Pub Date : 2024-09-18DOI: 10.1177/09544089241279724
Satyajeet Kumar, Shailesh Mani Pandey
Thermal barrier coatings (TBCs) are advanced ceramic layers applied to metal components to provide insulation and protection against high temperatures in extreme operating environments. This study investigated the effects of graphene nanoplatelet (GNP) reinforcement on samarium niobate (SN: SmNbO4) TBCs for extreme environments. Four ceramic top coat compositions were plasma-sprayed onto Inconel 718 substrates: Yttria-stabilized zirconia (YSZ), SmNbO4 (SN), and SN reinforced with 1 and 1.5 wt% GNPs (SN-1GNP, SN-1.5GNP). The research examined microstructural characteristics, phase evolution, mechanical properties and toughening mechanisms. GNP reinforcement significantly improved coating density, with SN-1.5GNP reaching 97.4 ± 1.64% compared to 91.3 ± 1.69% for SN and 86.6 ± 1.47% for YSZ. Hardness and elastic modulus were enhanced by 86.38% and 57.91% for SN-1GNP, and 101.09% and 65.23% for SN-1.5GNP respectively. Moreover, fracture toughness experienced a significant increase from 1.86 ± 0.4 to 5.48 ± 0.7 MPa·m1/2, facilitated by toughening mechanisms, like splat bridging, GNP pull-out, crack arrest and ferroelastic domain switching. Additionally, the SN-1.5GNP coating exhibited a higher adhesion strength of 36.84 MPa, thereby leading to improved layer distribution and lesser chance of delamination. Compared to YSZ, these findings suggest that GNP-reinforced SN coatings offer enhanced performance for extreme environment applications.
{"title":"Tailoring mechanical, microstructural and toughening characteristics of plasma-sprayed graphene-reinforced samarium niobate coatings for extreme environments","authors":"Satyajeet Kumar, Shailesh Mani Pandey","doi":"10.1177/09544089241279724","DOIUrl":"https://doi.org/10.1177/09544089241279724","url":null,"abstract":"Thermal barrier coatings (TBCs) are advanced ceramic layers applied to metal components to provide insulation and protection against high temperatures in extreme operating environments. This study investigated the effects of graphene nanoplatelet (GNP) reinforcement on samarium niobate (SN: SmNbO<jats:sub>4</jats:sub>) TBCs for extreme environments. Four ceramic top coat compositions were plasma-sprayed onto Inconel 718 substrates: Yttria-stabilized zirconia (YSZ), SmNbO<jats:sub>4</jats:sub> (SN), and SN reinforced with 1 and 1.5 wt% GNPs (SN-1GNP, SN-1.5GNP). The research examined microstructural characteristics, phase evolution, mechanical properties and toughening mechanisms. GNP reinforcement significantly improved coating density, with SN-1.5GNP reaching 97.4 ± 1.64% compared to 91.3 ± 1.69% for SN and 86.6 ± 1.47% for YSZ. Hardness and elastic modulus were enhanced by 86.38% and 57.91% for SN-1GNP, and 101.09% and 65.23% for SN-1.5GNP respectively. Moreover, fracture toughness experienced a significant increase from 1.86 ± 0.4 to 5.48 ± 0.7 MPa·m<jats:sup>1/2</jats:sup>, facilitated by toughening mechanisms, like splat bridging, GNP pull-out, crack arrest and ferroelastic domain switching. Additionally, the SN-1.5GNP coating exhibited a higher adhesion strength of 36.84 MPa, thereby leading to improved layer distribution and lesser chance of delamination. Compared to YSZ, these findings suggest that GNP-reinforced SN coatings offer enhanced performance for extreme environment applications.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"97 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142266670","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-09-18DOI: 10.1177/09544089241283285
K Palaksha Reddy, T.K. Kandavel, V.M. Sreehari
Heavy-duty machinery demands materials with strong wear resistance and good frictional properties, which conventional materials often lack. The knowledge of PM alloys’ friction and wear characteristics versus standard steel materials is limited. ATOMET 4601, a high-strength prealloyed powder with excellent compressibility, allows for parts with densities over 6.8 g/cm³. Carbon (0, 0.5, 1.0 wt.%) was added to enhance performance. These alloys, compacted to 75% of theoretical density and sintered at 1100 ± 10°C, were tested for wear and friction against EN31 steel. Results showed carbon improved tribological performance, with ATOMET 4601 + 1.0%C exhibiting the best wear resistance. Regression models and interaction plots indicated significant effects of load and speed on wear rate and coefficient of friction. Microstructural analysis revealed carbides and oxides in the ferrite matrix, with adhesive, abrasive, and oxidative wear as primary mechanisms.
