Disc Machine Research Articles

WEAR AND CORROSION STUDIES ON FERRITIC STAINLESS STEEL (SS 409M)

The wear and corrosion behavior of SS 409M have been evaluated and compared with Mild steel ferritic stainless steel SS 430, and austenitic stainless steel SS 304. The SS 409M is a utility grade ferritic stainless steel, and has a very low Ni percentage less than 0.30%. Annealed SS 409M contains ferrite and low percentage of tempered martensite whereas normalized SS 409M has low ferrite and higher percentage of tempered martensite. The manufacturing cost for this steel is low as compared to other grades of stainless steel but it has high strength with excellent corrosion resistance, abrasion resistance and can be easily fabricated. Thus SS 409M has been found to be a suitable material for replacing mild steel in structural applications. SS 409M has also got good wear resistance and this can be considered as an alternate material for mild steel in the railway wagons, track armor, and chemical tanks. The dry wear test has been carried out using the pin on disc machine for all the specimens. The results show that 409M has higher wear resistance as compared to mild steel and SS 430. The corrosion test has been carried out using the potentiostat for SS 409M both in annealed and in the normalized condition and the results are compared with SS 430 and SS 304. SS 304 and SS 430 stainless steels show excellent corrosion resistance while SS 409M both in annealed and in normalized condition reveal higher corrosion resistance than mild steel. Results are discussed with published work on these steels.

Analysis of the effect of different types of additives added to a low viscosity polyalphaolefin base on micropitting

This article explores the influence of the appearance of micropitting in different types of additives added to a polyalphaolefinic low-viscosity base oil, namely a polyalphaolefin PAO6. Additives commonly used in mechanical transmissions by gears were used, i.e., extreme pressure, anti-wear and friction modifier.For the study, we have conducted a series of tests on a disc machine under various operating conditions. The temperature and surface roughness of the test specimens have been changed in order to study different lubricant specific film thicknesses, as the last is one of the most influential parameters on the appearance of micropitting.Tests have shown the important influence of the additives, and their concentration, in the development of micropitting and their associated effects, depending on the operating conditions of the contact. Along with the study of the effect of additives, the influence of specific film thickness on the friction coefficient, surface appearance, conditions of lubrication, and wear was also studied.

Evaluation of Palm Stearin as Shaft Lubricant

The shaft is very important which have been used to transmit the power. Over a longer period, shaft may be worn. Hence to reduce the worn effect, the shaft must be lubricated. Nowadays, Malaysia is being one of the biggest producers and exporters of palm oil product. Thus, by using this advantage, Palm Stearin which is solid fraction obtained by the fractionation of palm oil after crystallization is being used as a shaft lubricant. This research has been conducted to determine the frictional force of rotational shaft and to observe the wear and surface roughness. The experiment is conducted within 20 mins for each speed which are variance from 200 rpm to 1200 rpm with increment by 200 rpm by using modified pin on disc machine. Based on the result, Palm Stearin show the good performance which is has the lower frictional force compare with two others industrial lubricants. Besides that, surface roughness and wear of shaft did show any significance difference for before and after the experiments. It can be conclude that the Palm Stearin has the lower frictional force which is in the range from 2 N to 4.1 N.

Identification of the characteristics of motorcycle and scooter tyres in the presence of large variations in inflation pressure

Stability and safety of road vehicles are largely affected by tyre properties. Single-track vehicles are characterised by weakly damped modes of vibration (weave and wobble) and therefore this phenomenon is even more important. This article focuses on the study of both steady-state and transient properties of motorcycle and scooter tyres in the presence of very low and very high inflation pressures. The steady-state properties are defined as lateral forces (side-slip and camber forces) and yaw torques (self-aligning and twisting). The transient properties are described in terms of relaxation length, which represents the distance needed to reach a certain percentage of the steady-state value of the tyre force. Experimental tests are carried out on a specific rotating disk machine. Three sets of tyres are analysed. Steady-state properties are measured by increasing step by step the values of camber and side-slip angles. Transient properties are studied carrying out tests with harmonic side-slip excitation and measuring the phase lag between the excitation (input) and the tyre force (output). Experimental results show important variations in tyre properties with inflation pressure with general trends of all the tested tyres and particular features related to the tyre's geometry. After the analysis and discussion of experimental results, the measured data are fitted by means of a specific version of the Magic Formula. The dependence of the Magic Formula's coefficients on inflation pressure is analysed and interpolation curves are given.

Two Body Wear of Newly Introduced Nanocomposite Teeth and Cross Linked Four Layered Acrylic Teeth: a Comparitive In Vitro Study.

