Search results for: wear prediction.

Authors: Tadahiro Wada, Hiroyuki Hanyu

Abstract:

In this study, to clarify the effectiveness of an aluminum/chromium/tungsten-based-coated tool for cutting sintered steel, tool wear was experimentally investigated. The sintered steel was turned with the (Al60,Cr25,W15)N-, (Al60,Cr25,W15)(C,N)- and (Al64,Cr28,W8)(C,N)-coated cemented carbide tools according to the physical vapor deposition (PVD) method. Moreover, the tool wear of the aluminum/chromium/tungsten-based-coated item was compared with that of the (Al,Cr)N coated tool. Furthermore, to clarify the tool wear mechanism of the aluminum/chromium/tungsten-coating film for cutting sintered steel, Scanning Electron Microscope observation and Energy Dispersive x-ray Spectroscopy mapping analysis were conducted on the abraded surface. The following results were obtained: (1) The wear progress of the (Al64,Cr28,W8)(C,N)-coated tool was the slowest among that of the five coated tools. (2) Adding carbon (C) to the aluminum/chromium/tungsten-based-coating film was effective for improving the wear-resistance. (3) The main wear mechanism of the (Al60,Cr25,W15)N-, the (Al60,Cr25,W15)(C,N)- and the (Al64,Cr28,W8)(C,N)-coating films was abrasive wear.

Keywords: Cutting, physical vapor deposition coating method, tool wear, tool wear mechanism, sintered steel.

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Authors: Lin. Yan, Wenyu. Yang, Hongping. Jin, Zhiguang Wang

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This paper presents a experiment to estimate the influences of cutting conditions in microstructure changes of machining austenitic 304 stainless steel, especially for wear insert. The wear insert were prefabricated with a width of 0.5 mm. And the forces, temperature distribution, RS, and microstructure changes were measured by force dynamometer, infrared thermal camera, X-ray diffraction, XRD, SEM, respectively. The results told that the different combinations of machining condition have a significant influence on machined surface microstructure changes. In addition to that, the ANOVA and AOMwere used to tell the different influences of cutting speed, feed rate, and wear insert.

Keywords: Microstructure Changes, Wear width, Stainless steel

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Authors: Binnur Sagbas

Abstract:

Artificial joint replacements such as total knee and total hip prosthesis have been applied to the patients who affected by osteoarthritis. Although different material combinations are used for these joints, biopolymers are most commonly preferred materials especially for acetabular cup and tibial component of hip and knee joints respectively. The main limitation that shortens the service life of these prostheses is wear. Wear is complicated phenomena and it must be considered with friction and lubrication. In this study, micro wave (MW) induced argon+oxygen plasma surface modification were applied on ultra-high molecular weight polyethylene (UHMWPE) and vitamin E blended UHMWPE (VE-UHMWPE) biopolymer surfaces to improve surface wettability and wear resistance of the surfaces. Contact angel measurement method was used for determination of wettability. Ball-on-disc wear test was applied under 25% bovine serum lubrication conditions. The results show that surface wettability and wear resistance of both material samples were increased by plasma surface modification.

Keywords: Artificial joints, plasma surface modification, UHMWPE, vitamin E, wear.

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Authors: J. Ramos, V. Gil, A. F. Torres

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In this research (using induction furnace process) nodular iron with three different percentages of copper (residual, 0.5% and 1,2%) was obtained. Chemical analysis was performed by mass spectrometry and microstructures were characterized by Optical Microscopy (ASTM E3) and Scanning Electron Microscopy (SEM). The study of mechanical behavior was carried out in a mechanical test machine (ASTM E8) and a Pin on disk tribometer (ASTM G99) was used to assess wear resistance. It is observed that the dissolution of copper in crystal lattice increases the pearlite structure improving the wear and hardness behavior, but producing a contrary effect on the energy absorption.

Keywords: Ferritic and perlite structure, mechanical properties, nodular iron, wear.

