scholarly journals Experimental Investigation on the Wear and Damage Behaviors of Machined Wheel-Rail Materials under Dry Sliding Conditions

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 540
Author(s):  
Peijie Liu ◽  
Yanming Quan ◽  
Junjie Wan ◽  
Lang Yu
Keyword(s):  
Surface Roughness ◽  
Surface Defects ◽  
Numerical Control ◽  
Wear Loss ◽  
Wear Property ◽  
Initial Surface ◽  
Surface Microhardness ◽  
Machined Surface ◽  
Dry Conditions ◽  
Grinding Machine

Rail grinding and wheel turning can effectively remove surface defects and unevenness, which is a crucial process for the safe and smooth operation of trains. Machined surface integrity of wheel/rail materials significantly influences their tribological property. In this study, firstly, the rail blocks were ground via a cylindrical grinding machine, and the wheel rings were turned by a computer numerical control (CNC) lathe with varied parameters. Then, the sliding wear and damage characteristics of the machined wheel/rail samples under dry conditions were studied by virtue of a block-on-ring tribometer. The results show that the surface microhardness of the ground rail blocks is larger than that of wheel rings, while the surface roughness and the thickness of the subsurface plastic deformation layer (SPDL) of rail blocks are much smaller than those of wheel rings. After sliding, the surface microhardness of wheel/rail samples increases remarkably. The thickness of the SPDL, the wear loss, and the increase degree of surface microhardness of rail blocks are larger than those of wheel rings. Surface microhardness, roughness and the SPDL of the machined wheel/rail samples impose a combined influence on the anti-wear property, and the tribological pair with proper initial surface roughness and microhardness engenders the smallest amount of total wear loss.

scholarly journals Experimental Investigation on the Wear and Damage Characteristics of Machined Wheel/Rail Materials under Dry Rolling-Sliding Condition

Metals ◽  
2020 ◽  
Vol 10 (4) ◽  
pp. 472
Author(s):  
Peijie Liu ◽  
Yanming Quan ◽  
Junjie Wan ◽  
Lang Yu
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Surface Defects ◽  
Wear Behavior ◽  
Friction Pair ◽  
Surface Hardness ◽  
Wear Testing ◽  
Wear Loss ◽  
Machining Parameters ◽  
Deformation Layer

To guarantee the smooth operation of trains, rail grinding and wheel turning are necessary practices to remove surface defects. Surface integrity of machined wheel/rail materials is significant to affect their tribological performance. In this paper, firstly, the wheel specimens were turned by a CNC lathe and the rail specimens were ground by a cylindrical grinding machine with various machining parameters. Then, the wear and damage behavior of the machined wheel/rail discs was systematically investigated via a twin-disc wear testing apparatus under dry rolling-sliding condition. The experimental results show that the surface hardness of rail discs after machining is slightly higher than that of wheel discs, while the surface roughness and plastic deformation layer of wheel discs are much larger than those of rail discs. The surface hardness increase degree of rail discs and their thickness of plastic deformation layer are greater than those of wheel discs after the rolling-sliding test. The wear loss of wheel discs is much larger than that of rail discs. Surface roughness, hardness and plastic deformation layer of wheel/rail discs after machining exert a comprehensive effect on the wear behavior, and friction pair with appropriate original surface hardness and roughness generates the smallest amount of wear loss.

A study on the Surface Properties of Nitrogen Implanted H13 Steel by Plasma Immersion Ion Implantation

2006 ◽  
Vol 118 ◽  
pp. 275-280
Author(s):  
Y.Z. You ◽  
D.I. Kim ◽  
H.G. Chun
Keyword(s):  
Surface Roughness ◽  
Ion Implantation ◽  
Surface Properties ◽  
Photoelectron Spectroscopy ◽  
Surface Hardness ◽  
Wear Loss ◽  
Wear Property ◽  
H13 Steel ◽  
Near Surface ◽  
Plasma Immersion Ion Implantation

The near surface of the H13 steel was implanted by using Plasma immersion ion implantation (PIII) system at constant bias voltage of −20 kV with varying nitrogen (N+ ) ion dose (3, 6, 9, 12, 15×1017 ions/cm2 ). The surface properties of the N+ ion implanted steel were investigated by measuring the microhardness, wear loss and friction coefficient. As increasing N+ ion dose (12×1017 ions/cm2), both wear property and surface hardness were increased. However, these properties were decreased as the incident ion dose increased over 12×1017 ions/cm2. The elemental depth profile and surface roughness were obtained with X-ray photoelectron spectroscopy (XPS) and surface roughness tester, respectively.

