scholarly journals Detecting Safety Zone Drill Process Parameters for Uncoated HSS Twist Drill in Machining GFRP Composites by Integrating Wear Rate and Wear Transition Mapping

2016 ◽  
Vol 2016 ◽  
pp. 1-8 ◽  
Author(s):  
Sathish Rao Udupi ◽  
Lewlyn Lester Raj Rodrigues
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Process Parameters ◽  
Wear Mechanism ◽  
High Speed Steel ◽  
Gfrp Composites ◽  
Safety Zone ◽  
Fatigue Wear ◽  
Wear Mechanism Map

The previous research investigations informed that the tool wear of any machining operation could be minimized by controlling the machining factors such as speed, feed, geometry, and type of cutting tool. Hence the present research paper aims at controlling the process parameters to minimize the drill tool wear, during the machining of Glass Fiber Reinforced Polymer (GFRP) composites. Experiments were carried out to find the tool wear rate and a wear mechanism map of uncoated High Speed Steel (HSS) drill of 10 mm diameter was developed for the drilling of GFRP composite laminates. The surface micrograph images on the drill land surface displayed dominant wear mechanisms induced on HSS drill during machining of GFRP and they were found to be adhesive wear, adhesive and abrasive wear, abrasive wear, and diffusion and fatigue wear. A “safety wear zone” was identified on the wear mechanism map, where the minimum tool wear of the HSS drill occurs. From the safety zone boundaries, it was inferred that the drill spindle speed should be set between 1200 and 1590 rpm and feed rate must be set within a range of 0.10–0.16 mm/rev for GFRP work and HSS tool combination to enhance the service life of 10 mm HSS drills and to minimize the tool wear.

Effect of CeO2 addition on microstructure and tribological characteristics of laser cladded Cu10Al–MoS2 coating under oil lubrication

2021 ◽  
pp. 146442072110309
Author(s):  
Shao Lifan ◽  
Ge Yuan ◽  
Kong Dejun
Keyword(s):  
Abrasive Wear ◽  
Wear Mechanism ◽  
Mass Fraction ◽  
Friction Reduction ◽  
Depth Of Field ◽  
Oil Lubrication ◽  
Wear Properties ◽  
Fatigue Wear ◽  
Wear Rates ◽  
Mass Fractions

In order to improve the friction and wear properties of Cu10Al–MoS2 coating, the addition of CeO2 is one of the present research hot spots. In this work, Cu10Al–MoS2 coatings with different CeO2 mass fractions were successfully fabricated on Q235 steel using a laser cladding. The microstructure and phase compositions of obtained coatings were analyzed using an ultra-depth of field microscope and X-ray diffraction, respectively. The friction-wear test was carried out under oil lubrication using a ball-on-disk wear tester, and the effects of CeO2 mass fraction on the microstructure, hardness, and friction-wear properties were studied, and the wear mechanism was also discussed. The results show that the laser cladded Cu10Al–MoS2 coatings with the different CeO2 mass fractions were mainly composed of Cu9Al4, Cu, AlFe3, Ni, MoS2, and CeO2 phases. The Vickers-hardness (HV) of Cu10Al–8MoS2–3CeO2, Cu10Al–8MoS2–6CeO2, and Cu10Al–8MoS2–9CeO2 coatings was 418, 445, and 457 HV0.3, respectively, which indicates an increase in hardness with the increase of CeO2 mass fraction. The average coefficients of friction (COF) and wear rates decrease with the increase of CeO2 mass fraction, presenting the outstanding friction reduction and wear resistance performances. The wear mechanism of Cu10Al–MoS2 coatings is changed from abrasive wear with slight fatigue wear to abrasive wear with the increase of CeO2 mass fraction.

Wear Performance of GCr15 Friction Pairs with Effect of Initial Radial Micro-Grooves

2019 ◽  
Vol 11 (1) ◽  
pp. 56-61
Author(s):  
Wei Yuan ◽  
Shengkai Mei ◽  
Song Li ◽  
Zhiwen Wang ◽  
Jie Yu ◽  
...  
Keyword(s):  
Wear Rate ◽  
Abrasive Wear ◽  
Electrical Discharge Machining ◽  
Friction Pair ◽  
Wear Volume ◽  
Fatigue Wear ◽  
Wear Performance ◽  
Wear Process ◽  
Groove Test ◽  
On Line

