Pub Date : 2024-11-07DOI: 10.1016/j.wear.2024.205614
Amrit Shankar Verma , Chun-Yen Wu , Miguel Alonso Díaz , Julie J.E. Teuwen
Accelerated laboratory testing is essential to understand the rain erosion behavior of coated samples applied to the leading edge surface of a wind turbine blade. This study investigates the impact of droplet impact frequencies and dry intervals on the incubation time for damage on polyurethane-coated samples using a Pulsating Jet Erosion Tester (PJET). A novel theoretical model for water slug volume is introduced, allowing for a more accurate comparison across different impact velocities and frequencies. The effect of dry intervals on coating performance is quantified, revealing that longer dry intervals and shorter pre-dry rain exposure can significantly increase the number of impacts a coating can withstand before damage. The study challenges the traditional continuous impingement testing by demonstrating that dry intervals can extend incubation time by a factor of three to five. Additionally, this paper proposes a recalibrated approach to PJET testing, which better mimics the cyclic nature of real-world rainfall, leading to improved predictive models for material degradation. The findings emphasize the importance of considering the visco-elastic behavior of coatings and the role of intermittent rain exposure in erosion testing, offering invaluable insights for designing future PJET test parameters.
{"title":"Analyzing rain erosion using a Pulsating Jet Erosion Tester (PJET): Effect of droplet impact frequencies and dry intervals on incubation times","authors":"Amrit Shankar Verma , Chun-Yen Wu , Miguel Alonso Díaz , Julie J.E. Teuwen","doi":"10.1016/j.wear.2024.205614","DOIUrl":"10.1016/j.wear.2024.205614","url":null,"abstract":"<div><div>Accelerated laboratory testing is essential to understand the rain erosion behavior of coated samples applied to the leading edge surface of a wind turbine blade. This study investigates the impact of droplet impact frequencies and dry intervals on the incubation time for damage on polyurethane-coated samples using a Pulsating Jet Erosion Tester (PJET). A novel theoretical model for water slug volume is introduced, allowing for a more accurate comparison across different impact velocities and frequencies. The effect of dry intervals on coating performance is quantified, revealing that longer dry intervals and shorter pre-dry rain exposure can significantly increase the number of impacts a coating can withstand before damage. The study challenges the traditional continuous impingement testing by demonstrating that dry intervals can extend incubation time by a factor of three to five. Additionally, this paper proposes a recalibrated approach to PJET testing, which better mimics the cyclic nature of real-world rainfall, leading to improved predictive models for material degradation. The findings emphasize the importance of considering the visco-elastic behavior of coatings and the role of intermittent rain exposure in erosion testing, offering invaluable insights for designing future PJET test parameters.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"562 ","pages":"Article 205614"},"PeriodicalIF":5.3,"publicationDate":"2024-11-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142660339","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 : 2024-11-07DOI: 10.1016/j.wear.2024.205633
Ru Liu , Diange Guo , Xiaoxiao Du , Guo Du , Xia Zhang
As a typical two-dimensional layered material, hexagonal boron nitride nanosheets (BNNSs) have high mechanical strength, good conductivity, and excellent lubrication performance, which have great potential as solid nano lubricant additives in tribology. When BNNS is used as a water-based or oil-based lubricant additive, its inherent chemical inertness and poor dispersion stability make it difficult to achieve optimal anti-friction and anti-wear performance. In this paper, a simple and efficient preparation method for obtaining hexagonal boron nitride nanosheets (C-HPC-BNNSs) with surface carbonization modification and excellent dispersion stability in water-based lubricants was proposed. Using hydroxypropyl cellulose (HPC) as a modifier, a wet ball milling process combined with high-temperature carbonization treatment effectively reduced the thickness of BNNSs while uniformly modifying N-doped carbon layers on the surface of the nanosheets. Benefit from the smaller layer thickness of C-HPC-BNNSs, they exhibit excellent dispersion stability in the water-glycol solution and can maintain no significant agglomeration behavior for up to 30 days, which is the basis for the excellent lubrication performance of lubricant systems. In addition, the N-doped carbon layer modified on the surface is beneficial for enhancing the hydrophilicity of BNNSs and synergistically enhances the tribological properties of the material with BNNSs. The test results of the four-ball friction tester show that compared with the pure water-glycol solution and the water-glycol system with added C-HPC-BNNSs, the friction coefficient (COF) and wear volume of the system with added C-HPC-BNNSs could be as low as 0.095 and 1.99 × 10−4 mm3, respectively. This work has positive significance for the preparation, surface modification, and tribological application expansion of two-dimensional layered material BNNSs, which is conducive to further understanding the relationship between.
