Production Of Wheels Research Articles

Study on the Preparation and Performance of Silicone-Modified Phenolic Resin Binder for Rail Grinding Wheels.

A scheme for manufacturing heavy-duty rail grinding wheels with silicone-modified phenolic resin (SMPR) as a binder in the field of rail grinding is presented to improve the performance of grinding wheels. To optimize the heat resistance and mechanical performance of rail grinding wheels, an SMPR for industrial production of rail grinding wheels was prepared in a two-step reaction using methyl-trimethoxy-silane (MTMS) as the organosilicon modifier by guiding the occurrence of the transesterification and addition polymerization reactions. The effect of MTMS concentration on the performance of silicone-modified phenolic resin for application in rail grinding wheels was investigated. The molecular structure, thermal stability, bending strength, and impact strength values of the SMPR were characterized by Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and mechanical property testing, and the effect of MTMS content on the resin properties was investigated. The results indicated that MTMS successfully improved the performance of the phenolic resin. The thermogravimetric weight loss temperature of the SMPR modified by MTMS with 40% phenol mass at 30% weight loss is 66% higher than that of common phenolic resin (UMPR), exhibiting the best thermal stability; in addition, its bending strength and impact strength were enhanced by approximately 14% and 6%, respectively, compared with those of common UMPR. This study utilized an innovative Bronsted acid as a catalyst and simplified several intermediate reactions in the conventional silicone-modified phenolic resin technology. This new investigation of the synthesis process decreases the manufacturing cost of the SMPR, liberates it from the restrictions of grinding applications, and enables the SMPR to maximize its performance in the rail grinding industry. This study serves as a reference for future work on resin binders for grinding wheels and the development of rail grinding wheel manufacturing technology.

Implementasi Kebijakan Anti-Dumping Oleh Uni Eropa Terhadap Impor Velg Mobil Asal Tiongkok

The steel industry plays an important role in the EU’s (European Union) economy. Its main product is car steel road wheels (velg), which are an important component for the automotive industry. Many imported Chinese car steel road wheels have harmed and disadvantaged domestic producers and manufacturers. This is caused by the dumping practice that China applies to its car and steel road wheel products. In fact, China's dumping practice has also been repeatedly implemented for a variety of products that are exported to the EU market. For that reason, the EU took firm action by implementing an anti-dumping policy on imports of Chinese car steel road wheels. This research aims to describe the anti-dumping policy, its implementation objectives, and its impacts. This research uses the pay-off structure theory of multilateral strategy to explore the idea of cooperation under anarchy, which is derived from the neoliberalism-institutionalism concept. This study also uses a qualitative narrative analysis method by including a research question, namely, "How is the implementation of the anti-dumping policy by the EU on the import of China’s car steel road wheels?" The implementation of the EU’s anti-dumping policy on China’s car steel road wheels has several goals. The first was the EU's firm action against China's repeated dumping practices. Second, as a safeguard for the steel industry, particularly local steel road wheel manufacturers. Third, as a form of regional cohesiveness in order to face any economic injuries. Keywords: European Union, Car Wheel Steel (Velg), China, Dumping, Anti-Dumping Policy

Mechanical Properties of NiTi Based Shape Memory Alloy used in Manufacturing of Mars Rover Wheels: Short Review

Shape memory alloys (SMA) are innovatively designed for engineering applications including, but not limited to, medical devices, actuators, micromechanical systems, deployable structures, and elastocaloric devices. Prior to the manufacture of any component for the above mentioned applications, an extensive simulation study is recommended as the basic properties are required to be filled in the software. The unavailability of to-the-point literature makes this task difficult for researches. In this paper, an overview of binary NiTi based shape memory alloy is given, where its characteristic physical properties i.e. shape memory effect and super elastic effect, and mechanical properties like fatigue failure, stress-strain characteristics and yield and ultimate strength is stated for several different specimens prepared using thermomechanical methods.