Background: Grooves may inevitably occur on the surface of the friction pair caused by severe wear or residual stress, which will play an important role on the reliability of machine parts during operation. Objective: The effect of the micro-grooves perpendicular to sliding direction on the wear performance of the friction pairs should be studied. Method: Micro-grooves can be machined on discs of friction pairs using electrical discharge machining. On-line visual ferrograph method was used to monitor the wear process to research the wear rate changing characteristic. Profilemeter and metallurgical microscope were used to observe the wear scars. Results: Comparing to the non-groove test, i) in one-groove test, wear volume and rate were approximate the same, and the wear scar was smooth, ii) when the grooves more than 4, the test running-in stage will be obviously prolonged, particularly for the test with 8 grooves on the disc, the duration of running-in stage is 4 times than that without grooves on specimen, and the wear rate and volume increase significantly, and then decrease with fluctuation, iii) the abrasive wear can be avoid with the debris stagnating in the groove, however, fatigue wear will significantly emerge. Conclusion: Abrasive wear can be avoided and smooth running-in surfaces can be obtained with proper amount of initial radial micro-grooves.

scholarly journals Process Parameter Optimization in EDM using Heat Treated Al Tool and without Heat Treated Al Tool

2020 ◽  
Vol 9 (5) ◽  
pp. 862-866
Keyword(s):  
Carbon Steel ◽  
Wear Rate ◽  
Tool Wear ◽  
Process Parameters ◽  
Low Carbon Steel ◽  
Low Carbon ◽  
Tool Wear Rate ◽  
Heat Treated ◽  
Main Factors ◽  
Pulse On Time

In this experimental work , we investigated optimization of process parameters in EDM using Taguchi method by taking Low carbon steel as work piece. Process parameters chosen were Pulse on-time (Ton), Flushing pressure(P) and Pulse Current(IP) . Here we have chosen L9 orthogonal array to study the effect of main factors and interaction between factors on the response variable i.e. Surface Roughness (SR), Material removal Rate (MRR) and Tool Wear Rate (TWR). The contribution of the main factors and interaction were determine here. The MR), TWR and surface integrity are some of the important performance attributes of EDM process. The objective of EDM is to get high MRR along with achieving reasonably good surface quality of machined component with reduced tool wear rate for Low carbon steel material.

scholarly journals Dry Rolling/Sliding Wear of Bainitic Rail Steels under Different Contact Stresses and Slip Ratios

Materials ◽  
2020 ◽  
Vol 13 (20) ◽  
pp. 4678
Author(s):  
Jiapeng Liu ◽  
Yingqi Li ◽  
Yinhua Zhang ◽  
Yue Hu ◽  
Lubing Shi ◽  
...  
Keyword(s):  
Friction Coefficient ◽  
Abrasive Wear ◽  
Contact Stress ◽  
Wear Mechanism ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Wear Loss ◽  
Fatigue Wear ◽  
Slip Ratio

This study aims to deeply understand the effect of contact stress and slip ratio on wear performances of bainitic rail steels. The results showed that the wear loss increased as the contact stress and slip ratio increased. Based on the surface damage morphology and microstructural analyses, it revealed that the rolling contact fatigue wear mechanism played a significant role under the low slip ratio, but the dominant wear mechanism transferred to the abrasive wear at the high slip ratio. Meanwhile, the bainitic steel specifically presented worse wear resistance under the abrasive wear mode. Compared with the influence of a slip ratio, the increase in contact stress led to severer plastic flows and contributed to the propagation of cracks. In addition, the contact stress and slip ratio had the opposite effect on the friction coefficient, that is, the friction coefficient of bainitic steels behaved the inverse proportion with the contact stress, but positive proportion with the slip ratio. At last, the increase in slip ratio had more significant effect on the reduction of retained austenite (RA) than the enlargement of contact stress due to the fact that the RA would probably be removed before the martensitic transformation occurred under the abrasive wear mechanism.

Corrosive wear and electrochemical corrosion performances of arc sprayed Al coating in 3.5% NaCl solution

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Peng Li ◽  
Xiya Huang ◽  
Dejun Kong
Keyword(s):  
Abrasive Wear ◽  
Wear Mechanism ◽  
Electrochemical Corrosion ◽  
Corrosive Wear ◽  
Corrosion Mechanism ◽  
Nacl Solution ◽  
Fatigue Wear ◽  
Wear Performance ◽  
Content Type ◽  
Al Coating

