaded heavy vehicles or permissible gross vehicle weight (GVW) violations recorded at selected areas in Malaysia assigned by its type and category. Thus, the objective of this study is to investigate the correlation and effect of the GVW on heavy vehicle stability during cornering event using simulation. Various selected heavy vehicle types and category are simulated using IPG/Truck Maker® with different GVW and road condition (coefficient of friction of road surface), while the speed, driver characteristic, center of gravity of load and road geometry are constant. Based on the analysis, the relationship between GVW and lateral acceleration were established. As expected, on the same value of coefficient of friction, the maximum lateral acceleration would be increased as the GVW increases.

Keywords: heavy vehicle, road safety, vehicle stability, lateral acceleration, gross vehicle weight

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Authors: R. Rishi Jain, S. V. Viswanath, R. Naveen Vasanthan

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Generally all the IC engines, alternators, air conditioner compressors, oil pumps and coolant pumps are driven by a crankshaft utilizing V-belt drivers. An increase in the number of idle pulleys results in the increase of frictional power. Further, components like idler and belt tensioner are also needed to run the belt drive which adds to the frictional power. The aspiration of this paper is to minimize the friction power by introducing a new system that could combine all the accessories in one shaft within a single casing. This is conceptualized to minimize the friction power, service and maintenance cost, space and also time. The validation of this work can be executed through a simpler drive transmitting power from the crank shaft.

Keywords: single drive, idler pulley, belt tensioner, friction power, casing, space and cost

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Authors: Lingaraju Dumpala, Narasa Raju Gosangi

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Friction Stir Welding (FSW) is relatively new, environmentally friendly, versatile, and widely used joining technique for soft materials such as aluminum. FSW has got a lot of attention as a solid-state joining method which avoids many common problems of fusion welding and provides an improved way of producing aluminum joints in a faster way. FSW can be used for various aerospace, defense, automotive and transportation applications. It is necessary to understand the friction stir welded joints and its characteristics to use this new joining technique in critical applications. This study investigated the mechanical properties of friction stir welded aluminum 6063 alloys. FSW is carried out based on the design of experiments using L16 mixed level array by considering tool rotational speeds, tool feed rate and tool tilt angles as process parameters. The optimization of process parameters is carried by Taguchi based regression analysis and the significance of process parameters is analyzed using ANOVA. It is observed that the considered process parameters are high influences the mechanical properties of Al6063.

Keywords: FSW, aluminum alloy, mechanical properties, optimization, Taguchi, ANOVA

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Authors: M. Hadji, A. Haddad, Y. Hadji

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The effects of boronizing treatment on the friction coefficient and wear behavior of 0.35 Vf TiC- Ti3 SiC2 composite were investigated. In order to modify the surface properties of Ti3SiC2, boronizing treatment was carried out through powder pack cementation in the 1150-1350 °C temperature range. After boronizing treatment, one mixture layer, composed of TiB2 and SiC, forms on the surface of Ti3SiC2. The growth of the coating is processed by inward diffusion of Boron and obeys a linear rule. The Boronizing treatment increases the hardness of Ti3SiC2 from 6 GPa to 13 GPa. In the pin-on-disc test, i twas found that the material undergoes a steady-state coefficient of friction of around 0.8 and 0.45 in case of Ti3SiC2/Al2O3 tribocouple under 7 N load for the non treated and the boronized samples, respectively. The wear resistance of Ti3SiC2 under Al2O3 ball sliding has been significantly improved, which indicated that the boronizing treatment is a promising surface modification way of Ti3SiC2.

Keywords: MAX phase, boronizing, hardness, wear

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Authors: Farid Yuristiawan, Aulina R. Rahmi, Detty Iryani, Gunawan