{"title":"Influence of carbon percentage on the wear and friction characteristics of ATOMET 4601 alloys in heavy-duty machinery","authors":"K Palaksha Reddy, T.K. Kandavel, V.M. Sreehari","doi":"10.1177/09544089241283285","DOIUrl":"https://doi.org/10.1177/09544089241283285","url":null,"abstract":"Heavy-duty machinery demands materials with strong wear resistance and good frictional properties, which conventional materials often lack. The knowledge of PM alloys’ friction and wear characteristics versus standard steel materials is limited. ATOMET 4601, a high-strength prealloyed powder with excellent compressibility, allows for parts with densities over 6.8 g/cm³. Carbon (0, 0.5, 1.0 wt.%) was added to enhance performance. These alloys, compacted to 75% of theoretical density and sintered at 1100 ± 10°C, were tested for wear and friction against EN31 steel. Results showed carbon improved tribological performance, with ATOMET 4601 + 1.0%C exhibiting the best wear resistance. Regression models and interaction plots indicated significant effects of load and speed on wear rate and coefficient of friction. Microstructural analysis revealed carbides and oxides in the ferrite matrix, with adhesive, abrasive, and oxidative wear as primary mechanisms.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"20 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142266671","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-09-18DOI: 10.1177/09544089241279168
Nirmal Garg, Paras Kumar
Nowadays, polymers frequently replace metals in several applications where comparable properties are desired due to the convenience of processing them as per the requirement. The present work intends to fabricate a thermoplastic polyurethane suitable for journal bearing application using fused deposition modelling (FDM) additive manufacturing method. The cylindrical samples were prepared for experiments using central composite design to examine the effect of FDM machine parameters (such as layer thickness, infill density, and printing speed) on response such as specific wear rate (SWR), coefficient of friction (COF) and hardness. Layer thickness was noticed to be the most significant parameter for the selected responses with a percentage contribution of ∼34% to 72%. Further, as observed from interaction plots the COF and SWR are lowest, and hardness is highest at highest infill density and lowest printing speed. To obtain an optimized set of FDM machine parameters for minimum SWR, COF and maximum hardness, genetic algorithm based multi-objective optimization is performed. The optimized values are SWR of 4.97 × 10−5 mm3/N-m, COF of 0.37 and hardness value of 37.
{"title":"Multi-objective optimization of 3D printing parameters to fabricate TPU for tribological applications","authors":"Nirmal Garg, Paras Kumar","doi":"10.1177/09544089241279168","DOIUrl":"https://doi.org/10.1177/09544089241279168","url":null,"abstract":"Nowadays, polymers frequently replace metals in several applications where comparable properties are desired due to the convenience of processing them as per the requirement. The present work intends to fabricate a thermoplastic polyurethane suitable for journal bearing application using fused deposition modelling (FDM) additive manufacturing method. The cylindrical samples were prepared for experiments using central composite design to examine the effect of FDM machine parameters (such as layer thickness, infill density, and printing speed) on response such as specific wear rate (SWR), coefficient of friction (COF) and hardness. Layer thickness was noticed to be the most significant parameter for the selected responses with a percentage contribution of ∼34% to 72%. Further, as observed from interaction plots the COF and SWR are lowest, and hardness is highest at highest infill density and lowest printing speed. To obtain an optimized set of FDM machine parameters for minimum SWR, COF and maximum hardness, genetic algorithm based multi-objective optimization is performed. The optimized values are SWR of 4.97 × 10<jats:sup>−5</jats:sup> mm<jats:sup>3</jats:sup>/N-m, COF of 0.37 and hardness value of 37.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"5 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142266674","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The current experiment examined the friction and wear characteristics of Ni-based composite coatings developed by cold spray route. In the developed coatings, fixed concentration of MoS2 (10 wt. %) and varying concentrations of Ag (5, 10, and 15 wt. %) were incorporated to evaluate the lubricating potential of reinforcing elements. The specimens were slid in various working regimes of loads (6, 11, 16, & 21 N) and at a fixed sliding speed of 0.3 m/s under room temperature (RT). According to the investigation, all participating composite coatings have revealed a lower coefficient of friction (COF) and wear rate as the testing load increased from 6 to 16 N, beyond which a reverse trend was recorded till 21 N. However, composite coating with 10 wt. % Ag has shown excellent tribological properties in terms of the lowest COF (0.29) as well as wear rate (4.0 × 10−5 mm3/Nm) at 16 N and 0.3 m/s. The superior tribological characteristics of the aforesaid coating have been explained and well connected to the synergistic effect of solid lubricants (Ag and MoS2) as well as the optimal weight percent of Ag in the creation of tribo layer on the wear track.