{"title":"Fabrication of surface-carbonated boron nitride nanosheets and their application as water-based lubrication additives","authors":"Ru Liu , Diange Guo , Xiaoxiao Du , Guo Du , Xia Zhang","doi":"10.1016/j.wear.2024.205633","DOIUrl":"10.1016/j.wear.2024.205633","url":null,"abstract":"<div><div>As a typical two-dimensional layered material, hexagonal boron nitride nanosheets (BNNSs) have high mechanical strength, good conductivity, and excellent lubrication performance, which have great potential as solid nano lubricant additives in tribology. When BNNS is used as a water-based or oil-based lubricant additive, its inherent chemical inertness and poor dispersion stability make it difficult to achieve optimal anti-friction and anti-wear performance. In this paper, a simple and efficient preparation method for obtaining hexagonal boron nitride nanosheets (C-HPC-BNNSs) with surface carbonization modification and excellent dispersion stability in water-based lubricants was proposed. Using hydroxypropyl cellulose (HPC) as a modifier, a wet ball milling process combined with high-temperature carbonization treatment effectively reduced the thickness of BNNSs while uniformly modifying N-doped carbon layers on the surface of the nanosheets. Benefit from the smaller layer thickness of C-HPC-BNNSs, they exhibit excellent dispersion stability in the water-glycol solution and can maintain no significant agglomeration behavior for up to 30 days, which is the basis for the excellent lubrication performance of lubricant systems. In addition, the N-doped carbon layer modified on the surface is beneficial for enhancing the hydrophilicity of BNNSs and synergistically enhances the tribological properties of the material with BNNSs. The test results of the four-ball friction tester show that compared with the pure water-glycol solution and the water-glycol system with added C-HPC-BNNSs, the friction coefficient (COF) and wear volume of the system with added C-HPC-BNNSs could be as low as 0.095 and 1.99 × 10<sup>−4</sup> mm<sup>3</sup>, respectively. This work has positive significance for the preparation, surface modification, and tribological application expansion of two-dimensional layered material BNNSs, which is conducive to further understanding the relationship between.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205633"},"PeriodicalIF":5.3,"publicationDate":"2024-11-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142651169","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Particle impact damage significantly affects the safe and stable operation of energy and chemical process equipment. During particle transportation, a liquid film may form on the wall, influencing the damage mechanism caused by particle effect. This study investigates the effects of liquid film parameters, specifically viscosity and thickness, on wall damage. Hydroxypropyl Methylcellulose (HPMC) solution was applied as a liquid film, and the effect of the liquid film's viscosity and thickness was examined through impact damage experiments using a particle (45 steel) and a wall (1060 aluminum alloy) with the liquid film. Results indicate that the presence of a liquid film can inhibit wall damage. Increased liquid film viscosity and thickness reduce wall damage, but they affect the turning points of damage characteristic parameters differently concerning impact angle and velocity. Finally, the study establishes correlation between dry and wet impact by introducing the effect coefficient of liquid film. This reveals the alteration rules of the influence coefficient and proposes a wet impact damage model, providing a reference for the damage prediction in process equipment.
