Abstract: Cathodic plasma electrolysis (CPE) is used to create surface textures on cast iron samples for improving the tribological properties. Micro craters with confined size distribution were successfully formed by CPE process. These craters can generate extra hydrodynamic pressure that separates two sliding surfaces, increase the oil film thickness and accelerate the transition from boundary to mixed lubrication. It was found that the optimal crater size was 1.7 μm, at which the maximum lubrication efficiency was achieved. The Taguchi method was used to optimize the process parameters (voltage and roughness) for CPE surface texturing. The orthogonal array and the signal-to-noise ratio were employed to study the effect of each process parameter on the coefficient of friction. The results showed that with higher voltage and lower roughness, the lower friction coefficient can be obtained, and thus the lubrication can be more efficiently used for friction reduction.
Abstract: High cycle fatigue comprising up to 107 load cycles has been the subject of many studies, and the behavior of many materials was recorded adequately in this regime. However, many applications involve larger numbers of load cycles during the lifetime of machine components. In this ultra-high cycle regime, other failure mechanisms play, and the concept of a fatigue endurance limit (assumed for materials such as steel) is often an oversimplification of reality. When machine component design demands a high geometrical complexity, cast iron grades become interesting candidate materials. Grey cast iron is known for its low cost, high compressive strength, and good damping properties. However, the ultra-high cycle fatigue behavior of cast iron is poorly documented. The current work focuses on the ultra-high cycle fatigue behavior of EN-GJL-250 (GG25) grey cast iron by developing an ultrasonic (20 kHz) fatigue testing system. Moreover, the testing machine is instrumented to measure the temperature and the displacement of the specimen, and to control the temperature. The high resonance frequency allowed to assess the behavior of the cast iron of interest within a matter of days for ultra-high numbers of cycles, and repeat the tests to quantify the natural scatter in fatigue resistance.
Abstract: Brakes are one of the most important safety and performance components in automobiles and airplanes. Development of brakes has mainly focused on increasing braking power and stability. Nowadays, brake noise, vibration and harshness (NVH) together with brake dust emission and pad life are very important to vehicle drivers. The main objective of this research is to define the relationship between compressibility of friction materials and their tendency to generate vibration. An experimental study of the friction-induced vibration obtained by the disc brake system of a passenger car is conducted. Three commercial brake pad materials from different manufacturers are tested and evaluated under various brake conditions against cast iron disc brake. First of all, compressibility test for the brake friction material are measured for each pad. Then, brake dynamometer is used to simulate and reproduce actual vehicle braking conditions. Finally, a comparison between the three pad specimens is conducted. The results showed that compressibility have a very significant effect on reduction the vibration occurrence.
Abstract: In this study, an approach to identify factors affecting on surface roughness in a machining process is presented. This study is based on 81 data about surface roughness over a wide range of cutting tools (conventional, cutting tool with holes, cutting tool with composite material), workpiece materials (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). A single decision tree (SDT) analysis was done to identify factors for predicting a model of surface roughness, and the CART algorithm was employed for building and evaluating regression tree. Results show that a single decision tree is better than traditional regression models with higher rate and forecast accuracy and strong value.
Abstract: The machinability of workpieces (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron) in turning operation has been carried out using different types of cutting tool (conventional, cutting tool with holes in toolholder and cutting tool filled up with composite material) under dry conditions on a turning machine at different stages of spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). Experimentation was performed as per Taguchi’s orthogonal array. To evaluate the relative importance of factors affecting surface roughness the single decision tree (SDT), Decision tree forest (DTF) and Group method of data handling (GMDH) were applied.
Abstract: Vibration during machining process is crucial since it affects cutting tool, machine, and workpiece leading to a tool wear, tool breakage, and an unacceptable surface roughness. This paper applies a nonparametric statistical method, single decision tree (SDT), to identify factors affecting on vibration in machining process. Workpiece material (AISI 1045 Steel, AA2024 Aluminum alloy, A48-class30 Gray Cast Iron), cutting tool (conventional, cutting tool with holes in toolholder, cutting tool filled up with epoxy-granite), tool overhang (41-65 mm), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev) and depth of cut (0.05-0.15 mm) were used as input variables, while vibration was the output parameter. It is concluded that workpiece material is the most important parameters for natural frequency followed by cutting tool and overhang.