Purpose The purpose of this paper is to investigate the effects of load and speed on the corrosive wear performance of Al coating in 3.5% NaCl solution, which provided an experimental reference for the anti-corrosion engineering on offshore platforms. Design/methodology/approach A layer of Al coating was prepared on S355 steel using an arc spraying. The corrosive wear test was carried out with CFT–1 type surface property tester. The effects of load and speed on the corrosive wear performance of Al coating were investigated and the wear mechanism was also discussed. The electrochemical tests were conducted using a CHI660E type electrochemical workstation, the anti-corrosion mechanism was analyzed. Findings The average coefficient of frictions (COFs) of Al coating under loads of 1.5, 2.5 and 3.5 N are 0.745, 0.847 and 0.423, the wear mechanism is abrasive wear. The average COFs of Al coating at the speeds of 200, 400 and 600 rpm are 0.745, 0.878 and 0.617, respectively, the wear mechanism at the speeds of 200 and 400 rpm are abrasive wear, while that at the speed of 600 rpm is abrasive wear and fatigue wear. The anti-corrosion mechanism is the isolation of Cl– corrosion and cathodic protection of sacrificial anode. Originality/value This paper mainly studied corrosive wear and electrochemical corrosion performances of Al coating. This study hereby confirms that this manuscript is the original work and has not been published nor has it been submitted simultaneously elsewhere. This paper further confirms that all authors have checked the manuscript and have agreed to the submission.

scholarly journals Effects of CeO2 Content on Friction and Wear Properties of SiCp/Al-Si Composite Prepared by Powder Metallurgy

Materials ◽  
2020 ◽  
Vol 13 (20) ◽  
pp. 4547
Author(s):  
Bin Yang ◽  
Aiqin Wang ◽  
Kunding Liu ◽  
Chenlu Liu ◽  
Jingpei Xie ◽  
...  
Keyword(s):  
Powder Metallurgy ◽  
Friction Coefficient ◽  
Wear Rate ◽  
Abrasive Wear ◽  
Wear Mechanism ◽  
Friction And Wear ◽  
Wear Properties ◽  
Minimum Value ◽  
Maximum Value ◽  
Friction And Wear Properties

SiCp/Al-Si composites with different CeO2 contents were prepared by a powder metallurgy method. The effect of CeO2 content on mechanical properties, friction and wear properties of the composites was studied. The results show that with the increase in CeO2 content from 0 to 1.8 wt%, the density, hardness, friction coefficient of the composites first increases and then decreases, the coefficient of thermal expansion (CTE) and wear rate of the composites first decreases and then increases. When the content of CeO2 was 0.6 wt%, the density and hardness of the composite reached the maximum value of 98.54% and 113.7 HBW, respectively, the CTE of the composite reached the minimum value of 11.1 × 10−6 K−1, the friction coefficient and wear rate of the composite reached the maximum value of 0.32 and the minimum value of 1.02 mg/m, respectively. CeO2 has little effect on the wear mechanism of composites, and the wear mechanism of composites with different CeO2 content is mainly abrasive wear under the load of 550 N. Compared with the content of CeO2, load has a great influence on the wear properties of the composites. The wear mechanism of the composites is mainly oxidation wear and abrasive wear under low load. With the increase in load, the wear degree of abrasive particles is aggravated, and adhesive wear occurs under higher load.

scholarly journals Microstructure and Properties of AA6061/SiCp Composites Sintered under Ultra High-Pressure

2020 ◽  
Vol 10 (20) ◽  
pp. 7363
Author(s):  
Lei Xu ◽  
Erkuo Yang ◽  
Yasong Wang ◽  
Changyun Li ◽  
Zhiru Chen ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Wear Resistance ◽  
Wear Rate ◽  
Abrasive Wear ◽  
Wear Mechanism ◽  
Adhesive Wear ◽  
Wear Property ◽  
Ultra High Pressure ◽  
High Pressure Sintering

Ultra high-pressure sintering (UHPS) was used to prepare AA6061/SiCp composites with different contents and the effect of sintering temperatures on microstructure and mechanical properties was investigated in this study. The results showed that a uniform distribution of nano-SiC particles (N-SiCp) is obtained by the UHPS method. With the increase in N-SiCp contents, the higher hardness and better wear resistance could be inspected. The interfacial reactions and Al4C3 phase appeared above 550 °C. The relative density of composites first increased and then decreased; with the temperature raising it reached 99.58% at 600 °C. The hardness and wear property showed the same trend with the hardness reaching 52 HRA and wear rate being 1.0 × 10−6 g/m at 600 °C. Besides, the wear mechanism of the composites is mainly composed of abrasive wear and adhesive wear.