{"title":"Characteristics of particle-wet wall impact damage: Effects of liquid film parameters","authors":"Junyu Tao, Jiabao Guo, Xiaoxiao Chen, Zhe Lin, Zuchao Zhu","doi":"10.1016/j.wear.2024.205627","DOIUrl":"10.1016/j.wear.2024.205627","url":null,"abstract":"<div><div>Particle impact damage significantly affects the safe and stable operation of energy and chemical process equipment. During particle transportation, a liquid film may form on the wall, influencing the damage mechanism caused by particle effect. This study investigates the effects of liquid film parameters, specifically viscosity and thickness, on wall damage. Hydroxypropyl Methylcellulose (HPMC) solution was applied as a liquid film, and the effect of the liquid film's viscosity and thickness was examined through impact damage experiments using a particle (45 steel) and a wall (1060 aluminum alloy) with the liquid film. Results indicate that the presence of a liquid film can inhibit wall damage. Increased liquid film viscosity and thickness reduce wall damage, but they affect the turning points of damage characteristic parameters differently concerning impact angle and velocity. Finally, the study establishes correlation between dry and wet impact by introducing the effect coefficient of liquid film. This reveals the alteration rules of the influence coefficient and proposes a wet impact damage model, providing a reference for the damage prediction in process equipment.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"562 ","pages":"Article 205627"},"PeriodicalIF":5.3,"publicationDate":"2024-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142660335","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 : 2024-11-05DOI: 10.1016/j.wear.2024.205626
S Joyson Selvakumar , D. Samuel Raj
The effectiveness of SiALON ceramic inserts during MQL machining of Inconel 625 under different depth of cut (DoC) – 1.00, 1.25, and 1.5 mm - is investigated through tool wear and chip morphology analysis, and compared with dry and flood conditions. Under MQL conditions, the SiALON tools encounter lower wear and edge chipping than both dry and flood conditions for all DoC. The chip serration height, pitch between serrations, adiabatic shear bandwidth (ASB) in the primary as well as the secondary shear zone, and segmentation height on the free surface of the chip are lower for MQL conditions than dry and flood conditions for all DoC. The shear affected zone (SAZ) or transition layer is noticed near the ASB under dry and flood conditions. More transverse shear lines are seen in the vicinity of the ASB under dry and flood conditions for 1.25 mm DoC, indicating a higher degree of plastic deformation. While coarse grains are present near the ASB, the absence of SAZ in the vicinity of the ASB under MQL conditions points to improved cutting zone lubrication and chip removal under MQL. For the first time, the variation in the chip segmentation along the chip width is studied and is also found to be minimal for MQL as compared to dry and flood conditions pointing to the superior penetration capability of MQL deep into the cutting zone.
{"title":"Tribological characteristics of SiALON ceramic inserts during sustainable machining of Inconel 625 based on comprehensive chip morphology analysis","authors":"S Joyson Selvakumar , D. Samuel Raj","doi":"10.1016/j.wear.2024.205626","DOIUrl":"10.1016/j.wear.2024.205626","url":null,"abstract":"<div><div>The effectiveness of SiALON ceramic inserts during MQL machining of Inconel 625 under different depth of cut (DoC) – 1.00, 1.25, and 1.5 mm - is investigated through tool wear and chip morphology analysis, and compared with dry and flood conditions. Under MQL conditions, the SiALON tools encounter lower wear and edge chipping than both dry and flood conditions for all DoC. The chip serration height, pitch between serrations, adiabatic shear bandwidth (ASB) in the primary as well as the secondary shear zone, and segmentation height on the free surface of the chip are lower for MQL conditions than dry and flood conditions for all DoC. The shear affected zone (SAZ) or transition layer is noticed near the ASB under dry and flood conditions. More transverse shear lines are seen in the vicinity of the ASB under dry and flood conditions for 1.25 mm DoC, indicating a higher degree of plastic deformation. While coarse grains are present near the ASB, the absence of SAZ in the vicinity of the ASB under MQL conditions points to improved cutting zone lubrication and chip removal under MQL. For the first time, the variation in the chip segmentation along the chip width is studied and is also found to be minimal for MQL as compared to dry and flood conditions pointing to the superior penetration capability of MQL deep into the cutting zone.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"562 ","pages":"Article 205626"},"PeriodicalIF":5.3,"publicationDate":"2024-11-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142660338","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 : 2024-11-05DOI: 10.1016/j.wear.2024.205625
Jeng-Haur Horng , Thi-Na Ta , Chun-Wei Kuo , Sheng-Jie Liao , Yang-Yuan Chen
The application of grease under contaminated environmental conditions typically leads to its degradation and subsequent damage to lubricated surfaces. This study examines the effects of various concentrations of environmental particles and water content, both separately and in combination, on the variation of tribological characteristics of lithium-based grease during wear. Wear and pitting curves are established for grease contaminated with varying weight percentages of water and particles. The introduction of water into grease reduces wear by absorbing friction heat but increases pitting, while particles extend the running-in period and destabilize surface roughness. In mixed conditions, particles exert a greater influence on the tribological behavior than water. To improve pitting monitoring, vibration indicators FM4 and NA4 are modified by incorporating the cumulative effect of the friction coefficient over time, accounting for the progressive accumulation of wear and vibration energy. The modified FM4 indicator proves more effective in detecting pitting variations under contaminated conditions.
