Hollow Cylindrical Components Research Articles

Design and development of a novel MR finishing method for hollow cylindrical surfaces

ABSTRACT Hollow cylindrical components of longer length are a crucial necessity in industries catering to products like gun barrels, cylinder liners of ship and locomotive engines, pneumatic and hydraulic cylinders, etc. A highly finished inner surface improves resistance to corrosion, wear, and friction. Conventional magnetorheological (MR) finishing techniques typically use axis-based CNC setups, which are limited in their ability to finish longer components (>30 cm) due to the Z-axis tool restriction. In this work, a novel MR finishing method has been designed and developed that is based on the pneumatic cylinder and has extremely high reach for the length of the hollow cylindrical workpiece thereby successfully mitigating the limitation of conventional CNC-based MR finishing techniques. Using mild steel as the material, the new technique achieved a significant reduction in surface roughness, with a minimum average roughness of 0.059 µm after 150 minutes of finishing.

Tribological and mechanical characterization of as-cast and thermal treated Al-9Si/SiC graded composite

Tribology and mechanical properties of thermal treated Al-9Si/10wt%SiC functionally graded composite are compared with as-cast condition. The composite was centrifugally cast as a hollow cylindrical component (Ø(outer) 100 × Ø(inner) 60 × 100 mm), characterized at three wall layers (up to 3, 10, and 18 mm) from the outer periphery. Metallographic analysis on as-cast composite and thermal treated components revealed graded structure and spheroidization of acicular Si, respectively. Elemental mapping and phase formations were confirmed through Energy-dispersive Spectroscopy (EDS) and X-Ray Diffraction (XRD) analysis. Outer layer of thermal treated component revealed maximum improvement in hardness (26%) and tensile strength (15%) compared to as-cast. Brittle mode of failure was featured through fractography. A combination of adhesive and abrasive mechanisms were predominant during reciprocating wear. EDS analysis of wear debris formed at intermediate sliding distance (1250 m) confirmed the oxide layer formation. Thus, the thermal treated composites are developed for automotive engine components vulnerable to wear.

A Review on Identification and Elimination of Ovality in Circular Holes During Manufacturing of Hollow Cylindrical Components

This review paper aims toward the investigation of manufacturing process of hollow cylindrical component to identify the defects causing ovality in circular holes. The manufacturing refers to the processes required to convert raw material into the final product which may include casting, machining, welding, finishing, heat treatment processes and ends with final inspection to check for defects. Mostly the circular holes of hollow cylindrical components show ovality after manufacturing, exceeding tolerance values and such defect leads to poor fittings. After careful study of the variety of research papers related to ovality, it was found that the ovality may occur due to component characteristics or due to defects in manufacturing process of the component. The results of these research papers concluded that machining parameters, unbalanced workpiece, clamping pressure, clamping geometry and clamping technique influence the dimensional deviations and it can be prevented by improving the production with corrective techniques.

Torsional and compression properties of cylindrical glass fiber reinforced polymer composite

Abstract Composite materials play a vital role in many industrial applications. Researchers are working on fabrication of new composite materials worldwide to enhance the applicability of these materials. GFRP (Glass Fiber reinforced polymer) is a composite material made of a polymer matrix reinforced with glass fiber. Fiber reinforced polymer composites are known for their stiffness and strength in tension and compression along its axis, controllable electrical conductivity, and low coefficient of thermal expansion, good fatigue resistance and suitability for the production of complex shape materials. This study-project comprises of the manual fabrication of Glass Fiber reinforced polymer - hollow cylindrical component with varying layers of different types of glass fiber fabrics and testing the torsion and compression strength of the specimens. The different types of glass fiber fabrics include pure unidirectional fiber form, veil mats, and woven fabrics. Finally a comparative analysis is conducted among the different kinds of specimens fabricated and suitable application is found based on their strength. Thus the result of the study shows the influence of varying layers of the glass fiber fabrics on their strength and the possibility of replacing the low power transmitting metallic shafts with composite (GFRP) shafts.

Fabrication of LM 25/WC functionally graded composite for automotive applications and investigation of its mechanical and wear properties

Functionally graded Al LM 25/10 wt% WC composite of dimension ∅out 100 × ∅in 60 × 100 mm was fabricated using centrifugal casting method. Mechanical and tribological properties of outer (1 mm), middle (11 mm) and inner (18 mm) layers from outer periphery of hollow cylindrical component were studied. Microstructural investigation revealed maximum distribution of reinforcements in outer layer, followed by middle and inner layer. Outer periphery had the highest hardness while outer zone displayed better tensile characteristics. Fractographs revealed brittle nature at outer layer due to high concentration of WC particles while a combined mode of ductile and brittle failure was observed at inner layer. Wear rate of outer layer increased linearly with increasing applied load, nonlinearly with increasing sliding velocity and sliding distance. Worn surface morphologies revealed fine and shallow grooves at outer layer ensuring mild material removal. Mild to severe wear transition was observed with increasing applied load. Mechanically mixed layer formation was observed with increasing velocity. This composite having enhanced mechanical and wear properties at outer zone is suitable for automotive applications such as pistons, liners, brake disks and bearings.