Wear of complete denture teeth results in compromise in denture esthetics and functions. To counteract this problem, artificial teeth with increased wear resistance had been introduced in the market such as nanocomposite teeth. The purpose of this study was to compare the amount of wear between nanocomposite teeth and acrylic teeth. Fifteen specimens were chosen from each group namely the nanocomposite teeth (SR_-PHONARES) and the acrylic teeth (ACRY PLUS). Maxillary premolar was only chosen for testing and the samples were customized according to the specifications of the pin on disc machine. Pin on disc machine is a two body tribometer which quantifies the amount of wear under a specific load and time. Test samples were mounted on to the receptacle of the pin on disc machine and tested under a load of 0.3kg for 1,000 cycles of rotation against a 600 grit emery paper. The amount of wear is displayed from the digital reading obtained from the pin on disc machine. After statistical analysis, it was found that, the amount of wear is more in four layered acrylic teeth. The p value obtained is 0.002 (<0.005) thus implies that the difference in wear between nanocomposite teeth and acrylic teeth is statistically significant. Though the nanocomposite teeth has less amount of wear than the four layered acrylic teeth, the difference is very less and adds only to a little clinical significance but the cost of the nanocomposite is four times that of the acrylic teeth. Further clinical studies must be performed to confirm our results.

Lubricant additives for improved pitting performance through a reduction of thin-film friction

This paper describes an investigation into possibilities of enhancement of pitting lives of rolling components by using additive combinations with low thin-film friction. Various viscosity index improvers, anti-wear and extreme-pressure additive combinations were analysed in terms of their frictional behaviour, which in turn was compared to the oils pitting lives. For the pitting studies, a rolling four-ball test was employed. Friction was measured using a ball on disc machine as well as indirectly through “near contact” temperature measurements performed during rolling four-ball tests. The results show that additive combinations that result in low friction at the specific running condition can enhance pitting performance.

Friction and Wear Performance of Double Fraction Palm Olein Lubricant Using Pin-on-Disk Tribometer

In the present of analysis, the wear rate and friction coefficient of various material is investigated and it were compared below the result of sliding speed wherever the equipment pin on disk machine has been used. Experiments were carried out with 2 totally different pins fabricated from aluminum alloy (AA5083) and pure aluminum (A1100). Experiments were conducted at normal load in step with according to testing, 10 N with totally different sliding speed 1, 3, 5 m/s ,continuous flow lubricating substance, double fraction palm olein (DFPO). The result shows that the material from pure aluminum higher material compared to the aluminum alloy in sliding condition. The morphology of the worn surface was ascertained using high optical research. The magnitude of the friction constant and wear rate are totally different in material depending on the speeds and additionally material.

The Development and Characterisation of Aluminium Dross-Epoxy Resin Composite Materials

The effects of aluminium dross filler on the wear behaviour and thermal stability of epoxy resin (ER) system were investigated. The microstructure of the samples was examined with aids of scanning electron microscope (SEM) to explain the basis for the observed changes in the epoxy resin due to the filler additions. A carbon steel die mould was used for casting the aluminium dross-epoxy resin composites. SEM, X-ray Diffractometer (XRD), Thermogravimetric Analyser (TGA) and spin on disc machine was used to characterise the microstructure, composition, thermal stability and wear behaviour under dry lubrication conditions of the developed composites. The study showed that additions of particulate aluminium dross significantly improved the thermal and wear resistance of the developed composite. The wear resistance increased as the speed and applied load increased. The improved thermal stability is attributable to the presence of new phase (refractory oxide and carbide). The aluminium dross-epoxy resin composite is an excellent material in an application requiring low, tensile strength, low wear resistance and moderate thermal resistance especially in the handle for domestic cooking pot; spoon; screw driver and protecting case for electric iron, television and radio.

The Effect of Copper Addition on the Mechanical and Wear Properties of Grey Cast Iron

An alloy of cast iron and copper (Fe-Cu) has been developed using a stir cast process. The compo-sitional, microstructural characterization and wear property of the developed Fe-Cu alloy were carried out with the aids of X-ray diffractometer, scanning electron microscope (SEM) and pin on Disc machine. The mechanical properties such as hardness and impact energy were investigated. Wear linear equations were generated with the aids of MATLAB linear fitting. The results revealed that the presence of copper (99% pure) in the melt of grey cast iron inhibited the formation of cementite. However, the impact energy of the grey cast iron increased with %weight (wt) of copper addition. Hence, the hardness and wear resistance of the developed Fe-Cu alloy were sacrificed. Hence, the developed Fe-Cu alloy is an excellent material which can be used in the vibration damping application especially in the shock absorber.

