Search results for: shaft friction
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 902

Search results for: shaft friction

722 Mechanical Analysis and Characterization of Friction Stir Processed Aluminium Alloy

Authors: Jaswinder Kumar, Kulbir Singh Sandhu

Abstract:

Friction stir processing (FSP) is a solid-state surface processing technique. A single-pass FSP was performed on Aluminum alloy at combinations of different tool rotational speeds with cylindrical threaded pin profiled tool. The effect of these parameters on tribological properties was studied. The wear resistance is found to be increased from base metal to a single pass FSP sample. The results revealed that with an increase in tool rotational speed, the wear rate increases. The high heat generation causes matrix softening, which results in an increased wear rate; on the other hand, high heat generation leads to coarse grains, which also affected tribological properties. Furthermore, Microstructure results showed that FSPed alloy has a more refined grain structure as compare to the base material, which may be resulted in enhancement of hardness and resistance to wear in FSP.

Keywords: friction stir processing, aluminium alloy, microhardness, microstructure

Procedia PDF Downloads 71
721 Performance Evaluation of Solid Lubricant Characteristics at Different Sliding Conditions

Authors: Suresh Kumar Reddy Narala, Rakesh Kumar Gunda

Abstract:

In modern industry, mechanical parts are subjected to friction and wear, leading to heat generation, which affects the reliability, life and power consumption of machinery. To overcome the tribological losses due to friction and wear, a significant portion of lubricant with high viscous properties allows very smooth relative motion between two sliding surfaces. Advancement in modern tribology has facilitated the use of applying solid lubricants in various industrial applications. Solid lubricant additives with high viscous thin film formation between the sliding surfaces can adequately wet and adhere to a work surface. In the present investigation, an attempt has been made to investigate and evaluate the tribological studies of various solid lubricants like MoS¬2, graphite, and boric acid at different sliding conditions. The base oil used in this study was SAE 40 oil with a viscosity of 220 cSt at 400C. The tribological properties were measured on pin-on-disc tribometer. An experimental set-up has been developed for effective supply of solid lubricants to the pin-disc interface zone. The results obtained from the experiments show that the friction coefficient increases with increase in applied load for all the considered environments. The tribological properties with MoS2 solid lubricant exhibit larger load carrying capacity than that of graphite and boric acid. The present research work also contributes to the understanding of the behavior of film thickness distribution of solid lubricant using potential contact technique under different sliding conditions. The results presented in this research work are expected to form a scientific basis for selecting the best solid lubricant in various industrial applications for possible minimization of friction and wear.

Keywords: friction, wear, temperature, solid lubricant

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720 Influence of Natural Rubber on the Frictional and Mechanical Behavior of the Composite Brake Pad Materials

Authors: H. Yanar, G. Purcek, H. H. Ayar

Abstract:

The ingredients of composite materials used for the production of composite brake pads play an important role in terms of safety braking performance of automobiles and trains. Therefore, the ingredients must be selected carefully and used in appropriate ratios in the matrix structure of the brake pad materials. In the present study, a non-asbestos organic composite brake pad materials containing binder resin, space fillers, solid lubricants, and friction modifier was developed, and its fillers content was optimized by adding natural rubber with different rate into the specified matrix structure in order to achieve the best combination of tribo-performance and mechanical properties. For this purpose, four compositions with different rubber content (2.5wt.%, 5.0wt.%, 7.5wt.% and 10wt.%) were prepared and then test samples with the diameter of 20 mm and length of 15 mm were produced to evaluate the friction and mechanical behaviors of the mixture. The friction and wear tests were performed using a pin-on-disc type test rig which was designed according to NF-F-11-292 French standard. All test samples were subjected to two different types of friction tests defined as periodic braking and continuous braking (also known as fade test). In this way, the coefficient of friction (CoF) of composite sample with different rubber content were determined as a function of number of braking cycle and temperature of the disc surface. The results demonstrated that addition of rubber into the matrix structure of the composite caused a significant change in the CoF. Average CoF of the composite samples increased linearly with increasing rubber content into the matrix. While the average CoF was 0.19 for the rubber-free composite, the composite sample containing 20wt.% rubber had the maximum CoF of about 0.24. Although the CoF of composite sample increased, the amount of specific wear rate decreased with increasing rubber content into the matrix. On the other hand, it was observed that the CoF decreased with increasing temperature generated in-between sample and disk depending on the increasing rubber content. While the CoF decreased to the minimum value of 0.15 at 400 °C for the rubber-free composite sample, the sample having the maximum rubber content of 10wt.% exhibited the lowest one of 0.09 at the same temperature. Addition of rubber into the matrix structure decreased the hardness and strength of the samples. It was concluded from the results that the composite matrix with 5 wt.% rubber had the best composition regarding the performance parameters such as required frictional and mechanical behavior. This composition has the average CoF of 0.21, specific wear rate of 0.024 cm³/MJ and hardness value of 63 HRX.

Keywords: brake pad composite, friction and wear, rubber, friction materials

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719 Bidirectional Pendulum Vibration Absorbers with Homogeneous Variable Tangential Friction: Modelling and Design

Authors: Emiliano Matta

Abstract:

Passive resonant vibration absorbers are among the most widely used dynamic control systems in civil engineering. They typically consist in a single-degree-of-freedom mechanical appendage of the main structure, tuned to one structural target mode through frequency and damping optimization. One classical scheme is the pendulum absorber, whose mass is constrained to move along a curved trajectory and is damped by viscous dashpots. Even though the principle is well known, the search for improved arrangements is still under way. In recent years this investigation inspired a type of bidirectional pendulum absorber (BPA), consisting of a mass constrained to move along an optimal three-dimensional (3D) concave surface. For such a BPA, the surface principal curvatures are designed to ensure a bidirectional tuning of the absorber to both principal modes of the main structure, while damping is produced either by horizontal viscous dashpots or by vertical friction dashpots, connecting the BPA to the main structure. In this paper, a variant of BPA is proposed, where damping originates from the variable tangential friction force which develops between the pendulum mass and the 3D surface as a result of a spatially-varying friction coefficient pattern. Namely, a friction coefficient is proposed that varies along the pendulum surface in proportion to the modulus of the 3D surface gradient. With such an assumption, the dissipative model of the absorber can be proven to be nonlinear homogeneous in the small displacement domain. The resulting homogeneous BPA (HBPA) has a fundamental advantage over conventional friction-type absorbers, because its equivalent damping ratio results independent on the amplitude of oscillations, and therefore its optimal performance does not depend on the excitation level. On the other hand, the HBPA is more compact than viscously damped BPAs because it does not need the installation of dampers. This paper presents the analytical model of the HBPA and an optimal methodology for its design. Numerical simulations of single- and multi-story building structures under wind and earthquake loads are presented to compare the HBPA with classical viscously damped BPAs. It is shown that the HBPA is a promising alternative to existing BPA types and that homogeneous tangential friction is an effective means to realize systems provided with amplitude-independent damping.

Keywords: amplitude-independent damping, homogeneous friction, pendulum nonlinear dynamics, structural control, vibration resonant absorbers

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718 Factors Affecting Early Antibiotic Delivery in Open Tibial Shaft Fractures

Authors: William Elnemer, Nauman Hussain, Samir Al-Ali, Henry Shu, Diane Ghanem, Babar Shafiq

Abstract:

Introduction: The incidence of infection in open tibial shaft injuries varies depending on the severity of the injury, with rates ranging from 1.8% for Gustilo-Anderson type I to 42.9% for type IIIB fractures. The timely administration of antibiotics upon presentation to the emergency department (ED) is an essential component of fracture management, and evidence indicates that prompt delivery of antibiotics is associated with improved outcomes. The objective of this study is to identify factors that contribute to the expedient administration of antibiotics. Methods: This is a retrospective study of open tibial shaft fractures at an academic Level I trauma center. Current Procedural Terminology (CPT) codes identified all patients treated for open tibial shaft fractures between 2015 and 2021. Open fractures were identified by reviewing ED and provider notes, and with ballistic fractures were considered open. Chart reviews were performed to extract demographics, fracture characteristics, postoperative outcomes, time to operative room, time to antibiotic order, and delivery. Univariate statistical analysis compared patients who received early antibiotics (EA), which were delivered within one hour of ED presentation, and those who received late antibiotics (LA), which were delivered outside of one hour of ED presentation. A multivariate analysis was performed to investigate patient, fracture, and transport/ED characteristics contributing to faster delivery of antibiotics. The multivariate analysis included the dependent variables: ballistic fracture, activation of Delta Trauma, Gustilo-Andersen (Type III vs. Type I and II), AO-OTA Classification (Type C vs. Type A and B), arrival between 7 am and 11 pm, and arrival via Emergency Medical Services (EMS) or walk-in. Results: Seventy ED patients with open tibial shaft fractures were identified. Of these, 39 patients (55.7%) received EA, while 31 patients (44.3%) received LA. Univariate analysis shows that the arrival via EMS as opposed to walk-in (97.4% vs. 74.2%, respectively, p = 0.01) and activation of Delta Trauma (89.7% vs. 51.6%, respectively, p < 0.001) was significantly higher in the EA group vs. the LA group. Additionally, EA cases had significantly shorter intervals between the antibiotic order and delivery when compared to LA cases (0.02 hours vs. 0.35 hours, p = 0.007). No other significant differences were found in terms of postoperative outcomes or fracture characteristics. Multivariate analysis shows that a Delta Trauma Response, arrival via EMS, and presentation between 7 am and 11 pm were independent predictors of a shorter time to antibiotic administration (Odds Ratio = 11.9, 30.7, and 5.4, p = 0.001, 0.016, and 0.013, respectively). Discussion: Earlier antibiotic delivery is associated with arrival to the ED between 7 am and 11 pm, arrival via EMS, and a coordinated Delta Trauma activation. Our findings indicate that in cases where administering antibiotics is critical to achieving positive outcomes, it is advisable to employ a coordinated Delta Trauma response. Hospital personnel should be attentive to the rapid administration of antibiotics to patients with open fractures who arrive via walk-in or during late-night hours.

Keywords: antibiotics, emergency department, fracture management, open tibial shaft fractures, orthopaedic surgery, time to or, trauma fractures

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717 Design and Implementation of Power Generation Mechanism Using Speed Breaker

Authors: Roman Kalvin, Anam Nadeem, Saba Arif, Juntakan Taweekun

Abstract:

In the current scenario demand of power is increasing day by day with increasing population. It is needed to sort out this problem with a technique which will not only overcome this energy crisis but also should be environment friendly. This project emphasizes on idea which shows that power could be generated by specially designed speed breaker. This project shows clearly how power can be generated by using Cam Mechanism where basically linear motion is converted into rotatory motion that can be used to generate electricity. When vehicle passes over the speed breaker, presses the cam with the help of connecting rod which rotate main shaft attached with large pulley. A flywheel is coupled with the shaft whose purpose is to normalize the oscillation in the energy and to make the energy unvarying. So, the shafts will spin with firm rpm. These shafts are coupled from end to end with a belt drive. The results show that power generated from this mechanism is 12 watts. The generated electricity does not required any fuel consumption it only generates power which can be used for the street light as well as for the traffic signals.