Transverse forced vibration of a diamond wire under support excitations

Diamond wire sawing is a key technology for wafer processing in the semiconductor industry. Transverse wire vibration decreases the wire web gap to below the critical adhesion spacing between the wires, which is an important factor that limits the development of diamond wire slicing technology toward narrower kerf losses and thinner as-cut wafers. In fact, the external excitation source that causes the diamond wire vibration comes primarily from the supports at both ends of the wire. Therefore, an analytic model for transverse forced vibration of a diamond wire under support excitations was developed in this study based on the transverse vibration theory of an axially-moving string fixed at both ends. This partial differential equation with non-homogeneous boundary conditions was solved using the superposition principle and the finite element method. To verify the theoretical model, experimental equipment to text the transverse vibration of a diamond wire with support excitations was developed. The support excitation signal and the wire vibration response were obtained using accelerometer measurements and machine vision detection, respectively. The theoretical results agree well with the experimental results, indicating the correctness of this proposed model. The effects of the vibration source and the installation parameters on the transverse vibration displacement of a diamond wire are discussed. The results show that hysteresis in the movement of the center of the wire causes a certain additional high-frequency vibration, which can make this maximum transverse displacement to be greater than the excitation amplitude, thus making the wire transverse vibration change non-linearly with some parameters. The maximum transverse vibration displacement at the center of the diamond wire increases with increases in the guide wheel machining error amplitude and the wire diameter as well as the wire span, while it decreases with increases in the wire groove diameter and the wire tension. This maximum transverse vibration displacement decreases by approximately 100.22 % and 6.17 % when the guide wheel manufacturing error amplitude and the wire groove diameter are reduced by half and doubled, respectively. Improving the manufacturing accuracy of the guide wheel is still the most effective way of reducing the transverse vibration displacement of the wire. In addition, appropriate increases in the groove diameter and the wire tension and decreases in the wire span are also beneficial for suppressing the wire vibration.

Generating precise non-flat grinding wheel surfaces via CO2 laser ablation: Understanding the relationship between overlap rate and feed rate on composite materials

Non-flat structures are essential features in key mechanical functional surfaces such as aero-space engine blade tenons, screw rods and machine tool guide rails etc., which usually require profile grinding as the finishing process to meet demanding working requirements. However, the precise manufacturing of profile grinding wheels remains challenging as it is hard to remove the superhard materials within the grinding wheel in a controllable way. Dressing the target wheel by laser ablation appears promising, however, the interactions between the laser energy beam and target composite materials are quite complex, especially the combined behaviours among a serial of adjacent ablation tracks are hard to understand when concerning the ever-changing Overlap Rates (ORs) and feed rates in the ablation process. In this study, the nature of the laser beam and the characteristics of the beam energy distribution are analysed. The shapes for the laser ablation under various ORs and feed rates are theoretically analysed and experimentally validated. Based on the results, empirical prediction models regarding ablation depth, width, and topography changing with ORs and feed rates are established. Finally, the possibility of manufacturing profiled grinding wheels by controlling overlap and feed rates is studied. An attempt to generate precise non-flat structures (including stepped and curved surfaces) via ablation with a CO2 laser using the developed strategies is performed, and a smooth profile with a relative error of 2.2 % is achieved without any extra focal plane change manipulations. The work provides a novel strategy for the manufacturing of complex-profile grinding wheels.

Applying machine learning and GA for process parameter optimization in car steering wheel manufacturing

Applying machine learning and GA for process parameter optimization in car steering wheel manufacturing

An intelligent collaboration framework of IoT applications based on event logic graph

Realizing the dynamic collaboration between Internet of Things (IoT) services is the key to developing intelligent IoT applications. However, heterogeneity, changeable invocation logic, and spatio-temporal constraints of the IoT services are significant challenges. To solve these problems, a framework based on the event logic graph is proposed. It employs the event logic graph to describe the collaboration between IoT services and uses related methods to dynamically select appropriate services according to the spatio-temporal constraint. Specifically, event instances are first recognized from data generated by IoT services with a divide-and-conquer-based strategy. Next, event logic graphs are constructed based on the serial episode mining method. The related event prediction method is established for determining the service invocation logic. And a spatio-temporal constrained mechanism is designed to select the appropriate services. The proposed framework is applied to wheel manufacturing to promote autonomous production and is further compared with related works. The results show the feasibility of the proposed framework and its advantages in adaptability, dynamics, and spatio-temporal relevancy.