{"title":"Tribological behavior of Ni-based composite coatings produced by cold spray","authors":"Rohit Kumar Singh Gautam, Vivek Mani Tripathi, Jitendra Kumar Gautam, Subhash Mishra, Hemant Nautiyal, Raj Bahadur Singh, Pushkar Jha, Sudesh Singh","doi":"10.1177/09544089241280696","DOIUrl":"https://doi.org/10.1177/09544089241280696","url":null,"abstract":"The current experiment examined the friction and wear characteristics of Ni-based composite coatings developed by cold spray route. In the developed coatings, fixed concentration of MoS<jats:sub>2</jats:sub> (10 wt. %) and varying concentrations of Ag (5, 10, and 15 wt. %) were incorporated to evaluate the lubricating potential of reinforcing elements. The specimens were slid in various working regimes of loads (6, 11, 16, & 21 N) and at a fixed sliding speed of 0.3 m/s under room temperature (RT). According to the investigation, all participating composite coatings have revealed a lower coefficient of friction (COF) and wear rate as the testing load increased from 6 to 16 N, beyond which a reverse trend was recorded till 21 N. However, composite coating with 10 wt. % Ag has shown excellent tribological properties in terms of the lowest COF (0.29) as well as wear rate (4.0 × 10<jats:sup>−5</jats:sup> mm<jats:sup>3</jats:sup>/Nm) at 16 N and 0.3 m/s. The superior tribological characteristics of the aforesaid coating have been explained and well connected to the synergistic effect of solid lubricants (Ag and MoS<jats:sub>2</jats:sub>) as well as the optimal weight percent of Ag in the creation of tribo layer on the wear track.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"32 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142266672","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Multidisciplinary design optimization (MDO) involving aero-elastic simulations still proves challenging for computational cost. This paper proposes a competitive cost-effective multi-fidelity MDO strategy based on two ideas. Firstly, a new multi-fidelity fluid-structure interaction model (MF-FSI) is proposed, allowing a considerable saving of the FSI simulation cost. Secondly, the optimization cost is further reduced using a meta-model approximation of the MF-FSI computations during optimization. Therefore, the MF-FSI model is validated on an experimental case of supersonic projectile fins. Then, it is combined with a meta-model-based optimization strategy (MBO) to improve the fins design. The constrained multi-objective problem aiming to maximize the lift-to-drag ratio and minimize the fin mass is solved using both high-fidelity (HFMDO) and multi-fidelity (MFMDO). The results showed that the proposed MFMDO strategy could produce the same optimal solutions as the HFMDO one with a 52% lower cost.