Research on ELID Grinding Efficient Surface Forming Mechanism of SiCp/Al Composites

2014 ◽  
Vol 1027 ◽  
pp. 107-110
Author(s):  
Jia Liang Guan ◽  
Lei Zhu ◽  
Ling Chen ◽  
Xin Qiang Ma ◽  
Xiao Hui Zhang
Keyword(s):  
Surface Roughness ◽  
Surface Defects ◽  
Volume Fraction ◽  
Removal Mechanism ◽  
Precision Grinding ◽  
Machined Surface ◽  
Forming Mechanism ◽  
Elid Grinding ◽  
Machined Surface Roughness

The electrolytic in-process dressing (ELID) grinding technology was adopted for precision grinding experiments of volume fraction of 40% of SiCp/Al composites, obtaining the machined surface roughness of Ra0.030μm. Studying the forming mechanism of processed surface, analyzing several typical grinding surface defects, summarizing the grinding characteristics and removal mechanism of SiCp/Al composites.

Effect of Drill Point Angle on Surface Integrity when Drilling Titanium Alloy

2013 ◽  
Vol 845 ◽  
pp. 966-970
Author(s):  
Muhamad Nasir Murad ◽  
Safian Sharif ◽  
E.A. Rahim ◽  
Rival
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Surface Microhardness ◽  
Machined Surface ◽  
Safety Requirements ◽  
Subsurface Deformation ◽  
Aerospace Applications ◽  
Average Hardness ◽  
Drill Point ◽  
Deformation Layer

Surface integrity of machined component is of major importance for the reliability and safety requirements during in service especially for the aerospace applications. This paper presents an investigation on the effect of drill geometry on the surface integrity of drilled hole of Ti-6AL-4V during drilling operation. Drilling experiments were conducted under the MQL using a special vegetable oil known as Jatropha oil. Experimental results revealed that drill point angle and coolant-lubricant conditions significantly influence the surface integrity which include surface roughness, micorhardness and microstructure defects. The surface roughness decreased with greater drill point angle. The subsurface deformation layer thickness was approximately 9 - 15 μm from the top of the machined surface. Microhardness profiles of the last hole indicated that the subsurface deformation extend up to a 150 to 200 μm until it reaches to the average hardness.

scholarly journals FEASIBILITY STUDY OF ULTRASONIC FREQUENCY APPLICATION ON FDM TO IMPROVE PARTS SURFACE FINISH

2015 ◽  
Vol 77 (32) ◽  
Author(s):  
Maidin, S. ◽  
Muhamad, M.K. ◽  
Pei, E.
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Surface Defects ◽  
Complex Geometry ◽  
Acrylonitrile Butadiene Styrene ◽  
Optical Microscope ◽  
Machining Process ◽  
Ultrasonic Frequency ◽  
Machined Surface ◽  
Machining Parameter

Fuse Deposition Modeling (FDM) offer several advantages such as less expensive material, lack of expensive lasers and allows complex geometry to be built. However, FDM have limitations such as seam lines appear between layers and excess material residue, leading to surface roughness and poor finish. Ultrasound has been applied in various conventional machining process and shows good machined surface finish. However, from the literature review, it was found there is no investigation made on the application of ultrasound for Additive Manufacturing (AM) especially for FDM. This paper presents an adaptive approach to improve surface finish of FDM sample by applying ultrasonic vibration. The papers discuss the result of the surface finish of test piece printed via a desktop FDM system whereby an ultrasound device that was securely mounted onto the platform during printing process. Frequency that was used in the experiment is 11, 16 and 21 kHz with acrylonitrile butadiene styrene (ABS) material. Optical microscope with the aid of pro VIS software version 2.90 was used to measure the surface roughness of the four samples printed with a vibration in the above specified frequency. It was found that a 21 kHz frequency applied to the FDM process achieved the best surface finish due to less surface defects found and thickness had finer layers being produced. The results from this study could potentially be applied to other AM system such as the selective laser sintering, electron beam machining and stereolithography. The new data on effects of ultrasonic FDM technique and machining parameter for achieving improved surface finish has potential benefit to be used in various industries such as automotive, consumer, medical, sports, etc to produce prototypes or customized end used product or part. The data will benefit in term of product design and development elimination of manual post processing. Further study that could be done is to use different types of material such as polyactic acid (PLA) or composite material.