Effects of Graphite Additions and Heat Treatment on the Microstructure, Mechanical and Tribological Properties of 13% Chromium White Iron

A 13% chromium white iron was produced using a stir cast process. Samples of the produced white iron were austenised at 1450°C and then quenched in water to the room temperature. The characterisation tools such as X-ray diffractometer, scanning electron microscope, Brinell hardness tester and pin on disc machine were employed in the studies of the phase orientation and morphology, hardness value measurement and investigation of wear behaviour. The results revealed that water quenching the 13% chromium white iron led to the precipitation of fine iron chromides and cementite in the matrix of martensite. Moreover, there is an about 22% to 45% increase in hardness values of the as-cast 13% chromium white iron as the %composition of graphite additions increased from 1.36 to 3.04. However, the impact energy values are sacrificed. The increase in hardness values is attributable to hard intermetallic compounds such as iron chromides and cementite phases in the iron matrix. Also, there is an about 32% - 42% increase in hardness values of the heat treated samples of 13% chromium white iron when compared with those of the as-cast. The increased hardness values are attributable to even distribution of the fine intermetallic compounds in the fine grains of martensitic matrix. The wear rate increased as the sliding moments per unit time increased due to increasing work done by the friction to oppose the rotation of the pin on disc. The water quenched 13% chromium white iron samples have greater wear resistances than the as-cast samples due to their greater hardness values than those of the as-cast samples. The effect of speed increase on decreasing wear resistances is more pronounced on the heat treated samples than on the as-cast samples. Hence, the water quenched 13% chromium white iron is an excellent material in application requiring high wear resistance and low impact energy especially in grinding mill liner plate, bottom or casing used in the concrete pipe production, roller for crushing and pulverising mills.

Experimental Investigations into Wear Characteristics of M2 Steel Using Cotton Seed Oil

Vegetable oils have traditionally been applied in food uses but recent trends suggest their economic usefulness as industrial fluids. Increasing crude oil prices and emphasis on the development of renewable, environmentally friendly fluids have brought vegetable oils to a place of importance. As environment pollution and health problem became more and more seriously concerned, the use of environmentally friendly lubricants is strongly supported by political parties, regional and local governments. The objective of this work is to determine the influence of lubricant on wear and frictional force by using pin on disc machine with M2 HSS tool. Further an attempt has been made to identify the influence of cottonseed oil in reducing the wear and frictional force. The performance of cottonseed oil is also being compared with dry and wet conditions by using SAE 40 oil. The results indicated that in general, cottonseed oil performed better than the other two conditions in reducing wear and frictional force.

Assessment of Automotive Coatings Used on Different Metallic Substrates

Four epoxy primers commonly used in the automotive industry were applied by gravity pneumatic spray gun over metallic substrates, specifically, steel, electrogalvanized steel, hot-dip galvanized steel, and aluminum. A two-component polyurethane resin was used as topcoat. To evaluate the performance of the different coating systems, the treated panels were submitted to mechanical testing using Persoz hardness, impact resistance, cupping, lattice method, and bending. Tribological properties of different coating systems were conducted using pin on disc machine. Immersion tests were carried out in 5% NaCl and immersion tests in 3% NaOH solutions. Results showed which of the coating systems is more suitable for each substrate in terms of mechanical, tribological, and anticorrosive performance.

Wear Properties of Hot Extruded Aluminum Powder Compacts

Aluminum powder compacts have low wear resistance due to the reduction in ductility. The ductility enhances using the metalwork technology like the hot extrusion process. The wear test is done using pin on disc machine for all hot extruded aluminum ...

Wear resistance of nitrided and DLC coated PH stainless steel

Precipitation hardening stainless steels are extensively used as a material for plastic injection dies because of their dimensional stability during hardening, impact strength and wear and corrosion resistance. Plasma surface engineering can enhance even more the working life of these components preserving them from wear and corrosion damage by means of surface modification or coatings. In this work PH stainless steel Corrax® was ion nitrided and coated with DLC in a modified PACVD duplex process. DLC films are known not only for their hardness but also for their low friction coefficient, features that improve the wear resistance of steel components. Adhesion tests were performed; wear resistance was tested in a pin on disk machine with different counterparts and in the abrasion ASTM G65 test. Nitrided samples were compared in all tests with DLC only coated samples and the duplex ones (nitriding+coating). The thickness of the nitrided layer was of 14μm, and the coating, 1.8μm. The duplex samples had the best abrasive wear resistance; their mass loss was almost negligible and within the error of the instrument. The only coated samples had a very low mass loss compared with the only aged steel, but the coating was detached.The coated samples presented a low friction coefficient, about 0.03 against alumina and the no wear loss was detected. On the other hand, only the duplex samples presented an acceptable adhesion in the Rockwell C indentation test with 600N and the critical load was 28N in the scratch test.