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Authors: Paul Dallyn, Ashraf El-Hamalawi, Alessandro Palmeri, Bob Knight

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In order to better understand the long term implications of the grout wear failure mode in large-diameter plainsided grouted connections, a numerical model has been developed and calibrated that can take advantage of existing operational plant data to predict the wear accumulation for the actual load conditions experienced over a given period, thus limiting the requirement for expensive monitoring systems. This model has been derived and calibrated based on site structural condition monitoring (SCM) data and supervisory control and data acquisition systems (SCADA) data for two operational wind turbine generator substructures afflicted with this challenge, along with experimentally derived wear rates.

Keywords: Grouted Connection, Numerical Model, Offshore Structure, Wear, Wind Energy.

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Authors: M. S. Kaiser, Swagata Dutta

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In the present work, the effect of load and sliding distance on the performance tribology of commercially used aluminium-silicon engine block and piston was evaluated at ambient conditions with humidity of 80% under dry sliding conditions using a pin-on-disc with two different loads of 5N and 20N yielding applied pressure of 0.30MPa and 1.4MPa, respectively, at sliding velocity of 0.29ms-1 and with varying sliding distance ranging from 260m- 4200m. Factors and conditions that had significant effect were identified. The results showed that the load and the sliding distance affect the wear rate of the alloys and the wear rate increased with increasing load for both the alloys. Wear rate also increases almost linearly at low loads and increase to a maximum then attain a plateau with increasing sliding distance. For both applied loads the piston alloy showed the better performance due to higher Ni and Mg content. The worn surface and wear debris was characterized by optical microscope, SEM and EDX analyzer. The worn surface was characterized by surface with shallow grooves at loads while the groove width and depth increased as the loads increases. Oxidative wear was found to be the predominant mechanisms in the dry sliding of Al-Si alloys at low loads.

Keywords: Wear, friction, gravimetric analysis, aluminiumsilicon alloys, SEM, EDX.

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Authors: M.Jalali Azizpour, S.norouzi, H.mohammadi majd, H.Talebi, A.Ghamari

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In this paper, the application of thermal spray coatings in high speed shafts by a revolution up to 23000 RPM has been studied. Gas compressor shafts are worn in contact zone with journal therefore will be undersized. Wear mechanisms of compressor shaft were identified. The predominant wear mechanism is abrasion wear. The worn surface was coated by hard WC-Co cermets using high velocity oxy fuel (HVOF) after preparation. The shafts were in satisfactory service in 8000h period. The metallurgical and Tribological studies has been made on the worn and coated shaft using optical microscopy, scanning electron microscopy (SEM) and X-ray diffraction.

Keywords: Thermal spray, Residual stress, Wear mechanism, HVOF, Gas compressor shafts.

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Authors: Antônio P. de Araújo Neto, Ruy D. A. da Silva Neto, Juliana R. de Souza, Salete K. P. de Medeiros, João T. N. de Medeiros

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The tribological test with Pin-On-Disc configuration measures friction and wear properties in dry or lubricated sliding surfaces of a variety of materials and coatings. Polymeric matrix composites loaded with mineral filler were used, 1%, 3%, 10%, 30%, and 50% mass percentage of filler, to reduce the material cost by using mineral tailings. Using a pin-on-disc tribometer to quantify coefficient of friction and wear resistance of the specimens. The parameters known to performing the test were 300 rpm rotation, normal load of 16N and duration of 33.5 minutes. The composite with 10% mineral filler performed better, considering that the wear resistance was good when compared to the other compositions and an average low coefficient of friction, in the order of μ ≤ 0.15.

Keywords: Microcomposites, microparticles tailings of scheelite, PTFE, tribology.

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Authors: Ajay Likhite, Prashant Parhad, D. R. Peshwe, S. U. Pathak

Abstract:

Chromium bearing Austempered Ductile Iron (ADI) has been recently in the news for its improved wear performance over the ADI. The work presented below was taken up to study the effect of different austenitisation temperatures on the microstructure and wear performance of the Carbidic Austempered Ductile Iron (CADI). In this investigation Cr bearing ductile iron was subjected to austempering treatment to obtain an ausferritic microstructure. Two different austenitisation temperatures were selected whereas, the austempering temperature and time was kept unchanged. Microstructure and wear performance of this alloy, austenitized at two different temperatures was studied.

