Scholarly

Evaluation of PTFE Composites with Mineral Tailing Considering Friction, Wear and Cost

Year: 2016 Volume: 10 Issue: 1 89 - 93 Pages

Abstract: The tribological test with Pin-On-Disc configuration measures friction and wear properties in dry or lubricated sliding surfaces of a variety of materials and coatings. Polymeric matrix composites loaded with mineral filler were used, 1%, 3%, 10%, 30%, and 50% mass percentage of filler, to reduce the material cost by using mineral tailings. Using a pin-on-disc tribometer to quantify coefficient of friction and wear resistance of the specimens. The parameters known to performing the test were 300 rpm rotation, normal load of 16N and duration of 33.5 minutes. The composite with 10% mineral filler performed better, considering that the wear resistance was good when compared to the other compositions and an average low coefficient of friction, in the order of μ ≤ 0.15.

Effective Work Roll Cooling toward Stand Reduction in Hot Strip Process

Year: 2014 Volume: 8 Issue: 7 1339 - 1344 Pages

Abstract: The maintenance of work rolls in hot strip processing has been lengthy and difficult tasks for hot strip manufacturer because heavy work rolls have to be taken out of the production line, which could take hours. One way to increase the time between maintenance is to improve the effectiveness of the work roll cooling system such that the wear and tear more slowly occurs, while the operation cost is kept low. Therefore, this study aims to improve the work roll cooling system by providing the manufacturer the relationship between the work-roll temperature reduced by cooling and the water flow that can help manufacturer determining the more effective water flow of the cooling system. The relationship is found using simulation with a systematic process adjustment so that the satisfying quality of product is achieved. Results suggest that the manufacturer could reduce the water flow by 9% with roughly the same performance. With the same process adjustment, the feasibility of finishing-mill-stand reduction is also investigated. Results suggest its possibility.

High Specific Speed in Circulating Water Pump Can Cause Cavitation, Noise and Vibration

Year: 2015 Volume: 9 Issue: 12 2147 - 2159 Pages

Authors:
Chandra Gupt Porwal

Abstract: Excessive vibration means increased wear, increased repair efforts, bad product selection & quality and high energy consumption. This may be sometimes experienced by cavitation or suction/discharge recirculation which could occur only when net positive suction head available NPSHA drops below the net positive suction head required NPSHR. Cavitation can cause axial surging, if it is excessive, will damage mechanical seals, bearings, possibly other pump components frequently, and shorten the life of the impeller. Efforts have been made to explain Suction Energy (SE), Specific Speed (Ns), Suction Specific Speed (Nss), NPSHA, NPSHR & their significance, possible reasons of cavitation /internal recirculation, its diagnostics and remedial measures to arrest and prevent cavitation in this paper. A case study is presented by the author highlighting that the root cause of unwanted noise and vibration is due to cavitation, caused by high specific speeds or inadequate net- positive suction head available which results in damages to material surfaces of impeller & suction bells and degradation of machine performance, its capacity and efficiency too. Author strongly recommends revisiting the technical specifications of CW pumps to provide sufficient NPSH margin ratios >1.5, for future projects and Nss be limited to 8500 - 9000 for cavitation free operation.