{"title":"Multi-fidelity multidisciplinary meta-model based optimization of a slender body with fins","authors":"Saidi Noureddine, Derbal Salh Eddine, Andrea Magrini, Khalfallah Smail, Cerdoun Mahfoudh, Ernesto Benini","doi":"10.1177/09544089241279024","DOIUrl":"https://doi.org/10.1177/09544089241279024","url":null,"abstract":"Multidisciplinary design optimization (MDO) involving aero-elastic simulations still proves challenging for computational cost. This paper proposes a competitive cost-effective multi-fidelity MDO strategy based on two ideas. Firstly, a new multi-fidelity fluid-structure interaction model (MF-FSI) is proposed, allowing a considerable saving of the FSI simulation cost. Secondly, the optimization cost is further reduced using a meta-model approximation of the MF-FSI computations during optimization. Therefore, the MF-FSI model is validated on an experimental case of supersonic projectile fins. Then, it is combined with a meta-model-based optimization strategy (MBO) to improve the fins design. The constrained multi-objective problem aiming to maximize the lift-to-drag ratio and minimize the fin mass is solved using both high-fidelity (HFMDO) and multi-fidelity (MFMDO). The results showed that the proposed MFMDO strategy could produce the same optimal solutions as the HFMDO one with a 52% lower cost.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"150 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142266681","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-09-14DOI: 10.1177/09544089241274050
Zhibo Geng, Min Chen, Junyang Li, Yanfeng Han
This paper introduces a metal rubber composite gear for gear vibration reduction. A comprehensive structural design calculation program is developed for the metal rubber composite gear pair. The design incorporates a gap between the tooth ring and the hub to accommodate thermal expansion and contraction, ensuring smooth transmission without jamming or seizing. The design process takes into consideration the compression and damping properties of the metal rubber material. A significant variable in the design process is the relative density of the metal rubber material. It is utilized to calculate the torsional stiffness, starting friction torque, and dynamic performance of the composite gear pair. To guide and optimize the design process, a nine-degree-of-freedom dynamic model is employed for dynamic analysis. The vibration reduction effect of the metal rubber composite gear is validated through numerical simulations and experimental testing. The results confirm the efficacy of the gear in reducing vibrations. This paper provides valuable insights and guidance for future designs focused on gear vibration reduction, paving the way for further advancements in this field.
{"title":"Structural design and dynamic analysis of a metal rubber composite gear pair","authors":"Zhibo Geng, Min Chen, Junyang Li, Yanfeng Han","doi":"10.1177/09544089241274050","DOIUrl":"https://doi.org/10.1177/09544089241274050","url":null,"abstract":"This paper introduces a metal rubber composite gear for gear vibration reduction. A comprehensive structural design calculation program is developed for the metal rubber composite gear pair. The design incorporates a gap between the tooth ring and the hub to accommodate thermal expansion and contraction, ensuring smooth transmission without jamming or seizing. The design process takes into consideration the compression and damping properties of the metal rubber material. A significant variable in the design process is the relative density of the metal rubber material. It is utilized to calculate the torsional stiffness, starting friction torque, and dynamic performance of the composite gear pair. To guide and optimize the design process, a nine-degree-of-freedom dynamic model is employed for dynamic analysis. The vibration reduction effect of the metal rubber composite gear is validated through numerical simulations and experimental testing. The results confirm the efficacy of the gear in reducing vibrations. This paper provides valuable insights and guidance for future designs focused on gear vibration reduction, paving the way for further advancements in this field.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"119 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142266676","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-09-14DOI: 10.1177/09544089241279215
Aqsa Fayyaz, Zaheer Abbas, Muhammad Yousuf Rafiq
The flow of non-Newtonian fluids is widely observed in industry and biology, for example, enhanced oil recovery, chemical processes such as in distillation towers and fixed-bed reactors and in the applications of pumping fluids such as synthetic lubricants, colloidal fluids, liquid crystals, and biofluids (e.g., animal and human blood). Therefore, the present study delineates the heat transfer analysis of a Casson fluid within the annular region of eccentric cylinders subjected to peristaltic motion, considering the influence of thermal radiation. The outer cylinder remains rigid and moves at a constant speed, while the inner cylinder, featuring a sinusoidal wave along its wall, exhibits flexibility. The governing two-dimensional equations for the movement of the Casson fluid are reformulated under the assumption of the lubrication hypothesis. The perturbation scheme is used to find approximate results for velocity, temperature, and pressure gradient. A graphical representation is utilized to study the fluctuation of various flow fields with different imperative parameters. The results reveal that the liquid velocity declines as the Casson parameter increases, while the temperature decreases due to the amplified effect of thermal radiation. This study has applications in endoscopy, which is important for diagnosing problems in internal organs. Additionally, the variation of the pressure gradient helps maintain the flow rate, which is essential during the insertion of a catheter into an artery.
