Wear Patterns Research Articles

Optimization of Rotary Blade Wear and Tillage Resistance Based on DEM-MBD Coupling Model

To solve the problems of high tillage resistance and the rapid wear of the rotary blade during tillage, this study employed a coupled algorithm of the discrete element method (DEM) and multi-body dynamics (MBD) with Hertz–Mindlin with JKR particle contact theory to establish a rotary blade–sandy soil model. The interaction between the rotary blade and sandy soil was analyzed. The results indicated that the lateral and horizontal resistances of the rotary blade reached the peak values near the maximum tilling depth, whereas the vertical resistance reached its peak earlier. Blade wear predominantly occurred on the side cutting edge, bending zone edge, and sidelong edge, with the most significant wear observed on the sidelong edge, followed by the bending zone edge and side cutting edge, which showed similar wear patterns. To reduce wear and tillage resistance, Box–Behnken optimization was applied to optimize the blade’s local parameters. The optimal parameters—the height of the tangent edge end face was 51 mm, the bending radius was 28 mm, and the bending angle was 116°—reduced wear by 22.4% and tillage resistance by 12%. A soil disturbance analysis demonstrated that the optimized blade performs better in terms of tillage width compared to the unoptimized blade. The optimized rotary blade achieves the effects of reduced resistance and wear, improves the lifespan of the blade, reducing material loss, and meeting the requirements of sustainable agricultural production.

A comparative analysis of anatomic total shoulder arthroplasty versus reverse shoulder arthroplasty for posterior glenoid wear patterns.

Reverse shoulder arthroplasty (RSA) and anatomic total shoulder arthroplasty (TSA) are well-known methods of treating glenohumeral arthritis, which often leads to posterior wear of the glenoid. This study compared minimum two-year outcome measures in patients treated with RSA and TSA for Walch B2 and B3 glenoids. Thirty-eight shoulders underwent TSA and 40 shoulders underwent RSA by two fellowship-trained shoulder surgeons at a tertiary referral center. The mean time for follow-up was 25.9 months and 25.5 months for RSA and TSA groups, respectively (P=0.47). The RSA group consisted of 27 males and 13 females; whereas the TSA group had 37 males and 1 female (P = <0.001). The mean age for RSA was 71 years old, 61 years for TSA (P = <0.001). TSA patients demonstrated superior average active external rotation (47° vs 40°; P=0.003) and internal rotation (60° vs 52°; P=0.002). Active forward elevation did not significantly differ. The TSA group had 7 (18.4%) postoperative complications, the RSA group had 3 (7.5%) (P=0.27). The most common complication was cephalic vein thrombosis. No complication required revision. Patients with shoulder osteoarthritis and posterior glenoid wear patterns with an intact rotator cuff who underwent TSA had similar outcomes as RSA. While the TSA group had superior active external rotation and internal rotation at 2 years postoperative compared with RSA, the 2-year active forward elevation was equivalent. Both groups had similar 2-year outcomes for strength in all planes and in all three clinical-outcome scoring systems. The TSA group demonstrated a higher incidence of postoperative complications. Neither group required reoperations. These results indicate that TSA and RSA can be safely utilized in posterior glenoid wear patterns with good clinical outcomes. Level III; Retrospective cohort study.

Study on the Influence Mechanism of Surface Morphology on Wear and Thermal Fatigue Performance of Laser-Treated Bionic Brake Drum

This study explores the mechanisms underlying the enhanced anti-wear and thermal fatigue performance of laser-treated bionic brake drums, aiming to extend their service life and improve design quality. Bionic brake drums treated with laser patterns—point, stripe, and grid—were tested with semi-metallic, non-asbestos organic (NAO), and ceramic brake pads. A mechanical model was developed to analyze wear performance, and bench tests were conducted to assess wear patterns. Thermal fatigue tests examined the impact of thermal cycling on the treated drums’ wear behavior. The results reveal that laser-treated bionic brake drums significantly outperformed untreated ones in both wear resistance and thermal fatigue. Among the treatments, the grid pattern showed the best wear performance, and thermal fatigue life was improved by 27% for the striped pattern and 38% for the grid pattern. The study concludes that laser treatment effectively enhances both wear resistance and thermal fatigue performance in bionic brake drums, especially for the grid pattern, offering valuable insights for future brake drum design.