Study on the Performances of the Ferromagnetic Poles Based on the Curved Surface Magnetic Abrasive Finishing

2007 ◽  
Vol 359-360 ◽  
pp. 365-368 ◽  
Author(s):  
Yan Hong Ding ◽  
Xin Gai Yao ◽  
Xing Xiang Wang ◽  
Shi Chun Yang
Keyword(s):  
Surface Roughness ◽  
Theoretical Foundation ◽  
Rotation Speed ◽  
Numerical Control ◽  
Curved Surfaces ◽  
Performance Parameters ◽  
Machined Surface ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Finishing ◽  
Finished Surface

Magnetic abrasive finishing (MAF) is a kind of method for polishing the surfaces and the edges. The investigation for the technique of MAF and the development of the ferromagnetic poles lay a theoretical foundation for developing a new method for finishing the curved surfaces automatically under the numerical control. In the paper, the performance parameters of the developed magneto poles, which are used for finishing the plane surfaces and the curved ones, have been tested. The curvature of the finished surface, the sloping angle of the machined surface and the rotation speed of the poles, which affect the surface roughness, are studied theoretically. What mentioned above supply references to the practical uses of the MAF, especially in the mould manufacturing.

A Study on the Effect of Manufacturing Conditions on Surface Roughness during Machining of Cu/Al2O3 Composites

2011 ◽  
Vol 672 ◽  
pp. 263-270
Author(s):  
Luisa N. Mîtcă ◽  
Mustafa Günay ◽  
Radu Liviu Orban ◽  
Ulvi Şeker
Keyword(s):  
Surface Roughness ◽  
Volume Fraction ◽  
Compaction Pressure ◽  
Cutting Tools ◽  
Cnc Machining ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Impact Surface ◽  
Surface Damages ◽  
Dry Conditions

In this study, the machinability of the Cu matrix composites reinforced with 5, 10, 15 and 20 vol.% of Al2O3 particulates produced by powder metallurgy have been investigated. The effects of compaction pressure, sintering duration and volume fraction of reinforcing component on the surface roughness during machining of the considered composites, obtained by the appropriate Cu-Al2O3 powder mixtures cool die pressing at 500, respectively 700 MPa, and sintered at 800 °C for durations of 45 and 60 minutes in an argon atmosphere were determined. The machining tests were performed on a CNC machining centre, by means of samples face milling in dry conditions, at two different feed rates and four different cutting speeds, while the depth of cut was kept constant. As cutting tools have been adopted commercial grade (H13A) uncoated cemented carbide inserts manufactured by Sandvik Coromant with the geometry of TPKN1603 PP-R. After the machining tests, the surface roughness measurements clearly showed an increasing trend in surface roughness when the feed rate is increased from 300 mm/min to 400 mm/min for both sintering durations. Surface damages created on the machined surface through release from the matrix of particles negatively impact surface roughness. The most stable results in terms of surface roughness were obtained at 20% reinforcing ratio for 700 MPa compacting pressure and 60 minutes sintering duration.

scholarly journals Effect of Different Cooling Strategies on Surface Quality and Power Consumption in Finishing End Milling of Stainless Steel 316

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 903
Author(s):  
Adel T. Abbas ◽  
Saqib Anwar ◽  
Elshaimaa Abdelnasser ◽  
Monis Luqman ◽  
Jaber E. Abu Qudeiri ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Surface Quality ◽  
Process Parameters ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Machined Surface ◽  
Cooling Strategies ◽  
Dry Conditions

