Steel EN Research Articles

Experimental Analysis of Heat Transfer Post Quenching of Medium Carbon Steel

<div>Transient temperature analysis is involved in the thermal simulation of the heat treatment process, in which the hot metal temperature changes with respect to time from an initial state to the final state. The critical part of the simulation is to determine the heat transfer coefficient (HTC) between the hot part and the quenching medium or quenchant. In liquid quenching, the heat transfer between the hot metal part and water becomes complicated and it is difficult to determine HTC. In the current experimentation a medium carbon steel EN 9 rod with a diameter of 50 mm and length 100 mm was quenched in water and ethylene glycol mixture with different concentrations. A part model was created; meshed and actual boundary conditions were applied to conduct computational fluid dynamics (CFD) analysis. In order to validate CFD analysis the experimental trials were conducted. Experimental results showed a reduced cooling rate for the specimen, and also a reduction in heat-carrying capacity of the mixture, which is attributed to the addition of ethylene glycol.</div>

Effect of Austempering and Martempering on Mechanical Properties and Structure of Bearing Steel (En31)

EN31 steel is easily available and cheap having all material properties that are acceptable for many applications. Heat treatment on low carbon steel is to improve ductility, to improve toughness, strength, hardness and tensile strength and to relive internal stress developed in the material. Here basically the experiment of harness and ultimate tensile strength is done to get idea about heat treated low carbon steel, which has extensive uses in all industrial and scientific fields.

Investigation of physical, mechanical, tribological and biodegradable properties of hybrid natural fibre reinforced polymer composite

This study has investigated the effect of natural fibres such as kenaf, coconut and jute and their combination as reinforced in an epoxy polymer matrix natural fiber reinforced polymer (NFRP) on mechanical properties (impact, flexural, tensile strength and hardness), thermal stability, tribological properties and biodegradability. The raw fibres were chemically treated with 3% NaOH for 24 h, and 10 wt.% was blended in the epoxy matrix. Further, a composite surface morphology and fibre dispersion were analysed using a scanning electron microscope. An improvement of an average of 30.39%, 1157.7% and 30.98% in impact strength, hardness and tensile strength, respectively, compared to pure epoxy composite. Further, the tribological study has shown a lesser frictional coefficient (∼0.275) in hybrid NFRP than in other composites where EN31 Steel disc is used as the counterbody. Moreover, the mixed NFRP has demonstrated excellent biodegradable properties compared to other NFRP and pure composites.

Sustainable Machining of EN19 Steel: Efficacy of Eco-Friendly Cooling Fluids and Hybrid Optimization Techniques

Sustainable Machining of EN19 Steel: Efficacy of Eco-Friendly Cooling Fluids and Hybrid Optimization Techniques

Development of an EN8 Steel Stepped Rotor by a Novel Engraving Milling Technique.

The rotor or impeller is a rotational and key part of a pump and compressor. This article presents the detailed development process of a rotor of small size constructed from an EN8 steel cylindrical blank using a novel technique based on a computer numerical control engraving milling machine (CNC-EMM) equipped with a 4 mm tungsten carbide end mill cutter. We fabricated a total of twenty-eight stepped rotors following the Box-Behnken Design (BBD) DoE technique at fourteen distinct combinations of CNC-EMM variable parameters, namely rotational speed, feed, and plunge feed. Average roughness 'Ra', an important surface quality indicator, has been considered and presented in this article, as a quality measure for the fabricated rotors. Feed and plunge feed have been identified as the most influencing variable parameters as per an analysis of variance (ANOVA) test. The lowest average roughness value obtained by this process for the rotor blade was 0.11 µm. A micrograph obtained from a field-emission scanning electron microscope (FE-SEM) showed a uniform and accurate tooth profile along with burr formation at corner edges. This study claims to establish engraving milling as a viable alternative to other manufacturing processes used for rotor blades. The findings of this study are useful to scholars, engineers, and researchers who are exploring new ways to fabricate mechanical parts and components.