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Glass ionomer cement is one of the filling material that often used in the field of dentistry because it is relatively less expensive and mostly available. Surface hardness is one of the most important properties of restoration material; it is the ability of material to stand against indentation, which is directly connected to the material compressive strength and its ability to withstand abrasion. The higher surface hardness of a material means it is better to withstand abrasion. The existence of glass ionomer cement in the mouth makes it susceptible to any substance that comes into mouth, one of them is mouthwash which is a solution that used for many purposes such as antiseptic, astringent, to prevent caries, and bad breath. The presence of alcohol in mouthwash could affect the properties of glass ionomer cement, surface hardness. Objective: To determine the comparison of surface hardness of glass ionomer cement which soaked in alcohol containing mouthwash and alcohol-free mouthwash. Methods: This research is a laboratory experimental type study. There were 30 samples made from GC FUJI IX GP EXTRA and then soaked in artificial saliva for the first 24 hours inside incubator which temperature and humidity were controlled. Samples then divided into three groups. The first group will be soaked in alcohol-containing mouthwash; second group will be soaked alcohol-free mouthwash and control group will be soaked in artificial saliva for 6 hours inside incubator. Listerine is the mouthwash that was used on this research and surface hardness was examined using Vickers Hardness Tester. The result of this research shows mean value for surface hardness of the first group is 16.36 VHN, 24.04 VHN for second group, and 43.60 VHN for control group. The result one way ANOVA with post hoc Bonferroni comparing test show significant results p = 0.00. Conclusions: The data showed there were statistically significant differences of surface hardness between each group, which surface hardness of the first group is lower than the second group, and both surface hardness of the first (alcohol mouthwash) and second group (alcohol-free mouthwash) are lowered than control group (p = 0.00).

Keywords: glass ionomer cement, mouthwash, surface hardness, Vickers hardness tester

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Authors: Murat Toren, Mehmet Çelebi

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Reducing the weight of transformers while providing good performance, cost reduction and increased efficiency is important. Weight is one of the most significant factors in all electrical machines, and as such, many transformer design parameters are related to weight calculations. This study presents a comparison of the weight of oil type transformers and dry type transformer weight. Oil type transformers are mainly used in industry; however, dry type transformers are becoming more widespread in recent years. MATLAB is typically used for designing transformers and design parameters (rated voltages, core loss, etc.) along with design in ANSYS Maxwell. Similar to other studies, this study presented that the dry type transformer option is limited. Moreover, the commonly-used 50 kVA distribution transformers in the industry are oil type and dry type transformers are designed and considered in terms of weight. Currently, the preference for low-cost oil-type transformers would change if costs for dry-type transformer were more competitive. The aim of this study was to compare the weight of transformers, which is a substantial cost factor, and to provide an evaluation about increasing the use of dry type transformers.

Keywords: weight, optimization, oil-type transformers, dry-type transformers

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Authors: Gurpreet Singh, Hazoor Singh, Kulbir Singh Sandhu

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Friction Stir Welding Process emerged as promising solid-state welding and eliminates various welding defects like cracks and porosity in joining of dissimilar aluminum alloys. In the present research, Friction Stir Welding (FSW) is carried out on dissimilar aluminum alloys 2000 series and 6000 series this combination of alloys are highly used in automobile and aerospace industry due to their good strength to weight ratio, mechanical, and corrosion properties. The joints characterized by applying various destructive and non-destructive tests. Three critical welding parameters were considered i.e. Tool Rotation speed, Transverse speed, and Tool Geometry. The effective range of tool rotation speed from 1200-1800 rpm and transverse speed from 60-240 mm/min and tool geometry was studied. The two-different difficult to weld alloys were successfully welded. All the samples showed different microstructure with different set of welding parameters. It has been revealed with microstructure scans that grain refinement plays a crucial role in mechanical properties.

Keywords: aluminum alloys, friction stir welding, mechanical properties, microstructure

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Authors: Yu Chen, Weiwei Ren, Xiaojing Mu, Feng Zhang, Yi Xu

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The superhydrophobic surface is widely used to reduce friction for the flow inside micro-channel and can be used to control/manipulate fluid, cells and even proteins in lab-on-chip. Fabricating micro grooves on hydrophobic surfaces is a common method to obtain such superhydrophobic surface. This study utilized the numerical method to investigate the effect of eccentric micro-grooves on the friction of flow inside micro-channel. A detailed parametric study was conducted to reveal how the eccentricity of micro-grooves affects the micro-channel flow under different grooves sizes, channel heights, Reynolds number. The results showed that the superhydrophobic surface with eccentric micro-grooves induces less friction than the counter part with aligning micro-grooves, which means requiring less power for pumps.

Keywords: eccentricity, micro-channel, micro-grooves, superhydrophobic surface

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Authors: Hesham A. Elkaranshawy, Amr M. Abdelrazek, Hosam M. Ezzat

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The system of ordinary nonlinear differential equations describing sliding velocity during impact with friction for a three-dimensional rigid-multibody system is developed. No analytical solutions have been obtained before for this highly nonlinear system. Hence, a power series solution is proposed. Since the validity of this solution is limited to its convergence zone, a suitable time step is chosen and at the end of it a new series solution is constructed. For a case study, the trajectory of the sliding velocity using the proposed method is built using 6 time steps, which coincides with a Runge-Kutta solution using 38 time steps.

