Wear Problems Research Articles

Effect of lubricant functional groups on tribological properties of epoxy/graphene composites

AbstractThe functional group in the molecular chain of lubricants is a key factor for a boundary lubricating film, which can further enhance the friction performance by interfacial tribochemistry. In this paper, the tribological behavior of epoxy/graphene (EP/Gra) composites was investigated through varying lubrication conditions, including dry friction, or different lubricants (such as water, hexadecane, oleylamine, and oleic acid). The porosity and Shore hardness (SHD) of the EP composites were significantly improved by the addition of graphene. Results showed that the porosity of the EP/0.75 wt.% Gra composites was reduced by 75.6% and their SHD increased by 5.4 compared with the EP/0.05 wt.% Gra composites. The average coefficient of friction (COF) of the composites was reduced by at least 27.3% under dry friction conditions. For water as lubricant, the EP/0.5 wt.% Gra composite exhibited the lowest COF (0.0455). The EP/0.75 wt.% Gra composite displayed the lowest COF (0.0466) when hexadecane acted as lubricant. By contrast, EP/0.05 wt.% Gra showed the lowest COF (0.0389) with oleylamine as lubricant, and the EP/0.25 wt.% Gra composites gave the lowest COF (0.0433) under oleic acid. The amine group of oleylamine reacted with the EP group to form a hydroxyl group, resulting in a polymer with low friction adhered to the friction interface. Simultaneously, the EP group reacted with the carboxyl group, forming a network of hydrogen bonds with graphene, which reduced the shear stress on the friction interface. Therefore, the functional groups of lubricants have a vital influence on the tribological properties of frictional composites, which may provide a new approach to solving the problem of wear.

Thermal shock resistance of WC–Cr3C2–Ni coatings deposited via high-velocity air fuel spraying

In this study, the high-velocity air fuel (HVAF) spraying technique was used to deposit WC–Cr3C2–Ni wear-resistant coatings on the surface of crystallization rollers to overcome the wear problem of the substrate of thin-strip continuous-casting crystallization rollers and thus improve their efficiency. The performance and durability of the WC–Cr3C2–Ni coatings on the surface of the roller body during the actual continuous casting process were investigated by performing thermal shock tests. It was found that the thermal shock resistance of the closed-curved surface coatings increased with their thickness. The coatings exhibited the best thermal shock resistance at a thickness of 300 μm, and the number of cycles they could withstand at 800 °C reached 15. The results of the high-temperature wear tests showed that the WC–Cr3C2–Ni coatings deposited on the surface of the crystallization roller via HVAF reduced the friction coefficient of the surface of the roller body (from 0.425 to 0.362), and greatly reduced the wear loss volume during the wear process (reduced by 83 %). The WC-Cr3C2-Ni coating showed excellent resistance to crack initiation and propagation during wear and can be stabilized in long-cycle production and protect the substrate of the crystallization roller effectively. This study provides a theoretical basis for the selection and preparation of surface coatings for thin-strip continuous-casting crystallization rollers.

Biomimetic Design of Soil-Engaging Components: A Review.

Soil-engaging components play a critical role in agricultural production and engineering construction. However, the soil-engaging components directly interacting with the soil often suffer from the problems of high resistance, adhesion, and wear, which significantly reduce the efficiency and quality of soil operations. A large number of featured studies on the design of soil-engaging components have been carried out while applying the principles of bionics extensively, and significant research results have been achieved. This review conducts a comprehensive literature survey on the application of biomimetics in the design of soil-engaging components. The focus is on performance optimization in regard to the following three aspects: draught reduction, anti-adhesion, and wear resistance. The mechanisms of various biomimetic soil-engaging components are systematically explained. Based on the literature analysis and biomimetic research, future trends in the development of biomimetic soil-engaging components are discussed from both the mechanism and application perspectives. This research is expected to provide new insights and inspiration for addressing related scientific and engineering challenges.

Design and Performance Prediction of a Vortex Pump Based on CFD for High Concentration Sludge Dredging

Abstract Aiming at solving the problems of clogging and severe wear of the delivery pump in the sludge dredging project, a design method for a vortex pump was summarized. An open impeller and a cross shaped blade was designed with good passing ability, simple structure, and easy maintenance. The volute flow path profile of the vortex pump was designed as a spiral, and the relationship between the width of the vaneless cavity and the diameter of the impeller was established. Based on CFD, the external characteristics of the DRC45-200-VLS vortex pump were simulated and predicted, with a flow rate of 600 m3/h, a head of 20 m, and a water efficiency of 50%. The effects of medium viscosity, solid phase distribution, and gas phase distribution on the flow field of the vortex pump were analyzed. The results showed that the designed vortex pump had good adaptability to transport high concentration sludge and aerated sludge. Combined with a municipal sludge dredging project, a vortex pump transportation scheme for high concentration sludge dredging was formed.

