An Investigation of Friction During Friction Stir Welding of Metallic Materials

The technique of friction stir welding (FSW) puts effective use frictional heat for the purpose of joining metallic materials. In this research article, we present and discuss an experimental method to determine the coefficient of friction during FSW. The experiments were conducted to study the interaction between the FSW tool (a die steel) and the base metal (a high strength aluminum alloy) at various contact pressures (13MPa, 26MPa, and 39MPa) and rotation speeds (200rpm, 600rpm, 1000rpm, and 1400rpm). The experimental results, the microstructure, and the process temperature reveal the experimental setup to be capable of simulating the conditions during FSW. The coefficient of friction was found to vary from 0.15 to 1.4, and the temperature increased to as high as 450C. The coefficient of friction was found to increase with temperature. There exists a critical temperature at which point a steep increase in the coefficient of friction was observed. The critical temperature decreases from 250C at a contact pressure of 26MPa to 200C at contact pressure of 34MPa. Below the critical temperature at a specific contact pressure the maximum coefficient of friction is 0.6, and above the critical temperature it reaches a value as high as 1.4. The steep increase in the coefficient of friction is found to be due to the seizure phenomenon and the contact condition during FSW between the tool and the workpiece (base metal) is found to be sticking.

Nonsimilar incompressible laminar boundary layers with magnetic field.

The solution of the steady laminar incompressible nonsimilar magneto-hydrodynamic boundary layer flow and heat transfer problem with viscous dissipation for electrically conducting fluids over two-dimensional and axisymmetric bodies with pressure gradient and magnetic field has been presented. The partial differential equations governing the flow have been solved numerically using an implicit finite-difference scheme. The computations have been carried out for flow over a cylinder and a sphere. The results indicate that the magnetic field tends to delay or prevent separation. The heat transfer strongly depends on the viscous dissipation parameter. When the dissipation parameter is positive (i.e. when the temperature of the wall is greater than the freestream temperature) and exceeds a certain value, the hot wall ceases to be cooled by the stream of cooler air because the ‘heat cushion’ provided by the frictional heat prevents cooling whereas the effect of the magnetic field is to remove the ‘heat cushion’ so that the wall continues to be cooled. The results are found to be in good agreement with those of the local similarity and local nonsimilarity methods except near the point of separation, but they are in excellent agreement with those of the difference-differential technique even near the point of separation.

Effects of temperature in relation to sheet metal stamping

The demand to reduce the use of lubricants and increase tool life in sheet metal stamping has resulted in increased research on the sliding contact between the tool and the sheet materials. Unlubricated sliding wear tests for soft carbon steel sliding on D2 tool steel were performed using a pin-on-disk tribometer. The results revealed that temperature has an influencing role in the wear of tool steel and that material transfer between tool and sheet can be minimized at a certain temperature range in sheet metal stamping.

Application of the Minimum Quantity Lubrication (MQL) Technique in the Plunge Cylindrical Grinding Operation

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Specific depth cone resistivity measurements to determine soil engineering properties

The University of British Columbia (UBC) began performing piezocone penetration tests (CPTU) with electrical resistivity measurements (RCPTU) in 1989. Since then, RCPTU research at UBC has focused on obtaining geo-environmental parameters such as fluid resistivity and soil engineering properties such as porosity and degree of saturation from measurements of bulk soil electrical resistivity using the empirical relationship proposed by Archie (1942). Within this framework, the paper illustrates and discusses important design and calibration issues for resistivity modules such as the use of isolated circuitry to achieve linear calibrations over large ranges of resistivity. The suitability of RCPTU measurements for determination of geo-environmental and geotechnical parameters are assessed using typical ranges of soil and groundwater properties and methods of isolating individual factors for study are discussed. Illustrative examples of RCPTU research efforts including the environmental characterization of mine tailings, delineation of saline water intrusions in fresh water aquifers and the quality control of geotechnical ground densification are presented throughout the text. It is shown that groundwater temperature and hence ion mobility is not significantly altered by frictional heat generated during piezocone penetration and that ratio-based approaches to monitoring soil porosity can be used to eliminate the requirement for extensive groundwater sampling programs. Lastly, it is shown that RCPTU measurements above the water table can only be made using resistivity modules that are stable over a large range of resistivities and that such measurements are the most difficult to interpret because of grain surface conduction effects and generally unknown fluid resistivities.