In this paper, an experimental investigation into the machinability of AISI 316 alloy during finishing end milling operation under different cooling conditions and with varying process parameters is presented. Three environmental-friendly cooling strategies were utilized, namely, dry, minimal quantity lubrication (MQL) and MQL with nanoparticles (Al2O3), and the variable process parameters were cutting speed and feed rate. Power consumption and surface quality were utilized as the machining responses to characterize the process performance. Surface quality was examined by evaluating the final surface roughness and surface integrity of the machined surface. The results revealed a reduction in power consumption when MQL and MQL + Al2O3 strategies were applied compared to the dry case by averages of 4.7% and 8.6%, respectively. Besides, a considerable reduction in the surface roughness was noticed with average values of 40% and 44% for MQL and MQL + Al2O3 strategies, respectively, when compared to the dry condition. At the same time, the reduction in generated surface roughness obtained by using MQL + Al2O3 condition was marginal (5.9%) compared with using MQL condition. Moreover, the results showed that the improvement obtained in the surface quality when using MQL and MQL + Al2O3 coolants increased at higher cutting speed and feed rate, and thus, higher productivity can be achieved without deteriorating final surface quality, compared to dry conditions. From scanning electron microscope (SEM) analysis, debris, furrows, plastic deformation irregular friction marks, and bores were found in the surface texture when machining under dry conditions. A slight smoother surface with a nano-polishing effect was found in the case of MQL + Al2O3 compared to the MQL and dry cooling strategies. This proves the effectiveness of lubricant with nanoparticles in reducing the friction and thermal damages on the machined surface as the friction marks were still observed when machining with MQL comparable with the case of MQL + Al2O3.

scholarly journals Cutting Speed and Feed Influence on Surface Microhardness of Dry-Turned UNS A97075-T6 Alloy

2020 ◽  
Vol 10 (3) ◽  
pp. 1049 ◽  
Author(s):  
Sergio Martín-Béjar ◽  
Francisco Javier Trujillo Vilches ◽  
Carolina Bermudo Gamboa ◽  
Lorenzo Sevilla Hurtado
Keyword(s):  
Surface Roughness ◽  
Thermal Effects ◽  
General Trend ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Corrosion Process ◽  
Surface Microhardness ◽  
Before And After ◽  
Dry Conditions ◽  
Parameter Values

In this work, an analysis of the cutting speed and feed influence on surface roughness and microhardness of UNS A97075-T6 alloy, turned under dry conditions, was carried out. The results were compared before and after a corrosion process. The influence of these cutting parameters on each of these variables was analyzed, as well as the possible interrelation between them. The microgeometrical deviations showed a general trend to increase with feed. However, no significant modifications were observed as a function of the cutting speed. This trend was softer after the corrosion process, due to the surface alterations produced by pitting corrosion, which resulted in higher dispersion of the experimental data. In addition, a surface microhardness increment was observed in all samples, after machining and before corrosion, regardless of the cutting parameter values. The experimental results revealed that the mechanical effects, produced by the feed, should not be neglected against the thermal effects, produced by the cutting speed, within the range of the tested cutting speed. Finally, the corrosion process negatively affected the microhardness, but it was not possible to establish a direct relationship between the cutting parameters, surface roughness, and microhardness after a corrosion process.

scholarly journals Experimental Research on the Surface Quality of Milling Contour Bevel Gears

2021 ◽  
Author(s):  
Mingyang Wu ◽  
Jianyu Zhang ◽  
Chunjie Ma ◽  
Yali Zhang ◽  
Yaonan Cheng
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Defects ◽  
Low Noise ◽  
Tooth Surface ◽  
Machining Accuracy ◽  
Machined Surface ◽  
Bevel Gears ◽  
Machined Surface Roughness

Abstract Contour bevel gears have the advantages of high coincidence, low noise and large bearing capacity, which are widely used in automobile manufacturing, shipbuilding and construction machinery. However, the quality of the tooth surface has a significant impact on the transmission accuracy of the gear, so it is of great significance to optimize the surface quality of the contour bevel gear. This paper firstly analyzes the formation process of machined surface roughness of contour bevel gears on the basis of generating machining method, and dry milling experiments of contour bevel gears are conducted to analyze the effects of cutting speed and feed rate on the machined surface roughness and surface topography of the workpiece. Then, the surface defects on the machined surface of the workpiece are studied by SEM, and the causes of the surface defects are analyzed by EDS. After that, XRD is used to compare the microscopic grains of the machined surface and the substrate material for diffraction peak analysis, and the effect of cutting parameters on the microhardness of the workpiece machined surface is investigated by work hardening experiment. The research results are of great significant for improving the machining accuracy of contour bevel gears, reducing friction losses and improving transmission efficiency.

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