Abstract: Partially lubricated sliding wear behaviour of a zinc-based alloy reinforced with 10wt% SiC particles has been studied as a function of applied load and solid lubricant particle size and has been compared with that of matrix alloy and conventionally used grey cast iron. The wear tests were conducted at the sliding velocities of 2.1m/sec in various partial lubricated conditions using pin on disc machine as per ASTM G-99-05. Base oil (SAE 20W-40) or mixture of the base oil with 5wt% graphite of particle sizes (7-10 µm) and (100 µm) were used for creating lubricated conditions. The matrix alloy revealed primary dendrites of a and eutectoid a + h and Î phases in the Inter dendritic regions. Similar microstructure has been depicted by the composite with an additional presence of the dispersoid SiC particles. In the case of cast iron, flakes of graphite were observed in the matrix; the latter comprised of (majority of) pearlite and (limited quantity of) ferrite. Results show a large improvement in wear resistance of the zinc-based alloy after reinforcement with SiC particles. The cast iron shows intermediate response between the matrix alloy and composite. The solid lubrication improved the wear resistance and friction behaviour of both the reinforced and base alloy. Moreover, minimum wear rate is obtained in oil+ 5wt % graphite (7-10 µm) lubricated environment for the matrix alloy and composite while for cast iron addition of solid lubricant increases the wear rate and minimum wear rate is obtained in case of oil lubricated environment. The cast iron experienced higher frictional heating than the matrix alloy and composite in all the cases especially at higher load condition. As far as friction coefficient is concerned, a mixed trend of behaviour was noted. The wear rate and frictional heating increased with load while friction coefficient was affected in an opposite manner. Test duration influenced the frictional heating and friction coefficient of the samples in a mixed manner.
Abstract: The aim of this study is to evaluate the influence of raw material composition on the microstructure, mechanical and fatigue properties and micromechanisms of failure of nodular cast iron. In order to evaluate the influence of charge composition, the structural analysis, mechanical and fatigue tests and microfractographic analysis were carried out on specimens of ten melts with different charge compositions. The basic charge of individual melts was formed by different ratio of pig iron and steel scrap and by different additive for regulation of chemical composition (silicon carbide or ferrosilicon). The results show differences in mechanical and fatigue properties, which are connected with the microstructure. SiC additive positively influences microstructure. Consequently, mechanical and fatigue properties of nodular cast iron are improved, especially in the melts with higher ratio of steel scrap in the charge.
Abstract: For briquetting of metal chips are used hydraulic and
mechanical presses. The density of the briquettes in this case is about
60% - 70 % on the density of solid metal. In this work are presented
the results of experimental studies for briquetting of metal chips, by
using a new technology for impact briquetting. The used chips are by
Armco iron, steel, cast iron, copper, aluminum and brass. It has been
found that: (i) in a controlled impact the density of the briquettes can
be increases up to 30%; (ii) at the same specific impact energy Es
(J/sm3) the density of the briquettes increases with increasing of the
impact velocity; (iii), realization of the repeated impact leads to
decrease of chips density, which can be explained by distribution of
elastic waves in the briquette.
Abstract: In present global scenario, aluminum alloys are
coining the attention of many innovators as competing structural
materials for automotive and space applications. Comparing to other
challenging alloys, especially, 7xxx series aluminum alloys have
been studied seriously because of benefits such as moderate strength;
better deforming characteristics and affordable cost. It is expected
that substitution of aluminum alloys for steels will result in great
improvements in energy economy, durability and recyclability.
However, it is necessary to improve the strength and the formability
levels at low temperatures in aluminum alloys for still better
applications. Aluminum–Zinc–Magnesium with or without other
wetting agent denoted as 7XXX series alloys are medium strength
heat treatable alloys. In addition to Zn, Mg as major alloying
additions, Cu, Mn and Si are the other solute elements which
contribute for the improvement in mechanical properties by suitable
heat treatment process. Subjecting to suitable treatments like age
hardening or cold deformation assisted heat treatments; known as low
temperature thermomechanical treatments (LTMT) the challenging
properties might be incorporated. T6 is the age hardening or
precipitation hardening process with artificial aging cycle whereas T8
comprises of LTMT treatment aged artificially with X% cold
deformation. When the cold deformation is provided after solution
treatment, there is increase in hardness related properties such as
wear resistance, yield and ultimate strength, toughness with the
expense of ductility. During precipitation hardening both hardness
and strength of the samples are increasing. The hardness value may
further improve when room temperature deformation is positively
supported with age hardening known as thermomechanical treatment.