Numerical prediction of erosion of Francis turbine in sediment laden flow

Abstract Francis turbine is adopted in many hydropower stations widely. Usually, the operating environment is sandy water flow, and the unit will suffer from sediment wear, affecting the operating life of the unit. This article focuses on the wear problem of hydraulic turbines and uses numerical simulation to conduct research on sediment wear. Lagrange model is adopted to predict the sediment concentration in the flowpassageof the unit, and Tabakoff model is used as the wear model. The results indicate that the guide vane blades, seat rings, end clearance, and runner blades and lower rings of hydraulic turbines are prone to sediment erosion. According to friction mechanics, these areas are mainly subjected to impact wear caused by particle impact at the inlet of the guide vane and the runner. The wear on the surface of the blade passage is mainly caused by frictional wear caused by particle sliding motion. The research results provide a certain help for the optimization of hydraulic turbine wear resistance in engineering.

Investigation on tribological properties of high-velocity air fuel spraying WC–Cr3C2–Ni coating on the surface of continuous casting crystallization rollers

To overcome the wear problem of the substrate of thin-strip continuous casting crystallization rollers and improve economic efficiency, high-velocity air fuel (HVAF) technology was used to deposit WC–Cr3C2–Ni wear-resistant coatings on the surface of the crystallization rollers. The existing performance and wear condition of curved WC–Cr3C2–Ni coatings during continuous casting were investigated by the ring-block wear system. The experimental results showed that the WC–Cr3C2–Ni coating with a thickness of 300 μm effectively reduced the coefficient of friction (by 16.4 %) and the wear rate (by 82.5 %) on the surface of the crystallization roller and significantly reduced the roughness of the wear interface (by 71.2 %), which provided reliable protection for the substrate. The results of high-temperature (200 °C) wear tests showed that the WC–Cr3C2–Ni coating deposited via HVAF protected the substrate in actual long-cycle production and exhibited an excellent resistance to the emergence and expansion of failure cracks. This study provided a theoretical basis for the selection and preparation of surface coatings for thin strip continuous casting crystallization rollers.

Surface Wear Monitoring System of Industrial Transformer Tap-Changer Contacts by Using Voice Signal

Surface wear of the tap-changer contacts of industrial transformers (due to frequent switching times) easily leads to operation failure of industrial transformers, which affects the safety and stability of the transmission network. In this paper, an intelligent voice signal monitoring system was proposed for the abnormal condition (surface wear) of tap-changer contacts. This monitoring system was composed of a voice signal acquisition system, voice analysis system and voice processing system. First, the voice signal of the tap-changer contacts was collected, and the collected voice signal was analyzed in the time domain and the frequency domain. Secondly, the characteristic curve of the voice signal was proposed, and the voice curve was compared with that of the normal operation state. In this case, the running state and surface wear abnormal situation of the tap changer could be monitored and determined, and the cause of the abnormal state could also be further analyzed. This method solved the surface wear problem of the tap changer in industrial transformers, which could be not monitored effectively in real time. This method improved the operational reliability of industrial transformers and had high economic and social benefits.

ANALYSIS OF UNCONTROLLED WEAR IN THE AREA OFA BELLEVILLE SPRING OF A FRICTION TORSIONAL VIBRATIONDAMPER IN A MOTOR VEHICLE CLUTCH

The article describes the problem of excessive tribological wear of a torsional vibration damper built intoa single-disc friction clutch of a truck vehicle. In contrast to the controlled, design-based wear of damper’sfriction rings, i.e., wear whose kinetics are known and predictable, uncontrolled wear at Belleville springcontact surfaces effects in a premature decrease in the damper’s friction torque and, consequently, loss ofdurability. As a result of the analyses and experimental work, the causes of accelerated wear were identified.Sets of springs and friction rings from the 10 used vibration dampers that worked under similar operatingconditions but with different operating periods were used as the basic research material. The influence ofabrasive wear of Belleville springs on their load-deflection characteristic was identified. A comparativeanalysis of the characteristics of the new spring and the used springs is also presented to illustrate changes inthe axial load in the assemblies of the analyzed dampers.