Dynamic Simulation of IC Engine Bearings for Fault Detection and Wear Prediction

Year: 2015 Volume: 9 Issue: 11 1993 - 2002 Pages

Abstract: Journal bearings used in IC engines are prone to premature failures and are likely to fail earlier than the rated life due to highly impulsive and unstable operating conditions and frequent starts/stops. Vibration signature extraction and wear debris analysis techniques are prevalent in industry for condition monitoring of rotary machinery. However, both techniques involve a great deal of technical expertise, time, and cost. Limited literature is available on the application of these techniques for fault detection in reciprocating machinery, due to the complex nature of impact forces that confounds the extraction of fault signals for vibration-based analysis and wear prediction. In present study, a simulation model was developed to investigate the bearing wear behaviour, resulting because of different operating conditions, to complement the vibration analysis. In current simulation, the dynamics of the engine was established first, based on which the hydrodynamic journal bearing forces were evaluated by numerical solution of the Reynold’s equation. In addition, the essential outputs of interest in this study, critical to determine wear rates are the tangential velocity and oil film thickness between the journals and bearing sleeve, which if not maintained appropriately, have a detrimental effect on the bearing performance. Archard’s wear prediction model was used in the simulation to calculate the wear rate of bearings with specific location information as all determinative parameters were obtained with reference to crank rotation. Oil film thickness obtained from the model was used as a criterion to determine if the lubrication is sufficient to prevent contact between the journal and bearing thus causing accelerated wear. A limiting value of 1 μm was used as the minimum oil film thickness needed to prevent contact. The increased wear rate with growing severity of operating conditions is analogous and comparable to the rise in amplitude of the squared envelope of the referenced vibration signals. Thus on one hand, the developed model demonstrated its capability to explain wear behaviour and on the other hand it also helps to establish a co-relation between wear based and vibration based analysis. Therefore, the model provides a cost effective and quick approach to predict the impending wear in IC engine bearings under various operating conditions.

Ion Thruster Grid Lifetime Assessment Based on Its Structural Failure

Year: 2015 Volume: 9 Issue: 11 1989 - 1992 Pages

Abstract: This article developed an ion thruster optic system sputter erosion depth numerical 3D model by IFE-PIC (Immersed Finite Element-Particle-in-Cell) and Mont Carlo method, and calculated the downstream surface sputter erosion rate of accelerator grid; compared with LIPS-200 life test data. The results of the numerical model are in reasonable agreement with the measured data. Finally, we predicted the lifetime of the 20cm diameter ion thruster via the erosion data obtained with the model. The ultimate result demonstrated that under normal operating condition, the erosion rate of the grooves wears on the downstream surface of the accelerator grid is 34.6μm⁄1000h, which means the conservative lifetime until structural failure occurring on the accelerator grid is 11500 hours.

Mechanism and Kinetic of Layers Growth: Application to Nitriding of 32CrMoV13 Steel

Year: 2015 Volume: 9 Issue: 12 1387 - 1392 Pages

Authors:
L. Torchane

Abstract: In this work, our goal is to optimize the nitriding treatment at a low-temperature of the steel 32CrMoV13 using gas mixtures of ammonia, nitrogen and hydrogen to improve the mechanical properties of the surface (good wear resistance, friction and corrosion), and of the diffusion layer of the nitrogen (good resistance to fatigue and good tenacity with heart). By limiting our work to the pure iron and to the alloys iron-chromium and iron-chromium-carbon, we have studied the various parameters which manage the nitriding: flow rate and composition of the gaseous phase, the interaction chromium-nitrogen and chromium-carbon by the help of experiments of nitriding realized in the laboratory by thermogravimetry. The acquired knowledge has been applied by the mastery of the growth of the γ' combination layer on the α diffusion layer in the case of the industrial steel 32CrMoV13.

Biodiesel Production from Broiler Chicken Waste

Year: 2015 Volume: 9 Issue: 12 1190 - 1193 Pages

Abstract: Broiler slaughter waste has become a major source of pollution throughout the world. Utilization of broiler slaughter waste by dry rendering process produced Rendered Chicken Oil (RCO), a cheap raw material for biodiesel production and Carcass Meal a feed ingredient for pets and fishes. Conversion of RCO into biodiesel may open new vistas for generating wealth from waste besides controlling the major havoc of environmental pollution. A two-step process to convert RCO to good quality Biodiesel was invented. Acid catalysed esterification of FFA followed by base catalysed transesterification of triglycerides was carried out after meticulously standardizing the methanol molar ratio, catalyst concentration, reaction temperature, and reaction time to obtain the maximum biodiesel yield of 97.62% and lowest glycerol yield of 6.96%. RCO biodiesel blend was tested in a CRDI diesel engine. The results revealed that the blending of commercial diesel with 20% RCO biodiesel (B20) lead to less engine wear, a quieter engine and better fuel economy. The better lubricating qualities of RCO B20 prevented over heating of engine, which prolongs the engine life. RCO B20 can reduce the import of crude oil and substantially reduce the engine emissions as proved by significantly lower smoke levels, thus mitigating climatic changes.