Evidence for a Frozen Bed, Byrd Glacier, Antarctica

Ice thickness, computed within the fjord region of Byrd Glacier on the assumptions that Byrd Glacier is in mass-balance equilibrium and that ice velocity is entirely due to basal sliding, are on average 400 m less than measured ice thicknesses along a radio-echo profile. We consider four explanations for these differences: (1) active glacier ice is separated from a zone of stagnant ice near the base of the glacier by a shear zone at depth; (2) basal melting rates are some 8 m/yr; (3) internal shear occurs with no basal sliding in much of the region above the grounding zone; or (4) internal creep and basal sliding contribute to the flow velocity in varying proportions above the grounding zone. Large gradients of surface strain rate seem to invalidate the first explanation. Computed values of basal shear stress (140 to 200 kPa) provide insufficient frictional heat to melt the ice demanded by the second explanation. Both the third and fourth explanations were examined by making simplifying assumptions that prevented a truly quantitative evaluation of their merit. Nevertheless, there is no escaping the qualitative conclusion that internal shear contributes strongly to surface velocities measured on Byrd Glacier, as is postulated in both these explanations.

Calculating Basal Thermal Zones Beneath the Antarctic Ice Sheet

A procedure is presented for using a simple flowline model to calculate the fraction of the bed that is thawed beneath present-day ice sheets, and therefore for mapping thawed, frozen, melting and freezing basal thermal zones. The procedure is based on the proposition, easily demonstrated, that variations in surface slope along ice flowlines are due primarily to variations in bed topography and ice-bed coupling, where ice-bed coupling for sheet flow is represented by the basal thawed fraction. This procedure is then applied to the central flowlines of flow bands on the Antarctic ice sheet where accumulation rates, surface elevations and bed topography are mapped with sufficient accuracy, and where sheet flow rather than stream flow prevails. In East Antarctica, the usual condition is a low thawed fraction in subglacial highlands, but a high thawed fraction in subglacial basins and where ice converges on ice streams. This is consistent with a greater depression of the basal melting temperature and a slower rate of conducting basal heat to the surface where ice is thick, and greater basal frictional heat production where ice flow is fast, as expected for steady-state flow. This correlation is reduced or even reversed where steady-state flow has been disrupted recently, notably where ice-stream surges produced the Dibble and Dalton Iceberg Tongues, both of which are now stagnating. In West Antarctica, for ice draining into the Pine Island Bay polynya of the Amundsen Sea, the basal thawed fraction is consistent with a prolonged and ongoing surge of Pine Island Glacier and with a recently initiated surge of Thwaites Glacier. For ice draining into the Ross Ice Shelf, long ice streams extend nearly to the West Antarctic ice divide. Over the rugged bed topography near the ice divide, no correlation consistent with steady-state sheet flow exists between ice thickness and the basal thawed fraction. The bed is wholly thawed beneath ice streams, even where stream flow is slow. This is consistent with ongoing gravitational collapse of ice entering the Ross Sea embayment and with unstable flow in the ice streams.

Temperature changes in dental pulp associated with use of power grinding equipment on equine teeth

Objective To quantify the temperature changes in the dental pulp associated with equine dental procedures using power grinding equipment. Design A matrix experimental design with replication on the same sample was followed to allow the following independent variables to be assessed: horse age (young or old), tooth type (premolar or molar), powered grinding instrument (rotating disc or die grinder), grinding time (15 or 20 seconds) and the presence or absence of water coolant. Procedure Sound premolar and molar teeth from a 6-year-old horse and a 15-year-old horse, which had been removed postmortem, were sectioned parallel to the occlusal plane to allow placement of a miniature thermocouple at the level of the dental pulp. The maximum temperature increase, the time taken to reach this maximum and the cooling time were measured (n=10 in each study). The teeth were placed in a vice and the instrument used on the tooth as per clinical situation. Results Significant differences were recorded for horse age (P < 0.001), instrument type (P < 0.001), grinding time (P < 0.001) and presence or absence of coolant (P < 0.001). There was no significant difference for tooth type. Conclusion Thermal insult to the dental pulp from the use of power instruments poses a significant risk to the tooth. This risk can be reduced or eliminated by appropriate selection of treatment time and by the use of water irrigation as a coolant. The increased dentine thickness in older horses appears to mitigate against thermal injury from frictional heat.

The lattice solid model to simulate the physics of rocks and earthquakes: Incorporation of friction

The particle-based lattice solid model developed to study the physics of rocks and the nonlinear dynamics of earthquakes is refined by incorporating intrinsic friction between particles. The model provides a means for studying the causes of seismic wave attenuation, as well as frictional heat generation, fault zone evolution, and localisation phenomena. A modified velocity-Verlat scheme that allows friction to be precisely modelled is developed. This is a difficult computational problem given that a discontinuity must be accurately simulated by the numerical approach (i.e., the transition from static to dynamical frictional behaviour). This is achieved using a half time step integration scheme. At each half time step, a nonlinear system is solved to compute the static frictional forces and states of touching particle-pairs. Improved efficiency is achieved by adaptively adjusting the time step increment, depending on the particle velocities in the system. The total energy is calculated and verified to remain constant to a high precision during simulations. Numerical experiments show that the model can be applied to the study of earthquake dynamics, the stick-slip instability, heat generation, and fault zone evolution. Such experiments may lead to a conclusive resolution of the heat flow paradox and improved understanding of earthquake precursory phenomena and dynamics. (C) 1999 Academic Press.