Theoretical investigation of thermal analysis in aluminum and titanium alloys filled in nanofluid through a square cavity having the uniform thermal condition

The enhancement of the heat transfer of fluids is a very important task in engineering and technology which can be accomplished through the hybrid nanoparticles. In this theoretical investigation, the natural convection flow of nanoliquid through a square container is examined under the impacts of thermal boundary conditions. The considered nanoliquid is a combination of titanium alloy Ti6Al4V (class of titanium) and aluminum alloy AA7075 (class of aluminum) nanoparticles and water as a base fluid. Aluminum alloys are commonly used in household wiring and manufacturing of wheels, etc. The titanium alloy Ti6Al4V is commonly acknowledged as the “workhorse” of titanium which is extensively used in aerospace and biomedical engineering. The mathematical model is developed in the form of nonlinear partial differential equations and later transformed into dimensionless form. The resultant dimensionless set of equations is simulated numerically by using the eminent finite element method (FEM). The iterative Newton’s Raphson method is used to get the optimal solutions. The stream function and temperature contours are displayed against the Rayleigh number and nanoparticle volume friction. The variation of local and average Nusselt numbers is also plotted. The outcomes revealed that water-based titanium alloy is the best choice to enhance the heat transfer rate in the cavity. The results obtained in this investigation are very important in engineering research, academic, and discussion about the heat transfer analysis with these two types of alloy nanoparticles inside the cavity flows.

Sustainable Manufacturing of Asymmetric Miniature-Sized Ratchet Wheels by Wire Electrical Discharge Machining

In this paper, the outcomes of an investigation conducted on the sustainable manufacturing of asymmetric rotary miniature-sized ratchet wheels of stainless steel (SS) 304 by a vertically traveling wire electrical discharge machining (WEDM) process are reported. The consumptions of energy and wire material are the process sustainability indicators considered in this work. Box-Behnken-based seventeen experiments were conducted by varying spark-on-time ‘Ton’, spark-off-time ‘Toff’, and wire rigidity ‘WT’. Desirability function analysis (DFA) based on multi-response optimization was performed to obtain an optimum setting of WEDM parameters to manufacture miniature-sized ratchet wheels with minimum energy and wire consumption. Sustainable manufacturing of ratchet wheels is performed at the optimum parameter combination of Ton-1.5 µs; Toff-40.5 µs; WT-1260 g, for the least values of energy consumption of 0.64 kWh and wire consumption of 20.11 g with no wire breakage and a significant reduction in total idle time. This ratchet wheel, manufactured at optimum parameters of WEDM, was also found to have a good finish (average surface roughness ‘Ra’-1.08 µm and maximum surface roughness ‘Rt’-6.81 µm) and defect-free tooth flank surfaces. Overall, it is concluded that WEDM has the potential to achieve sustainability in the manufacturing of miniature-sized ratchet wheels and other gears. The outcomes of this work will extensively facilitate engineers and researchers in selecting a suitable range of machining parameters for sustainable manufacturing of miniature-sized wheels and gears.

Modelling of Off-Road Truck Tire-Rim Slip Using Finite Element Analysis

<div class="section abstract"><div class="htmlview paragraph">Slip or relative rotation between the tire and rim is a significant concern for vehicle operation and wheel manufacturing since it leads to wheel imbalance and vibration as well as power losses. A slip situation typically occurs due to improper bead lubrication and mounting, irregularities in the bead seat, and extreme loading conditions with high torques and low tire pressures. Currently, there are relatively few published studies on the tire-rim interface, and they mainly focus on topics such as the mounting process, load transfer, and friction modelling. This leaves a gap to explore the measurement and variation of gross tire-rim slip under the dynamic conditions of a driven tire. In this paper, a previously developed and validated FEA truck tire model was modified to include a frictional contact surface between the tire and rim, and then the slip ratio between the tire and rim was measured under different operating conditions. The new model’s static behavior was compared to the previously validated model with the fixed tire-rim connection, then the model parameters such as vertical load, inflation pressure, drawbar load, longitudinal wheel speed, and tire-rim friction were varied and their effects on the tire-rim slip of the driven truck tire were investigated. It was discovered that factors affecting the torque transmitted through the wheel, including the tire-rim friction, vertical load, and inflation pressure, had the most significant effect, while the longitudinal wheel speed had a minimal effect on the tire-rim slip. The findings of this research work will be useful for determining the tire-rim slip under various operating conditions.</div></div>