It is intended to perform heat treatment and evaluate hardness, tensile
strength, wear resistance and distribution pattern of reinforcement in
the matrix. 2 to 2.5 and 3 to 3.5 times increase in hardness is reported
in age hardening and LTMT treatments respectively as compared to
as-cast composite. There was better distribution of reinforcements in
the matrix, nearly two fold increase in strength levels and up to 5
times increase in wear resistance are also observed in the present
study.
Abstract: The approach in analyzing defects on different pipe lines is conducted through Failure Assessment Diagram (FAD). These methods of analyses have further extended in recent years. This approach is used to identify and stress out a solution for the defects which randomly occur with gas pipes such are corrosion defects, gauge defects, and combination of defects where gauge and dents are included. Few of the defects are to be analyzed in this paper where our main focus will be the fracture of cast Iron pipes, elastic-plastic failure and plastic collapse of X52 steel pipes for gas transport. We need to conduct a calculation of probability of the defects in order to predict and avoid such costly defects.
Abstract: This paper presents a novel three-phase utility
frequency to high frequency soft switching power conversion circuit
with dual mode pulse width modulation and pulse density modulation
for high power induction heating applications as melting of steel and
non ferrous metals, annealing of metals, surface hardening of steel
and cast iron work pieces and hot water producers, steamers and
super heated steamers. This high frequency power conversion circuit
can operate from three-phase systems to produce high current for
high power induction heating applications under the principles of
ZVS and it can regulate its ac output power from the rated value to a
low power level. A dual mode modulation control scheme based on
high frequency PWM in synchronization with the utility frequency
positive and negative half cycles for the proposed high frequency
conversion circuit and utility frequency pulse density modulation is
produced to extend its soft switching operating range for wide ac
output power regulation. A dual packs heat exchanger assembly is
designed to be used in consumer and industrial fluid pipeline systems
and it is proved to be suitable for the hot water, steam and super
heated steam producers. Experiment and simulation results are given
in this paper to verify the operation principles of the proposed ac
conversion circuit and to evaluate its power regulation and
conversion efficiency. Also, the paper presents a mutual coupling
model of the induction heating load instead of equivalent transformer
circuit model.
Abstract: Particulate reinforced metal matrix composites
(MMCs) are potential materials for various applications due to their
advantageous of physical and mechanical properties. This paper
presents a study on the performance of stir cast Al2O3 SiC reinforced
metal matrix composite materials. The results indicate that the
composite materials exhibit improved physical and mechanical
properties, such as, low coefficient of thermal expansion, high
ultimate tensile strength, high impact strength, and hardness. It has
been found that with the increase of weight percentage of
reinforcement particles in the aluminium metal matrix, the new
material exhibits lower wear rate against abrasive wearing. Being
extremely lighter than the conventional gray cast iron material, the
Al-Al2O3 and Al-SiC composites could be potential green materials
for applications in the automobile industry, for instance, in making
car disc brake rotors.
Abstract: The exploration of this paper will focus on the Cshaped
transition curve. This curve is designed by using the concept
of circle to circle where one circle lies inside other. The degree of
smoothness employed is curvature continuity. The function used in
designing the C-curve is Bézier-like cubic function. This function has
a low degree, flexible for the interactive design of curves and
surfaces and has a shape parameter. The shape parameter is used to
control the C-shape curve. Once the C-shaped curve design is
completed, this curve will be applied to design spur gear tooth. After
the tooth design procedure is finished, the design will be analyzed by
using Finite Element Analysis (FEA). This analysis is used to find
out the applicability of the tooth design and the gear material that
chosen. In this research, Cast Iron 4.5 % Carbon, ASTM A-48 is
selected as a gear material.