Tribological impact on borosilicate glass powder reinforced Al-MMC by variation of sliding velocity and the study of its machinability

Now-a-days, metal matrix composites based on pure aluminium are widely used as a replacement for a wide range of applications thanks to their high strength-to-weight ratio, ductility, and thermal conductivity. Micron-sized (10−3 mm) borosilicate (mixer of Silica (SiO2) and Boron Oxide (B2O3)) glass particles were used to create a dispersion in an aluminium matrix composite (Al7075- borosilicate glass MMC) utilizing a stir casting technique while in a liquid condition. The present study examines the effect of borosilicate glass particle content (0, 3, 6, and 9 wt%) and changes in sliding velocity (0.5, 1, 1.5, and 2 m s−1) on the wear behaviour of a composite rubbing against an EN31 steel disc at a constant load of 20N and a sliding distance of 1000 m. Analysis of wear showed that the presence of borosilicate glass increased the wear rate and countered the trend shown in the coefficient of friction. In a similar vein, the sliding velocity of the counter plate rotated faster resulted in a higher coefficient of friction and a higher wear rate. A reliable mathematical model is developed to find the best combination of machining parameters for Al7075-borosilicate glass metal matrix composite (MMC). This model will consider important performance measures like surface smoothness and material removal rate. The authors will also use a sophisticated statistical method called the Taguchi L9 orthogonal array design of experiments (DOE) to understand how different machining settings affect how easily the composite can be machined. By analyzing the results from the DOE, it can optimize the machining parameters for efficient and cost-effective processing. This work can lead to manufacturing innovation in the future.

Accelerated tool wear-life estimation of carbide tool machining on steel using life data analysis

In the machining process, tool life is one of the key phenomena. The longevity and dependability of the tool directly affects its inventory. A tungsten carbide tool, which is typically used in moderate-strength materials cutting, was chosen as a test sample for turning EN24 steel. Under normal situations, traditional life cycle data will be time-consuming. Hence, quantitative accelerated tests were used to determine the tool's life. An accelerated test of the tungsten carbide tool was carried out with three varying levels of the selected parameters. ANOVA was adopted for finding significant factors. The gathered experimental data was investigated using an inverse power law-lognormal distribution in the ALTA PRO 6 analytic tool. The results of the accelerated data are then extrapolated to see how the accelerated data will translate to the different life characteristics associated with the tool under normal conditions.

Study of Hot Deformation Behavior of EN25 Steel in the Presence of Non-metallic Inclusions

Study of Hot Deformation Behavior of EN25 Steel in the Presence of Non-metallic Inclusions

Enhancing machining performance of EN24 steel with CVD diamond coated tool and minimal quantity lubrication

The research aims to investigate the effect of chemical vapour deposition (CVD) diamond coatings on cemented tungsten carbide (WC-Co) inserts when machining EN24 steel. In addition to the diamond coating, the research also incorporates the use of minimal quantity lubrication (MQL) technique during the machining process. The research involves experimental studies to evaluate the machinability characteristics of EN24 steel using tungsten carbide cutting inserts with diamond coatings and MQL. Diamond-coated tools are extremely effective in machining EN24 steel, particularly in applications requiring high precision, wear resistance, and long tool life. They are commonly used in industries such as aerospace, automotive, and manufacturing, where quality and durability of the machined components are critical. L12 orthogonal array was used to design experiments with the type of cutting insert used, test condition and cutting speed as control factors. Various parameters such as tool wear, cutting temperature and surface roughness were measured and compared with conventional machining techniques. The results reveal that average flank wear of cutting inserts decreased by 67.4% as a result of MQL when compared with dry machining conditions. Average flank wear decreased by 77.6% after diamond coating were applied compared with uncoated inserts. Diamond coated inserts subjected to MQL exhibit largest percentage reduction of 74.11% for surface roughness when compared to uncoated inserts. The average cutting temperature decreased by 53.09% due to MQL compared to dry machining.

Investigation on the dry sliding friction and wear properties of Fe-ZrO2 composite

The present work investigated the wear behaviour of powder metallurgy-processed ZrO2 (10 wt.%) reinforced Fe-based metal matrix composite under dry sliding conditions. The friction and wear properties were evaluated under varying loads and sliding speeds ranging from 5 to 10 N, and 0.75 to 1.25 m/s, respectively. The wear tests were performed against a counter face of EN31 steel (HRC 60) employing pin-on-disc tribometer under room temperature. Microstructural examination of the composite by field-emission scanning electron microscopy (FE-SEM), equipped with energy dispersive spectroscopy (EDS), displayed the presence as well as a homogeneous dispersion of reinforcement phase into the matrix. At a particular load and sliding speed, transition behaviour was observed in the coefficient of friction, whereas wear rate increased with increasing load and sliding speed. The analysis of worn surface indicated that the adhesive wear was dominant at relatively high operating conditions, while abrasive wear remained operative at lower load and sliding speed.