Keywords: impact with friction, nonlinear ordinary differential equations, power series solutions, rough collision

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Authors: I. Kurashvili, A. Sichinava, G. Bokuchava, G. Darsavelidze

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Si-Ge solid solutions (bulk poly- and monocrystalline samples, thin films) are characterized by high perspectives for application in semiconductor devices, in particular, optoelectronics and microelectronics. In this light complex studying of structural state of the defects and structural-sensitive physical properties of Si-Ge solid solutions depending on the contents of Si and Ge components is very important. Present work deals with the investigations of microstructure, electrophysical characteristics, microhardness, internal friction and shear modulus of Si1-xGex(x≤0,02) bulk monocrystals conducted at a room temperatures. Si-Ge bulk crystals were obtained by Czochralski method in [111] crystallographic direction. Investigated monocrystalline Si-Ge samples are characterized by p-type conductivity and carriers concentration 5.1014-1.1015cm-3, dislocation density 5.103-1.104cm-2, microhardness according to Vickers method 900-1200 Kg/mm2. Investigate samples are characterized with 0,5x0,5x(10-15) mm3 sizes, oriented along [111] direction at torsion oscillations ≈1Hz, multistage changing of internal friction and shear modulus has been revealed in an interval of strain amplitude of 10-5-5.10-3. Critical values of strain amplitude have been determined at which hysteretic changes of inelastic characteristics and microplasticity are observed. The critical strain amplitude and elasticity limit values are also determined. Tendency to decrease of dynamic mechanical characteristics is shown with increasing Ge content in Si-Ge solid solutions. Observed changes are discussed from the point of view of interaction of various dislocations with point defects and their complexes in a real structure of Si-Ge solid solutions.

Keywords: Microhardness, internal friction, shear modulus, Monocrystalline

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Authors: Gurjinder Singh, Ankur Gill, Amardeep Singh Kang

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In the present work an effort has been made to study the influence of the welding parameters on tensile strength of friction stir welding of aluminum. Three process parameters tool rotation speed, welding speed, and shoulder diameter were selected for the study. Two level factorial design of eight runs was selected for conducting the experiments. The mathematical model was developed from the data obtained. The significance of coefficients and adequacy of developed models were tested by ‘t’ test and ‘F’ test respectively. The effects of process parameters on mechanical properties have been represented in the form of graphs for better understanding.

Keywords: friction stir welding, aluminium alloy, mathematical model, welding speed

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Authors: Boukhris Lahouari, Bouchetara Mostefa

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The active safety of a vehicle is mainly influenced by the properties of the installed braking system. With the increase in road traffic density and travel speeds, increasingly stringent requirements are placed on the vehicle's behaviour during braking. The achievable decelerations are limited by the physical aspect characterized by the coefficient of friction between the tires and the ground. As a result, it follows that an optimized distribution of braking forces becomes necessary for a better use of friction coefficients. This objective could only be achieved if sufficient knowledge is available on the theory of vehicle dynamics during braking and on current standards for the approval of braking systems. These will facilitate the development of a braking force calculation algorithm that will enable an optimized distribution of braking forces to be achieved. Operating safety is conditioned by the requirements of efficiency, progressiveness, regularity or fidelity of a braking system without obviously neglecting the recommendations imposed by the legislator.

Keywords: brake force distribution, distribution diagram, friction coefficient, brake by wire

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Authors: A. M. Khourshid, A. M. El-Kassas, I. Sabry

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The objective of this work was to investigate the mechanical properties in order to demonstrate the feasibility of friction stir welding for joining Al 6061 aluminium alloys. Welding was performed on pipe with different thickness (2, 3 and 4 mm), five rotational speeds (485, 710, 910, 1120 and 1400 rpm) and a traverse speed of 4mm/min. This work focuses on two methods which are artificial neural networks using software and Response Surface Methodology (RSM) to predict the tensile strength, the percentage of elongation and hardness of friction stir welded 6061 aluminium alloy. An Artificial Neural Network (ANN) model was developed for the analysis of the friction stir welding parameters of 6061 pipe. Tensile strength, the percentage of elongation and hardness of weld joints were predicted by taking the parameters tool rotation speed, material thickness and axial force as a function. A comparison was made between measured and predicted data. Response Surface Methodology (RSM) was also developed and the values obtained for the response tensile strength, the percentage of elongation and hardness are compared with measured values. The effect of FSW process parameters on mechanical properties of 6061 aluminium alloy has been analysed in detail.