Keywords: Austempered Ductile Iron, Carbidic Austempered Ductile Iron.Austenitization temperature.

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Authors: Praveen Kumar, Nitin Kumar, Hemant Kumar

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The modernization of computer technology and commercial computational fluid dynamic (CFD) simulation has given better detailed results as compared to experimental investigation techniques. CFD techniques are widely used in different field due to its flexibility and performance. Evaluation of pipeline erosion is complex phenomenon to solve by numerical arithmetic technique, whereas CFD simulation is an easy tool to resolve that type of problem. Erosion wear behaviour due to solid–liquid mixture in the slurry pipeline has been investigated using commercial CFD code in FLUENT. Multi-phase Euler-Lagrange model was adopted to predict the solid particle erosion wear in 22.5° pipe bend for the flow of bottom ash-water suspension. The present study addresses erosion prediction in three dimensional 22.5° pipe bend for two-phase (solid and liquid) flow using finite volume method with standard k-ε turbulence, discrete phase model and evaluation of erosion wear rate with varying velocity 2-4 m/s. The result shows that velocity of solid-liquid mixture found to be highly dominating parameter as compared to solid concentration, density, and particle size. At low velocity, settling takes place in the pipe bend due to low inertia and gravitational effect on solid particulate which leads to high erosion at bottom side of pipeline.

Keywords: Computational fluid dynamics, erosion, slurry transportation, k-ε Model.

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Authors: B. Sir, M. Podhoranyi, S. Kuchar, T. Kocyan

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Rainfall runoff models play important role in hydrological predictions. However, the model is only one part of the process for creation of flood prediction. The aim of this paper is to show the process of successful prediction for flood event (May 15 – May 18 2014). Prediction was performed by rainfall runoff model HEC–HMS, one of the models computed within Floreon+ system. The paper briefly evaluates the results of automatic hydrologic prediction on the river Olše catchment and its gages Český Těšín and Věřňovice.

Keywords: Flood, HEC-HMS, Prediction, Rainfall – Runoff.

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Authors: Jaruphan Supprung

Abstract:

Aims of this research were to study Thai Buddhist temple festivals and Balinese Hindu temple festivals, to compare Thai Buddhist temple festival dress with Balinese Hindu temple festival dress, and to create the knowledge which can be useful for Thai attitudes and cultural perceptions, especially for Thai children and youth. The findings of the research disclosed that there are four temple festivals of Thai Buddhists in Thailand, namely Songkran Festival, Buddhist Lent Festival, Sart Thai Festival and End of Buddhist Lent Festival. In island of Bali, Indonesia, there are three Balinese Hindu temple festivals, namely Odalan Festival, Galungan Festival and Nyepi Festival. Thai Songkran Festival is similar to New Year Celebration in Balinese Nyepi Festival. Thai Songkran Festival and Sart Thai Festival have the same purpose as that of Balinese Galungan Festival in practice of dedicating merit to the spirits of deceased relatives. In these temple festivals, Thai Buddhist men will wear round collar outerwear and wide leg trousers or loincloths but will never wear headdresses, while Balinese Hindu men wear turbans or fabric headbands, shirts and Sarong, which are similar to Sarong of Thai Buddhist men in central and northern part of Thailand. Most of Thai Buddhist women wear Sarong like Balinese Hindu women but wear only round collar outerwear, while Balinese Hindu women wear diamond neck camisole as inner wear and shawl collar as outerwear.

Keywords: Temple festival dresses, Thai Buddhists, Balinese Hindus.