Wear Patterns in Modern Dental Materials Used in Extensive Tooth Replacement Treatments

Wear patterns in dental materials are critical to understanding their performance and longevity in extensive tooth replacement treatments. Modern materials such as ceramics, composites, and hybrid polymers have been developed to replicate the natural characteristics of enamel and dentin, balancing mechanical strength and aesthetic properties. Despite their advancements, these materials are subjected to wear mechanisms, including attrition, abrasion, and erosion, which affect their functionality over time. The integration of nanotechnology and computer-aided design and manufacturing (CAD/CAM) has contributed to improvements in material durability and precision, enabling restorations that closely mimic natural teeth. Research has revealed that wear resistance in dental materials depends on a variety of factors, including material composition, hardness, and elasticity. These properties influence the interaction between the restorative material and opposing dentition, often resulting in differential wear patterns. For example, harder materials may preserve their integrity but cause accelerated wear on natural teeth, whereas softer materials may degrade more rapidly under occlusal forces. Innovations such as nanocomposites have demonstrated enhanced stress distribution and resistance to surface degradation, offering promising results in clinical applications. Patient-specific factors, including dietary habits, bruxism, and occlusal dynamics, further impact the wear behavior of these materials. Environmental factors, such as pH variations and thermal cycling, also play a role in material degradation. Emerging technologies and biocompatible materials aim to address these challenges by optimizing wear performance while maintaining structural integrity. However, the need for extensive in vivo studies and long-term evaluations persists to validate their effectiveness and reliability. Understanding the wear characteristics of dental materials is essential for their selection and application in restorative dentistry, particularly in cases requiring extensive tooth replacement. Advances in materials science and fabrication techniques continue to drive innovation, improving patient outcomes and the longevity of restorative treatments.

Computational wear prediction of articular cartilage based on a new anisotropic wear law.

Excessive wear can result in irreversible damage to the cartilage. Experimental studies indicate that cartilage wear is significantly influenced by both the orientation of unidirectionally aligned surface fibers and the biphasic structure of the tissue. Given challenges with invasive in vivo wear experiments, there is a pressing need for computational models to predict wear of the cartilage accurately. However, existing models that account for anisotropic and biphasic wear behaviors are lacking. The aim of this study was to develop a finite element (FE) wear prediction model that accounts for the complex anisotropic and biphasic nature of the cartilage. To achieve this, an anisotropic wear law was proposed based on the wear tests conducted on bovine cartilage pins reciprocally rubbed against cobalt chromium molybdenum plates. Subsequently, this anisotropic wear law was integrated into a biphasic FE model of the cartilage. Compared to the isotropic wear model, this model demonstrates improved accuracy in capturing cartilage wear patterns, effectively representing both the anisotropic wear behavior influenced by the angle between the superficial fiber orientation and the sliding direction, and the biphasic wear behavior affected by solid phase stresses. This modelling framework not only holds promise for assessing cartilage wear in physiological conditions but also offers potential applications to a broader range of materials and may facilitate the development of osteochondral grafts.

Self-Organization of Surface Structures during Friction Coatings Based on Forsterite

In the work, the patterns of friction and wear of forsterite-based coatings were studied, and their structural-phase composition, conditions of formation and self-regulation of surface structures were determined from the standpoint of the structural-energy theory of friction. Detonation coatings developed on the basis of forsterite are characterized by high anti-friction properties. The conducted studies showed that the most appropriate application of the investigated coatings is to increase the reliability of operation of friction nodes during strengthening and restoration, for example, for moving pairs of control mechanisms, hinges of guide surfaces, cams, sliding supports, pairs with reciprocating movement, bearings, sliding guides, etc. in which the use of traditional lubricants is undesirable. Compounds of complex oxides of magnesium orthosilicate were used as the basis of composite coatings. The structural and phase composition of the coatings, the peculiarities of the formation of complex alloyed secondary structures, taking into account both the properties of the alloying elements and the structures formed by them, were established. The physical mechanism was determined and the main factors determining the level of thermodynamic graphitization were clarified. The studied self-lubricating compositions can be used both for strengthening and for high-quality restoration of worn triboelements by any technological methods using powder materials.