Keywords: revolution per minute, RPM, cam, speed breaker, rotatory motion

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716 Linear Dynamic Stability Analysis of a Continuous Rotor-Disk-Blades System

Authors: F. Rahimi Dehgolan, S. E. Khadem, S. Bab, M. Najafee

Abstract:

Nowadays, using rotating systems like shafts and disks in industrial machines have been increased constantly. Dynamic stability is one of the most important factors in designing rotating systems. In this study, linear frequencies and stability of a coupled continuous flexible rotor-disk-blades system are studied. The Euler-Bernoulli beam theory is utilized to model the blade and shaft. The equations of motion are extracted using the extended Hamilton principle. The equations of motion have been simplified using the Coleman and complex transformations method. The natural frequencies of the linear part of the system are extracted, and the effects of various system parameters on the natural frequencies and decay rates (stability condition) are clarified. It can be seen that the centrifugal stiffening effect applied to the blades is the most important parameter for stability of the considered rotating system. This result highlights the importance of considering this stiffing effect in blades equation.

Keywords: rotating shaft, flexible blades, centrifugal stiffness, stability

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715 Experimental Modelling Gear Contact with TE77 Energy Pulse Setup

Authors: Zainab Mohammed Shukur, Najlaa Ali Alboshmina, Ali Safa Alsaegh

Abstract:

The project was investigated tribological behavior of polyether ether ketone (PEEK1000) against PEEK1000 rolling sliding (non-conformal) configuration with slip ratio 83.3%, were tested applications using a TE77 wear mechanisms and friction coefficient test rig. Under marginal lubrication conditions and the absence of film thick conditions, load 100 N was used to simulate the torque in gears 7 N.m. The friction coefficient and wear mechanisms of PEEK were studied under reciprocating roll/slide conditions with water, ethylene glycol, silicone, and base oil. Tribological tests were conducted on a TE77 high-frequency tribometer, with a disc-on-plate slide/roll (the energy pulse criterion) configuration. An Alicona G5 optical 3D micro-coordinate measurement microscope was used to investigate the surface topography and wear mechanisms. The surface roughness had been a significant effect on the friction coefficient for the PEEK/PEEK the rolling sliding contact test ethylene glycol and on the wear mechanisms. When silicone, ethylene glycol, and oil were used as a lubricant, the steady state of friction coefficient was reached faster than the other lubricant. Results describe the effect of the film thick with slip ratio of 83.3% on the tribological performance.

Keywords: polymer, rolling- sliding, energy pulse, gear contact

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714 Influence of Counter-Face Roughness on the Friction of Bionic Microstructures

Authors: Haytam Kasem

Abstract:

The problem of quick and easy reversible attachment has become of great importance in different fields of technology. For the reason, during the last decade, a new emerging field of adhesion science has been developed. Essentially inspired by some animals and insects, which during their natural evolution have developed fantastic biological attachment systems allowing them to adhere and run on walls and ceilings of uneven surfaces. Potential applications of engineering bio-inspired solutions include climbing robots, handling systems for wafers in nanofabrication facilities, and mobile sensor platforms, to name a few. However, despite the efforts provided to apply bio-inspired patterned adhesive-surfaces to the biomedical field, they are still in the early stages compared with their conventional uses in other industries mentioned above. In fact, there are some critical issues that still need to be addressed for the wide usage of the bio-inspired patterned surfaces as advanced biomedical platforms. For example, surface durability and long-term stability of surfaces with high adhesive capacity should be improved, but also the friction and adhesion capacities of these bio-inspired microstructures when contacting rough surfaces. One of the well-known prototypes for bio-inspired attachment systems is biomimetic wall-shaped hierarchical microstructure for gecko-like attachments. Although physical background of these attachment systems is widely understood, the influence of counter-face roughness and its relationship with the friction force generated when sliding against wall-shaped hierarchical microstructure have yet to be fully analyzed and understood. To elucidate the effect of the counter-face roughness on the friction of biomimetic wall-shaped hierarchical microstructure we have replicated the isotropic topography of 12 different surfaces using replicas made of the same epoxy material. The different counter-faces were fully characterized under 3D optical profilometer to measure roughness parameters. The friction forces generated by spatula-shaped microstructure in contact with the tested counter-faces were measured on a home-made tribometer and compared with the friction forces generated by the spatulae in contact with a smooth reference. It was found that classical roughness parameters, such as average roughness Ra and others, could not be utilized to explain topography-related variation in friction force. This has led us to the development of an integrated roughness parameter obtained by combining different parameters which are the mean asperity radius of curvature (R), the asperity density (η), the deviation of asperities high (σ) and the mean asperities angle (SDQ). This new integrated parameter is capable of explaining the variation of results of friction measurements. Based on the experimental results, we developed and validated an analytical model to predict the variation of the friction force as a function of roughness parameters of the counter-face and the applied normal load, as well.

Keywords: friction, bio-mimetic micro-structure, counter-face roughness, analytical model

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713 Direct Measurement of Pressure and Temperature Variations During High-Speed Friction Experiments

Authors: Simon Guerin-Marthe, Marie Violay

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Thermal Pressurization (TP) has been proposed as a key mechanism involved in the weakening of faults during dynamic ruptures. Theoretical and numerical studies clearly show how frictional heating can lead to an increase in pore fluid pressure due to the rapid slip along faults occurring during earthquakes. In addition, recent laboratory studies have evidenced local pore pressure or local temperature variation during rotary shear tests, which are consistent with TP theoretical and numerical models. The aim of this study is to complement previous ones by measuring both local pore pressure and local temperature variations in the vicinity of a water-saturated calcite gouge layer subjected to a controlled slip velocity in direct double shear configuration. Laboratory investigation of TP process is crucial in order to understand the conditions at which it is likely to become a dominant mechanism controlling dynamic friction. It is also important in order to understand the timing and magnitude of temperature and pore pressure variations, to help understanding when it is negligible, and how it competes with other rather strengthening-mechanisms such as dilatancy, which can occur during rock failure. Here we present unique direct measurements of temperature and pressure variations during high-speed friction experiments under various load point velocities and show the timing of these variations relatively to the slip event.