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Authors: H. Soleimanimehr, M. J. Nategh , S. Amini

Abstract:

Development of artificial neural network (ANN) for prediction of aluminum workpieces' surface roughness in ultrasonicvibration assisted turning (UAT) has been the subject of the present study. Tool wear as the main cause of surface roughness was also investigated. ANN was trained through experimental data obtained on the basis of full factorial design of experiments. Various influential machining parameters were taken into consideration. It was illustrated that a multilayer perceptron neural network could efficiently model the surface roughness as the response of the network, with an error less than ten percent. The performance of the trained network was verified by further experiments. The results of UAT were compared with the results of conventional turning experiments carried out with similar machining parameters except for the vibration amplitude whence considerable reduction was observed in the built-up edge and the surface roughness.

Keywords: Aluminum, Artificial Neural Network (ANN), BuiltupEdge, Surface Roughness, Tool Wear, Ultrasonic VibrationAssisted Turning (UAT).

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Authors: N. H. Adenan, M. S. M. Noorani

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River flow prediction is an essential to ensure proper management of water resources can be optimally distribute water to consumers. This study presents an analysis and prediction by using nonlinear prediction method involving monthly river flow data in Tanjung Tualang from 1976 to 2006. Nonlinear prediction method involves the reconstruction of phase space and local linear approximation approach. The phase space reconstruction involves the reconstruction of one-dimensional (the observed 287 months of data) in a multidimensional phase space to reveal the dynamics of the system. Revenue of phase space reconstruction is used to predict the next 72 months. A comparison of prediction performance based on correlation coefficient (CC) and root mean square error (RMSE) have been employed to compare prediction performance for nonlinear prediction method, ARIMA and SVM. Prediction performance comparisons show the prediction results using nonlinear prediction method is better than ARIMA and SVM. Therefore, the result of this study could be used to develop an efficient water management system to optimize the allocation water resources.

Keywords: River flow, nonlinear prediction method, phase space, local linear approximation.

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Authors: N. H. Adenan, M. S. M. Noorani

Abstract:

River flow prediction is an essential tool to ensure proper management of water resources and the optimal distribution of water to consumers. This study presents an analysis and prediction by using nonlinear prediction method with monthly river flow data for Tanjung Tualang from 1976 to 2006. Nonlinear prediction method involves the reconstruction of phase space and local linear approximation approach. The reconstruction of phase space involves the reconstruction of one-dimension (the observed 287 months of data) in a multidimensional phase space to reveal the dynamics of the system. The revenue of phase space reconstruction is used to predict the next 72 months. A comparison of prediction performance based on correlation coefficient (CC) and root mean square error (RMSE) was employed to compare prediction performance for the nonlinear prediction method, ARIMA and SVM. Prediction performance comparisons show that the prediction results using the nonlinear prediction method are better than ARIMA and SVM. Therefore, the results of this study could be used to develop an efficient water management system to optimize the allocation of water resources.

Keywords: River flow, nonlinear prediction method, phase space, local linear approximation.

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Authors: A. Elyousfi, A. Tamtaoui, E. Bouyakhf

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The H.264/AVC standard uses an intra prediction, 9 directional modes for 4x4 luma blocks and 8x8 luma blocks, 4 directional modes for 16x16 macroblock and 8x8 chroma blocks, respectively. It means that, for a macroblock, it has to perform 736 different RDO calculation before a best RDO modes is determined. With this Multiple intra-mode prediction, intra coding of H.264/AVC offers a considerably higher improvement in coding efficiency compared to other compression standards, but computational complexity is increased significantly. This paper presents a fast intra prediction algorithm for H.264/AVC intra prediction based a characteristic of homogeneity information. In this study, the gradient prediction method used to predict the homogeneous area and the quadratic prediction function used to predict the nonhomogeneous area. Based on the correlation between the homogeneity and block size, the smaller block is predicted by gradient prediction and quadratic prediction, so the bigger block is predicted by gradient prediction. Experimental results are presented to show that the proposed method reduce the complexity by up to 76.07% maintaining the similar PSNR quality with about 1.94%bit rate increase in average.

Keywords: Intra prediction, H.264/AVC, video coding, encodercomplexity.