Software Development for Automated Design of Principal Women Wear Patterns

In this article the review of IT-tools for pattern design is carried out. The problems and disadvantages of the used software are identified and the development of a software for the automated principal pattern design of women's clothing “PIONY”, which has a number of advantages, is described. These include free functionality, three modes of operation (“Guest”, “Shaper”, “Shaper+”), personal account, the ability to save the pattern in the required format and scale. Also, this system allows for an unauthorized user to work in the system, providing him with incomplete functionality ofdesigning a pattern of one product on a standard size in accordance withRussian National Standard GOST. The main advantage of the software is the ability todesign patterns of five items (top, robe, pants, shorts and skirt) according to individual user’smeasurements, taking into account additional parameters (additions, and type of silhouette), and print it in real scale. The software structure is presented in the form of a UML-diagram. It reflects the activities of the administrator and the user. The program part of the functionality is developed using the programming languages JavaScript, PHP, built-in GD Library, which allows creation drawings using graphical primitives and work with image files. Library functions are used to build geometric objects, drawing simple shapes such as lines, circles, which are the pattern elements. A set of hypertext markup HTML and CSS stylingwas usedfor the interface part. The proposed software will allow people who do not have professional knowledge in the field of sewing to design patterns automatically according to individual measurements by entering data and pressing a few buttons.

Interface Enhancement and Tribological Properties of Cattle Manure-Derived Corn Stalk Fibers for Friction Materials: The Role of Silane Treatment Concentration

Corn stalk fibers extracted from cattle manure (CSFCM) represent a unique class of natural fibers that undergo biological pre-treatment during ruminant digestion. This study systematically investigates the optimization of CSFCM-reinforced friction materials through controlled silane treatment (2–10 wt.%). The biological pre-treatment through ruminant digestion creates distinctive fiber properties that influence subsequent chemical modification. Physical characterization revealed that optimized interface modification at 6 wt.% silane treatment (CSFCM-3) effectively enhanced the fiber–matrix compatibility while achieving a 34.2% reduction in water absorption and decreased apparent porosity from 9.03% to 7.85%. Tribological evaluation demonstrated superior performance stability, with CSFCM-3 maintaining friction coefficients of 0.35–0.45 across 100–350 °C and exhibiting enhanced thermal stability through a fade ratio of 14.48% and recovery ratio of 95%. The total wear rate showed significant improvement, reducing by 26.26% to 3.433 × 10−7 cm3 (N·m)−1 compared to untreated specimens. Microscopic analysis confirmed that the optimized silane modification promoted the formation of stable secondary plateaus and uniform wear patterns, contributing to enhanced tribological performance. This investigation establishes an effective approach for developing high-performance friction materials through precise control of silane treatment parameters. The findings demonstrate the potential for developing sustainable friction materials with enhanced performance characteristics, offering new pathways for eco-friendly material design that effectively utilizes agricultural waste resources.

Experimental and computational evaluation of knee implant wear and creep under in vivo and ISO boundary conditions