Keywords: friction stir welding, aluminium alloy, response surface methodology, artificial neural network

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Authors: Hassan Mohammad Alkomy, Hesham Elkaranshawy, Ahmed Ibrahim Ashour, Khaled Tawfik Mohamed

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For a rigid body sliding on a rough surface, a range of uncertainty or non-uniqueness of solution could be found, which is termed: Painlevé paradox. Painlevé paradox is the reason of a wide range of bouncing motion, observed during sliding of robotic manipulators on rough surfaces. In this research work, the existence of the paradox zone during the sliding motion of a two-link (P-R) robotic manipulator with a unilateral constraint is investigated. Parametric study is performed to investigate the effect of friction, link-length ratio, total height and link-mass ratio on the paradox zone.

Keywords: dynamical system, friction, multibody system, painlevé paradox, robotic systems, sliding robots, unilateral constraint

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Authors: Boukhris Lahouari, Bouchetara Mostefa

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The active safety of a vehicle is mainly influenced by the properties of the installed braking system. With the increase in road traffic density and travel speeds, increasingly stringent requirements are placed on the vehicle's behaviour during braking. The achievable decelerations are limited by the physical aspect characterized by the coefficient of friction between the tires and the ground. As a result, it follows that an optimized distribution of braking forces becomes necessary for a better use of friction coefficients. This objective could only be achieved if sufficient knowledge is available on the theory of vehicle dynamics during braking and on current standards for the approval of braking systems. This will facilitate the development of a braking force calculation algorithm that will enable an optimized distribution of braking forces to be achieved. Operating safety is conditioned by the requirements of efficiency, progressiveness, regularity or fidelity of a braking system without obviously neglecting the recommendations imposed by the legislator.

Keywords: brake force distribution, distribution diagram, friction coefficient, brake by wire

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Authors: Itissam Abuiziah

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In several hydraulic systems, it is necessary to calculate the head losses which depend on the resistance flow friction factor in Darcy equation. Computing the resistance friction is based on implicit Colebrook-White equation which is considered as the standard for the friction calculation, but it needs high computational cost, therefore; several explicit approximation methods are used for solving an implicit equation to overcome this issue. It follows that the relative error is used to determine the most accurate method among the approximated used ones. Steel, cast iron and polyethylene pipe materials investigated with practical diameters ranged from 0.1m to 2.5m and velocities between 0.6m/s to 3m/s. In short, the results obtained show that the suitable method for some cases may not be accurate for other cases. For example, when using steel pipe materials, Zigrang and Silvester's method has revealed as the most precise in terms of low velocities 0.6 m/s to 1.3m/s. Comparatively, Halland method showed a less relative error with the gradual increase in velocity. Accordingly, the simulation results of this study might be employed by the hydraulic engineers, so they can take advantage to decide which is the most applicable method according to their practical pipe system expectations.

Keywords: Colebrook–White, explicit equation, friction factor, hydraulic resistance, implicit equation, Reynolds numbers

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Authors: Anand K. Vinu, Vaishnav Vimal, Sasi Gopalan