METHODOLOGY OF DEFINITION OF OPTIMAL DIAMOND WHEEL CHARACTERISTICS AT STAGES OF PRODUCTION AND OPERATION

The problem of increase of effectiveness of manufacturing and application of diamond-abrasive tool is still a challenging research subject. Development of computer facilities opens up possibilities for development of three-dimensional (3D) methodology of integrated study of the interconnected processes of manufacturing and exploitation of diamond-abrasive tool and improvement of the single-point tool reliability at the stage of tool sharpening. Creation of the methodology of 3D simulation of processes of diamond-abrasive tool sintering and processes of machining allows to increase essentially validity of the obtained results, to reduce volume of experimental researches for definition of optimum grinding conditions and to develop new technologies, tools and equipment. The developed methodology gives the opportunity to create expert system for assignment of rational characteristics of diamond wheels and grinding modes. The proposed 3D methodology to research processes of diamond-abrasive machining covers all basic stages of life cycle of the tool, including processes of manufacturing and exploitation. Subsystem of computer-generated determination of conditions of manufacturing of defect-free diamond wheels and grinding of superhard materials on the base of 3D simulation of deflected mode of elements of the "SHM crystal grain – metal phase – grain – bond" system at process of diamond wheel sintering and grinding is developed.

Development of three-dimensional simulation model of rolling operation in railway wheel manufacturing process

Development of three-dimensional simulation model of rolling operation in railway wheel manufacturing process

Increasing the effectiveness of cut-off wheels on a bakelite bond

The composition of the molding mixture for the manufacture of cut-off wheels on a bakelite bond with the content of surfactants in the form of fine powders of molybdenum disulfide and chromium diiodide is proposed. The performance indicators of these cut-off wheels are investigated. Keywords: cut-off wheel, bakelite bond, thermomechanical destruction, surfactants, cutting coefficient. safoklovbb@mail.ru

Light automobile steel wheel manufacturing technology

It is known that welding is an important technological process in the manufacture of automotive parts, and many types of welding are used. Contact triangular welding is the most effective, and in some cases the only, method for the production of steel wheels for cars. Because this type of welding is fast, without any filling electrodes, shielding gases, does not require special training, suitable for serial production. In the line of preparation of air conditioning based on modern technology, from 0.01% to 0.05% of air conditioning can be defective. The quality of the material does not meet the requirements and the welding technology is not sufficiently improved, which leads to an increase in the level of defects up to 20%. This leads to excessive material consumption, an increase in the cost of production, and a decrease in economic efficiency.

Modelling and Analysis of Topographic Surface Properties of Grinding Wheels

Grinding is one of the effective manufacturing processes with which to produce highly accurate parts with an ultra-fine surface finish. The tool used to remove materials in grinding is called the grinding wheel. Abrasive grains made of extremely hard materials (alumina, silica, cubic boron nitride, and diamond) having a definite grit size but a random shape are bonded on the circumferential surface of the grinding wheel. The fabrication process is controlled so that the wheel exhibits a prescribed structure (in the scale of soft to hard). At the same time, the distribution of grains must follow a prescribed grade (in the scale of dense to open). After the fabrication, the wheel is dressed to make sure of its material removal effectiveness, which itself depends on the surface topography. The topography is quantified by the distribution and density of active abrasive grains located on the circumferential surface, the grains’ protrusion heights, and their pore volume ratio. The prediction of the surface topography mentioned above requires a model that considers the entire manufacturing process and the influences on the grinding wheel properties. This study fills this gap in modelling the grinding wheel by presenting a surface topography model and simulation framework for the effect of the grinding wheel fabrication process on the surface topography. The simulation results have been verified by conducting experiments. This study will thus help grinding wheel manufacturers in developing more effective grinding wheels.

Analisis Signifikansi Roda Skateboard Berbahan Komposit Serbuk Batang Pisang Terhadap Perfoma Kecepatan Dengan Metode Anova

In general, skateboard wheels are made from a mixture of polyurethane (PU) so that they are elastic, lightweight, and strong. However, this material is classified as a toxic material, difficult to obtain, and the price is relatively expensive. Therefore, alternative raw materials that are more environmentally friendly, non-toxic, easy to find, and have sufficient availability are needed. Banana trees are the most abundant and easily found plants in Indonesia , especially Medan . This tree has a soft structure and absorbs vibrations. Thus, the research was conducted to obtain the characteristics of skateboard wheel products from banana stem powder (SBP) composite material as an alternative raw material. The purpose of this study was to analyze the speed of skateboards made of PU (commercial) and SB P in order to obtain the optimum composition of SB P for the manufacture of skateboard wheels. The test uses a sliding platform with a slope of 30 o against a flat plane. The number of variations consists of the composition of SB P 5%, 10%, and 15%. As a control, commercial PU wheels were also tested. Analysis of data using the analysis method of mean variation (ANOVA) with the condition of acceptance of the hypothesis H 0 at a <0.05. The results obtained are that there is an increase in the speed of skateboards made of SB P composite up to 6, 85% compared to commercial wheels. Based on the Anova test results, it was found that the application of SB P composite materials as raw material for skateboard wheels was proven to significantly increase the speed performance of these wheels.