Research on Intelligent Control System of High Speed and High Precision Filling Disc Machine

Traditional filling disc assembly requires a lot of manual operations and the efficiency of filling disc is not high. Human-machine interface (HMI) and image positioning system of the filling disc machine are developed in this paper, and the whole system and structure are studied on the programmable control technology. The machine realizes the functions of data real-time collection and fast accurate localization. Equipment has reached the accurate filling disc, and got an excellent application in the enterprises.

Experimental study of the thermal and wear properties of recycled polyethylene/breadfruit seed hull ash particulate composites

The experimental study of the thermal and wear properties of developed composite material from recycled polyethylene/breadfruit seed hull ash particulate (BFSHAp) composites were investigated. The composites were produced by compounding and compressive moulding method. Thermogravimetric analyzer was used for the thermal analysis. The wear test was performed using pin on disc machine. Both tests were conducted using full factorial design of three factors-two levels. Scanning electron microscope was used for the morphology of the samples before and after the wear test. The results obtained show that for the thermal analysis the temperatures of weight loss from 10% to 100% (777.33) was the most significant parameter having the highest statistical influence on the thermal decomposition, followed by breadfruit fruit seed hull ash (520.11) and the interaction between the temperatures of weight loss from 10% to 100% and breadfruit fruit seed hull ash (133.75). The wear rate, the sliding speed (p=0.0021), applied load (p=0.0060), BFSHAp (0.0060) has the great influence on the wear behavior of the developed composites. The interaction between applied load/BFSHAp (0.0061) also has an influence on the wear. The values obtained from the empirical models were found to compare favorably with the experimental values. These models performances were therefore found to be satisfactory and show good predictability.

An Approximate Approach to Predict the Degree of Starvation in Ball–Disk Machine Based on the Relative Friction

This article focuses on analyzing the correlation between the degree of starvation and friction under the sliding motion in a ball–disk machine. The objective of this study was to define approximately the degree of starvation in the contact based on measuring one parameter (the relative coefficient of friction). Such an approximate approach could be useful in cases of opaque contacts where the optical interferometry technique cannot be used; for example, a steel ball on a metal disk. Experimental measurements were conducted under different degrees of starvation using a tribometer equipped with a torque sensor and a high-speed digital camera. The results showed agreement between the theoretical equations and the experimental measurements. Thus, it can be stated that the approximate ratio of the film thickness reduction can be predicted based on accurate measurements of friction.

Electrodeposition and characterization of Co–BN (h) nanocomposite coatings

Co–BN (h) nanocomposite coatings were prepared by means of the conventional electrodeposition in a chloride solution containing different concentrations of hexagonal boron nitride particles, and pure Co coating was also prepared as a comparison. Morphology of the coatings and the effect of incorporated particles on metal matrix structure and composition were investigated via scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction analysis. Microhardness, roughness, friction coefficient and wear resistance of the coatings were also evaluated using Vickers microhardness, stylus profilometer and pin-on disk machine. The results showed that Co–BN (h) nanocomposite coatings exhibit higher hardness and lower friction coefficient. Roughness and wear resistance compared with that of the pure Co coating obtained under the same electrodeposition condition and the wear mechanism of the coatings were also discussed.

Identification of the mechanical properties of bicycle tyres for modelling of bicycle dynamics

Advanced simulation of the stability and handling properties of bicycles requires detailed road–tyre contact models. In order to develop these models, in this study, four bicycle tyres are tested by means of a rotating disc machine with the aim of measuring the components of tyre forces and torques that influence the safety and handling of bicycles. The effect of inflation pressure and tyre load is analysed. The measured properties of bicycle tyres are compared with those of motorcycle tyres.

Mechanical Properties and Tribological Behaviour of Recycled Polyethylene/Cow Bone Particulate Composite

The effects of particulate cow bone additions on the mechanical properties and tribological behaviour of cow bone reinforced polyethylene composite was evaluated to assess the possibility of using it as a new material for engineering applications. Cow bone particles reinforced with recycled low density polyethylene (RLDPE) was prepared by varying the cow bone particles from 5-25 wt% with 5 wt% interval using compression method. The mechanical properties of the developed composite were investigated. Scanning electron Microscopy (SEM) was used to examine the surface morphology of the composites. Wear of the composites were conducted using pin on disc machine by varying speed, time and load. Factorial design experiment was conducted as per standard 1.8 orthogonal arrays, with a view to investigate which of the design parameters; speed, load and time most significantly affect the dry sliding wear on the composites. The results revealed that tensile strength and the hardness values of the composite increases with increased in wt% cow bone particles while the impact strength and rigidity decreased. The study revealed that the additions of the particulate cow bone have the most significant main effect on the wear behaviour of the composite while the interactions between load and time has no significant. Hence, cow bone particles can be use to improve the strength and wear properties of RLDPE.