A comparative experimental study of different magnetic field intensities on electrical discharge turning of EN24 steel alloy

This comparative study investigates the effect of various magnetic field (MF) intensities on the precision machining of cylindrical workpiece of EN24 Steel alloy in the electrical discharge turning configuration. EN24 steel is a high-strength alloy commonly employed in aerospace, automotive, and general engineering applications. The objective of this research is to evaluate the impact of MF intensity on the material removal rate (MRR), tool wear rate (TWR), overcut (OC), and surface roughness ( Ra). The rotational speed of the workpiece, peak current, and pulse-on time were kept constant machining parameters throughout the experiments. The experimental results reveal that increasing MF intensity enhances MRR, OC, and surface finish. However, it is observed that higher MF intensities lead to an elevate TWR which was a negative effect on machining performance. SEM analysis was conducted on the machined surface, revealing that higher magnetic intensity resulted in the formation of a reduced recast layer and remelted debris. The findings were further supported by energy-dispersive spectrum results, which indicated a lower presence of oxide and carbide formations on the machined surface when subjected to higher MF intensity.

Comparison of Effect of Ferritic Nitrocarburising on En-19,En-24 and En-37 Steels

Nitrocarburizing is one of the prominent surface treatment methods for steels. The effects of ferritic nitro carburizing on En-19, En-24 and En-37 steels are compared. Microstructural investigations of FNC treated samples are carried out. Micro hardness profiles of FNC treated steels are drawn. Further wear investigations are carried out. It is observed that FNC treated En-19 steel has more wear resistance in comparison to En-24 and En-37 steels.

Istraživanje proizvodnje malog stepenastog rotorskog točka postupkom graviranja

This study aims to explore the potential of the engraving milling process to manufacture 3D structures and layouts like rotor wheels. An experimental study was carried out to manufacture a stepped rotor wheel from EN8 steel blank using a computer numeric control (CNC) engraving milling machine tool. The impact of variable parameters, namely rotational speed (SR), feed (f), and plunge feed (Pf), on maximum roughness depth (Rt) and material removal rate (MRR) was determined through a total of fourteen tests, each with two replications based on Box-Behnken design (BBD) of the response surface methodology (RSM). The best variable combination was found using desirability functional analysis (DFA) with goals of minimizing Rt and maximizing the MRR. The best values achieved at the optimal combination of variable parameters were 2.95 µm as Rt and 43.45 mm³/min as MRR. Micrographs of the rotor wheel blades and cutting tool supported the findings.

Effect of hybrid plant-based cutting fluid in turning operation of EN19 steel and modelling of heat transfer equation for multiple phase colloids

Effect of hybrid plant-based cutting fluid in turning operation of EN19 steel and modelling of heat transfer equation for multiple phase colloids

Wear Characteristics of AZ91D Magnesium Alloy under Dry Sliding Condition against Hardened Alloy EN31 Steel Disc

Magnesium alloys are very interesting materials used for engineering applications such as automotive, and aerospace industries. Wear is a degradation of material from surface of the workpiece when it is subjected to sliding motion. Also, coefficient of friction is important factor which affects the rate of wear and application of engineering materials. Wear and friction are important characteristics for making the mechanical components subjected to sliding motion. Hence study of wear and friction phenomenon of engineering materials like magnesium alloy is necessary. In this article tribological characteristics of magnesium alloy AZ91D against hardened alloy EN31 steel as counter disc has been studied. The pin-on-disc (POD) wear and friction test had been used for the analysis of failure of materials under sliding motion. The wear test was performed on 10N, 20N, 30N, and 40 N loads with sliding velocities of 0.42m/s, 0.52m/s, 0.63m/s and 0.73m/s. The effect of the sliding distance and the normal load on the wear rate, wear depth and the coefficient of friction has been investigated. The main wear mechanism was found to be plastic deformation and thermal softening.

