Search results for: wear mechanism.

Authors: Z. Rihova, K. Saksl, C. Siemers, D. Ostroushko

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Titanium alloys like the modern alloy Ti 6Al 2Sn 4Zr 6Mo (Ti-6246) combine excellent specific mechanical properties and corrosion resistance. On the other hand,due to their material characteristics, machining of these alloys is difficult to perform. The aim of the current study is the analyses of wear mechanisms of coated cemented carbide tools applied in orthogonal cutting experiments of Ti-6246 alloy. Round bars were machined with standard coated tools in dry conditions on a CNC latheusing a wide range of cutting speeds and cutting depths. Tool wear mechanisms were afterwards investigated by means of stereo microscopy, optical microscopy, confocal microscopy and scanning electron microscopy. Wear mechanisms included fracture of the tool tip (total failure) and abrasion. Specific wear features like crater wear, micro cracks and built-up edgeformation appeared depending of the mechanical and thermal conditions generated in the workpiece surface by the cutting action.

Keywords: Alloy 6246, machining, tool wear, optical microscopy, SEM, EDX analysis

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Authors: Alluru Gopala Krishna, Thella Babu Rao

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In machining, there is always a problem with heat generation and friction produced during the process as they consequently affect tool wear and surface finish. An instant heat transfer mechanism could protect the cutting tool edge and enhance the tool life by cooling the cutting edge of the tool. In the present work, carbon nanotube (CNT) based nano-cutting fluid is proposed for machining a hard-to-cut material. Tool wear and surface roughness are considered for the evaluation of the nano-cutting fluid in turning process. The performance of nanocoolant is assessed against the conventional coolant and dry machining conditions and it is observed that the proposed nanocoolant has produced better performance than the conventional coolant.

Keywords: CNT based nanocoolant, turning, tool wear, surface roughness.

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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: Bruno Bacci Fernandes, Stephan Mändl, Ataíde Ribeiro da Silva Junior, José Osvaldo Rossi, Mário Ueda

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Nitrogen implantation in aluminum and its alloys is acquainted for the difficulties in obtaining modified layers deeper than 200 nm. The present work addresses a new method to overcome such a problem; although, the coating with nitrogen and oxygen obtained by plasma immersion ion implantation (PIII) into a 7075 aluminum alloy surface was too shallow. This alloy is commonly used for structural parts in aerospace applications. Such a layer was characterized by secondary ion mass spectroscopy, electron microscopy, and nanoindentation experiments reciprocating wear tests. From the results, one can assume that the wear of this aluminum alloy starts presenting severe abrasive wear followed by an additional adhesive mechanism. PIII produced a slight difference, as shown in all characterizations carried out in this work. The results shown here can be used as the scientific basis for further nitrogen PIII experiments in aluminum alloys which have the goal to produce thicker modified layers or to improve their surface properties.

Keywords: Aluminum alloys, plasma immersion ion implantation, tribological properties, hardness, nanofatigue.

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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

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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: Jaruphan Supprung

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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: S. M. Ali, N. R. Dhar

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Tool wear and surface roughness prediction plays a significant role in machining industry for proper planning and control of machining parameters and optimization of cutting conditions. This paper deals with developing an artificial neural network (ANN) model as a function of cutting parameters in turning steel under minimum quantity lubrication (MQL). A feed-forward backpropagation network with twenty five hidden neurons has been selected as the optimum network. The co-efficient of determination (R2) between model predictions and experimental values are 0.9915, 0.9906, 0.9761 and 0.9627 in terms of VB, VM, VS and Ra respectively. The results imply that the model can be used easily to forecast tool wear and surface roughness in response to cutting parameters.

Keywords: ANN, MQL, Surface Roughness, Tool Wear.

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Authors: Hatim Laalej, Salvador Sumohano-Verdeja, Thomas McLeay

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Monitoring of tool wear in milling operations is essential for achieving the desired dimensional accuracy and surface finish of a machined workpiece. Although there are numerous statistical models and artificial intelligence techniques available for monitoring the wear of cutting tools, these techniques cannot pin point which cutting edge of the tool, or which insert in the case of indexable tooling, is worn or broken. Currently, the task of monitoring the wear on the tool cutting edges is carried out by the operator who performs a manual inspection, causing undesirable stoppages of machine tools and consequently resulting in costs incurred from lost productivity. The present study is concerned with the development of a flute tracking system to segment signals related to each physical flute of a cutter with three flutes used in an end milling operation. The purpose of the system is to monitor the cutting condition for individual flutes separately in order to determine their progressive wear rates and to predict imminent tool failure. The results of this study clearly show that signals associated with each flute can be effectively segmented using the proposed flute tracking system. Furthermore, the results illustrate that by segmenting the sensor signal by flutes it is possible to investigate the wear in each physical cutting edge of the cutting tool. These findings are significant in that they facilitate the online condition monitoring of a cutting tool for each specific flute without the need for operators/engineers to perform manual inspections of the tool.