Determination of the Pullout/Holding Strength at the Taper-Trunnion Junction of Hip Implants

Year: 2015 Volume: 9 Issue: 9 727 - 730 Pages

Abstract: Excessive fretting wear at the taper-trunnion junction (trunnionosis) apparently contributes to the high failure rates of hip implants. Implant wear and corrosion lead to the release of metal particulate debris and subsequent release of metal ions at the tapertrunnion surface. This results in a type of metal poisoning referred to as metallosis. The consequences of metal poisoning include; osteolysis (bone loss), osteoarthritis (pain), aseptic loosening of the prosthesis and revision surgery. Follow up after revision surgery, metal debris particles are commonly found in numerous locations. Background: A stable connection between the femoral ball head (taper) and stem (trunnion) is necessary to prevent relative motions and corrosion at the taper junction. Hence, the importance of component assembly cannot be over-emphasized. Therefore, the aim of this study is to determine the influence of head-stem junction assembly by press fitting and the subsequent disengagement/disassembly on the connection strength between the taper ball head and stem. Methods: CoCr femoral heads were assembled with High stainless hydrogen steel stem (trunnion) by Push-in i.e. press fit; and disengaged by pull-out test. The strength and stability of the two connections were evaluated by measuring the head pull-out forces according to ISO 7206-10 standards. Findings: The head-stem junction strength linearly increases with assembly forces.

Ni-B Coating Production on Magnesium Alloy by Electroless Deposition

Year: 2015 Volume: 9 Issue: 6 772 - 775 Pages

Authors:
Ferhat Bülbül

Abstract: The use of magnesium alloys is limited due to their susceptibility to corrosion although they have many attractive physical and mechanical properties. To increase mechanical and corrosion properties of these alloys, many deposition method and coating types are used. Electroless Ni–B coatings have received considerable interest recently due to its unique properties such as cost-effectiveness, thickness uniformity, good wear resistance, lubricity, good ductility and corrosion resistance, excellent solderability and electrical properties and antibacterial property. In this study, electroless Ni-B coating could been deposited on AZ91 magnesium alloy. The obtained coating exhibited a harder and rougher structure than the substrate.

Effect of Polymer Molecular Structures on Properties of Dental Cement Restoratives

Year: 2015 Volume: 9 Issue: 7 585 - 592 Pages

Abstract: The objective of this study was to synthesize and characterize the poly(alkenoic acid)s with different molecular structures, use these polymers to formulate a dental cement restorative, and study the effect of molecular structures on reaction kinetics, viscosity, and mechanical strengths of the formed polymers and cement restoratives. In this study, poly(alkenoic acid)s with different molecular structures were synthesized. The purified polymers were formulated with commercial Fuji II LC glass fillers to form the experimental cement restoratives. The reaction kinetics was studied via 1HNMR spectroscopy. The formed restoratives were evaluated using compressive strength, diametral tensile strength, flexural strength, hardness and wear-resistance tests. Specimens were conditioned in distilled water at 37oC for 24 h prior to testing. Fuji II LC restorative was used as control. The results show that the higher the arm number and initiator concentration, the faster the reaction was. It was also found that the higher the arm number and branching that the polymer had, the lower the viscosity of the polymer in water and the lower the mechanical strengths of the formed restorative. The experimental restoratives were 31-53% in compressive strength, 37- 55% in compressive modulus, 80-126% in diametral tensile strength, 76-94% in flexural strength, 4-21% in fracture toughness and 53-96% in hardness higher than Fuji II LC. For wear test, the experimental restoratives were only 5.4-13% of abrasive and 6.4-12% of attritional wear depths of Fuji II LC in each wear cycle. The aging study also showed that all the experimental restoratives increased their strength continuously during 30 days, unlike Fuji II LC. It is concluded that polymer molecular structures have significant and positive impact on mechanical properties of dental cement restoratives.

Effect of the Workpiece Position on the Manufacturing Tolerances

Year: 2015 Volume: 9 Issue: 11 1943 - 1946 Pages

Abstract: Manufacturing tolerancing is intended to determine the intermediate geometrical and dimensional states of the part during its manufacturing process. These manufacturing dimensions also serve to satisfy not only the functional requirements given in the definition drawing, but also the manufacturing constraints, for example geometrical defects of the machine, vibration and the wear of the cutting tool. The choice of positioning has an important influence on the cost and quality of manufacture. To avoid this problem, a two-step approach has been developed. The first step is dedicated to the determination of the optimum position. As for the second step, a study was carried out for the tightening effect on the tolerance interval.

