Tribology of ethylene-air diffusion flame soot under dry and lubricated contact conditions

Soot particles are generated in a flame caused by burning ethylene gas. The particles are collected thermophoretically at different locations of the flame. The particles are used to lubricate a steel/steel ball on flat reciprocating sliding contact, as a dry solid lubricant and also as suspended in hexadecane. Reciprocating contact is shown to establish a protective and low friction tribo-film. The friction correlates with the level of graphitic order of the soot, which is highest in the soot extracted from the mid-flame region and is low in the soot extracted from the flame root and flame tip regions. Micro-Raman spectroscopy of the tribo-film shows that the a priori graphitic order, the molecular carbon content of the soot and the graphitization of the film as brought about by tribology distinguish between the frictions of soot extracted from different regions of the flame, and differentiate the friction associated with dry tribology from that recorded under lubricated tribology.

Elastic-plastic contact conditions for frictionally constrained bodies under cyclic tangential loading

A Frictionally constrained condition implies dependence of friction force on tangential displacement amplitude. The condition may occur due to chemical, physical, and/or mechanical interaction between the contacting surfaces. The condition, sometimes also referred to as the presliding condition or partial slip condition, is characterized under fretting. Under such conditions, various experimental studies indicate the existence of two distinguishable regions, that is, stick region and slip region. In the present study, frictionally constrained conditions are identified and the evolutions of stick-slip regions are investigated in detail. Investigations have been performed on self-mated stainless steel and chromium carbide coated surfaces mated against stainless steel, under both vacuum and ambient conditions. Contact conditions prevailing at the contact interface were identified based on the mechanical responses and were correlated with the surface damage observed. Surface degradation has been observed in the form of microcracks and material transfer. Detailed numerical analysis has also been performed in order to understand the energy dissipation and the damage mode involved in the surface or subsurface damage. It has been observed that under frictionally constrained conditions, the occurrence of annular slip features are mainly due to the junction growth, resulting from elastic-plastic deformation at the contact interface. Ratcheting has been observed as the governing damage mode under cyclic tangential loading condition.

Properties of a composite material with mixed imperfect contact conditions

We present an analytical solution of a mixed boundary value problem for an unbounded 2D doubly periodic domain which is a model of a composite material with mixed imperfect interface conditions. We find the effective conductivity of the composite material with mixed imperfect interface conditions, and also give numerical analysis of several of their properties such as temperature and flux.

Evaluation of Different Conditions of Contact for Caprolactam Migration from Multilayer Polyamide Films into Food Simulants

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Investigation of surface ratchetting due to rail/wheel contact

This project advances the knowledge of rail wear and crack formation due to rail/wheel contact in Australian heavy-haul railway lines. This comprehensive study utilised numerous techniques including: simulation using a twin-disk test-rig, scanning electron microscope particle analysis and finite element modeling for material failure prediction. Through this work, new material failure models have been developed which may be used to predict the lifetime and reliability of materials undergoing severe contact conditions.

Damage mechanisms in stainless steel and chromium carbide coatings under controlled environment fretting conditions

Fretting is of a serious concern in many industrial components, specifically, in nuclear industry for the safe and reliable operation of various component and/or system. Under fretting condition small amplitude oscillations induce surface degradation in the form of surface cracks and/or surface wear. Comprehensive experimental studies have been carried out simulating different fretting regimes under ambient and vacuum (10(-9) MPa) conditions and, temperature up to 400 degrees C. Studies have been carried out with stainless steel spheres on stainless steel flats, and stainless steel spheres against chromium carbide, with 25% nickel chrome binder coatings. Mechanical responses are correlated with the damage observed. It has been observed that adhesion plays a vital role in material degradation process, and its effectiveness depends on mechanical variables such as normal load, interfacial tangential displacement, characteristics of the contacting bodies and most importantly on the environment conditions. Material degradation mechanism for ductile materials involved severe plastic deformation, which results in the initiation or nucleation of cracks. Ratcheting has been observed as the governing damage mode for crack nucleation under cyclic tangential loading condition. Further, propagation of the cracks has been observed under fatigue and their orientation has been observed to be governed by the contact conditions prevailing at the contact interface. Coated surfaces show damage in the form of brittle fracture and spalling of the coatings. Existence of stick slip has been observed under high normal load and low displacement amplitude. It has also been observed that adhesion at the contact interface and instantaneous cohesive strength of the contacting bodies dictates the occurrence of material transfer. The paper discusses the mechanics and mechanisms involved in fretting damage under controlled environment conditions. (C) 2015 Elsevier B.V. All rights reserved.