A review paper on materials used for manufacturing of alloy wheels

In this review paper we have done a detailed study on the different types of material that we can use for the manufacturing of alloy wheels in order to meet the need of the market. During this project we studied the fatigue analysis of aluminium, magnesium, and titanium alloy wheels on the basis of their deformation under load, maximum shear stress of materials, and equivalent stress of the materials. Also we studied the different methods of production of alloy wheels.

Production of High-Quality Wheel Steel. Part 1. Production Aspects of Continuously-Cast Billet Quality for Railway Wheel Manufacture

Production of High-Quality Wheel Steel. Part 1. Production Aspects of Continuously-Cast Billet Quality for Railway Wheel Manufacture

Experience and prospects of use of structural steels for nitridated gears

The experience of using known and new steels to improve the manufacturability and strength of the main parts of machines, hardened by nitriding, is generalized. New approaches to manufacture of gear wheels hardened by nitriding, both when using aluminum-containing steels and a new material, steel 40ХМФА, are considered. To improve the efficiency and man ufacturability of parts production from aluminum-containing steel 38Х2МЮА, widely used in mechanical engineering, a fundamentally new technology of preliminary heat treatment of workpieces of parts – “incomplete hardening” has been developed, which provides both an increase in the machinability and accuracy of large-sized gear wheels, and an increase in strength due to the elimination of the brittleness of nitrided layer. The high hardness of the nitrided surface of the parts – up to 900 HV – also ensures high wear resistance of the parts. Gear wheels made of new aluminum-containing steel 20ХН4МФЮА solidified at the nitriding stage, have strength characteristics equal to cemented parts, which allows not only increasing the bearing capacity of a number of products, but significant simplification of the technology of manufacturing precise parts that are complex in shape, replacing carburizing with nitriding, thereby eliminating the necessary after-carburizing finishing operation – grinding. Steel 40ХМФА, which does not contain aluminum, has increased heat resistance, hardenability and machinability of parts, as well as the characteristics of their hardened layer. The nitrided layer of gears 0.5–0.7 mm thick does not contain brittle components, which, with a core hardness of 300–320 HB, excludes its “flaking” and subsequent destruction of parts. The use of 40ХМФА steel makes it possible to solve the problems of reliability and service life of large-sized nitrided gears, but it is also promising for the entire range of gears with internal gearing, as well as parts of movable spline gearings. These characteristics also in some cases allow replacing the carburizing of gears (modulus less than 4 mm) by nitriding when using 40ХМФА steel.

Geometric Specification of Non-Circular Pulleys Made with Various Additive Manufacturing Techniques.

The paper presents the procedure of generating geometrical features on the contours of non-circular pulleys through the selection of materials and technological parameters for easy and efficient production of these parts. Based on the models designed in the computer aided design (CAD) system, several prototype non-standard pulleys were made, which were assessed for functional characteristics and correct operation of non-linear gears. The effect of additive technology on the geometric specification of non-circular pulleys was also assessed. The results showed that thanks to the use of additive methods, the need for costly manufacturing of such wheels with subtractive methods was eliminated. Additionally, it is not necessary to design specialized cutting tools or to use conventional or numerically controlled machine tools to manufacture these wheels. The test results showed that in case of selective laser sintering (SLS) the highest accuracy of mapping (0.01 mm) of geometrical features of the surface was obtained. This result is confirmed by the assessment of the morphology of the surface of the teeth of gears made with this technique, characterized by a uniform structure of the working surface of the wheel while maintaining a high tolerance of the outer profile of gear for selective laser sintering at the level of ±0.03 mm. Research has shown that most of the additive methods used to manufacture non-circular pulleys meet the required geometrical features and due to the short production time of these pulleys, these methods also facilitate quick verification of the designed pulley geometry.