Chatter Suppression in Boring Process Using Passive Damper

Year: 2015 Volume: 9 Issue: 11 1932 - 1936 Pages

Abstract: During machining process, chatter is an unavoidable phenomenon. Boring bars possess the cantilever shape and due to this, it is subjected to chatter. The adverse effect of chatter includes the increase in temperature which will leads to excess tool wear. To overcome these problems, in this investigation, Cartridge brass (Cu – 70% and Zn – 30%) is passively fixed on the boring bar and also clearance is provided in order to reduce the displacement, tool wear and cutting temperature. A conventional all geared lathe is attached with vibrometer and pyrometer is used to measure the displacement and temperature. The influence of input parameters such as cutting speed, depth of cut and clearance on temperature, tool wear and displacement are investigated for various cutting conditions. From the result, the optimum conditions to obtain better damping in boring process for chatter reduction is identified.

Effect of UV Radiation to Change the Properties of the Composite PA+GF

Year: 2015 Volume: 9 Issue: 10 1224 - 1227 Pages

Abstract: The development of composite materials and the related design and manufacturing technologies is one of the most important advances in the history of materials. Composites are multifunctional materials having unprecedented mechanical and physical properties that can be tailored to meet the requirements of a particular application. Some composites also exhibit great resistance to high-temperature corrosion, oxidation, and wear. Polymers are widely used indoors and outdoors, therefore they are exposed to a chemical environment which may include atmospheric oxygen, acidic fumes, acidic rain, moisture heat and thermal shock, ultra-violet light, high energy radiation, etc. Different polymers are affected differently by these factors even though the amorphous polymers are more sensitive. Ageing is also important and it is defined as the process of deterioration of engineering materials resulting from the combined effects of atmospheric radiation, heat, oxygen, water, microorganisms and other atmospheric factors.

Transformation of Aluminum Unstable Oxyhydroxides in Ultrafine α-Al2O3 in Presence of Various Seeds

Year: 2015 Volume: 9 Issue: 7 907 - 911 Pages

Abstract: Ceramic obtained on the base of aluminum oxide has wide application range, because it has unique properties, for example, wear-resistance, dielectric characteristics, and exploitation ability at high temperatures and in corrosive atmosphere. Low temperature synthesis of α-Al2O3 is energo-economical process and it is topical for developing technologies of corundum ceramics fabrication. In the present work possibilities of low temperature transformation of oxyhydroxides in α-Al2O3, during the presence of small amount of rare–earth elements compounds (also Th, Re), have been discussed. Aluminum unstable oxyhydroxides have been obtained by hydrolysis of aluminium isopropoxide, nitrates, sulphate, and chloride in alkaline environment at 80-90ºC temperatures. β-Al(OH)3 has been received from aluminum powder by ultrasonic development. Drying of oxyhydroxide sol has been conducted with presence of various types seeds, which amount reaches 0,1-0,2% (mas). Neodymium, holmium, thorium, lanthanum, cerium, gadolinium, disprosium nitrates and rhenium carbonyls have been used as seeds and they have been added to the sol specimens in amount of 0.1-0.2% (mas) calculated on metals. Annealing of obtained gels is carried out at 70– 1100ºC for 2 hrs. The same specimen transforms in α-Al2O3 at 1100ºC. At this temperature in case of presence of lanthanum and gadolinium transformation takes place by 70-85%. In case of presence of thorium stabilization of γ-and θ-phases takes place. It is established, that thorium causes inhibition of α-phase generation at 1100ºC, and at the time when in all other doped specimens α-phase is generated at lower temperatures (1000-1050ºC). Synthesis of various type compounds and simultaneous consolidation has developed in the furnace of OXY-GON. Composite materials containing oxide and non-oxide components close to theoretical data have been obtained in this furnace respectively. During the work the following devices have been used: X-ray diffractometer DRON-3M (Cu-Kα, Ni filter, 2º/min), High temperature vacuum furnace OXY-GON, electronic scanning microscopes Nikon ECLIPSE LV 150, NMM-800TRF, planetary mill Pulverisette 7 premium line, SHIMADZU Dynamic Ultra Micro Hardness Tester, DUH-211S, Analysette 12 Dyna sizer.