{"title":"Development of wear and pitting curves with vibration analysis for lubricating grease under contamination conditions","authors":"Jeng-Haur Horng , Thi-Na Ta , Chun-Wei Kuo , Sheng-Jie Liao , Yang-Yuan Chen","doi":"10.1016/j.wear.2024.205625","DOIUrl":"10.1016/j.wear.2024.205625","url":null,"abstract":"<div><div>The application of grease under contaminated environmental conditions typically leads to its degradation and subsequent damage to lubricated surfaces. This study examines the effects of various concentrations of environmental particles and water content, both separately and in combination, on the variation of tribological characteristics of lithium-based grease during wear. Wear and pitting curves are established for grease contaminated with varying weight percentages of water and particles. The introduction of water into grease reduces wear by absorbing friction heat but increases pitting, while particles extend the running-in period and destabilize surface roughness. In mixed conditions, particles exert a greater influence on the tribological behavior than water. To improve pitting monitoring, vibration indicators FM4 and NA4 are modified by incorporating the cumulative effect of the friction coefficient over time, accounting for the progressive accumulation of wear and vibration energy. The modified FM4 indicator proves more effective in detecting pitting variations under contaminated conditions.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205625"},"PeriodicalIF":5.3,"publicationDate":"2024-11-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142651168","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 : 2024-11-04DOI: 10.1016/j.wear.2024.205622
K. Shu , N. Zani , L. Ghidini , C. Petrogalli , L.L. Yu , A. Mazzù , H.H. Ding , W.J. Wang
In desert environments, the phenomenon of sand particles depositing on the rail top and contaminating the wheel-rail interface is common because the railway is an open system. This work aimed to investigate the wear and damage behaviors of wheel-rail with different material matchings under various sand deposition densities of rail top in desert environments. The results showed that as sand deposition density increased, adhesion coefficient first decreased sharply and then increased slowly, and finally decreased slowly. It was caused by the combined effect of sand solid lubrication, oxide solid lubrication, and surface roughness of wheel and rail. The oxidative wear increased first, peaking at about 0.2 g/m2, and then decreased, whereas the fatigue wear decreased consistently. For wheel and rail materials with similar hardness, the wheel-rail material matching with high carbon content exhibited excellent anti-wear and anti-fatigue performances. The wear and damage of wheel and rail were relatively mild when the sand deposition density was lower than 0.4 g/m2.