Abstract Background Experimental knee implant wear testing according to ISO 14243 is a standard procedure, but it inherently possesses limitations for preclinical evaluations due to extended testing periods and costly infrastructure. In an effort to overcome these limitations, we hereby develop and experimentally validate a finite-element (FE)-based algorithm, including a novel cross-shear and contact pressure dependent wear and creep model, and apply it towards understanding the sensitivity of wear outcomes to the applied boundary conditions. Methods Specifically, we investigated the application of in vivo data for level walking from the publicly available “Stan” data set, which contains single representative tibiofemoral loads and kinematics derived from in vivo measurements of six subjects, and compared wear outcomes against those obtained using the ISO standard boundary conditions. To provide validation of the numerical models, this comparison was reproduced experimentally on a six-station knee wear simulator over 5 million cycles, testing the same implant Stan’s data was obtained from. Results Experimental implementation of Stan’s boundary conditions in displacement control resulted in approximately three times higher wear rates (4.4 vs. 1.6 mm3 per million cycles) and a more anterior wear pattern compared to the ISO standard in force control. While a force-controlled ISO FE model was unable to reproduce the bench test kinematics, and thus wear rate, due to a necessarily simplified representation of the simulator machine, similar but displacement-controlled FE models accurately predicted the laboratory wear tests for both ISO and Stan boundary conditions. The credibility of the in silico wear and creep model was further established per the ASME V&amp;V-40 standard. Conclusions The FE wear model is suitable for supporting future patient-specific models and development of novel implant designs. Incorporating the Stan data set alongside ISO boundary conditions emphasized the value of using measured kinematics in displacement control for reliably replicating in vivo joint mechanics in wear simulation. Future work should focus on expanding the range of daily activities simulated and addressing model sensitivity to contact mechanics to further enhance predictive accuracy.

Wear resistance of 3D printed, milled, and prefabricated methacrylate-based resin materials: An in vitro study.

Three-dimensional (3D) printing and milling technologies have been increasingly used in prosthodontic practice for fabricating digital prostheses. Nevertheless, evidence relating to the wear resistance of denture teeth fabricated using these methods is lacking. The purpose of this in vitro study was to compare the wear resistance exhibited by denture teeth fabricated using 3D printing and milling technologies with prefabricated denture teeth. Fifty specimens of resin denture teeth from 3 types of manufacturing processes were prepared and divided into 5 groups: 1 group of 3D printed denture teeth (NextDent C&B MFH), 2 groups of milled denture teeth (Ivotion Dent and VIPI Block), and 2 groups of prefabricated denture teeth (Major Dent and Cosmo HXL). Each group of specimens was occluded with a zirconia antagonist under a 49-N load with thermocycling conditions for 120 000 cycles. The antagonist was horizontally displaced back and forth at a 2-mm distance and a frequency of 1.6Hz. The quantification of the volume loss and the maximal wear depth of the worn specimens were recorded, while the wear characteristics were assessed with a scanning electron microscope (SEM). Data were analyzed using the Kruskal-Wallis test followed by pairwise comparison tests (α=.05). Significantly different wear depths and volume losses were found among groups (P<.05). The highest wear depth and volume loss were observed in the VIPI Block (0.513 ±0.147 mm and 3.094 ±0.790 mm³), followed by Cosmo HXL group (0.312 ±0.020 mm and 1.446 ±0.134 mm³), Major Dent (0.261 ±0.034 mm and 1.219 ±0.196 mm³), Ivotion Dent (0.253 ±0.021 mm and 1.082 ±0.089 mm³), and NextDent C&B MFH (0.208 ±0.059 mm and 0.843 ±0.372 mm³). Based on the analysis of the SEM images, distinct groups of specimens exhibited varying degrees of crack formation. Furthermore, their worn surfaces showed diverse characteristics in terms of wear patterns and roughness attributes. The manufacturing methods for fabricating 3D printed, milled, and prefabricated denture teeth exhibit comparable wear resistance, with 3D printed denture teeth demonstrating the highest level of wear resistance.