Keywords: thermal pressurization, double-shear test, high-speed friction, dilatancy

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712 Opposed Piston Engine Crankshaft Strength Calculation Using Finite Element Method

Authors: Konrad Pietrykowski, Michał Gęca, Michał Bialy

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The paper presents the results of the crankshaft strength simulation. The crankshaft was taken from the opposed piston engine. Calculations were made using finite element method (FEM) in Abaqus software. This program allows to perform strength tests of individual machine parts as well as their assemblies. The crankshaft that was used in the calculations will be used in the two-stroke aviation research aircraft engine. The assumptions for the calculations were obtained from the AVL Boost software, from one-dimensional engine cycle model and from the multibody model using the method developed in the MSC Adams software. The research engine will be equipped with 3 combustion chambers and two crankshafts. In order to shorten the calculation time, only one crankcase analysis was performed. The cut of the shaft has been selected with the greatest forces resulting from the engine operation. Calculations were made for two cases. For maximum piston force when maximum bending load occurs and for the maximum torque. Cast iron material was adopted. For this material, Poisson's number, density, and Young's modulus were determined. The computational grid contained of 1,977,473 Tet elements. This type of elements was chosen because of the complex design of the crankshaft. Results are presented in the form of stress distributions maps and displacements on the surface and inside the geometry of the shaft. The results show the places of tension stresses, however, no stresses are exceeded at any place. The shaft can thus be applied to the engine in its present form. Acknowledgement: This work has been realized in the cooperation with The Construction Office of WSK 'PZL-KALISZ’ S.A. and is part of Grant Agreement No. POIR.01.02.00-00-0002/15 financed by the Polish National Centre for Research and Development.

Keywords: aircraft diesel engine, crankshaft, finite element method, two-stroke engine

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711 The Effect of Bearing Surface Finish on the Engine's Lubrication System Performance

Authors: Kudakwashe Diana Nyamugure

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Engine design has evolved to suit new industry standards of smaller compact designs that operate at high temperatures and even higher stress loads. Research has proven that the interaction of the bearing surface and the lubrication film is affected by the bearing's surface texture, geometry, and dimensional tolerances. The challenge now for the automotive manufacturing industry is to understand which processes can be applied on bearing surfaces to reduce the 65% energy loss in engines, 15% of which is caused by friction. This paper will discuss a post grinding process known as microfinishing which optimises the characteristics of a manufactured surface such as roughness, profile, and waviness. Microfinishing is becoming an increasing trend within the automotive industry and has so far been applied on high performance and mass production crank or cam bearing surfaces in bid of friction reduction and extended engine service life. In the near future, microfinishing will be applied to more engine components because of the stringent environmental regulations demands on fuel consumption, reliability, power, and service life of engine components.

Keywords: bearings, tribology, friction reduction, energy efficiency

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710 Analysis of Friction Stir Welding Process for Joining Aluminum Alloy

Authors: A. M. Khourshid, I. Sabry

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Friction Stir Welding (FSW), a solid state joining technique, is widely being used for joining Al alloys for aerospace, marine automotive and many other applications of commercial importance. FSW were carried out using a vertical milling machine on Al 5083 alloy pipe. These pipe sections are relatively small in diameter, 5mm, and relatively thin walled, 2 mm. In this study, 5083 aluminum alloy pipe were welded as similar alloy joints using (FSW) process in order to investigate mechanical and microstructural properties .rotation speed 1400 r.p.m and weld speed 10,40,70 mm/min. In order to investigate the effect of welding speeds on mechanical properties, metallographic and mechanical tests were carried out on the welded areas. Vickers hardness profile and tensile tests of the joints as a metallurgical feasibility of friction stir welding for joining Al 6061 aluminum alloy 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 (4, 8 and 10)mm/min was applied. This work focuses on two methods such as artificial neural networks using software (pythia) and response surface methodology (RSM) to predict the tensile strength, the percentage of elongation and hardness of friction stir welded 6061 aluminum alloy. An artificial neural network (ANN) model was developed for the analysis of the friction stir welding parameters of 6061 pipe. The tensile strength, the percentage of elongation and hardness of weld joints were predicted by taking the parameters Tool rotation speed, material thickness and travel speed as a function. A comparison was made between measured and predicted data. Response surface methodology (RSM) also developed and the values obtained for the response Tensile strengths, the percentage of elongation and hardness are compared with measured values. The effect of FSW process parameter on mechanical properties of 6061 aluminum alloy has been analyzed in detail.

Keywords: friction stir welding (FSW), al alloys, mechanical properties, microstructure

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709 Diagnosis of Intermittent High Vibration Peaks in Industrial Gas Turbine Using Advanced Vibrations Analysis

Authors: Abubakar Rashid, Muhammad Saad, Faheem Ahmed

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This paper provides a comprehensive study pertaining to diagnosis of intermittent high vibrations on an industrial gas turbine using detailed vibrations analysis, followed by its rectification. Engro Polymer & Chemicals Limited, a Chlor-Vinyl complex located in Pakistan has a captive combined cycle power plant having two 28 MW gas turbines (make Hitachi) & one 15 MW steam turbine. In 2018, the organization faced an issue of high vibrations on one of the gas turbines. These high vibration peaks appeared intermittently on both compressor’s drive end (DE) & turbine’s non-drive end (NDE) bearing. The amplitude of high vibration peaks was between 150-170% on the DE bearing & 200-300% on the NDE bearing from baseline values. In one of these episodes, the gas turbine got tripped on “High Vibrations Trip” logic actuated at 155µm. Limited instrumentation is available on the machine, which is monitored with GE Bently Nevada 3300 system having two proximity probes installed at Turbine NDE, Compressor DE &at Generator DE & NDE bearings. Machine’s transient ramp-up & steady state data was collected using ADRE SXP & DSPI 408. Since only 01 key phasor is installed at Turbine high speed shaft, a derived drive key phasor was configured in ADRE to obtain low speed shaft rpm required for data analysis. By analyzing the Bode plots, Shaft center line plot, Polar plot & orbit plots; rubbing was evident on Turbine’s NDE along with increased bearing clearance of Turbine’s NDE radial bearing. The subject bearing was then inspected & heavy deposition of carbonized coke was found on the labyrinth seals of bearing housing with clear rubbing marks on shaft & housing covering at 20-25 degrees on the inner radius of labyrinth seals. The collected coke sample was tested in laboratory & found to be the residue of lube oil in the bearing housing. After detailed inspection & cleaning of shaft journal area & bearing housing, new radial bearing was installed. Before assembling the bearing housing, cleaning of bearing cooling & sealing air lines was also carried out as inadequate flow of cooling & sealing air can accelerate coke formation in bearing housing. The machine was then taken back online & data was collected again using ADRE SXP & DSPI 408 for health analysis. The vibrations were found in acceptable zone as per ISO standard 7919-3 while all other parameters were also within vendor defined range. As a learning from subject case, revised operating & maintenance regime has also been proposed to enhance machine’s reliability.