{"title":"Wear and damage behaviors of wheel-rail with different material matchings under various sand deposition densities of rail top in desert environments","authors":"K. Shu , N. Zani , L. Ghidini , C. Petrogalli , L.L. Yu , A. Mazzù , H.H. Ding , W.J. Wang","doi":"10.1016/j.wear.2024.205622","DOIUrl":"10.1016/j.wear.2024.205622","url":null,"abstract":"<div><div>In desert environments, the phenomenon of sand particles depositing on the rail top and contaminating the wheel-rail interface is common because the railway is an open system. This work aimed to investigate the wear and damage behaviors of wheel-rail with different material matchings under various sand deposition densities of rail top in desert environments. The results showed that as sand deposition density increased, adhesion coefficient first decreased sharply and then increased slowly, and finally decreased slowly. It was caused by the combined effect of sand solid lubrication, oxide solid lubrication, and surface roughness of wheel and rail. The oxidative wear increased first, peaking at about 0.2 g/m<sup>2</sup>, and then decreased, whereas the fatigue wear decreased consistently. For wheel and rail materials with similar hardness, the wheel-rail material matching with high carbon content exhibited excellent anti-wear and anti-fatigue performances. The wear and damage of wheel and rail were relatively mild when the sand deposition density was lower than 0.4 g/m<sup>2</sup>.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205622"},"PeriodicalIF":5.3,"publicationDate":"2024-11-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142592593","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-11-03DOI: 10.1016/j.wear.2024.205624
Ruilin Wang , Junhao Qu , Huabo He , Jiachang Liu , Haibo Huang , Yanjun Wang , Yonggang Wang
Rubber filled with carbon nanotubes (CNTs) oriented along a specific direction exhibits excellent tribological performance owing to the unique directional structure of the CNTs, and offers significant application potential. However, when CNT-reinforced rubbers are worn, fine wear particles (WPs), including CNTs, are emitted, creating a potential respiratory health risk. This study explores the relationship between the emission of fine WPs (with sizes ) against a frosted glass disc under sliding conditions and the tribological performance of styrene-butadiene rubber (SBR) reinforced by aligned CNTs. The number of WPs per unit worn mass (QwpS/uwm, where S is the upper limit to the particle size in μm), was defined to quantify the emissions after a unit mass was worn. Using a pin-on-disc test rig developed for this study, the results showed that SBR with CNTs oriented perpendicular to the wear surface (denoted as CNTs-z-SBR) exhibited higher Qwp3.0/uwm and Qwp5.0/uwm values owing to its superior wear resistance. A greater worn mass resulted in larger amounts of WPs, but smaller Qwp3.0/uwm and Qwp5.0/uwm. Furthermore, both water lubrication and lower coefficients of friction (COF) increased the value of Qwp3.0/uwm, whereas a larger load and velocity decreased the values of Qwp3.0/uwm and Qwp5.0/uwm.
{"title":"Evaluation of fine wear particles emission from styrene-butadiene rubber reinforced with aligned carbon nanotubes: A study based on unit wear mass analysis","authors":"Ruilin Wang , Junhao Qu , Huabo He , Jiachang Liu , Haibo Huang , Yanjun Wang , Yonggang Wang","doi":"10.1016/j.wear.2024.205624","DOIUrl":"10.1016/j.wear.2024.205624","url":null,"abstract":"<div><div>Rubber filled with carbon nanotubes (CNTs) oriented along a specific direction exhibits excellent tribological performance owing to the unique directional structure of the CNTs, and offers significant application potential. However, when CNT-reinforced rubbers are worn, fine wear particles (WPs), including CNTs, are emitted, creating a potential respiratory health risk. This study explores the relationship between the emission of fine WPs (with sizes <span><math><mrow><mo>≤</mo><mn>10</mn><mspace></mspace><mi>μ</mi><mi>m</mi></mrow></math></span>) against a frosted glass disc under sliding conditions and the tribological performance of styrene-butadiene rubber (SBR) reinforced by aligned CNTs. The number of WPs per unit worn mass (Q<sub>wp</sub><sub>S</sub><sub>/uwm</sub>, where S is the upper limit to the particle size in μm), was defined to quantify the emissions after a unit mass was worn. Using a pin-on-disc test rig developed for this study, the results showed that SBR with CNTs oriented perpendicular to the wear surface (denoted as CNTs<sub>-z</sub>-SBR) exhibited higher Q<sub>wp3.0/uwm</sub> and Q<sub>wp5.0/uwm</sub> values owing to its superior wear resistance. A greater worn mass resulted in larger amounts of WPs, but smaller Q<sub>wp3.0/uwm</sub> and Q<sub>wp5.0/uwm</sub>. Furthermore, both water lubrication and lower coefficients of friction (COF) increased the value of Q<sub>wp3.0/uwm</sub>, whereas a larger load and velocity decreased the values of Q<sub>wp3.0/uwm</sub> and Q<sub>wp5.0/uwm</sub>.