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Authors: Murat Sarıkaya, Abdulkadir Güllü

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Haynes 25 alloy (also known as L-605 alloy) is cobalt based super alloy which has widely applications such as aerospace industry, turbine and furnace parts, power generators and heat exchangers and petroleum refining components due to its excellent characteristics. However, the workability of this alloy is more difficult compared to normal steels or even stainless. In present work, an experimental investigation was performed under cryogenic cooling to determine cutting tool wear patterns and obtain optimal cutting parameters in turning of cobalt based superalloy Haynes 25. In experiments, uncoated carbide tool was used and cutting speed (V) and feed rate (f) were considered as test parameters. Tool wear (VBmax) were measured for process performance indicators. Analysis of variance (ANOVA) was performed to determine the importance of machining parameters.

Keywords: Cryogenic machining, difficult-to-cut alloy, tool wear, turning.

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Authors: Dler Abdullah Ahmed, Zozan Ahmed Mohammed

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This study looked into contact surface temperature during a pin-on-disk test. Friction and wear between sliding surfaces raised the temperature differential between contact surface and ambient temperatures Tdiff. Tdiff was significantly influenced by wear test variables. Tdiff rose with the increase of sliding speed and applied load, while dropped with the increase in ambient temperature. The highest Tdiff was 289 °C during the tests at room temperature and 2.5 m/s sliding speed, while the minimum was only 24 °C during the tests at 400 °C and 0.5 m/s. However, the maximum contact temperature Tmax was found during tests conducted at high ambient temperatures. The Tmax was estimated based on the theoretical equation. The comparison of experimental and theoretical Tmax data was revealed good agreement.

Keywords: Pin-on-disk test, contact temperature, wear, sliding surface, friction, ambient temperature.

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Authors: Kefaya Qaddoum

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The aim of this study is to predict breast cancer and to construct a supportive model that will stimulate a more reliable prediction as a factor that is fundamental for public health. In this study, we utilize general regression neural networks (GRNN) to replace the normal predictions with prediction periods to achieve a reasonable percentage of confidence. The mechanism employed here utilises a machine learning system called conformal prediction (CP), in order to assign consistent confidence measures to predictions, which are combined with GRNN. We apply the resulting algorithm to the problem of breast cancer diagnosis. The results show that the prediction constructed by this method is reasonable and could be useful in practice.

Keywords: Neural network, conformal prediction, cancer classification, regression.

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Authors: Abdullah Yassin, Takashi Ueda, Syed Tarmizi Syed Shazali

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This paper presents an experimental investigation on the machinability of laser-sintered material using small ball end mill focusing on wear mechanisms. Laser-sintered material was produced by irradiating a laser beam on a layer of loose fine SCM-Ni-Cu powder. Bulk carbon steel JIS S55C was selected as a reference steel. The effects of powder consolidation mechanisms and unsintered powder on the tool life and wear mechanisms were carried out. Results indicated that tool life in cutting laser-sintered material is lower than that in cutting JIS S55C. Adhesion of the work material and chipping were the main wear mechanisms of the ball end mill in cutting laser-sintered material. Cutting with the unsintered powder surrounding the tool and laser-sintered material had caused major fracture on the cutting edge.

Keywords: Laser-sintered material, tool life, wear mechanism.

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Authors: Tadahiro Wada, Shinichi Enoki, Hiroyuki Hanyu

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In this study, WC-Ni-based cemented carbides having different nickel contents were used as the substrate for cutting tool materials. Hardened steel was turned by a (Ti,W,Si)N-coated WC-Ni-based cemented carbide tool, and the tool wear was experimentally investigated. The following results were obtained: (1) In the (Ti,W,Si)N-coated WC-Ni-based cemented carbide, the hardness of the coating film was not much different from the content of the binding material, Ni, and the adhesion strength increased with a decrease in Ni content. (2) There is little difference between the wear progress of the (Ti,W,Si)N-coated WC-7%Ni-based cemented carbide tool and that of the (Ti,W,Si)N-coated WC-6%Co-based cemented carbide tool. (3) The wear progress of the (Ti,W,Si)N-coated WC-Ni-based cemented carbide became slower with a decrease in Ni content.

From the above, it is has become clear that WC-Ni-based cemented carbide can be used as a substrate for cutting tool materials.