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All spacecraft components have a range of allowable temperatures that must be maintained to meet survival and operational requirements during all mission phases. Due to heat absorption, transfer, and emission on one side, the satellite surface presents an asymmetric temperature distribution and causes a change in momentum, which can manifest in spinning and non-spinning satellites in different manners. This problem can cause orbital decays in satellites which, if not corrected, will interfere with its primary objective. The thermal analysis of any satellite requires data from the power budget for each of the components used. This is because each of the components has different power requirements, and they are used at specific times in an orbit. There are three different cases that are run, one is the worst operational hot case, the other one is the worst non-operational cold case, and finally, the operational cold case. Sunlight is a major source of heating that takes place on the satellite. The way in which it affects the spacecraft depends on the distance from the Sun. Any part of a spacecraft or satellite facing the Sun will absorb heat (a net gain), and any facing away will radiate heat (a net loss). We can use the state-of-the-art foldable hybrid insulator/radiator panel. When the panels are opened, that particular side acts as a radiator for dissipating the heat. Here the insulator, in our case, the aerogel, is sandwiched with solar cells and radiator fins (solar cells outside and radiator fins inside). Each insulated side panel can be opened and closed using actuators depending on the telemetry data of the CubeSat. The opening and closing of the panels are dependent on the special code designed for this particular application, where the computer calculates where the Sun is relative to the satellites. According to the data obtained from the sensors, the computer decides which panel to open and by how many degrees. For example, if the panels open 180 degrees, the solar panels will directly face the Sun, in turn increasing the current generator of that particular panel. One example is when one of the corners of the CubeSat is facing or if more than one side is having a considerable amount of sun rays incident on it. Then the code will analyze the optimum opening angle for each panel and adjust accordingly. Another means of cooling is the passive way of cooling. It is the most suitable system for a CubeSat because of its limited power budget constraints, low mass requirements, and less complex design. Other than this fact, it also has other advantages in terms of reliability and cost. One of the passive means is to make the whole chase act as a heat sink. For this, we can make the entire chase out of heat pipes and connect the heat source to this chase with a thermal strap that transfers the heat to the chassis.

Keywords: passive cooling, CubeSat, efficiency, satellite, stationary satellite

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Authors: Antoine Lauvray, Fabien Poulhaon, Pierre Michaud, Pierre Joyot, Emmanuel Duc

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Additive Friction Stir Manufacturing (AFSM) is a new industrial process that follows the emergence of friction-based processes. The AFSM process is a solid-state additive process using the energy produced by the friction at the interface between a rotating non-consumable tool and a substrate. Friction depends on various parameters like axial force, rotation speed or friction coefficient. The feeder material is a metallic rod that flows through a hole in the tool. Unlike in Friction Stir Welding (FSW) where abundant literature exists and addresses many aspects going from process implementation to characterization and modeling, there are still few research works focusing on AFSM. Therefore, there is still a lack of understanding of the physical phenomena taking place during the process. This research work aims at a better AFSM process understanding and implementation, thanks to numerical simulation and experimental validation performed on a prototype effector. Such an approach is considered a promising way for studying the influence of the process parameters and to finally identify a process window that seems relevant. The deposition of material through the AFSM process takes place in several phases. In chronological order these phases are the docking phase, the dwell time phase, the deposition phase, and the removal phase. The present work focuses on the dwell time phase that enables the temperature rise of the system composed of the tool, the filler material, and the substrate and due to pure friction. Analytic modeling of heat generation based on friction considers as main parameters the rotational speed and the contact pressure. Another parameter considered influential is the friction coefficient assumed to be variable due to the self-lubrication of the system with the rise in temperature or the materials in contact roughness smoothing over time. This study proposes, through numerical modeling followed by experimental validation, to question the influence of the various input parameters on the dwell time phase. Rotation speed, temperature, spindle torque, and axial force are the main monitored parameters during experimentations and serve as reference data for the calibration of the numerical model. This research shows that the geometry of the tool as well as fluctuations of the input parameters like axial force and rotational speed are very influential on the temperature reached and/or the time required to reach the targeted temperature. The main outcome is the prediction of a process window which is a key result for a more efficient process implementation.

Keywords: numerical model, additive manufacturing, friction, process

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Authors: Sayed Ahmed El Sayed, Osama M. Mesalhy, Mohamed A. Abdelatief

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A numerical study has been conducted to clarify fluid flow characteristics, pressure distributions, and skin friction coefficient over a wing-shaped tubes bundle in staggered arrangement with the placement of longitudinal fins (LF) at downstream position of the tube. The air-side Rea were at 1.8 x 103 to 9.7 x 103. The tubes bundle were employed with various fin height [hf] and fin thickness (δ) from (2 mm ≤ hf ≤ 12 mm) and (1.5 mm ≤ δ ≤ 3.5 mm) respectively at the considered Rea range. The flow pattern around the staggered wing-shaped tubes bundle was predicted using the commercial CFD FLUENT 6.3.26 software package. The distribution of average skin friction coefficient around wing-shaped tubes bundle is studied. Correlation of pressure drop coefficient Pdc and skin friction coefficient (Cf) in terms of Rea, design parameters for the studied cases were presented. Results indicated that the values of Pdc for hf = 6 mm are lower than these of NOF and hf = 2 mm by about 11 % and 13 % respectively for considered Rea range. Cf decreases as Rea increases. LFTH with hf = 6 mm offers lower form drag than that with hf = 12 mm and that of NOF. The lowest values of the pumping power are achieved for arrangements of hf = 6 mm for the considered Rea range. δ has negligible effect on skin friction coefficient, while has a slightly variation in ∆Pa. The wing-shaped tubes bundle heat exchanger with hf = 6 mm has the lowest values of ∆Pa, Pdc, Cf, and pumping power and hence the best performance comparing with the other bundles. Comparisons between the experimental and numerical results of the present study and those obtained by similar previous studies showed good agreements.