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"562 ","pages":"Article 205624"},"PeriodicalIF":5.3,"publicationDate":"2024-11-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142660343","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 : 2024-11-02DOI: 10.1016/j.wear.2024.205621
Yu Zhang , Yun-Fei Jia , Xin-Wei Sun , Zhen-Hua Fang , Jian-Jun Yan , Cheng-Cheng Zhang , Li Xin , Xian-Cheng Zhang
The influence of solid particle erosion on aero-engine performance poses a potential threat to aviation safety. Accurate prediction of erosion rates for blades is crucial for assessing the engine's operational lifespan. Engine blades experience centrifugal forces during operation, resulting in erosion under tensile stress. This study has designed a specialized erosion-tension coupling test apparatus to explore the effect of tensile stress on specimens subjected to gas-solid erosion. Applying an axial tensile load equivalent to 60 % of the yield strength prompts a 90.2 % increase in erosion rate for aluminum alloy specimens at a 60° erosion angle. Additionally, fluid-structure interaction simulations systematically analyze the surface stress distribution of specimens under various erosion and tension conditions. Subsequently, a novel erosion model is proposed, incorporating an innovative acceleration factor that considers material yield strength, Von Mises stress distribution, and erosion crater volume. This developed model accurately predicts erosion rates under various loading conditions for cylindrical and simplified engine blade specimens, with a deviation from experimental erosion rates of less than 18.1 %. The constructed erosion model provides a concise and accurate prediction of erosion rates for specimens subjected to gas-solid erosion under tensile stress.
{"title":"A prediction model of erosion rate under erosion-tension coupling for engine blade","authors":"Yu Zhang , Yun-Fei Jia , Xin-Wei Sun , Zhen-Hua Fang , Jian-Jun Yan , Cheng-Cheng Zhang , Li Xin , Xian-Cheng Zhang","doi":"10.1016/j.wear.2024.205621","DOIUrl":"10.1016/j.wear.2024.205621","url":null,"abstract":"<div><div>The influence of solid particle erosion on aero-engine performance poses a potential threat to aviation safety. Accurate prediction of erosion rates for blades is crucial for assessing the engine's operational lifespan. Engine blades experience centrifugal forces during operation, resulting in erosion under tensile stress. This study has designed a specialized erosion-tension coupling test apparatus to explore the effect of tensile stress on specimens subjected to gas-solid erosion. Applying an axial tensile load equivalent to 60 % of the yield strength prompts a 90.2 % increase in erosion rate for aluminum alloy specimens at a 60° erosion angle. Additionally, fluid-structure interaction simulations systematically analyze the surface stress distribution of specimens under various erosion and tension conditions. Subsequently, a novel erosion model is proposed, incorporating an innovative acceleration factor that considers material yield strength, Von Mises stress distribution, and erosion crater volume. This developed model accurately predicts erosion rates under various loading conditions for cylindrical and simplified engine blade specimens, with a deviation from experimental erosion rates of less than 18.1 %. The constructed erosion model provides a concise and accurate prediction of erosion rates for specimens subjected to gas-solid erosion under tensile stress.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205621"},"PeriodicalIF":5.3,"publicationDate":"2024-11-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142587395","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 : 2024-11-02DOI: 10.1016/j.wear.2024.205620
