Abstract: Additive Friction Stir Manufacturing, or AFSM, is a new industrial process that follows the emergence of friction-based processes. The AFSM process is a solid-state additive process using the energy produced by the friction at the interface between a rotating non-consumable tool and a substrate. Friction depends on various parameters like axial force, rotation speed or friction coefficient. The feeder material is a metallic rod that flows through a hole in the tool. There is still a lack in understanding of the physical phenomena taking place during the process. This research aims at a better AFSM process understanding and implementation, thanks to numerical simulation and experimental validation performed on a prototype effector. Such an approach is considered a promising way for studying the influence of the process parameters and to finally identify a process window that seems relevant. The deposition of material through the AFSM process takes place in several phases. In chronological order these phases are the docking phase, the dwell time phase, the deposition phase, and the removal phase. The present work focuses on the dwell time phase that enables the temperature rise of the system due to pure friction. An analytic modeling of heat generation based on friction considers as main parameters the rotational speed and the contact pressure. Another parameter considered influential is the friction coefficient assumed to be variable, due to the self-lubrication of the system with the rise in temperature or the materials in contact roughness smoothing over time. This study proposes through a numerical modeling followed by an experimental validation to question the influence of the various input parameters on the dwell time phase. Rotation speed, temperature, spindle torque and axial force are the main monitored parameters during experimentations and serve as reference data for the calibration of the numerical model. This research shows that the geometry of the tool as well as fluctuations of the input parameters like axial force and rotational speed are very influential on the temperature reached and/or the time required to reach the targeted temperature. The main outcome is the prediction of a process window which is a key result for a more efficient process implementation.
Abstract: Current collection quality is one of the limiting factors when increasing trains movement speed in the rail sector. With the movement speed growth, the impact forces on the current collector from the rolling stock and the aerodynamic influence increase, which leads to the spread in the contact pressure values, separation of the current collector head from the contact wire, contact arcing and excessive wear of the contact elements. The upcoming trend in resolving this issue is the use of the automatic control systems providing stabilization of the contact pressure value. The present paper considers the features of the contemporary automatic control systems of the current collector’s pressure; their major disadvantages have been stated. A scheme of current collector pressure automatic control has been proposed, distinguished by a proactive influence on undesirable effects. A mathematical model of contact strips wearing has been presented, obtained in accordance with the provisions of the central composition rotatable design program. The analysis of the obtained dependencies has been carried out. The procedures for determining the optimal current collector pressure on the contact wire and the pressure control principle in the pneumatic drive have been described.
Abstract: Power generation effect, obtained by inserting a piezo- electric sheet in the backlash clearance of a circular arc helical gear, is evaluated. Such type of screw gear is preferred since, in comparison with the involute tooth profile, the circular arc profile leads to reduced stress-concentration effects, and improved life of the piezoelectric film. Firstly, geometry of the circular arc helical gear, and properties of the piezoelectric sheet are presented. Then, description of the test-rig, consisted of a right-hand thread gear meshing with a left-hand thread gear, and the voltage measurement procedure are given. After creating the tridimensional (3D) model of the meshing gears in SolidWorks, they are 3D-printed in acrylonitrile butadiene styrene (ABS) resin. Variation of the generated voltage versus time, during a meshing cycle of the circular arc helical gear, is measured for various values of the center distance. Then, the change of the maximal, minimal, and peak-to-peak voltage versus the center distance is illustrated. Optimal center distance of the gear, to achieve voltage maximization, is found and its significance is discussed. Such results prove that the contact pressure of the meshing gears can be measured, and also, the electrical power can be generated by employing the proposed technique.
Abstract: This paper aims at experimental and numerical investigation of springback behavior of sheet metals during L-bending process with emphasis on Stribeck-type friction modeling. The coefficient of friction in Stribeck curve depends on sliding velocity and contact pressure. The springback behavior of mild steel and aluminum alloy 6022-T4 sheets was studied experimentally and using numerical simulations with ABAQUS software with two types of friction model: Coulomb friction and Stribeck friction. The influence of forming speed on springback behavior was studied experimentally and numerically. The results showed that Stribeck-type friction model has better results in predicting springback in sheet metal forming. The FE prediction error for mild steel and 6022-T4 AA is 23.8%, 25.5% respectively, using Coulomb friction model and 11%, 13% respectively, using Stribeck friction model. These results show that Stribeck model is suitable for simulation of sheet metal forming especially at higher forming speed.
Abstract: The numerical simulation of the crack welding process is reported in this paper. The thermo-electro-structural coupled-field finite element analysis is adopted to investigate the welding process of crack surfaces. In the simulation, the pressure-dependent and temperature-dependent electrical contact conditions are considered. From the results, the crack surfaces can melt and weld together under the compressive load and electric current. The contact pressure effect must be considered in the finite element analysis to obtain more practical results.
Abstract: Railway vehicle wheels are designed to operate in harsh environments and to withstand high hydrostatic contact pressures. This situation may result in critical circumstances, in particular wheel breakage. This paper presents a time history of a series of broken wheels during a time interval [2007-2008] belongs to locomotive fleet on Iranian Railways. Such fractures in locomotive wheels never reported before. Due to the importance of this issue, a research study has been launched to find the potential reasons of this problem. The authors introduce a FEM model to indicate how and where the wheels could have been affected during their operation. Then, the modeling results are presented and discussed in detail.