Effect of Centrifugal Speed in Abrasive Wear Behavior of Al-Si5Cu3/SiC Functionally Graded Composite Fabricated by Centrifugal Casting

Centrifugal casting was adopted for fabricating AlSi5Cu3/10 wt% SiC functionally graded metal matrix composite under three different centrifugal speeds of 800, 1000 and 1200 rpm, and hollow cylindrical components (φout 150 × φin 132 × 150 mm) were obtained. Microstructures of outer and inner periphery of all composites were observed through optical microscope and micro hardness of outer, intermediate and inner region of composite was tested using Vicker’s hardness tester. Results revealed that outer region of the composites centrifuged at all speeds have particle rich region with higher hardness. Abrasive wear experiments were conducted only on surface of particle rich region based on Taguchi’s technique by varying parameters such as centrifugal speed of casting process, rotating speed and applied load of abrasive wear tester. Analysis of variance results revealed that, centrifugal speed had highest significance on wear rate. Abraded surfaces were examined using scanning electron microscope and the maximum wear resistance was observed on particle rich zone of composite centrifuged at 1200 rpm.

Mechanical Properties and Abrasive Wear Behaviour of Functionally Graded Al-Si12Cu/Al2O3 Metal Matrix Composite

Mechanical properties and abrasive wear behaviour of functionally graded Al-Si12Cu/Al2O3 metal matrix composite fabricated under centrifugal casting technique was investigated and compared with unreinforced aluminium alloy. Hollow cylindrical component with dimensions 150 × 150 × 16 mm was produced under the centrifuging speed of 1200 rpm by incorporating 10 wt% Al2O3 particles of size 30–50 µm. The distribution of the Al2O3 reinforcement particles at outer, middle and inner surfaces in matrix was examined through the microstructural analysis. Hardness and tensile strength of the aluminium alloy and functionally graded composite were tested through microhardness tester and universal testing machine respectively. Abrasive wear of aluminium alloy and functionally graded composite was tested through dry abrasion tester for various loads and speeds on outer, middle and inner surfaces of composite specimens. Scanning electron microscopy analysis was carried out on the fractured tensile specimens and worn out specimens. The results revealed that particles were segregated more on the outer periphery and less on the inner periphery. The mechanical properties and the abrasive wear resistance of the functionally graded material were found higher than the unreinforced alloy. The wear rate was found to increase with increase in load, speed and for the distance from the outer periphery of the casting. The worn out surfaces revealed more cutting and ploughing as a result of three body abrasion wear caused by silica sand particles.

Development of functionally graded aluminium composites using centrifugal casting and influence of reinforcements on mechanical and wear properties

Functionally graded Al/B4C, Al/SiC, Al/Al2O3 and Al/TiB2 composites with constant 12% (mass fraction) of reinforcement were fabricated by centrifugal casting and hollow cylindrical components were obtained. Microstructural characteristics were investigated at outer surface of all composites and segregation of reinforcement particles was observed. Graded property of the composites with different reinforcements was investigated through hardness and tensile measurements. Results revealed that the outer peripheries of all composites exhibit higher hardness except in Al/B4C composite and the outer zones of all composites show higher tensile strength. Abrasive wear test was conducted on the outer peripheries of all composites and Al/TiB2 composite exhibits less wear rate.

A new rolling–extrusion technology for the forming of the hollow cylindrical component

In this study, a new rolling–extrusion technology implementing plastic deformation is presented for the forming of the hollow cylindrical component, and the design criterion of the rollers with changeable internal diameter is introduced based on the prediction of the forward slip value. Moreover, in order to investigate the feasibility of this technology, a finite element (FE) simulation and an experiment are conducted. The result of the FE simulation shows that: the metal flow is caused only in the area where the rollers contact the billet, and influenced by the heat exchange between the billet and the rollers; a set of most reasonable technological parameters is selected through an evaluation of the deformation uniformity of 18 groups of simulations. In addition, the result of the experiment shows that the hollow cylindrical component can be formed, and the consumption for the material of each component can be saved at least 16.8 %.