Keywords: longitudinal fins, skin friction, flow characteristics, FLUENT, wing-shaped tubes

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Authors: Yukinori Taniguchi, Kazuyoshi Kurita, Kohei Mizuta, Keigo Nishitani, Ryuichi Fukuda

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Tungsten carbide is widely used as a tool material in metal manufacturing process. Since tungsten is typical rare metal, establishment of recycle process of tungsten carbide tools and restore into cemented carbide material bring great impact to metal manufacturing industry. Recently, recycle process of tungsten carbide has been developed and established gradually. However, the demands for quality of cemented carbide tool are quite severe because hardness, toughness, anti-wear ability, heat resistance, fatigue strength and so on should be guaranteed for precision machining and tool life. Currently, it is hard to restore the recycled tungsten carbide powder entirely as raw material for new processed cemented carbide tool. In this study, to suggest positive use of recycled tungsten carbide powder, we have tried to fabricate a carbon based sintered steel which shows reinforced mechanical properties with recycled tungsten carbide powder. We have made set of newly designed sintered steels. Compression test of sintered specimen in density ratio of 0.85 (which means 15% porosity inside) has been conducted. As results, at least 1.7 times higher in nominal strength in the amount of 7.0 wt.% was shown in recycled WC powder. The strength reached to over 600 MPa for the Fe-WC-Co-Cu sintered alloy. Wear test has been conducted by using ball-on-disk type friction tester using 5 mm diameter ball with normal force of 2 N in the dry conditions. Wear amount after 1,000 m running distance shows that about 1.5 times longer life was shown in designed sintered alloy. Since results of tensile test showed that same tendency in previous testing, it is concluded that designed sintered alloy can be used for several mechanical parts with special strength and anti-wear ability in relatively low cost due to recycled tungsten carbide powder.

Keywords: tungsten carbide, recycle process, compression test, powder metallurgy, anti-wear ability

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Authors: Eduard Marusic-Paloka

Abstract:

The Darcy-Weisbach formula is used to compute the pressure drop of the fluid in the pipe, due to the friction against the wall. Because of its simplicity, the Darcy-Weisbach formula became widely accepted by engineers and is used for laminar as well as the turbulent flows through pipes, once the method to compute the mysterious friction coefficient was derived. Particularly in the second half of the 20th century. Formula is empiric, and our goal is to derive it from the basic conservation law, via rigorous asymptotic analysis. We consider the case of the laminar flow but with significant Reynolds number. In case of the perfectly smooth pipe, the situation is trivial, as the Navier-Stokes system can be solved explicitly via the Poiseuille formula leading to the friction coefficient in the form 64/Re. For the rough pipe, the situation is more complicated and some effects of the roughness appear in the friction coefficient. We start from the Navier-Stokes system in the pipe with periodically corrugated wall and derive an asymptotic expansion for the pressure and for the velocity. We use the homogenization techniques and the boundary layer analysis. The approximation derived by formal analysis is then justified by rigorous error estimate in the norm of the appropriate Sobolev space, using the energy formulation and classical a priori estimates for the Navier-Stokes system. Our method leads to the formula for the friction coefficient. The formula involves resolution of the appropriate boundary layer problems, namely the boundary value problems for the Stokes system in an infinite band, that needs to be done numerically. However, theoretical analysis characterising their nature can be done without solving them.