Keywords: ADRE, bearing, gas turbine, GE Bently Nevada, Hitachi, vibration

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708 Numerical Investigation of the Effect of Geometrical Shape of Plate Heat Exchangers on Heat Transfer Efficiency

Authors: Hamed Sanei, Mohammad Bagher Ayani

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Optimizations of Plate Heat Exchangers (PHS) have received great attention in the past decade. In this study, heat transfer and pressure drop coefficients are compared for rectangular and circular PHS employing numerical simulations. Plates are designed to have equivalent areas. Simulations were implemented to investigate the efficiency of PHSs considering heat transfer, friction factor and pressure drop. Amount of heat transfer and pressure drop was obtained for different range of Reynolds numbers. These two parameters were compared with aim of F "weighting factor correlation". In this comparison, the minimum amount of F indicates higher efficiency. Results reveal that the F value for rectangular shape is less than circular plate, and hence using rectangular shape of PHS is more efficient than circular one. It was observed that, the amount of friction factor is correlated to the Reynolds numbers, such that friction factor decreased in both rectangular and circular plates with an increase in Reynolds number. Furthermore, such simulations revealed that the amount of heat transfer in rectangular plate is more than circular plate for different range of Reynolds numbers. The difference is more distinct for higher Reynolds number. However, amount of pressure drop in circular plate is less than rectangular plate for the same range of Reynolds numbers which is considered as a negative point for rectangular plate efficiency. It can be concluded that, while rectangular PHSs occupy more space than circular plate, the efficiency of rectangular plate is higher.

Keywords: Chevron corrugated plate heat exchanger, heat transfer, friction factor, Reynolds numbers

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707 A Review on the Studies on Mechanical and Tribological Properties of Aluminum and Magnesium Alloys Welded by Friction Stir Welding

Authors: Sukhdeep Singh Gill, Gurbhinder Singh Brar

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In recent years, friction stir welding (FSW) has attracted the main attention of the concerned researcher especially in case of joining of nonferrous alloys like aluminum and magnesium due to its unmatchable properties with respect to other welding techniques. Friction stir welding is a solid state welding process which is most suitable for the welding of nonferrous alloys, especially aluminum and magnesium alloys. Aluminum and magnesium alloys are widely used for structural applications of all types of automobiles due to their superior mechanical properties with their low density. This paper deals with the critical review of the different properties (like tensile strength, microhardness, impact strength, corrosion resistance, and metallurgical investigation on SEM) obtained by the FSW of aluminum and magnesium alloys. After a critical review of the existing published literature on concerned topics, all the properties of welding joins are compared in the tabulated manner to optimize the selection of materials and FSW parameters according to mechanical and tribological properties. Different tool designs used for the FSW process are also thoroughly studied, and the influence of the design of the tool used in FSW on the different properties has also been incorporated in this paper. It has been observed from the existing published literature that FSW is the most effective and practical technique for joining the non ferrous alloys especially aluminum and magnesium alloys, and among the different FSW tools, left hand threaded tri-flute (LHTTF) tool is best for the welding of non ferrous alloys like aluminum and magnesium alloys which gives the superior mechanical properties to welding joint.

Keywords: aluminum, friction stir welding, magnesium, structural applications, tool design

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706 Determination of Friction and Damping Coefficients of Folded Cover Mechanism Deployed by Torsion Springs

Authors: I. Yilmaz, O. Taga, F. Kosar, O. Keles

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In this study, friction and damping coefficients of folded cover mechanism were obtained in accordance with experimental studies and data. Friction and damping coefficients are the most important inputs to accomplish a mechanism analysis. Friction and damping are two objects that change the time of deployment of mechanisms and their dynamic behaviors. Though recommended friction coefficient values exist in literature, damping is differentiating feature according to mechanic systems. So the damping coefficient should be obtained from mechanism test outputs. In this study, the folded cover mechanism use torsion springs for deploying covers that are formerly close folded position. Torsion springs provide folded covers with desirable deploying time according to variable environmental conditions. To verify all design revisions with system tests will be so costly so that some decisions are taken in accordance with numerical methods. In this study, there are two folded covers required to deploy simultaneously. Scotch-yoke and crank-rod mechanisms were combined to deploy folded covers simultaneously. The mechanism was unlocked with a pyrotechnic bolt onto scotch-yoke disc. When pyrotechnic bolt was exploded, torsion springs provided rotational movement for mechanism. Quick motion camera was recording dynamic behaviors of system during deployment case. Dynamic model of mechanism was modeled as rigid body with Adams MBD (multi body dynamics) then torque values provided by torsion springs were used as an input. A well-advised range of friction and damping coefficients were defined in Adams DOE (design of experiment) then a large number of analyses were performed until deployment time of folded covers run in with test data observed in record of quick motion camera, thus the deployment time of mechanism and dynamic behaviors were obtained. Same mechanism was tested with different torsion springs and torque values then outputs were compared with numerical models. According to comparison, it was understood that friction and damping coefficients obtained in this study can be used safely when studying on folded objects required to deploy simultaneously. In addition to model generated with Adams as rigid body the finite element model of folded mechanism was generated with Abaqus then the outputs of rigid body model and finite element model was compared. Finally, the reasonable solutions were suggested about different outputs of these solution methods.