Mechanical and tribological properties of functionally graded aluminium/zirconia metal matrix composite synthesized by centrifugal casting

Abstract In the present study, functionally graded aluminium/zirconia metal matrix composite was fabricated using a liquid metallurgy route followed by centrifugal casting process and a hollow cylindrical component of dimensions 150 × 150 × 16 mm was obtained. Microstructural characteristics and mechanical properties along the radial direction were analysed to check the graded properties throughout the thickness of the casting. The tribological behaviour of the functionally graded composite was studied using a three body abrasion tester by varying the applied loads in the range of 33 – 80 N at two different rotating speeds of 100 and 200 rpm. The microstructural examination results showed that the outer surface of the composite has a particle rich zone due to centrifugal force as well as the density difference between alloy and reinforcement. Hardness was found to be higher at the outer surface and tensile strength was higher at the upper section of the composite due to the higher segregation of reinforcement particles. The abrasive wear test results revealed that the wear rate increases as applied load increases and decreases as rotating speed increases. The wear resistance was found to be maximum at the outer periphery compared to other surfaces under all conditions. Scanning electron microscopy analysis of worn surfaces revealed fine and shallow grooves on the external zone ensuring better wear resistance.

Development and Mechanical Testing of Filament Wound FRP Composite Components

Glass Fiber Reinforced Plastic composites are used for pipes, high pressure vessels, aircrafts, automobiles, sport goods and Glass Fiber Reinforced Plastic composites are used for pipes, high pressure vessels, aircrafts, automobiles, sport goods and structural applications due to their high corrosion resistance, high specific strength, low density, low coefficient of thermal expansion, durability, low maintenance and low cost. This paper presents the development and mechanical testing of filament wound Glass Fiber Reinforced Plastic composite hollow cylindrical components. In this present work, Glass Fiber Reinforced Plastic composite hollow cylindrical components were manufactured by helical filament winding process. ASTM: D2584 standard test method for ignition loss of cured reinforced resins was conducted on the specimen to determine the fiber to resin ratio. The tensile test was conducted as per ASTM: D638 standard. The three point flexural test was conducted as per ASTM: D790 standard. The hoop tensile strength test was conducted as per ASTM: D2290 standard. The external loading characteristics were determined by conducting the ASTM: D2412 standard test. The tensile strength and flexural strength in the axial direction are 50.76 MPa and 425.46 MPa respectively. The hoop tensile strength and the parallel-plate loading (Compression) stiffness are 156.33 MPa and 2750 N/mm respectively.

Inertia friction welds between nickel superalloy components: Analysis of residual stress by eigenstrain distributions

Machining, surface treatment, plastic forming and stretching, welding, and other manufacturing processes introduce residual stresses and distortion into work pieces and engineering components. These phenomena exert a significant influence on the behaviour of components affecting the response to thermal/mechanical in-service loading, e.g. in terms of crack initiation and propagation under the conditions of creep and fatigue, thus ultimately affecting their durability. In the present study, the inertia friction welding process is considered that is used for butt joining of hollow cylindrical components, such as shafts and drums. An inverse eigenstrain framework is used for the interpretation of neutron diffraction measurements in terms of the underlying eigenstrain distributions. Eigenstrain distributions that describe the nature of permanent inelastic deformation are found by minimizing the sum-of-squares measure of the disagreement between model prediction and experimental measurements of residual elastic strains. Experimental data obtained from neutron diffraction measurements are used in an inverse solution scheme in order to determine the underlying eigenstrain (strains permanently ‘locked in’) that give rise to the residual stress state. Once these are found, approximate reconstruction of the complete stress tensor within the entire component becomes straightforward. Eigenstrain distributions are first obtained for reduced size test specimens which have been characterized in detail using neutron diffraction. Subsequently, the eigenstrain distributions are scaled and applied to more complex, full-size real engine components, with scaling factors adjusted to match surface hole drilling measurements.

Mechanized production of hollow cylindrical components

Mechanized production of hollow cylindrical components

Cold Forging of Hollow Cylindrical Components Having an Intermediate Flange — Ubet Analysis and Experiment

Possible cold forging operations to form hollow cylindrical Componeats having a circular intermediate flange are first proposed. The material deformation and forging pressures for these program, the basic concept of which is hased on the Unit Element Regions due first to Kudo. With the emergence of the computer revolution, the use of the Unit Element Regions was implemented as the URET program by Avitzur and others. In the present study it is assumed that the material is non-hardening, and the frictional stress over the tool-workpiece interfaces is negligible. Cold forging experiments with annealed aluminium billets or slugs are also performed to observe deformation, defect formation and working pressure. The experimental results are compared with the theoretical results which are obtained by modification of the non-hardening results to allow for the work-hardening. The coincidence is found to be fair. Finally, the relative merits and demerits among the proposed forging methods with regard to the load, unit pressure, energy and defect are discussed on the basis of the theoretical and experimental results.