{"title":"Exploration of the dynamics of heated non-Newtonian Casson fluid within an annular region of eccentric cylinders subject to peristaltic motion","authors":"Aqsa Fayyaz, Zaheer Abbas, Muhammad Yousuf Rafiq","doi":"10.1177/09544089241279215","DOIUrl":"https://doi.org/10.1177/09544089241279215","url":null,"abstract":"The flow of non-Newtonian fluids is widely observed in industry and biology, for example, enhanced oil recovery, chemical processes such as in distillation towers and fixed-bed reactors and in the applications of pumping fluids such as synthetic lubricants, colloidal fluids, liquid crystals, and biofluids (e.g., animal and human blood). Therefore, the present study delineates the heat transfer analysis of a Casson fluid within the annular region of eccentric cylinders subjected to peristaltic motion, considering the influence of thermal radiation. The outer cylinder remains rigid and moves at a constant speed, while the inner cylinder, featuring a sinusoidal wave along its wall, exhibits flexibility. The governing two-dimensional equations for the movement of the Casson fluid are reformulated under the assumption of the lubrication hypothesis. The perturbation scheme is used to find approximate results for velocity, temperature, and pressure gradient. A graphical representation is utilized to study the fluctuation of various flow fields with different imperative parameters. The results reveal that the liquid velocity declines as the Casson parameter increases, while the temperature decreases due to the amplified effect of thermal radiation. This study has applications in endoscopy, which is important for diagnosing problems in internal organs. Additionally, the variation of the pressure gradient helps maintain the flow rate, which is essential during the insertion of a catheter into an artery.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"6 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142266677","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-09-14DOI: 10.1177/09544089241279232
Amarendhar Rao, Manish Tak, Narasimha Rao, Krishna Vallleti, Ravi Bathe
This paper presents an investigation into the effect of laser-assisted turning of the IN625 superalloy using uncoated and CrAlSiN nanocomposite-coated tungsten carbide tools. A hot hardness test was conducted for IN625 material, which showed there was a pronounced softening of the material above 850 °C. This exercise guided the choice of laser power for the subsequent laser-assisted turning experiments. The cutting forces (radial/thrust, Fx; axial/feed, Fy; and tangential/cutting, Fz), maximum flank wear (VBBmax), and surface roughness ( Ra) were measured and analyzed for the planned experiments. The results demonstrated that at 2500 W laser power, a 9%, 70%, and 59% reduction of cutting forces for uncoated tools, and a 31%, 77%, and 69% reduction for CrAlSiN coated tools were observed in the Fx, Fy, and Fz directions respectively. At 2250 W laser power, the uncoated tools exhibited a 33% (433–289 µm) reduction in VBBmax and a 28% (1.8–1.3 µm) reduction in Ra. The CrAlSiN-coated tools, at 2500 W laser power, showed even more significant improvements, with reductions of 46% (365–232 µm) in VBBmax and 56% (1.4–0.8 µm) in Ra. The results underline the improved performance of laser-assisted turning for cutting-force and tool-wear reduction and improved surface finish with CrAlSiN-coated tools. This paper presents the potential of laser-assisted machining as a viable method for machining difficult-to-machine materials like IN625, which offers enormous manufacturing productivity and tool life benefits.
{"title":"Investigations on laser-assisted turning of IN625 alloy with hot hardness approach using uncoated and CrAlSiN coated WC tools","authors":"Amarendhar Rao, Manish Tak, Narasimha Rao, Krishna Vallleti, Ravi Bathe","doi":"10.1177/09544089241279232","DOIUrl":"https://doi.org/10.1177/09544089241279232","url":null,"abstract":"This paper presents an investigation into the effect of laser-assisted turning of the IN625 superalloy using uncoated and CrAlSiN nanocomposite-coated tungsten carbide tools. A hot hardness test was conducted for IN625 material, which showed there was a pronounced softening of the material above 850 °C. This exercise guided the choice of laser power for the subsequent laser-assisted turning experiments. The cutting forces (radial/thrust, F<jats:sub>x</jats:sub>; axial/feed, F<jats:sub>y</jats:sub>; and tangential/cutting, F<jats:sub>z</jats:sub>), maximum flank wear (VB<jats:sub>Bmax</jats:sub>), and surface roughness ( R<jats:sub>a</jats:sub>) were measured and analyzed for the planned experiments. The results demonstrated that at 2500 W laser