Real-Time Acoustic Measurement System for Cutting-Tool Analysis During Stainless Steel Machining

This study presents a sound-based tool-wear monitoring system designed to overcome the limitations of conventional methods that focus solely on gradual and predictable wear patterns. The proposed system employs low-cost, high-frequency microphones and advanced signal processing—featuring analog/digital filtering, oversampling, signal conditioning, PLL-based synchronization, and feature extraction (ZCR, RMS)—to capture acoustic emissions during machining. Key innovations include optimized microphone placement, a custom PCB, and real-time data transfer via WiFi to MATLAB for analysis. Using the TreeBagger machine-learning algorithm, the system accurately predicts tool wear, detecting both gradual and abrupt wear patterns. Tested on EN 1.4307 (AISI/ASTM 304L) stainless steel, the system demonstrated robust performance in real-time tool-condition assessment. Its scalable and cost-effective design allows for the integration of additional sensors and features, providing a non-invasive and adaptive solution to enhance machining efficiency and reduce operational costs.

Determining the age classes of free-ranging female nilgai (Boselaphus tragocamelus) in southern Texas, USA

Age classification methods have not been evaluated for free-ranging nilgai antelope (Boselaphus tragocamelus) either on their native or introduced ranges of southern Texas, USA. Our objectives were to 1) determine if cementum annuli aging was a feasible method for aging nilgai, 2) measure the crown-lingual crest heights of nilgai molariform teeth to assess if these measurements were correlated to the cementum-annuli age of nilgai, and 3) develop nilgai age classes based on visual observations of tooth eruption and wear patterns. Six commercial nilgai meat harvests were conducted via helicopter from May–September 2018–2021 across 3 properties. We collected data from 225 harvested nilgai (n = 213 females and n = 12 juvenile males). We found significant relationships between cementum annuli ages and the crown-lingual crest heights of nilgai teeth (n = 63). However, the relationship was weak given the low R-squared values (0.23–0.46), suggesting that the age of female nilgai does not explain a large amount of variation among tooth heights (i.e., wear). From nilgai teeth samples, we documented 13 tooth eruption stages and 6 age classes. Female nilgai age classes presented provide land managers with the basic tools needed to assess population age structures. On the Indian subcontinent, our method could be used to evaluate age-biased predation on free-ranging nilgai.

Effects of Cutting Parameters on Tool Wear in Milling Inconel 625 Superalloys with a SiAlON Ceramic and the Prediction of Tool Life

Inconel 625 superalloys are widely preferred in various industries because of their superior mechanical properties at high temperatures. The superior properties they exhibit make the machinability of Inconel 625 alloys difficult. This situation can cause rapid wear of the cutting tools, making the cutting tool unusable in very short periods of time and causing deterioration of the workpiece surface quality. Therefore, improving the machining performance of Inconel 625 alloys, optimizing the machining parameters and using the optimum cutting tool material and geometry are important. In this study, SiAlON ceramic cutting tools, which have been widely used in recent years, were preferred. SiAlON tools supplied in raw rod form were subjected to various processes and finalized into final products. The effects of three different cutting speeds (vc), feed rates (f) and axial depth of cut (ap) on tool life (T), wear patterns and mechanisms were investigated with 9 tests designed according to the Taguchi L9 orthogonal array. The results revealed that the f values, the effects of which were analysed, had the most significant effect on T. By performing regression analysis with T values, the coefficients used in the extended Taylor T equation were determined, and T predictions were obtained. The regression model was found to be consistent with the experimental results, with an effect of 99.34%, and the model was significant according to analysis of variance. The predominant wear patterns of the cutting tools were flaking at a low vc, nose collapse at a high vc and an adhered workpiece under all conditions. The wear mechanism was found to be predominantly adhesion and fracture. The presence of Ni, Cr, Mo, Nb and Fe on the cutting tool surface was determined, and the effect of the concentrations was observed to increase/decrease significantly depending on the parameter values examined.

Influence of local tool angles and cutting conditions on abrasive wear in CFRP drilling

During drilling carbon fiber-reinforced polymer (CFRP), tool wear progresses relatively quickly and significantly increases workpiece defects. Optimizing the drilling process and selecting the appropriate tool design are essential for minimizing wear and preventing defects in the workpiece. Conventional investigation into tool wear progression during drilling often involves measuring the maximal wear in proximity to the outer corner. The diverse and pronounced variations in both geometric conditions and kinematic factors encountered along the tool edges in drilling operations result in considerable differences in observed wear.Consequently, an imperative need exists to enhance the comprehension of the micro-geometry evolution of tools on a localized scale, using parameters that describe the local cutting situation. This paper presents a robust methodology aimed at following the evolution of local wear along the cutting edge within the material flow plane (Poe). This method will contribute to a better understanding of wear phenomena with the variation of cutting parameters and angles. Finally, empirical models will correlate the criteria describing wear patterns on the rake and flank faces with influential parameters. This will help in predicting local wear and optimizing the manufacturing of cutting tools for improved lifespan.