Wear Resistance of Cu10Al5Fe5Ni Alloy

2015 ◽  
Vol 817 ◽  
pp. 571-576
Author(s):  
Jun Tao Zou ◽  
Chan Wang ◽  
Yang Li ◽  
Xian Hui Wang ◽  
Shu Hua Liang
Keyword(s):  
Wear Resistance ◽  
Wear Rate ◽  
Wear Mechanism ◽  
Adhesive Wear ◽  
Cast Alloy ◽  
Lubricating Oil ◽  
Fatigue Wear ◽  
Lubrication Condition ◽  
Increasing Temperature ◽  
Scanning Electron

The effect of ambient temperature, materials state and lubrication condition on wear resistance of Cu10Al5Fe5Ni alloy was investigated. The wear surface morphology was characterized by a scanning electron microscope (SEM), and the wear mechanism was discussed as well. The results show that the friction coefficient of Cu10Al5Fe5Ni alloy increases and then decreases with increasing temperature. The wear rate of the Cu10Al5Fe5Ni alloy after solid solution and ageing treatment is less than that of the as-cast alloy, and the wear rate of Cu10Al5Fe5Ni alloy reduces dramatically from 5.31×10-5 mm3 / (m· N) into 1.80×10-6 mm3 / (m·N) after adding lubricating oil. At elevated temperature, the prior wear mechanism is the fatigue wear, accompanying by slight abrasive wear and adhesive wear for the aged Cu10Al5Fe5Ni alloy.

Research on Wear Mechanism of Solid Lubrication Bearing in Vacuum Environment

2015 ◽  
Vol 798 ◽  
pp. 424-429
Author(s):  
Xiao Ming Lai ◽  
Jian Chao Han ◽  
Peng Gao ◽  
Jian Jun Qu ◽  
Yun Li ◽  
...  
Keyword(s):  
Abrasive Wear ◽  
Wear Mechanism ◽  
Steel Ball ◽  
Solid Lubrication ◽  
Bearing Surface ◽  
Fatigue Wear ◽  
Angular Contact Ball Bearing ◽  
Microstructure Observation ◽  
Bearing Raceway ◽  
Sputter Deposited

The wear mechanism of solid lubrication bearing in vacuum environment was researched. It experiment on the angular contact ball bearing of sputter-deposited MoS2 solid lubrication coating in bearing friction test device, and the time-varying characteristics of bearing temperature and vibration can be got. The MoS2 solid lubrication coating on bearing surface was gradually wear in the process of bearing rotation, and the temperature and vibration of bearing were increased. The transfer membrane was formation in bearing raceway with the increase of bearing rotation. The transfer membrane accumulation occurs due to uneven thickness of MoS2 solid lubrication coating, and the bearing produce serious vibration. Through the microstructure observation and energy spectrum analysis of the bearing surface, it finds there are pitting caused by fatigue wear and scratch caused by abrasive wear after test. The test result indicate that the wear mechanism of solid lubrication bearing in vacuum environment were fatigue wear of solid lubrication coating caused by steel ball circularly rolling and abrasive wear caused by steel ball sliding.

scholarly journals Optimization of milling process parameters and prediction of abrasive wear rate increment based on cutting force experiment

2021 ◽  
Vol 13 (8) ◽  
pp. 168781402110399
Author(s):  
Fei Li ◽  
Jun Liu
Keyword(s):  
Wear Rate ◽  
Abrasive Wear ◽  
Cutting Force ◽  
Process Parameters ◽  
Processing Time ◽  
Production Efficiency ◽  
Processing Parameters ◽  
Numerical Control ◽  
Cnc Milling ◽  
Milling Cutter

Tuning the parameters of Computerized Numerical Control (CNC) is essential for practical manufacturers. Well configured parameters ensure the efficiency of production and the accuracy of the products. However, with the abrasive wear on the flank of the milling cutter, the milling processing parameters should re-configure to adapt to the increment of the abrasive wear. This paper aims to propose a method to predict the abrasive wear rate increment on the flank of the milling cutter and optimize the processing parameters of CNC milling. Firstly, we set a cutting data acquisition system to sample the processing time and cutting force among X, Y coordinates based on the five-factor and four-level orthogonal experiments. Then, the sampled cutting force data increment is transformed into the abrasive wear rate increment by applying the incremental model. Next, five processing parameters for CNC milling are optimized by the gray relational method, which takes the limited abrasive wear rate increment of the flank face and the non-increasing processing time as the constrained conditions. We obtain the relationship between five processing parameters and abrasive wear rate increment. We also find the basic principle of selecting process parameters is to reduce the abrasive wear rate without increasing the processing time. The experimental results verify that the optimized process parameters make the gray relational degree increase by 0.02, and the abrasive wear rate increment decreases by 0.42432 × 10−10 mm3/s without affecting the production efficiency. In the prediction section, by applying the Back Propagation (BP) neural network, we obtain an accurate prediction model from measurable five factors to the abrasive wear increment on the flank of the milling cutter. The maximum error between the predicted value and the actual value is 0.0003, and the predicted value curve fits well with the actual value curve. From the perspective of abrasive wear rate increment prediction, it provides a new idea for online tool wear monitoring.

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