Experimental investigation of cutting force of powder metallurgy valve guide rod hole

Aiming at the problem of fast wear of machining tools in the special powder metallurgy valve guide rod hole and gasket seat of a certain engine cylinder head, in order to solve the technical problems in the cutting force (CF) of this kind of powder metallurgy materials, different tools are used and the analysis is carried out under different cutting test conditions. The cutting force law and surface roughness change law of similar powder metallurgy materials are determined to determine the appropriate tool materials and processing parameters. The experimental results show that under the same processing conditions, ceramic tools will suffer less than cemented carbide tools and cutting force can obtain a smaller surface roughness. In addition, the mass production process of valve seat, the blade material is ceramic knife.

SUBSTANTIATION OF SOLUTIONS TO INCREASE THE DURABILITY OF THE INNER ROWS OF STEEL TEETH OF ROLLER CONE BITS DURING DRILLING OF BOULDER-PEBBLE ROCK FORMATIONS

The article deals with issues concerning the increase in the productivity of roller bits when drilling soft and soft-medium rocks with inclusions of boulder-pebble formations by justifying solutions to increase the relative safety margin of steel teeth expressed in an increase of the impact strength of the material for making cones in combination with an increase in the geometry of steel teeth. The efficiency of the rock-crushing tool and, as a result, the destruction of rock during the entire drilling cycle, directly depends on the resource and durability of the elements of the roller bit. When drilling the upper intervals of deposits in the East Siberian region, composed of soft and soft-medium rocks with inclusions of boulder-pebble deposits, there is a problem of premature wear of the drill bit. Both PDC bits are subject to catastrophic wear due to chips and fractures of PDC cutters, as well as roller bits. The use of first-class roller bits with steel teeth leads to advanced wear, expressed by the scrapping of the teeth of the inner rows. This leads to a «hanging» of the bit and a loss of mechanical penetration speed. Based on this, the work provides recommendations for increasing the durability of steel teeth for first-class roller cone bits.

Multi-objective optimisation of a metro wheel profile to reduce wheel flange wear and RCF considering the distribution density of wheel−rail contact points

In this study, the problem of severe wheel flange wear and tread rolling contact fatigue (RCF) of metro wheels with two wheel profiles, i.e. the LM-30 profile and the DIN5573-30 profile, is investigated. The contact characteristics of the two profiles are compared to analyse the causes of wheel flange wear and RCF. Indices combining the density distribution of contact points are proposed to evaluate the wheel flange wear and RCF. The optimisation region of the wheel profile is defined by eight arc parameters, which is derived from the tangency of the arcs. A back-propagation neural network is constructed as a surrogate model for the design variables and the objective function. Four intelligent optimisation algorithms are compared and used to solve the optimisation problem. The vehicle—track dynamic model and the wheel wear and RCF prediction model are used to verify the performance of the optimised profile. The results show that the critical speed of the optimised profile is between that of the LM profile and that of the DIN5573 profile, and the curving performance of the optimised profile is significantly improved. At the same time, the optimised wheel profile can reduce wheel flange wear and tread RCF.

A simplified model for the wear prediction of plain bearings in the variable stator vane system

The wear of plain bearings in the variable stator vane (VSV) systems in a turbojet engine is a significant problem for compressor efficiency and stability requiring adapted models. The VSV bearings are located in a complex system and are exposed to combined and oscillating loads. This study aims to predict the wear evolution of the VSV bearings, considering the complexity of the system’s geometry and the loads with adapted computational time. This paper presents a three-dimensional formulation of this highly nonlinear wear problem under simplifying hypotheses in the objective to obtain a compromise between the quality of the prediction and the CPU time.

Analysis and design of multi-mode power split hybrid transmission scheme considering mode connection

For heavy-duty truck, multi-mode power split hybrid transmission scheme (MPSHTS) has good adaptability. However, the moment of inertia at both ends of the clutch is large. If there is a large speed difference in the clutch engagement process, it will increase clutch wear, engine stall and other problems. This paper proposed a new design method of multi-mode power split hybrid powertrain, which was different from the proof by exhaustion aiming at mode switching without speed difference. It included: the conditions for achieving mode connection without speed difference was obtained based on the lever method for dynamic characteristic analysis. Evaluation index for power split mechanisms that comprehensively considered power source and transmission system was established. Combining the mode connection conditions and the optimized basic configuration, the characteristic of no speed difference could be ensured by adjusting the power coupling mechanism. A multi-mode scheme based on optimized configuration and work mode requirements could be obtained. Finally, parameter matching and simulation verification on the designed scheme was carried out. It suggested that the designed system improved fuel economy by 4.14% compared with the original scheme.