Keywords: Rare metals, turning, WC-Ni-based cemented carbide, (Ti, W, Si)N coating film, hardened steel.

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Authors: Salah Gariani, Taher Dao, Ahmed Lajili

Abstract:

This paper presents an experimental optimisation of surface roughness (Ra) and tool wear in the precision turning of AISI 304L alloy using a wiper and conventional cutting tools under wet cutting conditions. The machining trials were conducted based on Taguchi methodology employing an L9 orthogonal array design with four process parameters: feed rate, spindle speed, depth of cut, and cutting tool type. The experimental results were utilised to characterise the main factors affecting Ra and tool wear using the analyses of means (AOM) and variance (ANOVA). The results show that the wiper tools outperformed conventional tools in terms of surface quality and tool wear at optimal cutting conditions. The ANOVA results indicate that the main factors contributing to lower Ra are cutting tool type and feed rate, with percentage contribution ratios (PCRs) of 58.69% and 25.18% respectively. This confirms that tool type is the most significant factor affecting surface quality when turning AISI 304L. Additionally, a substantial reduction in tool wear was observed when a wiper insert was used, whereas noticeable increases in tool wear occurred when higher cutting speeds were employed for both tool types. These trends confirm the ANOVA outcomes that cutting speed has a significant effect on tool wear, with a PCR value of 39.22%, followed by tool type with a PCR of 27.40%. All machining trials generated similar continuous spiral or curl-shaped chips. A noticeable difference was found in the radius of the produced curl-shaped chips at different cutting speeds when turning AISI 304L under wet cutting conditions.

Keywords: AISI 304L alloy, conventional and wiper carbide tools, wet turning, average surface roughness, tool wear.

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Authors: David Downey

Abstract:

With the introduction of additive manufacturing (3D printing) to produce titanium (Ti6Al4V) components in the medical, aerospace and automotive industries, intricate geometries can be produced with virtually complete design freedom. However, the consideration of microstructural anisotropy resulting from the additive manufacturing process becomes necessary due to this design flexibility and the need to print a geometric shape that can consist of numerous angles, radii, and swept surfaces. A femoral knee implant serves as an example of a 3D-printed near-net-shaped product. The mechanical properties of the printed components, and consequently, their machinability, are affected by microstructural anisotropy. Currently, finish-machining operations performed on titanium printed parts using selective laser melting (SLM) utilize the same cutting tools employed for processing wrought titanium components. Cutting forces for components manufactured through SLM can be up to 70% higher than those for their wrought counterparts made of Ti6Al4V. Moreover, temperatures at the cutting interface of 3D printed material can surpass those of wrought titanium, leading to significant tool wear. Although the criteria for tool wear may be similar for both 3D printed and wrought materials, the rate of wear during the machining process may differ. The impact of these issues on the choice of cutting tool material and tool lifetimes will be discussed.

Keywords: Additive manufacturing, build orientation, microstructural anisotropy, printed titanium Ti6Al4V, tool wear.

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Authors: Mohammad M. Khan, Gajendra Dixit

Abstract:

Partially lubricated sliding wear behaviour of a zinc-based alloy reinforced with 10wt% SiC particles has been studied as a function of applied load and solid lubricant particle size and has been compared with that of matrix alloy and conventionally used grey cast iron. The wear tests were conducted at the sliding velocities of 2.1m/sec in various partial lubricated conditions using pin on disc machine as per ASTM G-99-05. Base oil (SAE 20W-40) or mixture of the base oil with 5wt% graphite of particle sizes (7-10 µm) and (100 µm) were used for creating lubricated conditions. The matrix alloy revealed primary dendrites of a and eutectoid a + h and Î phases in the Inter dendritic regions. Similar microstructure has been depicted by the composite with an additional presence of the dispersoid SiC particles. In the case of cast iron, flakes of graphite were observed in the matrix; the latter comprised of (majority of) pearlite and (limited quantity of) ferrite. Results show a large improvement in wear resistance of the zinc-based alloy after reinforcement with SiC particles. The cast iron shows intermediate response between the matrix alloy and composite. The solid lubrication improved the wear resistance and friction behaviour of both the reinforced and base alloy. Moreover, minimum wear rate is obtained in oil+ 5wt % graphite (7-10 µm) lubricated environment for the matrix alloy and composite while for cast iron addition of solid lubricant increases the wear rate and minimum wear rate is obtained in case of oil lubricated environment. The cast iron experienced higher frictional heating than the matrix alloy and composite in all the cases especially at higher load condition. As far as friction coefficient is concerned, a mixed trend of behaviour was noted. The wear rate and frictional heating increased with load while friction coefficient was affected in an opposite manner. Test duration influenced the frictional heating and friction coefficient of the samples in a mixed manner.