Keywords: damping, friction, pyro-technic, scotch-yoke

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705 Capability of Intelligent Techniques for Friction Factor Simulation in Water Channels

Authors: Kiyoumars Roushangar, Shabnam Mirheidarian

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This study proposes metamodel approaches as a new intelligent technique for the explicit formulation of friction factors of water conveyance structures. For this purpose, experimental data of a movable bed flume with dune bed form were used. Analyzing the result clears the high capability of metamodel approaches (MNE= 0.05, R= 0.92) as a powerful tool for optimizing and explicit simulation of Manning's roughness coefficients of water conveyance structures compared to other nonlinear approaches.

Keywords: intelligent techniques, explicit simulation, roughness coefficient, water conveyance structure

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704 Investigation of the Flow in Impeller Sidewall Gap of a Centrifugal Pump Using CFD

Authors: Mohammadreza DaqiqShirazi, Rouhollah Torabi, Alireza Riasi, Ahmad Nourbakhsh

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In this paper, the flow in a sidewall gap of an impeller which belongs to a centrifugal pump is studied using numerical method. The flow in sidewall gap forms internal leakage and is the source of “disk friction loss” which is the most important cause of reduced efficiency in low specific speed centrifugal pumps. Simulation is done using CFX software and a high quality mesh, therefore the modeling error has been reduced. Navier-Stokes equations have been solved for this domain. In order to predict the turbulence effects the SST model has been employed.

Keywords: numerical study, centrifugal pumps, disk friction loss, sidewall gap

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703 Tribological Behavior of Pongamia Oil Based Biodiesel Blended Lubricant at Different Load

Authors: Yashvir Singh, Amneesh Singla, Swapnil Bhurat

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Around the globe, there is demand for the development of bio-based lubricant which will be biodegradable, non toxic, and environmentally-friendly. This paper outlines the friction and wear characteristics of ponagamia biodiesel contaminated bio-lubricant by using pin-on-disc tribometer. To formulate the bio-lubricants, Ponagamia oil based biodiesel were blended in the ratios 5, 10, and 20% by volume with the base lubricant SAE 20 W 40. Tribological characteristics of these blends were carried out at 2.5 m/s sliding velocity and loads applied were 50, 100, 150 N. Experimental results showed that the lubrication regime that occurred during the test was boundary lubrication while the main wear mechanisms was the adhesive wear. During testing, the lowest wear was found with the addition of 5 and 10% Ponagamia oil based biodiesel, and above this contamination, the wear rate was increased considerably. The addition of 5 and 10% Ponagamia oil based biodiesel with the base lubricant acted as a very good lubricant additive which reduced the friction and wear rate during the test. It has been concluded that the PBO 5 and PBO 10 can act as an alternative lubricant to increase the mechanical efficiency at 2.5 m/s sliding velocity and contribute in reduction of dependence on the petroleum based products.

Keywords: friction, load, pongamia oil blend, sliding velocity, wear

Procedia PDF Downloads 283
702 High-Temperature Behavior of Boiler Steel by Friction Stir Processing

Authors: Supreet Singh, Manpreet Kaur, Manoj Kumar

Abstract:

High temperature corrosion is an imperative material degradation method experienced in thermal power plants and other energy generation sectors. Metallic materials such as ferritic steels have special properties such as easy fabrication and machinibilty, low cost, but a serious drawback of these materials is the worsening in properties initiating from the interaction with the environments. The metallic materials do not endure higher temperatures for extensive period of time because of their poor corrosion resistance. Friction Stir Processing (FSP), has emerged as the potent surface modification means and control of microstructure in thermo mechanically heat affecting zones of various metal alloys. In the current research work, FSP was done on the boiler tube of SA 210 Grade A1 material which is regularly used by thermal power plants. The strengthening of SA210 Grade A1 boiler steel through microstructural refinement by Friction Stir Processing (FSP) and analyze the effect of the same on high temperature corrosion behavior. The high temperature corrosion performance of the unprocessed and the FSPed specimens were evaluated in the laboratory using molten salt environment of Na₂SO₄-82%Fe₂(SO₄). The unprocessed and FSPed low carbon steel Gr A1 evaluation was done in terms of microstructure, corrosion resistance, mechanical properties like hardness- tensile. The in-depth characterization was done by EBSD, SEM/EDS and X-ray mapping analyses with an aim to propose the mechanism behind high temperature corrosion behavior of the FSPed steel.

Keywords: boiler steel, characterization, corrosion, EBSD/SEM/EDS/XRD, friction stir processing

Procedia PDF Downloads 198
701 Two Kinds of Self-Oscillating Circuits Mechanically Demonstrated

Authors: Shiang-Hwua Yu, Po-Hsun Wu

Abstract:

This study introduces two types of self-oscillating circuits that are frequently found in power electronics applications. Special effort is made to relate the circuits to the analogous mechanical systems of some important scientific inventions: Galileo’s pendulum clock and Coulomb’s friction model. A little touch of related history and philosophy of science will hopefully encourage curiosity, advance the understanding of self-oscillating systems and satisfy the aspiration of some students for scientific literacy. Finally, the two self-oscillating circuits are applied to design a simple class-D audio amplifier.

Keywords: self-oscillation, sigma-delta modulator, pendulum clock, Coulomb friction, class-D amplifier

Procedia PDF Downloads 318
700 Hybrid Lubri-Coolants as an Alternatives to Mineral Based Emulsion in Machining Aerospace Alloy Ti-6Al-4V

Authors: Muhammad Jamil, Ning He, Wei Zhao

Abstract:

Ti-6Al-4V has poor thermal conductivity (6.7W/mK) accumulates shear and friction heat at the tool-chip interface zone. To dissipate the heat generation and friction effect, cryogenic cooling, Minimum quantity lubrication (MQL), nanofluids, hybrid cryogenic-MQL, solid lubricants, etc are applied frequently to underscore their significant effect on improving the machinability of Ti-6Al-4V. Nowadays, hybrid lubri-cooling is getting attention from researchers to explore their effect on machining Ti-6Al-4V.