Keywords: Tool condition monitoring, tool wear prediction, milling operation, flute tracking.

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Authors: Adewale O. Adegbenjo, Elsie Nsiah-Baafi, Mxolisi B. Shongwe, Mercy Ramakokovhu, Peter A. Olubambi

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The sintering step in powder metallurgy (P/M) processes is very sensitive as it determines to a large extent the properties of the final component produced. Spark plasma sintering over the past decade has been extensively used in consolidating a wide range of materials including metallic alloy powders. This novel, non-conventional sintering method has proven to be advantageous offering full densification of materials, high heating rates, low sintering temperatures, and short sintering cycles over conventional sintering methods. Ti6Al4V has been adjudged the most widely used α+β alloy due to its impressive mechanical performance in service environments, especially in the aerospace and automobile industries being a light metal alloy with the capacity for fuel efficiency needed in these industries. The P/M route has been a promising method for the fabrication of parts made from Ti6Al4V alloy due to its cost and material loss reductions and the ability to produce near net and intricate shapes. However, the use of this alloy has been largely limited owing to its relatively poor hardness and wear properties. The effect of sintering temperature on the densification, hardness, and wear behaviors of spark plasma sintered Ti6Al4V powders was investigated in this present study. Sintering of the alloy powders was performed in the 650–850°C temperature range at a constant heating rate, applied pressure and holding time of 100°C/min, 50 MPa and 5 min, respectively. Density measurements were carried out according to Archimedes’ principle and microhardness tests were performed on sectioned as-polished surfaces at a load of 100gf and dwell time of 15 s. Dry sliding wear tests were performed at varied sliding loads of 5, 15, 25 and 35 N using the ball-on-disc tribometer configuration with WC as the counterface material. Microstructural characterization of the sintered samples and wear tracks were carried out using SEM and EDX techniques. The density and hardness characteristics of sintered samples increased with increasing sintering temperature. Near full densification (99.6% of the theoretical density) and Vickers’ micro-indentation hardness of 360 HV were attained at 850°C. The coefficient of friction (COF) and wear depth improved significantly with increased sintering temperature under all the loading conditions examined, except at 25 N indicating better mechanical properties at high sintering temperatures. Worn surface analyses showed the wear mechanism was a synergy of adhesive and abrasive wears, although the former was prevalent.

Keywords: Hardness, powder metallurgy, Spark plasma sintering, wear.

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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: M. D. Haneef, R. B. Randall, Z. Peng

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Journal bearings used in IC engines are prone to premature failures and are likely to fail earlier than the rated life due to highly impulsive and unstable operating conditions and frequent starts/stops. Vibration signature extraction and wear debris analysis techniques are prevalent in industry for condition monitoring of rotary machinery. However, both techniques involve a great deal of technical expertise, time, and cost. Limited literature is available on the application of these techniques for fault detection in reciprocating machinery, due to the complex nature of impact forces that confounds the extraction of fault signals for vibration-based analysis and wear prediction. In present study, a simulation model was developed to investigate the bearing wear behaviour, resulting because of different operating conditions, to complement the vibration analysis. In current simulation, the dynamics of the engine was established first, based on which the hydrodynamic journal bearing forces were evaluated by numerical solution of the Reynold’s equation. In addition, the essential outputs of interest in this study, critical to determine wear rates are the tangential velocity and oil film thickness between the journals and bearing sleeve, which if not maintained appropriately, have a detrimental effect on the bearing performance. Archard’s wear prediction model was used in the simulation to calculate the wear rate of bearings with specific location information as all determinative parameters were obtained with reference to crank rotation. Oil film thickness obtained from the model was used as a criterion to determine if the lubrication is sufficient to prevent contact between the journal and bearing thus causing accelerated wear. A limiting value of 1 μm was used as the minimum oil film thickness needed to prevent contact. The increased wear rate with growing severity of operating conditions is analogous and comparable to the rise in amplitude of the squared envelope of the referenced vibration signals. Thus on one hand, the developed model demonstrated its capability to explain wear behaviour and on the other hand it also helps to establish a co-relation between wear based and vibration based analysis. Therefore, the model provides a cost effective and quick approach to predict the impending wear in IC engine bearings under various operating conditions.

Keywords: Condition monitoring, IC engine, journal bearings, vibration analysis, wear prediction.

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Authors: S. A. M. Elshourbagy

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This paper investigates the effects of lubrication on the quantity of heat emission of two spur gear. System with and without lubrication effected on the quantity of heat induced on the gear box (oil - bearings – gears). Both of lubrication and speed of motor are affected on the performance of gears. Research investigated the lubrication on the system with and without loading as well as the wear of gears and bearing's conditions. Gear box investigated includes the motor, pump, two spur gears, two shafts; speed change used pulleys and belts. Load used equal one weight ones of gear. Lubrication mechanism used jet system (upper and lower jet). Gear box we used system of jet lubrication is perpendicular direction of the contact line between two teeth. Results appeared in this work that the lubrication is the vital parameter which is affected on the performance and durability of gears and bearings. In macroscopic observation, we noted that damage of bearings happened during the absence of lubrication as well as abrasive of wear of teeth. Higher speed of motor without lubrication increased the noise, but in the presence of lubrication was decreased.