Machining of EN19 steel using cryogenically cooled electrode material in electric discharge machining

The machining of high-strength alloys like EN19 steel poses significant challenges due to their inherent hardness and susceptibility to surface defects during conventional machining processes. In this study, we explore a pragmatic approach to address these challenges by investigating the implementation of cryogenically cooled electrode materials in electric discharge machining (EDM) for EN19 steel. Specifically, cryogenic treatment is applied to copper electrodes with varying soaking durations of 12 and 24 h. The research considers input process parameters, including peak current ( IP), pulse on time ( Ton), flushing pressure, and soaking duration. Material removal rates (MRR), electrode wear rate (EWR), and surface roughness (SR) are considered as the response parameters. To optimize these input parameters, the study employs the VIKOR technique. Improving the in-depth analysis, our investigation incorporates using COMSOL Multiphysics simulation to intricately model the mechanical aspects of single-spark EDM, mainly focusing on the thermal and structural characteristics of both electrodes and the workpiece. The simulation lends strong support to the experimental findings in relation to MRR and EWR. The experimental data demonstrates notable enhancements after a 24 h cryogenic soaking period for copper electrodes. Specifically, we observed a remarkable 77.36% increase in electrical conductivity, a substantial 20% augmentation in MRR, a significant 39% reduction in EWR, and a noteworthy 9.8% decrease in SR. The meticulous synergy of experimental exploration, optimization, and simulation offers a transformative outlook toward augmenting machining efficacy and prolonging electrode longevity, particularly in the context of EDM.

Enhancing surface quality of en31 steel using Taguchi robust design

Enhancing surface quality of en31 steel using Taguchi robust design

Investigation of mechanical properties and microstructure characterisation of MMA-MIG-TIG-SAW welded EN8 steel joints via shot blasting method

The industries of energy, transportation, and other engineering components all benefit greatly from the use of medium carbon (C) steel EN8. For these applications, welding is typically used to join the material. Conventionally welded joints, however, struggle to meet the exacting standards of industrial applications. In this comprehensive study, the tensile strength, microhardness, and microstructure of joints made of medium C EN8 steel using manual metal arc (MMA), metal inert gas (MIG), tungsten inert gas (TIG), and submerged arc (SAW) welding were investigated. These weld joints were then subjected to the shot blasting method to determine the effect on the mechanical properties of these weldments, Different response characteristics have been studied in relation to the shot blasting with various time periods. A detailed characterisation of the samples has been carried out optical microscopy, surface electron microscopy (SEM), energy dispersive spectroscopy (EDS), optical emission spectroscopy (OES), microhardness, and tensile testing with fractographical analysis. The maximum percentage increase in the microhardness in fusion zone (FZ) occurred in case of TIG welded specimens, i.e. 29.63% after 25 min of abrasive blasting period. However, the maximum change in the tensile strength, i.e. 10.53% has been observed for MMA welded specimens after 15 min of abrasive blasting period. Microstructural analysis revealed TIG has a columnar dendritic structure, MIG and SAW have an equiaxed dendritic structure. MMA has a cellular dendritic structure. The outcomes revealed that abrasive blasting improves the mechanical characteristics of industrial MMA, MIG, TIG, and SAW welded specimens.

Microstructure, hardness and wear behavior of ZrC particle reinforced AZ31 surface composites synthesized via friction stir processing

Dry sliding wear behaviour of friction stir processed (FSP) AZ31 and AZ31/ZrC particles (5, 10, and 15 vol%) reinforced surface composite was investigated at different sliding speeds and loads. The samples were tested using a pin-on-disc apparatus with EN31 steel as the counter body to determine the role of FSP and ZrC reinforcement on the microstructure, hardness, and wear behaviour of AZ31. Base metal AZ31 alloy exhibits a hardness of 60 HV, whereas the 15 vol% ZrC-reinforced composites had the highest hardness of 108 HV. It was also identified that 15 vol% ZrC-reinforced composites exhibited lowest wear rate and friction coefficient under all testing conditions. Abrasion, delamination, oxidation, material softening, and plastic deformation are the primary wear mechanisms viewed from the wear tracks of the samples. Higher volume fraction of ZrC particles exhibited better wear resistance at all speeds and loads than AZ31 alloy. A wear map has been generated for different material compositions and wear conditions to identify the main wear mechanisms easily.

Study on Effects of Flow Rate of Coolant During CO2-Assisted MQL Turning of EN31 Steel

Study on Effects of Flow Rate of Coolant During CO2-Assisted MQL Turning of EN31 Steel