Keywords: Darcy-Weisbach law, pipe flow, rough boundary, Navier law

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Authors: Ashkan Nazari, Saied Taheri

Abstract:

Knowledge of tire-pavement interaction plays a crucial role in designing safer and more reliable tires. Characterizing the tire-pavement frictional interaction leads to a better understanding of vehicle performance in braking and acceleration. In this work, we devise a multi-scale simulation approach to incorporate the effect of pavement surface asperities in different length-scales. We construct two- and three-dimensional Finite Element (FE) models to simulate the interaction between a rubber block and a rough pavement surface with asperities in different scales. To achieve this, the road profile is scanned via a laser profilometer and the obtained asperities are implemented in an FE software (ABAQUS) in micro and macro length-scales. The hysteresis friction, which is due to the dissipative nature of rubber, is the main component of the friction force and therefore is the subject of study in this work. Using different scales not only will assist in characterizing the pavement asperities with sufficient details but also, it is highly effective in preventing extreme local deformations and stress gradients which results in divergence in FE simulations. The simulation results will be validated with experimental results as well as the results reported in the literature.

Keywords: friction, finite element, multi-scale modeling, rubber

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Authors: Prashant S. Humnabad

Abstract:

The objective of this work is to carry out a thermal heat transfer analysis to obtain the time dependent temperature field in welding process friction stir welded dissimilar materials with different preheating temperature. A series of joints were made on four mm thick aluminum and steel plates. The temperature used was 100ºC, 150ºC and 200ºC. The welding operation was performed with different rotational speeds and traverse speed (1000, 1400 and 2000 rmp and 16, 20 and 25 mm/min..). In numerical model, the welded plate was modeled as the weld line is the symmetric line. The work-piece has dimensions of 100x100x4 mm. The obtained result was compared with experimental result, which shows good agreement and within the acceptable limit. The peak temperature at the weld zone increases significantly with respect to increase in process time.

Keywords: FEA, thermal analysis, preheating, friction stir welding

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Authors: Khalil Aghapouramin

Abstract:

The aim of the present work is to investigate the mechanical and microstructural properties of dissimilar and similar aluminum alloys welded by Friction Stir Welding (FSW). The specimens investigated by applying different welding speed and rotary speed. Typically, mechanical properties of the joints performed through tensile test fatigue test and microhardness (HV) at room temperature. Fatigue test investigated by using electromechanical testing machine under constant loading control with similar since wave loading. The Maximum stress versus minimum got the range between 0.1 to 0.3 in the research. Based upon welding parameters by optical observation and scanning electron microscopy microstructural properties fulfilled with a cross section of welds, in addition, SEM observations were made of the fracture surfaces

Keywords: friction stir welding, fatigue and tensile test, Al alloys, microstructural behavior

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Authors: Muna Khethier Abbass, Khairia Salman Hussan, Huda Mohummed AbdudAlaziz

Abstract:

This work aims to study the effect of shot peening on the mechanical properties of welded joints which performed by two different welding processes: Tungsten inert gas (TIG) welding and friction stir welding (FSW) processes of aluminum alloy 6061 T6. Arc welding process (TIG) was carried out on the sheet with dimensions of (100x50x6 mm) to obtain many welded joints with using electrode type ER4043 (AlSi5) as a filler metal and argon as shielding gas. While the friction stir welding process was carried out using CNC milling machine with a tool of rotational speed (1000 rpm) and welding speed of (20 mm/min) to obtain the same butt welded joints. The welded pieces were tested by X-ray radiography to detect the internal defects and faulty welded pieces were excluded. Tensile test specimens were prepared from welded joints and base alloy in the dimensions according to ASTM17500 and then subjected to shot peening process using steel ball of diameter 0.9 mm and for 15 min. All specimens were subjected to Vickers hardness test and micro structure examination to study the effect of welding process (TIG and FSW) on the micro structure of the weld zones. Results showed that a general decay of mechanical properties of TIG and FSW welded joints comparing with base alloy while the FSW welded joint gives better mechanical properties than that of TIG welded joint. This is due to the micro structure changes during the welding process. It has been found that the surface hardening by shot peening improved the mechanical properties of both welded joints, this is due to the compressive residual stress generation in the weld zones which was measured using X-Ray diffraction (XRD) inspection.

Keywords: friction stir welding, TIG welding, mechanical properties, shot peening

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Authors: Mohamed Saïd Kahaleras, François Lanzetta, Mohamed Khan, Guillaume Layes, Philippe Nika

Abstract:

This paper presents an experimental work to characterize the dynamic operation of a metal regenerator crossed by dry compressible air alternating flow. Unsteady dynamic measurements concern the pressure, velocity and temperature of the gas at the ends and inside the channels of the regenerator. The regenerators are tested under isothermal conditions and thermal axial temperature gradient.

Keywords: friction factor, oscillating flow, regenerator, stirling machine

Procedia PDF Downloads 480