Keywords: hybrid lubri-cooling, tool wear, surface roughness, minimum quantity lubrication

Procedia PDF Downloads 95
699 Effect of Taper Pin Ratio on Microstructure and Mechanical Property of Friction Stir Welded AZ31 Magnesium Alloy

Authors: N. H. Othman, N. Udin, M. Ishak, L. H. Shah

Abstract:

This study focuses on the effect of pin taper tool ratio on friction stir welding of magnesium alloy AZ31. Two pieces of AZ31 alloy with thickness of 6 mm were friction stir welded by using the conventional milling machine. The shoulder diameter used in this experiment is fixed at 18 mm. The taper pin ratio used are varied at 6:6, 6:5, 6:4, 6:3, 6:2 and 6:1. The rotational speeds that were used in this study were 500 rpm, 1000 rpm and 1500 rpm, respectively. The welding speeds used are 150 mm/min, 200 mm/min and 250 mm/min. Microstructure observation of welded area was studied by using optical microscope. Equiaxed grains were observed at the TMAZ and stir zone indicating fully plastic deformation. Tool pin diameter ratio 6/1 causes low heat input to the material because of small contact surface between tool surface and stirred materials compared to other tool pin diameter ratio. The grain size of stir zone increased with increasing of ratio of rotational speed to transverse speed due to higher heat input. It is observed that worm hole is produced when excessive heat input is applied. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Welded specimens using taper pin ratio 6:1 shows higher tensile strength compared to other taper pin ratio up to 204 MPa. Moreover, specimens using taper pin ratio 6:1 showed better tensile strength with 500 rpm of rotational speed and 150mm/min welding speed.

Keywords: friction stir welding, magnesium AZ31, cylindrical taper tool, taper pin ratio

Procedia PDF Downloads 243
698 Estimation of Asphalt Pavement Surfaces Using Image Analysis Technique

Authors: Mohammad A. Khasawneh

Abstract:

Asphalt concrete pavements gradually lose their skid resistance causing safety problems especially under wet conditions and high driving speeds. In order to enact the actual field polishing and wearing process of asphalt pavement surfaces in a laboratory setting, several laboratory-scale accelerated polishing devices were developed by different agencies. To mimic the actual process, friction and texture measuring devices are needed to quantify surface deterioration at different polishing intervals that reflect different stages of the pavement life. The test could still be considered lengthy and to some extent labor-intensive. Therefore, there is a need to come up with another method that can assist in investigating the bituminous pavement surface characteristics in a practical and time-efficient test procedure. The purpose of this paper is to utilize a well-developed image analysis technique to characterize asphalt pavement surfaces without the need to use conventional friction and texture measuring devices in an attempt to shorten and simplify the polishing procedure in the lab. Promising findings showed the possibility of using image analysis in lieu of the labor-sensitive-variable-in-nature friction and texture measurements. It was found that the exposed aggregate surface area of asphalt specimens made from limestone and gravel aggregates produced solid evidence of the validity of this method in describing asphalt pavement surfaces. Image analysis results correlated well with the British Pendulum Numbers (BPN), Polish Values (PV) and Mean Texture Depth (MTD) values.

Keywords: friction, image analysis, polishing, statistical analysis, texture

Procedia PDF Downloads 275
697 Development and Experimental Evaluation of a Semiactive Friction Damper

Authors: Juan S. Mantilla, Peter Thomson

Abstract:

Seismic events may result in discomfort on occupants of the buildings, structural damage or even buildings collapse. Traditional design aims to reduce dynamic response of structures by increasing stiffness, thus increasing the construction costs and the design forces. Structural control systems arise as an alternative to reduce these dynamic responses. A commonly used control systems in buildings are the passive friction dampers, which adds energy dissipation through damping mechanisms induced by sliding friction between their surfaces. Passive friction dampers are usually implemented on the diagonal of braced buildings, but such devices have the disadvantage that are optimal for a range of sliding force and out of that range its efficiency decreases. The above implies that each passive friction damper is designed, built and commercialized for a specific sliding/clamping force, in which the damper shift from a locked state to a slip state, where dissipates energy through friction. The risk of having a variation in the efficiency of the device according to the sliding force is that the dynamic properties of the building can change as result of many factor, even damage caused by a seismic event. In this case the expected forces in the building can change and thus considerably reduce the efficiency of the damper (that is designed for a specific sliding force). It is also evident than when a seismic event occurs the forces in each floor varies in the time what means that the damper's efficiency is not the best at all times. Semi-Active Friction devices adapt its sliding force trying to maintain its motion in the slipping phase as much as possible, because of this, the effectiveness of the device depends on the control strategy used. This paper deals with the development and performance evaluation of a low cost Semiactive Variable Friction Damper (SAVFD) in reduced scale to reduce vibrations of structures subject to earthquakes. The SAVFD consist in a (1) hydraulic brake adapted to (2) a servomotor which is controlled with an (3) Arduino board and acquires accelerations or displacement from (4) sensors in the immediately upper and lower floors and a (5) power supply that can be a pair of common batteries. A test structure, based on a Benchmark structure for structural control, was design and constructed. The SAVFD and the structure are experimentally characterized. A numerical model of the structure and the SAVFD is developed based on the dynamic characterization. Decentralized control algorithms were modeled and later tested experimentally using shaking table test using earthquake and frequency chirp signals. The controlled structure with the SAVFD achieved reductions greater than 80% in relative displacements and accelerations in comparison to the uncontrolled structure.