Experimental study of temperatures during drilling of ex-vivo bovine bones

The thermal bone necrosis induced during a drilling process is a frequent and potential phenomenon, which contributes to post-operative problems. The frictional heat generated from the contact between the drill bit and the hole wall is unavoidable. However, understanding advanced techniques for acquiring reliable thermal data on bone drilling is important to ensure the quality of the drilled hole. The purpose of this study is to present two different experimental methods to analyse the drilling conditions that generate the lower temperatures, avoiding the occurrence of thermal bone necrosis. Ex-vivo bovine bones were used to simulate the drilling process considering the effect of drill bit diameter, drill speed and feed-rate. Different experiments were performed to assess the repeatability of the tests. The results identified the drill bit diameter as the most critical parameter for inducing higher temperatures in bone drilling.

Experimental study of temperatures during drilling of ex-vivo bovine bones

he thermal bone necrosis induced during a drilling process is a frequent and potential phenomenon, which contributes to post-operative problems. The frictional heat generated from the contact between the drill bit and the hole wall is unavoidable. However, understanding advanced techniques for acquiring reliable thermal data on bone drilling is important to ensure the quality of the drilled hole.

Two-Phase Frictional Pressure Drop and Flow Boiling Heat Transfer for R245fa in a 2.32-mm Tube

Experimental two-phase frictional pressure drop and flow boiling heat transfer results are presented for a horizontal 2.32-mm ID stainless-steel tube using R245fa as working fluid. The frictional pressure drop data was obtained under adiabatic and diabatic conditions. Experiments were performed for mass velocities ranging from 100 to 700 kg m−2 s−1 , heat flux from 0 to 55 kW m−2 , exit saturation temperatures of 31 and 41◦C, and vapor qualities from 0.10 to 0.99. Pressures drop gradients and heat transfer coefficients ranging from 1 to 70 kPa m−1 and from 1 to 7 kW m−2 K−1 were measured. It was found that the heat transfer coefficient is a strong function of the heat flux, mass velocity, and vapor quality. Five frictional pressure drop predictive methods were compared against the experimental database. The Cioncolini et al. (2009) method was found to work the best. Six flow boiling heat transfer predictive methods were also compared against the present database. Liu and Winterton (1991), Zhang et al. (2004), and Saitoh et al. (2007) were ranked as the best methods. They predicted the experimental flow boiling heat transfer data with an average error around 19%.

Steady incompressible flow of cohesionless granular materials through a wedge-shaped hopper: Frictional 14kinetic solution to the smooth wall, radial gravity problem

Hybrid frictional-kinetic equations are used to predict the velocity, grain temperature, and stress fields in hoppers. A suitable choice of dimensionless variables permits the pseudo-thermal energy balance to be decoupled from the momentum balance. These balances contain a small parameter, which is analogous to a reciprocal Reynolds number. Hence an approximate semi-analytical solution is constructed using perturbation methods. The energy balance is solved using the method of matched asymptotic expansions. The effect of heat conduction is confined to a very thin boundary layer near the exit, where it causes a marginal change in the temperature. Outside this layer, the temperature T increases rapidly as the radial coordinate r decreases. In particular, the conduction-free energy balance yields an asymptotic solution, valid for small values of r, of the form T proportional r-4. There is a corresponding increase in the kinetic stresses, which attain their maximum values at the hopper exit. The momentum balance is solved by a regular perturbation method. The contribution of the kinetic stresses is important only in a small region near the exit, where the frictional stresses tend to zero. Therefore, the discharge rate is only about 2.3% lower than the frictional value, for typical parameter values. As in the frictional case, the discharge rate for deep hoppers is found to be independent of the head of material.

Velocity profiles and frictional pressure drop for shear thinning materials in lid-driven cavities with fully developed axial flow

A finite element numerical study has been carried out on the isothermal flow of power law fluids in lid-driven cavities with axial throughflow. The effects of the tangential flow Reynolds number (Re-U), axial flow Reynolds number (Re-W), cavity aspect ratio and shear thinning property of the fluids on tangential and axial velocity distributions and the frictional pressure drop are studied. Where comparison is possible, very good agreement is found between current numerical results and published asymptotic and numerical results. For shear thinning materials in long thin cavities in the tangential flow dominated flow regime, the numerical results show that the frictional pressure drop lies between two extreme conditions, namely the results for duct flow and analytical results from lubrication theory. For shear thinning materials in a lid-driven cavity, the interaction between the tangential flow and axial flow is very complex because the flow is dependent on the flow Reynolds numbers and the ratio of the average axial velocity and the lid velocity. For both Newtonian and shear thinning fluids, the axial velocity peak is shifted and the frictional pressure drop is increased with increasing tangential flow Reynolds number. The results are highly relevant to industrial devices such as screw extruders and scraped surface heat exchangers. (c) 2006 Elsevier Ltd. All rights reserved.