Baoping Zou , Yu Chen , Yangjuan Bao , Zhiping Liu , Bo Hu , Jingyuan Ma , Guanglin Kuang , Chunan Tang , Honglei Sun , Qasim Zaheer , Xu Long
The assessment of disc cutter wear in subway shield construction beneath operational airports is a critical endeavor for evaluating the structural integrity of shield machines. This study delved into the linear tunnel project linking Station T1 to T3 within the Baiyun airport, focusing on the intricate relationship between tunneling parameters during rock-machine interactions and the impact of disc cutter installation radius on wear amount. In addition, dynamic impact transient rock-breaking tests of shield disc cutters were performed under the coupled thermo-hydro-mechanical triaxial conditions to ensure the validity of the relationship between mass-point velocity and the transient rock-breaking behavior of the disc cutter. The analysis revealed that when the shield thrust was between 17000 kN and 21000 kN, the total thrust of the shield had a significant effect on the advancement speed and cutterhead torque. Notably, the wear amount of the cutter increased approximately linearly with the installation radius, while the wear of the gauge cutter was also affected by the inclination angle. Furthermore, the study uncovered a linear correlation between the cutting length of the disc cutter and the magnitude of wear. Within a cutting length range between 440 km and 2276 km, the disc cutter's installation position had minimal impact on the wear coefficient. Simultaneously, this study employed the mass-point velocity to simulate the thrust and rolling forces in the equivalent shield tunneling processes. The findings underscored a positive correlation between disc cutter wear and shield advancement speed, cutterhead rpm, and mass-point velocity. When the mass-point velocity of the shield reached the maximum value of 0.666 m/s, the wear of the shield disc cutter also reached the maximum value of 27.5 mm, providing the quantitative reference for evaluating the influences of shield tunneling parameters on the cutter wear under transient impact rock breaking conditions.
在运营中的机场地下进行地铁盾构施工时，对圆盘刀磨损的评估是评价盾构机结构完整性的一项重要工作。本研究深入探讨了连接白云机场 T1 站和 T3 站的直线隧道工程，重点研究了岩机相互作用过程中隧道参数之间的复杂关系，以及圆盘刀安装半径对磨损量的影响。此外，还在热-水-机械三轴耦合条件下进行了盾构圆盘刀动态冲击瞬态破岩试验，以确保质点速度与圆盘刀瞬态破岩行为之间关系的有效性。分析结果表明，当盾构推力在 17000 kN 至 21000 kN 之间时，盾构总推力对推进速度和刀盘扭矩有显著影响。值得注意的是，刀盘的磨损量与安装半径呈近似线性增长，而轨距刀盘的磨损也受倾斜角的影响。此外，研究还发现圆盘铣挖机的铣挖长度与磨损程度之间存在线性关系。在 440 千米到 2276 千米的切割长度范围内，圆盘铣挖机的安装位置对磨损系数的影响微乎其微。同时，这项研究还利用质点速度模拟了等效盾构掘进过程中的推力和滚动力。研究结果表明，圆盘刀磨损与盾构推进速度、刀盘转速和质点速度之间存在正相关关系。当盾构的质点速度达到最大值 0.666 m/s 时，盾构圆盘刀盘的磨损也达到最大值 27.5 mm，为评估瞬态冲击破岩条件下盾构掘进参数对刀盘磨损的影响提供了定量参考。
{"title":"Impact of tunneling parameters on disc cutter wear during rock breaking in transient conditions","authors":"Baoping Zou , Yu Chen , Yangjuan Bao , Zhiping Liu , Bo Hu , Jingyuan Ma , Guanglin Kuang , Chunan Tang , Honglei Sun , Qasim Zaheer , Xu Long","doi":"10.1016/j.wear.2024.205620","DOIUrl":"10.1016/j.wear.2024.205620","url":null,"abstract":"<div><div>The assessment of disc cutter wear in subway shield construction beneath operational airports is a critical endeavor for evaluating the structural integrity of shield machines. This study delved into the linear tunnel project linking Station T1 to T3 within the Baiyun airport, focusing on the intricate relationship between tunneling parameters during rock-machine interactions and the impact of disc cutter installation radius on wear amount. In addition, dynamic impact transient rock-breaking tests of shield disc cutters were performed under the coupled thermo-hydro-mechanical triaxial conditions to ensure the validity of the relationship between mass-point velocity and the transient rock-breaking behavior of the disc cutter. The analysis revealed that when the shield thrust was between 17000 kN and 21000 kN, the total thrust of the shield had a significant effect on the advancement speed and cutterhead torque. Notably, the wear amount of the cutter increased approximately linearly with the installation radius, while the wear of the gauge cutter was also affected by the inclination angle. Furthermore, the study uncovered a linear correlation between the cutting length of the disc cutter and the magnitude of wear. Within a cutting length range between 440 km and 2276 km, the disc cutter's installation position had minimal impact on the wear coefficient. Simultaneously, this study employed the mass-point velocity to simulate the thrust and rolling forces in the equivalent shield tunneling processes. The findings underscored a positive correlation between disc cutter wear and shield advancement speed, cutterhead rpm, and mass-point velocity. When the mass-point velocity of the shield reached the maximum value of 0.666 m/s, the wear of the shield disc cutter also reached the maximum value of 27.5 mm, providing the quantitative reference for evaluating the influences of shield tunneling parameters on the cutter wear under transient impact rock breaking conditions.