Friction condition of aluminum alloy AA6061 lubricated with bio-lubricant in cold forging test

Purpose Cold forging operation is one of the widely used techniques in industry production. This paper aims to present a case study in highlighting and modelling the use of different type of palm oil-based [palm stearin (PS), palm kernel oil (PKO) and palm mid olein (PMO)] as a bio-lubricant in cold forging process using experimental and finite element method. Design/methodology/approach Ring compression test plays a fundamental role in the understanding of materials science and engineering because of the deformation, friction and wear behaviour. Aluminium (A6061) was used in this test to observe the deformation of the ring with different palm oil and its derivatives by comparing with commercial metal forming oil. Findings The presence of certain type of palm oil-based lubricant has a good performance compared to mineral-based oil in terms of surface roughness but when observed in terms of friction the result shows that palm oil-based lubricant has poor friction performance compared to mineral oil-based lubricant (m = 0.25), where PS has the lowest friction at m = 0.3 compared to PKO (m = 0.35) and PMO (m = 0.38). Research limitations/implications This research is using palm oil in cold forging test to study the friction, formation and stress at certain levels of stroke. The detail of the test is explained in the manuscript as attached. Social implications This research is trying to promote the use of biodegradable material to reduce pollution to the surrounding. Originality/value The originality of this paper has been checked using Turnitin and the result is 13%.

Experimental investigations on the wear behaviour of micro-EDM-fabricated textured tools during dry turning of Ti6Al4V

Purpose This paper aims to focus on analysing the wear characteristics of tungsten carbide tools on which various micro patterns are fabricated to study its effect on the machinability of Ti-6Al-4V at dry turning conditions. Design/methodology/approach Micro-patterns such as dimples, linear grooves and a novel combination of dimples and linear grooves were fabricated on rake faces of uncoated tools by micro-EDM process. Impact of these patterns on tool wear and chip morphology characteristics under dry machining conditions were analysed, and their performances were compared with the non-textured tool (NTT). Findings Encouraging results in terms of minimal tool wear and favourable chip morphology characteristics were observed in case of all the textured tools, which demonstrated better tribological characteristics in contrast to NTT. The average flank wear was reduced by 43.5, 32 and 24.7% in dimple textured tool (DTT), linear textured tool (LTT) and hybrid textured tool (HTT), respectively, as compared to NTT. The average chip curl diameters measured for NTT, DTT, LTT, and HTT were observed to be 6.60, 3.51, 4.0 and 4.31 mm, respectively. Originality/value The contribution of this work lies in fabricating innovative patterns using cost-effective micro-EDM process and analysing how the patterns, depending upon their dimensional area and wear debris accumulation characteristics, influence the machinability of Ti-6Al-4V in the absence of any lubrication mediums.

Study on Mechanical and Wear Behaviour of AA7075/TaC/Si3N4/Ti Hybrid Metal Matrix Composites

This research article focuses on the development of AA7075 alloy reinforced with different wt% of Tantalum Carbide (TaC), Silicon Nitride (Si3N4) and Titanium (Ti) particulates using stir casting. Mechanical characteristics like tensile, compression and microhardness of the developed composites were analysed. High temperature tribological properties of the hybrid MMCs were studied for various input control factors like sliding speed, load and temperature. Design analysis has been executed by Taguchi orthogonal array and ANOVA (Analysis of Variance). The incorporated reinforcements exhibited improved wear resistance at ambient temperature along with elevated temperatures. Monolithic dissemination of reinforcement’s in the prepared composites magnifies the mechanical and tribological characteristics for composites compared to matrix material. From the optimization technique, it was witnessed that Wear Rate and Frictional Coefficient are afflicted by temperature go after load & sliding speed. The optimal amalgamation of control parameters of distinct tribo-responses has been detected.

Study of Wear Behaviour of Titanium Grade 2 Using Application of Taguchi Method

Titanium Grade 2 sample piece were subjected to wear on standard linear reciprocating tribometer machine for dry sliding condition in the constant temperature. Taguchi method were use to predict the wear rate against parameter such as Load, Frequency, and time. Signal to noise ratio and ANOVA were used study the impact of these three parameter on the wear rate. In conclusion, the major statistical factor affecting wear rate is load, followed by frequency and duration. Multiple linear regression equations are developed. Keywords: Titanium grade 2, wear rate, Tribometer, ANOVA