Modeling of Frictional Inter-Bristle Contact in Brush Seals With Shaft Radial Movements

Abstract Brush seals are utilized in turbines to minimize leakage flows and enhance thermal efficiency. Their widespread use faces challenges like pressure-stiffening and hysteresis, leading to unpredictable performance. This work introduces an advanced numerical model to simulate inter-bristle frictional contact, shaft and backing ring interaction, and three-dimensional bristle bending. The model is adopted to investigate multi-bristle brush seal's behavior under shaft radial movements and pressure loading. Backing ring friction emerges as a vital factor in hysteresis modeling, lessening the impact of shaft friction. When the shaft retracts, modeling the bristle tip clearance becomes important. The clearance greatly increases leakage flow rate and changes bristles' aerodynamic loading distribution. With clearance, the normal force on upstream bristles rises markedly, opposing bristle hang-up, while the axial force decreases in downstream bristles, alleviating the bristle pack compression. Considering these factors, an improved model for pressurized seals in the shaft retraction phase is developed and compared to experimental data in the literature. Frictional inter-bristle contact significantly modifies the distribution of local tip force through the pack. These effects would influence localized wear and heat generation across the brush seal pack, shedding light on the uneven wear patterns often observed in experiments. The present high-fidelity model can capture these complex interactions, offering a means to deepen our understanding of the physical mechanisms underpinning novel brush seal designs.

Interplay Between Wear and Thermal Expansion in 6082 Aluminum: A Simulation and Experimental Study

This study investigates how wear and thermal expansion interact in 6082 aluminum, utilizing a pin-on-disc tribometer and finite element analysis under diverse mechanical conditions. The findings show that thermal expansion reduces contact area by forming a protrusion at the contact interface. This interaction between wear and thermal expansion causes dynamic shifts in the contact region and pressure distribution, affecting the disc center and altering wear progression and temperature patterns. High thermal expansion shifts maximum wear from the contact center to outer regions, especially at higher speeds and loads. Without thermal expansion, wear-only conditions overestimate friction dissipation, resulting in a higher peak temperature. These results highlight the critical role of thermal expansion in shaping wear patterns and contact behavior in sliding applications. This research offers insights for optimizing tribological performance in 6082 aluminum, with potential applications in other materials.

Analysis of abnormal carbody lateral low-frequency vibration in intercity EMU trains caused by double-hollow worn wheel profiles

Abnormal low-frequency lateral vibrations of the carbody present a significant issue in commercial train operations, severely affecting passenger comfort and potentially compromising operational safety. This is usually linked to carbody hunting, triggered by low equivalent conicity early in the wheel re-profiling cycle. However, in this study, it was observed during the later stages of the wheel re-profiling cycle in conjunction with atypical wear patterns in an intercity EMU train. To investigate the underlying causes, a long-term experimental study was conducted, tracking both carbody vibrations and wheel profile wear. A detailed vehicle dynamics model was developed to analyze the mechanism behind the phenomenon. The study identified that the combination of high hardness in the abrasive blocks of the tread cleaning device, high-pressure continuous operation, and the frequent start-stop cycles characteristic of intercity trains collectively contributed to the development of a double-hollow wear pattern on the wheel profile. This wear pattern reduced equivalent conicity, leading to carbody hunting phenomenon, resulting in a 1 Hz lateral harmonic vibration. To mitigate this issue, the hardness of the abrasive blocks was reduced, and their operation mode was adjusted to low-pressure intermittent operation. Validation through a subsequent re-profiling cycle demonstrated that these modifications effectively shifted the wheel profile to a single-hollow wear pattern, increased equivalent conicity, and prevented the recurrence of abnormal vibrations. This research provides essential insights and practical solutions for railway engineers seeking to mitigate carbody hunting, thereby enhancing operational safety and passenger comfort.