Innovation in “Low-Tech” Industries: Portuguese Footwear Industry

Year: 2015 Volume: 9 Issue: 9 3190 - 3194 Pages

Abstract: The Portuguese footwear industry had in the last five years a remarkable performance in the exportation values, the trade balance and others economic indicators. After a long period of difficulties and with a strong reduction of companies and employees since 1994 until 2009, the Portuguese footwear industry changed the strategy and is now a success case between the international players of footwear. Only the Italian industry sells footwear with a higher value than the Portuguese and the distance between them is decreasing year by year. This paper analyses how the Portuguese footwear companies innovate and make innovation, according the classification proposed by the Oslo Manual. Also, analyses the strategy follow in the innovation process and shows the linkage between the type of innovation and the strategy of innovation. The research methodology was qualitative and the strategy for data collection was the case study. The qualitative data will be analyzed with the MAXQDA software. The economic results of the footwear companies studied shows differences between all of them and these differences are related with the innovation strategy adopted. The companies focused in product and marketing innovation, oriented to their target market, have higher ratios “turnover per worker” than the companies focused in process innovation. However, all the footwear companies in this “low-tech” industry create value and contribute to a positive foreign trade of 1.310 million euros in 2013. The growth strategies implemented has the participation of the sectorial organizations in several innovative projects. And it’s obvious that cooperation between all of them is a critical element to the performance achieved by the companies and the innovation observed. The Portuguese footwear sector has in the last years an excellent performance (economic results, exportation values, trade balance, brands and international image) and his performance is strongly related with the strategy in innovation followed, the type of innovation and the networks in the cluster. A simplified model, called “Ace of Diamonds”, is proposed by the authors and explains the way how this performance was reached by the seven companies that participate in the study (two of them are the leaders in the setor), and if this model can be used in others traditional and “low-tech” industries.

Effect of Impact Angle on Erosive Abrasive Wear of Ductile and Brittle Materials

Year: 2015 Volume: 9 Issue: 9 1638 - 1642 Pages

Abstract: Erosion and abrasion are wear mechanisms reducing the lifetime of machine elements like valves, pump and pipe systems. Both wear mechanisms are acting at the same time, causing a “Synergy” effect, which leads to a rapid damage of the surface. Different parameters are effective on erosive abrasive wear rate. In this study effect of particle impact angle on wear rate and wear mechanism of ductile and brittle materials was investigated. A new slurry pot was designed for experimental investigation. As abrasive particle, silica sand was used. Particle size was ranking between 200- 500 μm. All tests were carried out in a sand-water mixture of 20% concentration for four hours. Impact velocities of the particles were 4.76 m/s. As ductile material steel St 37 with Vickers Hardness Number (VHN) of 245 and quenched St 37 with 510 VHN was used as brittle material. After wear tests, morphology of the eroded surfaces were investigated for better understanding of the wear mechanisms acting at different impact angles by using Scanning Electron Microscope. The results indicated that wear rate of ductile material was higher than brittle material. Maximum wear rate was observed by ductile material at a particle impact angle of 300 and decreased further by an increase in attack angle. Maximum wear rate by brittle materials was by impact angle of 450 and decreased further up to 900. Ploughing was the dominant wear mechanism by ductile material. Microcracks on the surface were detected by ductile materials, which are nucleation centers for crater formation. Number of craters decreased and depth of craters increased by ductile materials by attack angle higher than 300. Deformation wear mechanism was observed by brittle materials. Number and depth of pits decreased by brittle materials by impact angles higher than 450. At the end it is concluded that wear rate could not be directly related to impact angle of particles due to the different reaction of ductile and brittle materials.