Keywords: Lubrication, jet, laser gun, spur gear, temperature

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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

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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

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

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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: M.Jalali Azizpour, S.Norouzi, D.Sajedipour, H.Mohammadi majd, S.A.Hosseini, H.Talebi, A.Ghamari

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In this paper, the bond strength of thermal spray coatings in high speed shafts has been studied. The metallurgical and mechanical studies has been made on the coated samples and shaft using optical microscopy, scanning electron microscopy (SEM).

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

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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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Authors: Solomon Neway Jida, Jean-Francois Hetet, Pascal Chesse

Abstract:

Vehicular emission is the key source of air pollution in the urban environment. This includes both fine particles (PM_2.5) and coarse particulate matters (PM₁₀). However, particulate matter emissions from road traffic comprise emissions from exhaust tailpipe and emissions due to wear and tear of the vehicle part such as brake, tire and clutch and re-suspension of dust (non-exhaust emission). This study estimates the share of the two sources of pollutant particle emissions from on-roadside vehicles in the Addis Ababa municipality, Ethiopia. To calculate its share, two methods were applied; the exhaust-tailpipe emissions were calculated using the Europeans emission inventory Tier II method and Tier I for the non-exhaust emissions (like vehicle tire wear, brake, and road surface wear). The results show that of the total traffic-related particulate emissions in the city, 63% emitted from vehicle exhaust and the remaining 37% from non-exhaust sources. The annual roads transport exhaust emission shares around 2394 tons of particles from all vehicle categories. However, from the total yearly non-exhaust particulate matter emissions’ contribution, tire and brake wear shared around 65% and 35% emanated by road-surface wear. Furthermore, vehicle tire and brake wear were responsible for annual 584.8 tons of coarse particles (PM₁₀) and 314.4 tons of fine particle matter (PM_2.5) emissions in the city whereas surface wear emissions were responsible for around 313.7 tons of PM₁₀ and 169.9 tons of PM_2.5 pollutant emissions in the city. This suggests that non-exhaust sources might be as significant as exhaust sources and have a considerable contribution to the impact on air quality.

Keywords: Addis Ababa, automotive emission, emission estimation, particulate matters.

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Authors: Mohamed Amine Ben Abdallah, Imed Khemili, Nizar Aifaoui

Abstract:

This work denotes an insight into dynamic synthesis of multibody systems. A set of mechanism parameters design variable are synthetized based on a desired mechanism response, such as, velocity, acceleration and bodies deformations. Moreover, knowing the work space, for a robot, and mechanism response allow defining optimal parameters mechanism handling with the desired target response. To this end, evolutionary genetic algorithm has been deployed. A demonstrative example for imperfect mechanism has been treated, mainly, a slider crank mechanism with a flexible connecting rod. The transversal deflection of the connecting rod has been chosen as response to identify the mechanism design parameters.

Keywords: Dynamic response, flexible bodies, optimization, evolutionary genetic algorithm.

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Authors: Javier A. Dominguez Caballero, Graeme A. Manson, Matthew B. Marshall

Abstract:

Cutting tools with ceramic inserts are often used in the process of machining many types of superalloy, mainly due to their high strength and thermal resistance. Nevertheless, during the cutting process, the plastic flow wear generated in these inserts enhances and propagates cracks due to high temperature and high mechanical stress. This leads to a very variable failure of the cutting tool. This article explores the relationship between the continuous wear that ceramic SiAlON (solid solutions based on the Si3N4 structure) inserts experience during a high-speed machining process and the evolution of sparks created during the same process. These sparks were analysed through pictures of the cutting process recorded using an SLR camera. Features relating to the intensity and area of the cutting sparks were extracted from the individual pictures using image processing techniques. These features were then related to the ceramic insert’s crater wear area.

Keywords: Ceramic cutting tools, high speed machining, image processing, tool condition monitoring, tool wear.

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Authors: Jatinder Kumar, Vinod Kumar

Abstract:

Ultrasonic machining (USM) is a non-traditional machining process being widely used for commercial machining of brittle and fragile materials such as glass, ceramics and semiconductor materials. However, USM could be a viable alternative for machining a tough material such as titanium; and this aspect needs to be explored through experimental research. This investigation is focused on exploring the use of ultrasonic machining for commercial machining of pure titanium (ASTM Grade-I) and evaluation of tool wear rate (TWR) under controlled experimental conditions. The optimal settings of parameters are determined through experiments planned, conducted and analyzed using Taguchi method. In all, the paper focuses on parametric optimization of ultrasonic machining of pure titanium metal with TWR as response, and validation of the optimized value of TWR by conducting confirmatory experiments.

Keywords: Ultrasonic machining, titanium, tool wear rate

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