Keywords: earthquake response, friction damper, semiactive control, shaking table

Procedia PDF Downloads 347
696 Material Flow Modeling in Friction Stir Welding of AA6061-T6 Alloy and Study of the Effect of Process Parameters

Authors: B. SahaRoy, T. Medhi, S. C. Saha

Abstract:

To understand the friction stir welding process, it is very important to know the nature of the material flow in and around the tool. The process is a combination of both thermal as well as mechanical work i.e it is a coupled thermo-mechanical process. Numerical simulations are very much essential in order to obtain a complete knowledge of the process as well as the physics underlying it. In the present work a model based approach is adopted in order to study material flow. A thermo-mechanical based CFD model is developed using a Finite Element package, Comsol Multiphysics. The fluid flow analysis is done. The model simultaneously predicts shear strain fields, shear strain rates and shear stress over the entire workpiece for the given conditions. The flow fields generated by the streamline plot give an idea of the material flow. The variation of dynamic viscosity, velocity field and shear strain fields with various welding parameters is studied. Finally the result obtained from the above mentioned conditions is discussed elaborately and concluded.

Keywords: AA6061-T6, CFD modelling, friction stir welding, material flow

Procedia PDF Downloads 477
695 Effect of Forging Pressure on Mechanical Properties and Microstructure of Similar and Dissimilar Friction Welded Joints (Aluminium, Copper, Steel)

Authors: Sagar Pandit

Abstract:

The present work focuses on the effect of various process parameters on the mechanical properties and microstructure of joints produced by continuous drive friction welding and linear friction welding. An attempt is made to investigate the feasibility of obtaining an acceptable weld joint between similar as well as dissimilar components and the microstructural changes have also been assessed once the good weld joints were considered (using Optical Microscopy and Scanning Electron Microscopy techniques). The impact of forging pressure in the microstructure of the weld joint has been studied and the variation in joint strength with varying forge pressure is analyzed. The weld joints were obtained two pair of dissimilar materials and one pair of similar materials, which are listed respectively as: Al-AA5083 & Cu-C101 (dissimilar), Aluminium alloy-3000 series & Mild Steel (dissimilar) and High Nitrogen Austenitic Stainless Steel pair (similar). Intermetallic phase formation was observed at the weld joints in the Al-Cu joint, which consequently harmed the properties of the joint (less tensile strength). It was also concluded that the increase in forging pressure led to both increment and decrement in the tensile strength of the joint depending on the similarity or dissimilarity of the components. The hardness was also observed to possess maximum as well as minimum values at the weld joint depending on the similarity or dissimilarity of workpieces. It was also suggested that a higher forging pressure is needed to obtain complete joining for the formation of the weld joint.

Keywords: forging pressure, friction welding, mechanical properties, microstructure

Procedia PDF Downloads 68
694 A Modelling of Main Bearings in the Two-Stroke Diesel Engine

Authors: Marcin Szlachetka, Rafal Sochaczewski, Lukasz Grabowski

Abstract:

This paper presents the results of the load simulations of main bearings in a two-stroke Diesel engine. A model of an engine lubrication system with connections of its main lubrication nodes, i.e., a connection of its main bearings in the engine block with the crankshaft, a connection of its crankpins with its connecting rod and a connection of its pin and its piston has been created for our calculations performed using the AVL EXCITE Designer. The analysis covers the loads given as a pressure distribution in a hydrodynamic oil film, a temperature distribution on the main bush surfaces for the specified radial clearance values as well as the impact of the force of gas on the minimum oil film thickness in the main bearings depending on crankshaft rotational speeds and temperatures of oil in the bearings. One of the main goals of the research has been to determine whether the minimum thickness of the oil film at which fluid friction occurs can be achieved for each value of crankshaft speed. Our model calculates different oil film parameters, i.e., its thickness, a pressure distribution there, the change in oil temperature. Additional enables an analysis of an oil temperature distribution on the surfaces of the bearing seats. It allows verifying the selected clearances in the bearings of the main engine under normal operation conditions and extremal ones that show a significant increase in temperature above the limit value. The research has been conducted for several engine crankshaft speeds ranging from 1000 rpm to 4000 rpm. The oil pressure in the bearings has ranged 2-5 bar according to engine speeds and the oil temperature has ranged 90-120 °C. The main bearing clearance has been adopted for the calculation and analysis as 0.025 mm. The oil classified as SAE 5W-30 has been used for the simulations. The paper discusses the selected research results referring to several specific operating points and different temperatures of the lubricating oil in the bearings. The received research results show that for the investigated main bearing bushes of the shaft, the results fall within the ranges of the limit values despite the increase in the oil temperature of the bearings reaching 120˚C. The fact that the bearings are loaded with the maximum pressure makes no excessive temperature rise on the bush surfaces. The oil temperature increases by 17˚C, reaching 137˚C at a speed of 4000 rpm. The minimum film thickness at which fluid friction occurs has been achieved for each of the operating points at each of the engine crankshaft speeds. Acknowledgement: This work has been realized in the cooperation with The Construction Office of WSK ‘PZL-KALISZ’ S.A.’ and is part of Grant Agreement No. POIR.01.02.00-00-0002/15 financed by the Polish National Centre for Research and Development.

Keywords: diesel engine, main bearings, opposing pistons, two-stroke

Procedia PDF Downloads 97
693 Tribological Characterization of ZrN Coatings on Titanium Modified Austenitic Stainless Steel

Authors: Mohammad Farooq Wani

Abstract:

Tribological characterization of ZrN coatings deposited on titanium modified austenitic stainless steel (alloy D-9) substrates has been investigated. The coatings were deposited in the deposition temperature range 300–873 K, using the pulsed magnetron sputtering technique. Scratch adhesion tests were carried out using Rc indenter under various conditions of load. Detailed tribological studies were conducted to understand the friction and wear behaviour of these coatings. For all tribological studies steel and ceramic balls were used as counter face material. 3D-Surface profiles of all wear tracks was carried out using 3D universal profiler.

Keywords: ZrN, Surafce coating, thin film, tribology, friction and wear

Procedia PDF Downloads 388