power, a 9%, 70%, and 59% reduction of cutting forces for uncoated tools, and a 31%, 77%, and 69% reduction for CrAlSiN coated tools were observed in the F<jats:sub>x</jats:sub>, F<jats:sub>y</jats:sub>, and F<jats:sub>z</jats:sub> directions respectively. At 2250 W laser power, the uncoated tools exhibited a 33% (433–289 µm) reduction in VB<jats:sub>Bmax</jats:sub> and a 28% (1.8–1.3 µm) reduction in Ra. The CrAlSiN-coated tools, at 2500 W laser power, showed even more significant improvements, with reductions of 46% (365–232 µm) in VB<jats:sub>Bmax</jats:sub> and 56% (1.4–0.8 µm) in R<jats:sub>a</jats:sub>. The results underline the improved performance of laser-assisted turning for cutting-force and tool-wear reduction and improved surface finish with CrAlSiN-coated tools. This paper presents the potential of laser-assisted machining as a viable method for machining difficult-to-machine materials like IN625, which offers enormous manufacturing productivity and tool life benefits.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"49 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142266678","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Micro-holes and drilled workpiece dimensions must be more exact in the modern industrial age. Manufacturing micro-scale electronic devices used in automobiles and aerospace components with thermal sinking properties and bio-medical with germicidal properties requires micro-drilling on copper-like materials. Micro-EDM has emerged as a promising technique for micro-drilling. The primary challenge faced in µ-EDM drilling is the effective elimination of debris (mass of workpiece and tool). Therefore, this study aims to investigate the feasible parametric combination (Discharge Energy, Tool Feed Rate, Tool Rotation, and Nano-Powder) to achieve dimensionally correct with better surface characteristic µ-through holes in copper using tungsten carbide micro electrode in micro-EDM. Furthermore, this study examines the effect of Al2O3 nano-powder mixed dielectric on the process performance aspects. ANOVA and PCA-GRA multi-optimization techniques addressed performance aspects (MRR, TWR, and Machining Time) and dimensional aspects (Overcut, Taper Angle, and Aspect Ratio) with visualization of the surface (Texture and Recast Layer). The experimentation found that nano-powder mixed dielectric highly impacted dimensional aspects (Overcut increased by 55.13%, Taper Angle reduced by 37.9%) by diminishing TWR by 12.2% and aspect Ratio by 3.31%. Furthermore, discharge energy affects MRR by increasing 27.9%, and machining time is reduced by 3.48%. The FESEM micrograph illustrated that surface defects (cracks, voids, discharge bubbles, debris accumulations, etc.) were most eliminated, and recast layer thickness was reduced by 34.4% (at 2.81 µj DE) and 56.6% (at 7.81 µj DE) using nano-powder mixed dielectric application.
{"title":"An investigation on the effect of alumina nano powder mixed dielectric oil on EDM-assisted precision micro-drilling operation","authors":"Deepak Agarwal, Sharad Yadav, Rabesh Kumar Singh, Anuj Kumar Sharma","doi":"10.1177/09544089241277715","DOIUrl":"https://doi.org/10.1177/09544089241277715","url":null,"abstract":"Micro-holes and drilled workpiece dimensions must be more exact in the modern industrial age. Manufacturing micro-scale electronic devices used in automobiles and aerospace components with thermal sinking properties and bio-medical with germicidal properties requires micro-drilling on copper-like materials. Micro-EDM has emerged as a promising technique for micro-drilling. The primary challenge faced in µ-EDM drilling is the effective elimination of debris (mass of workpiece and tool). Therefore, this study aims to investigate the feasible parametric combination (Discharge Energy, Tool Feed Rate, Tool Rotation, and Nano-Powder) to achieve dimensionally correct with better surface characteristic µ-through holes in copper using tungsten carbide micro electrode in micro-EDM. Furthermore, this study examines the effect of Al<jats:sub>2</jats:sub>O<jats:sub>3</jats:sub> nano-powder mixed dielectric on the process performance aspects. ANOVA and PCA-GRA multi-optimization techniques addressed performance aspects (MRR, TWR, and Machining Time) and dimensional aspects (Overcut, Taper Angle, and Aspect Ratio) with visualization of the surface (Texture and Recast Layer). The experimentation found that nano-powder mixed dielectric highly impacted dimensional aspects (Overcut increased by 55.13%, Taper Angle reduced by 37.9%) by diminishing TWR by 12.2% and aspect Ratio by 3.31%. Furthermore, discharge energy affects MRR by increasing 27.9%, and machining time is reduced by 3.48%. The FESEM micrograph illustrated that surface defects (cracks, voids, discharge bubbles, debris accumulations, etc.) were most eliminated, and recast layer thickness was reduced by 34.4% (at 2.81 µj DE) and 56.6% (at 7.81 µj DE) using nano-powder mixed dielectric application.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"18 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204883","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-09-10DOI: 10.1177/09544089241265898