Inhibition of Pipelines Corrosion Using Natural Extracts

Year: 2015 Volume: 9 Issue: 9 1113 - 1117 Pages

Abstract: The present work is aimed at examining carbon steel oil pipelines corrosion using three natural extracts (Eruca Sativa, Rosell and Mango peels) that are used as inhibitors of different concentrations ranging from 0.05-0.1wt. %. Two sulphur compounds are used as corrosion mediums. Weight loss method was used for measuring the corrosion rate of the carbon steel specimens immersed in technical white oil at 100ºC at various time intervals in absence and presence of the two sulphur compounds. The corroded specimens are examined using the chemical wear test, scratch test and hardness test. The scratch test is carried out using scratch loads from 0.5 Kg to 2.0 Kg. The scratch width is obtained at various scratch load and test conditions. The Brinell hardness test is carried out and investigated for both corroded and inhibited specimens. The results showed that three natural extracts can be used as environmentally friendly corrosion inhibitors.

Analysis of Design Structuring and Performance of CPW Fed UWB Antenna in Presence of Human Arm Model

Year: 2014 Volume: 8 Issue: 12 1946 - 1951 Pages

Abstract: A compact Ultra Wide Band (UWB) antenna with coplanar waveguide feed has been designed and results are verified in this paper. The antenna has been designed on FR4 substrate with dielectric constant (εr) of 4.4 and dimensions of 32mm x 26mm x 0.8mm. The presented antenna shows return loss characteristics in the band of 3.1 to 10.6 GHz as prescribed by FCC, USA. Parametric studies have been done and results thus obtained have been presented. Simulated results have been verified on Rohde & Swartz VNA. The measured results are in good agreement with simulated results which make the presented antenna suitable to be used for wearable applications. Performance analysis of antenna has also been shown in the presence of three layered Human Arm model. Results obtained in presence of Human Arm model has been compared with that in free space.

The Impact of Surface Roughness and PTFE/TiF3/FeF3 Additives in Plain ZDDP Oil on the Friction and Wear Behavior Using Thermal and Tribological Analysis under Extreme Pressure Condition

Year: 2014 Volume: 8 Issue: 7 739 - 746 Pages

Abstract: The use of titanium fluoride and iron fluoride (TiF3/FeF3) catalysts in combination with polutetrafluoroethylene (PTFE) in plain zinc- dialkyldithiophosphate (ZDDP) oil is important for the study of engine tribocomponents and is increasingly a strategy to improve the formation of tribofilm and provide low friction and excellent wear protection in reduced phosphorus plain ZDDP oil. The influence of surface roughness and the concentration of TiF3/FeF3/PTFE were investigated using bearing steel samples dipped in lubricant solution at 100°C for two different heating time durations. This paper addresses the effects of water drop contact angle using different surface; finishes after treating them with different lubricant combination. The calculated water drop contact angles were analyzed using Design of Experiment software (DOE) and it was determined that a 0.05 μm Ra surface roughness would provide an excellent TiF3/FeF3/PTFE coating for antiwear resistance as reflected in the Scanning electron microscopy (SEM) images and the tribological testing under extreme pressure conditions. Both friction and wear performance depend greatly on the PTFE/and catalysts in plain ZDDP oil with 0.05 % phosphorous and on the surface finish of bearing steel. The friction and wear reducing effects, which was observed in the tribological tests, indicated a better micro lubrication effect of the 0.05 μm Ra surface roughness treated at 100°C for 24 hours when compared to the 0.1 μm Ra surface roughness with the same treatment.

Air Pollution Control from Rice Shellers - A Case Study

Year: 2015 Volume: 9 Issue: 6 743 - 746 Pages

Authors:
S. M. Ahuja

Abstract: A Rice Sheller is used for obtaining polished white rice from paddy. There are about 3000 Rice Shellers in Punjab and 50000 in India. During the process of shelling lot of dust is emitted from different unit operations like paddy silo, paddy shaker, bucket elevators, huskers, paddy separator etc. These dust emissions have adverse effect on the health of the workers and the wear and tear of the shelling machinery is fast. All the dust emissions spewing out of these unit operations of a rice Sheller were contained by providing suitable hoods and enclosures while ensuring their workability. These were sucked by providing an induced draft fan followed by a high efficiency cyclone separator that has got an overall dust collection efficiency of more than 90%. This cyclone separator replaced two cyclone separators and a filter bag house, which the Rice Sheller was already having. The dust concentration in the stack after the installation of cyclone separator is well within the stipulated standards. Besides controlling pollution, there is improvement in the quality of products like bran and the life of shelling machinery has enhanced. The payback period of this technology is less than four shelling months.

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