Effect of line parameters on wheel wear of heavy–haul freight vehicle

Purpose The serious wear problem of heavy-haul freight vehicle wheels affects the safety and economy of vehicle operation. This paper aims to study wheel wear evolution law and the influence of line parameters on wheel wear of heavy-haul freight, and provide the basis for operation and line maintenance. Design/methodology/approach The wheel wear test data of heavy-haul freight vehicles were analyzed. Then a heavy-haul freight vehicle dynamic model was established. The line parameters influencing wheel wear in heavy-haul freight vehicles were also analyzed by the Jendel wear model, and the effects of rail cant, rail gauge, rail profile and line ramp on wheel wear were analyzed. Findings A rail cant of 1:40 results in less wheel wear; an increase in the rail gauge can reduce wheel wear; and when matched with the CHN60 rail, the wear depth is relatively small. A decrease of 9.21% in wheel wear depth when matched with the CHN60 rail profile. The ramp of the heavy-haul line is necessary to consider for calculating wheel wear. When the ramp is considered, the wear depth increases by 8.47%. The larger the ramp, the greater the braking force and therefore, the greater of the wheel wear. Originality/value This paper first summarizes the wear characteristics of wheels in heavy-haul freight vehicles and then systematically analyzes the effect of line parameters on wheel wear. In particular, this study researched the effects of rail cant, rail gauge, rail profile and line ramp on wheel wear. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-02-2024-0038/

Multi-field coupling numerical simulation and experimental research of submerged arc surfacing process on the descaling rolls with different wall thickness

Iron and steel industry descale rolls long-term high-pressure water erosion, high temperature, easy to wear, corrosion failure and other problems, the continuous production of steel rolling impact, descale rolls base wall thickness is the main cause of cracking of the surfacing gradient lap organization. This article combines numerical simulation and experimental testing, the use of CALPHAD method to calculate the surfacing material temperature change physical parameters, based on the double ellipsoid heat source model, the establishment of the descale roller submerged arc surfacing process of multi-field coupling three-dimensional numerical model, calculations and reveal the descale roller submerged arc surfacing process of the temperature field, the stress field, the phase change field and the flow field of the transient evolution of the law, and further analyze the descale roller wall thickness of the surfacing process of the influence of the mechanism. Calculation results show that the depth of melting of the surfacing matrix is positively correlated with the width of the double ellipsoid heat source, and the larger the wall thickness, the faster the cooling rate, the greater the formation of residual stress. The austenite and martensite phase transformation of the overlay welding process is greatly influenced by the wall thickness. At the same time, SEM, EDS, XRD material science microcharacterization experiments were carried out to observe the micro-morphology, phase and elemental composition of the cladding layer. This study lays an important theoretical foundation for optimizing the submerged arc surfacing process of descale roller.

Experimental and numerical study on the high-speed gas-solid nozzle erosion of choke manifold material in high pressure and high production gas well

High pressure difference, high flow rate, and high sand content in throttling manifolds of high-pressure and high-production gas wells make the problems of high-speed gas-solid erosion wear especially prominent. The failure of the throttling manifold is frequent, which is easy to induce overflow, kick, and blowout accidents, aggravates well-controlled risks, and brings safety risks. Therefore, according to ASTM G76–2013, this paper adopts the gas-solid nozzle erosion test method and air jet erosion test rig. The high speed (107 m/s-49 m/s) gas-solid nozzle erosion test of 30CrMo alloy steel was carried out under different inlet pressures (0.06 MPa–0.15 MPa) and impact Angle (15°-90°), and the erosion rate of 30CrMo alloy steel under different experimental conditions was obtained. The erosion rate equation of 30CrMo alloy steel suitable for high-speed solid particle impact is established. Based on the results of erosion experiments, the optimal particle motion model for high-speed compressible flow is constructed. Combined with the discrete phase model (DPM) and gas-solid two-phase coupling calculation method, a three-dimensional CFD erosion model of the “reduced-tuber-nozzle-erosion cavity” was established. The erosion simulation of the gas-solid nozzle of 30CrMo alloy steel, a throttling manifold material, was carried out at different impact angles (15°-90°) and inlet pressure (0.06 MPa–0.15 MPa), and the distribution characteristics of the flow field, particle movement trajectory, impact velocity distribution, and slip characteristics were revealed. The accuracy and reliability of the CFD erosion model and simulation results have been validated by test data.