Keywords: Solid lubricant, sliding wear grey cast iron, zinc based metal matrix composites.

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Authors: Jun Sung Park, Hyo Jung Song

Abstract:

H.264/AVC offers a considerably higher improvement in coding efficiency compared to other compression standards such as MPEG-2, but computational complexity is increased significantly. In this paper, we propose selective mode decision schemes for fast intra prediction mode selection. The objective is to reduce the computational complexity of the H.264/AVC encoder without significant rate-distortion performance degradation. In our proposed schemes, the intra prediction complexity is reduced by limiting the luma and chroma prediction modes using the directional information of the 16×16 prediction mode. Experimental results are presented to show that the proposed schemes reduce the complexity by up to 78% maintaining the similar PSNR quality with about 1.46% bit rate increase in average.

Keywords: Video encoding, H.264, Intra prediction.

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Authors: J. K. Khare, Abhay Kumar Sharma, Ajay Tiwari, Amol A. Talankar

Abstract:

Powder metallurgy (P/M) is the only economic way to produce porous parts/products. P/M can produce near net shape parts hence reduces wastage of raw material and energy, avoids various machining operations. The most vital use of P/M is in production of metallic filters and self lubricating bush bearings and siding surfaces. The porosity of the part can be controlled by varying compaction pressure, sintering temperature and composition of metal powder mix. The present work is aimed for experimental analysis of friction and wear properties of self lubricating copper and tin bush bearing. Experimental results confirm that wear rate of sintered component is lesser for components having 10% tin by weight percentage. Wear rate increases for high tin percentage (experimented for 20% tin and 30% tin) at same sintering temperature. Experimental results also confirms that wear rate of sintered component is also dependent on sintering temperature, soaking period, composition of the preform, compacting pressure, powder particle shape and size. Interfacial friction between die and punch, between inter powder particles, between die face and powder particle depends on compaction pressure, powder particle size and shape, size and shape of component which decides size & shape of die & punch, material of die & punch and material of powder particles.

Keywords: Interfacial friction, porous bronze bearing, sintering temperature, wear rate.

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Authors: Han Bing, Yin Zhenjie

Abstract:

In order to analyze the status of a diesel engine, as well as conduct fault prediction, a new prediction model based on a gray system is proposed in this paper, which takes advantage of the neural network and the genetic algorithm. The proposed GBPGA prediction model builds on the GM (1.5) model and uses a neural network, which is optimized by a genetic algorithm to construct the error compensator. We verify our proposed model on the diesel faulty simulation data and the experimental results show that GBPGA has the potential to employ fault prediction on diesel.

Keywords: Fault prediction, Neural network, GM (1.5), Genetic algorithm, GBPGA.

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Authors: U. Achutha Kini, S. S. Sharma, K. Jagannath, P. R. Prabhu, Gowri Shankar M. C.