Study on failure analysis and erosion wear of four-way cross in high-pressure gas well test process

High pressure gas well ground testing process working pressure can reach up to 105 MPa. Under severe loading conditions and the influence of internal high-pressure media, the manifold is highly vulnerable to erosion wear damage from solid particles. This study focuses on a failed four-way cross at a high-pressure gas well test site, to characterize its failure modes and features. Utilizing methods such as macroscopic feature observation, scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) analysis. The primary failure mode is identified as the micro-cutting action of stratum solid particles, which cuts and collides with the inner wall under the carriage of high-speed fluid. The erosion defect features present as band-shaped wear marks and parabolic pits. To reveal the erosion failure mechanism of the four-way cross under the multiphase flow, an erosion wear prediction model is developed. This model is based on the theory of gas–solid two-phase flow and the operational parameters of the testing operation process. Secondly, an experiment on the gas–solid two-phase erosion wear of the main material 35CrMo used in the testing process is conducted for the specific operating conditions. Based on the experiment result, a comparative analysis of erosion simulations under different empirical erosion wear models is conducted, and the appropriate erosion wear model for the material is selected, and the empirical coefficient of the model is revised. Finally, an erosion wear simulation prediction of the four-way cross is performed based on the optimal erosion wear model, and the results are compared with the failure location of the failed parts on site. Simultaneously, a study is conducted on erosion wear patterns under varying conditions of gas displacement, sand production volume, particle size, and particle shape factors.

Impact of tool nose size on the performance and wear behavior of carbide tool when boring 1Cr17Ni2 martensitic stainless-steel parts

PurposeThis study aims to examine the cutting performance of a coated carbide tool during the boring of 1Cr17Ni2 martensitic stainless steel, with a focus on how the tool’s structural parameters, particularly the nose radius, affect the wear patterns, wear volume and lifetime of the cutting tool, and related mechanisms.Design/methodology/approachA full factorial boring experiment with three factors at two levels was conducted to analyze systematically the impact of cutting parameters on the tool wear behavior. The evolution of tool wear over the machining time was recorded, and the influences of the cutting parameters and nose radius on wear behavior of the tool were examined.FindingsThe results show that higher cutting parameters lead to significant wear or plastic deformation at the tool nose. When the cutting depth is less than the nose radius, the tool wear tends to be minimized. Larger nose radius tools have weaker chip-breaking but greater strength and wear resistance. Higher cutting parameters reduce wear for the tools with larger nose radius, maintaining their integrity. Wear mechanisms are primarily abrasive, adhesive and diffusion wear. Furthermore, the full-factorial analysis of variance revealed that for the tool with rε = 0.4 mm and 0.8 mm, the factors contributing the most to tool wear were cutting speed (38.76%) and cutting depth (86.43%), respectively.Originality/valueThis study is of great significance for selection of cutting tools and cutting parameters for boring 1Cr17Ni2 martensitic stainless-steel parts.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2024-0266/

Numerical Simulation of Flow Fields and Sediment-Induced Wear in the Francis Turbine

Based on the solid–liquid two-phase flow model and the Realizable k-ε Turbulence model, numerical simulations of the sediment–water flow in the flow components of the turbine were conducted. The distribution of sediment-induced wear within the turbine was obtained by analyzing the sediment volume fraction (SVF) and the erosion rate. The results revealed that sediment-induced wear on the stay and guide vanes was primarily distributed along the water inlet edge of the stay and guide vanes. For the runner blades, wear was predominantly localized along the water inlet edge and near the lower ring. The sediment-induced wear patterns on these flow components were found to be consistent with the sediment volume fractions (SVFs) on their surfaces.