High Efficiency Milling of Inconel 625 Alloy (Effect of Cutting Condition on Tool Life)

Inconel 625 alloy consisting of Ni and Cr and others has advantageous properties such as heat resistance and corrosion resistance, which make it a suitable material for application in aerospace, energy, and marine industries. However, it is also a difficult-to-machine material because of factors such as work hardening, low thermal conductivity, and high tool affinity. Therefore, the problems of the tool wear, chipping, and adhesion often occur in milling of Inconel 625 alloy using end mills. In this study, the milling of Inconel 625 was conducted using coated cemented carbide end mills, and the cutting conditions with the high efficiency were investigated under three rotational speeds and four feed rates. The results showed that increasing the feed rate increased the surface roughness, but did not increase the tool life. In addition, the results also showed that increasing the rotational speed did not increase the tool life, but reduced the surface roughness. As a result, the effects of the rotational speeds and feed rates on the tool life were clarified.

Influence of Quenching and Tempering on the Tribological and Corrosion Behavior of Plasma‐Nitrided Society of Automotive Engineers 52100

Society of automotive engineers (SAE) 52100 (100Cr6) steel, used in manufacturing bearings and shafts, deserves attention due to wear and corrosion problems that cause machine losses in the industry. To solve these problems, heat treatments such as quenching and tempering are adopted to reduce wear mechanisms. However, in this work, the effect of these previous heat treatments on the final properties of plasma nitrided steel at three different temperatures (400, 450, and 500 °C) is evaluated. Surface hardness, tribological behavior, and corrosion resistance are evaluated. In the results of Vickers hardness, wear, and electrochemical analysis, it is shown that performing plasma nitriding at 400 and 450 °C on previously heat‐treated SAE 52100 steel provides better mechanical resistance and chemical integrity in a corrosive environment, making the studied steel more comprehensive for important industrial applications.

Thermo-hydrodynamic lubrication and energy dissipation mechanism of a pump-turbine thrust bearing in load-rejection process

The dynamic behavior of the pump-turbine thrust bearing is important to the safety operation of the unit. This paper analyzed the lubrication and energy dissipation mechanism of pump-turbine thrust bearing during load-rejection based on the thermo-hydrodynamic model. The results show that the variation of the axial force and the maximum pad surface pressure is basically consistent with that of the inclination of the pad surface. The change of the friction loss is consistent with the change of rotational speed, while the change of pad surface temperature is affected by the combination of pad inclination and rotational speed. The chaotic flow in the oil tank is accompanied by different forms of vortices, such as Taylor vortices, vortex pairs, and Karman vortices, and results in a significant asymmetry in the pressure distribution. The flow in the bearing pad groove has an effect on the energy dissipation in the oil film. This paper provides a theoretical basis for the design and optimization of thrust bearings, and provides a reference for solving the problems of wear, oil mist, and other related problems of thrust bearings in engineering.

Further enhancement of surface mechanical properties of carburized 9310 steel by electropulsing-assisted ultrasonic surface rolling process

9310 carburized steel experiences significant wear and spalling problems when operating under high friction and heavy loads, which severely restricts its applications in the aviation industry. Therefore, it holds great significance to further enhance the surface mechanical properties of 9310 carburized steel through suitable surface strengthening technologies. The Electropulsing-Assisted Ultrasonic Surface Rolling Process (EP-USRP) has been successfully applied to carburized 9310 steel, yielding significant improvements in surface quality, hardness, friction and wear properties, and microstructure. Systematic investigations were conducted under varying EP-USRP parameters. Regarding the electric pulse parameters, it is observed that with the increase in output voltage, surface properties such as surface roughness and surface hardness tend to first optimize and then deteriorate. After applying EP-USRP with optimal parameters, the surface roughness of carburized 9310 steel was reduced to Ra 0.154 μm, a mere 5 % of its initial value. The surface hardness experienced a substantial increase, reaching 909.2 HV, representing a notable improvement of 29.9 % compared to the original sample, with a corresponding hardening depth of 1400 μm. Moreover, the wear amount of carburized 9310 steel witnessed a remarkable reduction to 11.8 % of its initial value, accompanied by a decrease in the coefficient of friction to 43.0 %. The enhancement of carburized 9310 steel through EP-USRP is attributed to two key mechanisms: deformation hardening induced by severe plastic deformation and microstructure strengthening resulting from strain-induced martensitic transformation. Among them, the severe plastic deformation mechanism is dominant, Through these mechanisms, the proportion of small-angle boundaries in carburized 9310 steel strengthened by EP-USRP increased. Additionally, the grain size of the surface layer decreased, and the content of retained austenite in the surface layer decreased, collectively contributing to significant improvements in surface properties, as well as friction and wear performance.