Subsonic interface crack with crack face contact

A steady-state subsonic interface crack propagating between an elastic solid and a rigid substrate with crack face contact is studied. Two cases with respective to the contact length are considered, i.e., semi-infinite and finite crack face contact. Different from a stationary or an open subsonic interface crack, stress singularity at the crack tip in the present paper is found to be non-oscillatory. Furthermore, in the semi-infinite contact case, the singularity of the stress field near the crack tip is less than 1/2. In the finite contact case, no singularity exists near the crack tip, but less than 1/2 singularity does at the end of the contact zone. In both cases, the singularity depends on the linear contact coefficient and the crack speed. Asymptotic solutions near the crack tip are given and analyzed. In order to satisfy the contact conditions, reasonable region of the linear contact coefficient is found. In addition, the solution predicts a non-zero-energy dissipation rate due to crack face contact.

Contact pressure prediction in sheet metal forming using finite element analysis

Tool wear has become a significant issue associated with the forming of high strength sheet steels in the automotive industry. In order to combat this problem, recent research has been devoted to utilizing the contact results obtained from current sheet metal forming software predictions, in order to develop/apply tool wear models or tool material selection criteria for use in the stamping plant. This investigation aims to determine whether a specialized sheet metal forming software package can correctly capture the complex contact conditions that occur during a typical sheet metal stamping process. The contact pressure at the die radius was compared to results obtained using a general-purpose finite element software package, for a simple channel-forming process. Although some qualitative similarities between the two predictions were observed, it was found that significant differences in the magnitude and distribution of the contact pressure exists. The reasons for the discrepancies in results are discussed with respect to the simplifications and assumptions adopted in the finite element model definitions, and with regards to other results available in the literature.

Contact pressure evolution at the die radius in sheet metal stamping

The contact conditions at the die radius are of primary importance to the wear response for many sheet metal forming processes. In particular, a detailed understanding of the contact pressure at the wearing interface is essential for the application of representative wear tests, the use of wear resistant materials and coatings, the development of suitable wear models, and for the ultimate goal of predicting tool life. However, there is a lack of information concerning the time-dependant nature of the contact pressure response in sheet metal stamping. This work provides a qualitative description of the evolution and distribution of contact pressure at the die radius for a typical channel forming process. Through an analysis of the deformation conditions, contact phenomena and underlying mechanics, it was identified that three distinct phases exist. Significantly, the initial and intermediate stages resulted in severe and localised contact conditions, with contact pressures significantly greater than the blank material yield strength. The final phase corresponds to a larger contact area, with steady and smaller contact pressures. The proposed contact pressure behaviour was compared to other results available in the literature and also discussed with respect to tool wear.

Sliding distance, contact pressure and wear in sheet metal stamping

This paper directly examines the contact sliding distance experienced during a typical sheet metal stamping process-an area that has largely been neglected in the literature. A method to numerically quantify the sliding distance is proposed. The sliding distance predicted from this method, and the contact pressure obtained from numerical simulation, allow the recently identified time-dependent contact conditions on the die and blank surfaces to be completely characterized. Consequently, a new insight into the wear/galling that occurs at the die radius in sheet metal stamping is gained. The results show that the region close to zero degrees on the die radius is likely to experience the most wear, with the identified transient stage contributing to a large proportion of the total wear. Additionally, the region on the blank surface often observed to be heavily burnished - the die impact line - is estimated to experience the highest wear severity due to the transient contact conditions. The proposed method to numerically quantify the sliding contact conditions can be applied as a general approach to study any other two-body sliding contact situations.

Turning of compacted graphite iron using commercial tiN coated Si 3N4 under dry machining conditions

Due to their high hardness and wear resistance Si3N4 based ceramics are one of the most suitable cutting tool materials for machining hardened materials. Therefore, their high degree of brittleness usually leads to inconsistent results and sudden catastrophic failures. Improvement of the functional properties these tools and reduction of the ecological threats may be accomplished by employing the technology of putting down hard coatings on tools in the state-of-the-art PVD processes, mostly by improvement of the tribological contact conditions in the cutting zone and by eliminating the cutting fluids. However in this paper was used a Si3N4 based cutting tool commercial with a layer TiN coating. In this investigation, the performance of TiN coating was assessed on turning used to machine an automotive grade compacted graphite iron. As part of the study were used to characterise the performance of cutting tool, flank wear, temperature and roughness. The results showed that the layer TiN coating failed to dry compacted graphite iron under aggressive machining conditions. However, using the measurement of flank wear technique, the average tool life of was increased by VC=160 m/min.The latter was also observed using a toolmakers microscope and scanning electron microscopy (SEM).

Understanding wear conditions during hot stamping

Wear and galling are significant issues during production hot stamping processes. This paper uses thermo-mechanical finite element analysis to study the contact pressure, sliding distance and temperature conditions that occur at the wearing interface during hot stamping. Several hot stamping processes are studied, representing the numerous methods that are used in industry to form a typical hat-shaped channel component. These process include crash forming (without blankholder), stamping with a blank holder with an applied blank holder pressure, and stamping with a clearance blank holder (i.e. with spacer blocks). This paper identifies the distinct contact pressure and temperature conditions that occur for each of these forming methods. The regions of the most severe contact conditions are notably different for each of the forming methods. The work from this paper will form the basis for the development of suitable temperature dependent wear models and low cost wear tests for industrial hot stamping applications.