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205620"},"PeriodicalIF":5.3,"publicationDate":"2024-11-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142572128","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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 : 2024-10-30DOI: 10.1016/j.wear.2024.205617
Kübra Gürcan Bayrak , Hadi Jahangiri , Gökhan Kula , Yağmur Can Gündoğan , Ferhat Kara , Alphan Sennaroğlu , Erhan Ayas
Microscale textures inspired by nature were created on the rake face of SiAlON ceramic inserts using a femtosecond laser system. A detailed investigation was carried out to study the effect of laser parameters such as power, focal length, passing frequency, and media (air/water) on the inserts. The cutting performance of both the non-textured and textured SiAlON inserts was evaluated in terms of tool wear, chip-tool contact length, shear angle, and chip morphology during high-speed turning operations on INC-718. The optimization of laser parameters revealed that grooves were successfully formed in air, but water disrupted the laser focus, resulting in non-linear grooves. A detailed analysis of cutting insert wear patterns at different feed rates indicated the significant impact of texturing on the rake face. The application of surface texturing reduced crater wear, enhanced wear resistance, and minimized tool-chip contact, especially on the inserts with textured grooves located 100 μm from the cutting edge. Examination of chip-tool contact length and chip flow angles on textured and non-textured inserts showed that surface texturing reduced contact length and facilitated gradual chip curling, resulting in a decrease in chip flow angles. Surface texturing also reduced chip thickness, increased shear angle, decreased burr formation, and changed chip morphology during high-speed machining of Inconel 718.
{"title":"Investigation of feed rate impact on microscale surface textures and turning performance of SiAlON ceramic cutting tools","authors":"Kübra Gürcan Bayrak , Hadi Jahangiri , Gökhan Kula , Yağmur Can Gündoğan , Ferhat Kara , Alphan Sennaroğlu , Erhan Ayas","doi":"10.1016/j.wear.2024.205617","DOIUrl":"10.1016/j.wear.2024.205617","url":null,"abstract":"<div><div>Microscale textures inspired by nature were created on the rake face of SiAlON ceramic inserts using a femtosecond laser system. A detailed investigation was carried out to study the effect of laser parameters such as power, focal length, passing frequency, and media (air/water) on the inserts. The cutting performance of both the non-textured and textured SiAlON inserts was evaluated in terms of tool wear, chip-tool contact length, shear angle, and chip morphology during high-speed turning operations on INC-718. The optimization of laser parameters revealed that grooves were successfully formed in air, but water disrupted the laser focus, resulting in non-linear grooves. A detailed analysis of cutting insert wear patterns at different feed rates indicated the significant impact of texturing on the rake face. The application of surface texturing reduced crater wear, enhanced wear resistance, and minimized tool-chip contact, especially on the inserts with textured grooves located 100 μm from the cutting edge. Examination of chip-tool contact length and chip flow angles on textured and non-textured inserts showed that surface texturing reduced contact length and facilitated gradual chip curling, resulting in a decrease in chip flow angles. Surface texturing also reduced chip thickness, increased shear angle, decreased burr formation, and changed chip morphology during high-speed machining of Inconel 718.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205617"},"PeriodicalIF":5.3,"publicationDate":"2024-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142572175","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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