Abstract: The tribological outcomes of micro dent are found to be outstanding in many engineering and natural surfaces. Ceramic (Al2O3) is considered one of the most potential material to bearing surfaces particularly, artificial hip or knee implant. A well-defined micro dent on alumina oxide interface could further decrease friction and wear rate, thus increase their stability and durability. In this study we fabricated circular micro dent surface profiles (Dia: 400µm, Depth 20µm, P: 1.5mm; Dia: 400µm, Depth 20µm, P: 2mm) on pure Al2O3 (99.6%) substrate by using a micro tool machines. A preliminary tribological experiment was carried out to compare friction coefficient of these fabricated dent surfaces with that of non-textured surfaces. The experiment was carried on well know pin-on-disk specimens while other experimental parameters such as hertz pressure, speed, lubrication, and temperature were maintained to standard of simulated hip joints condition. The experiment results revealed that micro dent surface texture reduced 15%, 8% and 4% friction coefficient under 0.132,0.162, 0.187 GPa contact pressure respectively. Since this is a preliminary tribological study, we will pursue further experiments considering higher ranges of dent profiles and longer run experiments. However, the preliminary results confirmed the suitability of fabricating dent profile to ceramic surfaces by using micro tooling, and also their improved tribological performance in simulated hip joints.
Abstract: The feasibility of applying a simple and cost effective sliding friction testing apparatus to study the friction behaviour of a clutch facing material, effected by the variation of temperature and contact pressure, was investigated. It was found that the method used in this work was able to give a convenient and cost effective measurement of friction coefficients and their transitions of a clutch facing material. The obtained results will be useful for the development process of new facing materials.
Abstract: In a metal forming process, the friction between the
material and the tools influences the process by modifying the stress
distribution of the workpiece. This frictional behaviour is often taken
into account by using a constant coefficient of friction in the finite
element simulations of sheet metal forming processes. However,
friction coefficient varies in time and space with many parameters.
The Stribeck friction model is investigated in this study to predict
springback behaviour of AA6061-T4 sheets during V-bending
process. The coefficient of friction in Stribeck curve depends on
sliding velocity and contact pressure. The plane-strain bending
process is simulated in ABAQUS/Standard. We compared the
computed punch load-stroke curves and springback related to the
constant coefficient of friction with the defined friction model. The
results clearly showed that the new friction model provides better
agreement between experiments and results of numerical simulations.
The influence of friction models on stress distribution in the
workpiece is also studied numerically
Abstract: Evaluation of contact pressure, surface and
subsurface contact stresses are essential to know the functional
response of surface coatings and the contact behavior mainly depends
on surface roughness, material property, thickness of layer and the
manner of loading. Contact parameter evaluation of real rough
surface contacts mostly relies on statistical single asperity contact
approaches. In this work, a three dimensional layered solid rough
surface in contact with a rigid flat is modeled and analyzed using
finite element method. The rough surface of layered solid is
generated by FFT approach. The generated rough surface is exported
to a finite element method based ANSYS package through which the
bottom up solid modeling is employed to create a deformable solid
model with a layered solid rough surface on top. The discretization
and contact analysis are carried by using the same ANSYS package.
The elastic, elastoplastic and plastic deformations are continuous in
the present finite element method unlike many other contact models.
The Young-s modulus to yield strength ratio of layer is varied in the
present work to observe the contact parameters effect while keeping
the surface roughness and substrate material properties as constant.
The contacting asperities attain elastic, elastoplastic and plastic states
with their continuity and asperity interaction phenomena is inherently
included. The resultant contact parameters show that neighboring
asperity interaction and the Young-s modulus to yield strength ratio
of layer influence the bulk deformation consequently affect the
interface strength.
Abstract: In this study, the contact problem of a layered composite which consists of two materials with different elastic constants and heights resting on two rigid flat supports with sharp edges is considered. The effect of gravity is neglected. While friction between the layers is taken into account, it is assumed that there is no friction between the supports and the layered composite so that only compressive tractions can be transmitted across the interface. The layered composite is subjected to a uniform clamping pressure over a finite portion of its top surface. The problem is reduced to a singular integral equation in which the contact pressure is the unknown function. The singular integral equation is evaluated numerically and the results for various dimensionless quantities are presented in graphical forms.
Abstract: This paper presents the influence of preloading on a)
the contact tractions, b) slip levels and c) stresses at the dovetail
blade-disc interface of an aero-engine through a three-dimensional
(3D) finite element (FE) modeling and analysis. The preloading is
applied by an interference fit at the dovetail interface and the bulk
loading is applied through the rotational speed of rotor. Preloading at
the dovetail interface reduces the peak contact pressure developed
due to bulk loading up to 35%, and reduces the peak contact pressure
and stress difference between top and bottom contact edges.
Increasing the level of preloading reduces the cyclic stress amplitude
at the interface up to certain values of preload and as a consequence,
an improvement in fatigue life could be expected. Fretting damage,
due to vibration and wind milling effect during engine ground
condition, can be minimized by preloading the dovetail interface.
Abstract: Modeling of the dynamic behavior and motion are
renewed interest in the improved tractive performance of an
intelligent air-cushion tracked vehicle (IACTV). This paper presents
a new dynamical model for the forces on the developed small scale
intelligent air-cushion tracked vehicle moving over swamp peat. The
air cushion system partially supports the 25 % of vehicle total weight
in order to make the vehicle ground contact pressure 7 kN/m2. As the
air-cushion support system can adjust automatically on the terrain, so
the vehicle can move over the terrain without any risks. The springdamper
system is used with the vehicle body to control the aircushion
support system on any undulating terrain by making the
system sinusoidal form. Experiments have been carried out to
investigate the relationships among tractive efficiency, slippage,
traction coefficient, load distribution ratio, tractive effort, motion
resistance and power consumption in given terrain conditions.
Experiment and simulation results show that air-cushion system
improves the vehicle performance by keeping traction coefficient of
71% and tractive efficiency of 62% and the developed model can
meet the demand of transport efficiency with the optimal power
consumption.