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Aluminium matrix composites with alumina reinforcements give superior mechanical & physical properties. Their applications in several fields like automobile, aerospace, defense, sports, electronics, bio-medical and other industrial purposes are becoming essential for the last several decades. In the present work, fabrication of hybrid composite was done by Stir casting technique using Al 6061 as a matrix with alumina and silicon carbide (SiC) as reinforcement materials. The weight percentage of alumina is varied from 2 to 4% and the silicon carbide weight percentage is maintained constant at 2%. Hardness and wear tests are performed in the as cast and heat treated conditions. Age hardening treatment was performed on the specimen with solutionizing at 550°C, aging at two temperatures (150 and 200°C) for different time durations. Hardness distribution curves are drawn and peak hardness values are recorded. Hardness increase was very sensitive with respect to the decrease in aging temperature. There was an improvement in wear resistance of the peak aged material when aged at lower temperature. Also increase in weight percent of alumina, increases wear resistance at lower temperature but opposite behavior was seen when aged at higher temperature.

Keywords: Hybrid composite, hardness test, wear test, heat treatment, pin on disc wear testing machine.

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Authors: Tadahiro Wada, Koji Iwamoto

Abstract:

In turning hardened steel, polycrystalline cubic boron nitride (cBN) compacts are widely used, due to their higher hardness and higher thermal conductivity. However, in milling hardened steel, fracture of cBN cutting tools readily occurs because they have poor fracture toughness. Therefore, coated cemented carbide tools, which have good fracture toughness and wear resistance, are generally widely used. In this study, hardened steel (ASTM D2, JIS SKD11, 60HRC) was milled with three physical vapor deposition (PVD)-coated cemented carbide end mill cutters in order to determine effective tool materials for cutting hardened steel at high cutting speeds. The coating films used were (Ti,W)N/(Ti,W,Si)N and (Ti,W)N/(Ti,W,Si,Al)N coating films. (Ti,W,Si,Al)N is a new type of coating film. The inner layer of the (Ti,W)N/(Ti,W,Si)N and (Ti,W)N/(Ti,W,Si,Al)N coating system is (Ti,W)N coating film, and the outer layer is (Ti,W,Si)N and (Ti,W,Si,Al)N coating films, respectively. Furthermore, commercial (Ti,Al)N-based coating film was also used. The following results were obtained: (1) In milling hardened steel at a cutting speed of 3.33 m/s, the tool wear width of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool was smaller than that of the (Ti,W)N/(Ti,W,Si)N-coated tool. And, compared with the commercial (Ti,Al)N, the tool wear width of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool was smaller than that of the (Ti,Al)N-coated tool. (2) The tool wear of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool increased with an increase in cutting speed. (3) The (Ti,W)N/(Ti,W,Si,Al)N-coated cemented carbide was an effective tool material for high-speed cutting below a cutting speed of 3.33 m/s.

Keywords: cutting, physical vapor deposition (PVD) coating system, hardened steel, tool wear

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Authors: Gabi Nehme

Abstract:

The relationship between different types of Molybdenum disulfide greases under extreme pressure loading and different speed situations have been studied using Design of Experiment (DOE) under 1200rpm steady state rotational speed and cyclic frequencies between 2400 and 1200rpm using a Plint machine software to set up the different rotational speed situations.  Research described here is aimed at providing good friction and wear performance while optimizing cyclic frequencies and MoS2 concentration due to the recent concern about grease behavior in extreme pressure applications. Extreme load of 785 Newton was used in conjunction with different cyclic frequencies (2400rpm -3.75min, 1200rpm -7.5min, 2400rpm -3.75min, 1200rpm -7.5min), to examine lithium based grease with and without MoS2 for equal number of revolutions, and a total run of 36000 revolutions; then compared to 1200rpm steady speed for the same total number of revolutions. 4 Ball wear tester was utilized to run large number of experiments randomly selected by the DOE software. The grease was combined with fine grade MoS2 or technical grade then heated to 750C and the wear scar width was collected at the end of each test. DOE model validation results verify that the data were very significant and can be applied to a wide range of extreme pressure applications. Based on simulation results and Scanning Electron images (SEM), it has been found that wear was largely dependent on the cyclic frequency condition. It is believed that technical grade MoS2 greases under faster cyclic speeds perform better and provides antiwear film that can resist extreme pressure loadings. Figures showed reduced wear scars width and improved frictional values.

 

Keywords: MoS2 grease, wear, friction, extreme load, cyclic frequencies, aircraft grade bearing.

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