MD Bindu, PC Shamla, AU Anooja, L Rekha, KK Ramachandran
The aim of this study is to develop a novel magnesium-based nanohybrid composite for potential orthopaedic bioimplant applications. The hybrid nanocomposites were fabricated with AZ91D magnesium alloy as the matrix and hydroxyapatite (HAp) and TiB2 nanoparticles as reinforcements, through the stir casting route. The nanocomposites were synthesized with a fixed concentration of HAp (5 wt%) and different concentrations of TiB2 (2, 4 and 6 wt%). The microstructure of the fabricated composites revealed that the grains are significantly refined with the addition of nanoparticles. The AZ91D-5wt%HAp-2wt%TiB2 hybrid nanocomposite is observed with relatively low porosity, without significant agglomeration of the reinforcement particles, and exhibited the highest tensile and compressive strength with considerably higher ductility than the base AZ91D alloy and the nanocomposites with 4 and 6 wt% TiB2 (about 21% and 34% improvement in compressive and tensile strengths, respectively, compared to the AZ91D alloy). The refinement of grains due to the addition of nanoreinforcements and the alleviation of micro-strain up to a certain extent due to the presence of HAp nanoparticles together with the negligible porosity and agglomeration are the major reasons for the superior strength and ductility. The wear test results showed that the nanocomposite with 2 wt% TiB2 has superior tribological properties. The studies revealed that the AZ91D-5 wt% HAp-2 wt% TiB2 hybrid nanocomposite is a potential material for temporary orthopaedic bioimplants due to its superior strength, ductility, and tribological properties together with the possible enhanced biocompatibility and corrosion resistance due to the presence of HAp particles.
{"title":"Microstructure, mechanical and tribological characteristics of AZ91D-HAp-TiB2 hybrid nanocomposites synthesized through the stir casting route","authors":"MD Bindu, PC Shamla, AU Anooja, L Rekha, KK Ramachandran","doi":"10.1177/09544089241265898","DOIUrl":"https://doi.org/10.1177/09544089241265898","url":null,"abstract":"The aim of this study is to develop a novel magnesium-based nanohybrid composite for potential orthopaedic bioimplant applications. The hybrid nanocomposites were fabricated with AZ91D magnesium alloy as the matrix and hydroxyapatite (HAp) and TiB<jats:sub>2</jats:sub> nanoparticles as reinforcements, through the stir casting route. The nanocomposites were synthesized with a fixed concentration of HAp (5 wt%) and different concentrations of TiB<jats:sub>2</jats:sub> (2, 4 and 6 wt%). The microstructure of the fabricated composites revealed that the grains are significantly refined with the addition of nanoparticles. The AZ91D-5wt%HAp-2wt%TiB<jats:sub>2</jats:sub> hybrid nanocomposite is observed with relatively low porosity, without significant agglomeration of the reinforcement particles, and exhibited the highest tensile and compressive strength with considerably higher ductility than the base AZ91D alloy and the nanocomposites with 4 and 6 wt% TiB<jats:sub>2</jats:sub> (about 21% and 34% improvement in compressive and tensile strengths, respectively, compared to the AZ91D alloy). The refinement of grains due to the addition of nanoreinforcements and the alleviation of micro-strain up to a certain extent due to the presence of HAp nanoparticles together with the negligible porosity and agglomeration are the major reasons for the superior strength and ductility. The wear test results showed that the nanocomposite with 2 wt% TiB<jats:sub>2</jats:sub> has superior tribological properties. The studies revealed that the AZ91D-5 wt% HAp-2 wt% TiB<jats:sub>2</jats:sub> hybrid nanocomposite is a potential material for temporary orthopaedic bioimplants due to its superior strength, ductility, and tribological properties together with the possible enhanced biocompatibility and corrosion resistance due to the presence of HAp particles.","PeriodicalId":20552,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.4,"publicationDate":"2024-09-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142204885","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
京公网安备 11010802042870号
京ICP备2023020795号-1
扫码关注我们
求助内容：
应助结果提醒方式：