Wear Evolution Research Articles

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

Purpose This 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/approach A 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. Findings The 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/value This study is of great significance for selection of cutting tools and cutting parameters for boring 1Cr17Ni2 martensitic stainless-steel parts. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2024-0266/

Evolution of tool wear and machining quality during dry milling of AlCoCrFeNi2.1 eutectic high entropy alloy

AlCoCrFeNi2.1, a new class of eutectic high entropy alloy (EHEA) has drawn significant interest owing to the lamellar structure of alternating face-centered cubic (FCC) and B2 phases. Properties such as high strength and high plasticity render the machining of this alloy challenging. Addressing this issue, the milling experiments were conducted under dry conditions to investigate the machining quality of AlCoCrFeNi2.1 EHEA as well as the tool wear. The cutting temperature and cutting force were measured to explain the changes in tool wear and machining quality. The tool wear mechanisms and evolution modes were clarified. Finally, the change of surface roughness and surface morphology under different parameters were analyzed and the characterization method of plastic flow marked by B2 phase was proposed. Results showed that both the cutting temperature and cutting force increase as the milling parameters become larger. The width of flank wear increases with the increase of the cutting speed and the feed rate when the volume of material removal volume is constant. The tool wear modes evolved differently with different cutting parameters, for instance, abrasive wear dominated while the cutting speed was less than 80 m/min, but for higher speeds up to 110 m/min, adhesive wear and coating peeling occurred. As the cutting speed increases further, crater wear on the rake face starts to arise in addition to the flank wear. Abrasive wear and adhesive wear with increasing feed rate were dominant until a certain threshold (0.10 mm/tooth) beyond which the coating peels off the tool. Furthermore, chipping occurred for a higher feed rate of 0.14 mm/tooth. In particular, the formation of tool adhesive wear is mainly caused by the FCC phase adheres. In terms of machining quality, larger cutting parameters will worsen the surface roughness and morphology as well as lead to deeper subsurface plastic flow. The research will be conducive to promoting the applications of AlCoCrFeNi2.1 HEA.

Research on wheel wear evolution of inside axlebox metro vehicles

Research on wheel wear evolution of inside axlebox metro vehicles

Investigation on meshing characteristics of spiral bevel gear under wear fault evolution with assembly errors

Spiral bevel gears have the advantage of transmitting high torque and power comparing to helical gear and straight bevel gear. However, they are susceptible to wear due to factors such as high loads, poor lubrication, and surface imperfections resulting from machining. In this study, we propose an autonomous model for predicting tooth wear and analyze the meshing characteristics of spiral bevel gear (SBG) pairs under different assembly errors. Concurrently, we establish a finite element model to validate the accuracy of our meshing characteristic analyses. We also compare the distribution patterns of wear depth on the tooth surface with existing literature. Our investigation delves into meshing characteristics, encompassing transmission errors and Time-varying mesh stiffness (TVMS), considering wear evolution under assembly errors. The results demonstrate that the fluctuations in TVMS remain consistent across all four types of assembly errors examined. Gear tooth wear leads to an increase in gear backlash and fluctuations in unloaded transmission error. The meshing stiffness fluctuation of the SBG pair enlarges under wear evolution. Assembly errors result in shifts in the initial contact line and contact pattern, subsequently altering the distribution of wear depth. Different forms of assembly errors may cause a similar effect on the distribution of wear depth and meshing characteristics.

Tool wear evolution and its influence on cutting performance during milling ultra-high-strength steel using different cooling conditions

Tool wear evolution and its influence on cutting performance during milling ultra-high-strength steel using different cooling conditions

Frictional Wear Behavior of Water-Lubrication Resin Matrix Composites under Low Speed and Heavy Load Conditions.

Resin matrix composites are commonly utilized in water-lubricated stern tube bearings for warship propulsion systems. Low-speed and high-load conditions are significant factors influencing the tribological properties of stern tube bearings. The wear characteristics of resin-based laminated composites (RLCs), resin-based winding composites (RWCs), and resin-based homogeneous polymer (RHP) blocks were investigated under simulated environmental conditions using a ring-on-block wear tester. Simulated seawater was prepared by combining sodium chloride with distilled water. The wetting angle, coefficient of friction (COF), and mass loss were measured and compared. Additionally, their surface morphologies were examined. The results indicate a significant increase in the COFs for the three materials with an increased speed or load under dry conditions. The COF of the RLCs is the lowest, indicating that it has superior self-lubricating properties. In wet conditions, the COFs of the three materials decrease with an increasing speed or load, exhibiting a pronounced hydrodynamic effect. The COF and mass loss of RWCs are the highest, while RLCs and RHP exhibit lower COFs and mass loss values. The reticulated texture and flocculent fibers on the surface of RLC enhance the heat diffusion and improve the material wettability and water storage capacity. The surface of RWC is dense, and the friction area under dry conditions is melted and brightened. The surface of RHP is smooth, while the worn material forms an agglomerate and exhibits susceptibility to burning and blackening under dry conditions. The laminated formation method demonstrates superior tribological performance throughout the wear evolution process.

A novel IoT sensor and evolution model for grinding mill liner wear monitoring

Tracking mill liner wear is essential for improved plant reliability and grinding performance. This study developed a novel IoT wear sensor and a Discrete Element Modelling coupled methodology to predict and continuously evolve shell liner’s wear pattern. The IoT sensor was purposely developed to track and report the live thickness of a shell liner. Global wear pattern was then obtained by coupling the qualitative wear intensity obtained in DEM and sensor results, from which a topological evolution model was established to generate the shell liner’s progressive wear profiles. Predictions of the wear evolution model were compared with 3D laser scan measurements collected during operation. Results indicated that the wear evolution model showed less than 8% error with laser scan measurements in quantitative wear rate comparison.

Wear characteristics evolution of helical gear with initial defects of bearing inner ring

This study investigated the wear characteristics and operational condition of gears with initial defects of the bearing inner ring. The working states of gears were evaluated through a combination of vibration signal analysis, wear debris concentration analysis, qualitative analysis of the wear debris, and tooth surface analysis. Based on the Hertz contact theory, a dynamic model for the gear drive system was constructed, enabling the simulation and comparison of vibration acceleration signals under normal and fault conditions. The research results revealed that bearing defects induced irregularities in vibration frequency and amplitude, adversely affecting the performance and stability of the gear system. Furthermore, these defects trigger the creation of substantial wear debris, which exacerbates gear wear and reduces the gear lifespan by about 15%. Additionally, bearing defects induced intermittent load spikes and uneven stress distribution across tooth contacts, resulting in localized high shear stresses, material flaking, and surface spalling. Consequently, initial defects of the bearing will accelerate gear wear progression and lead to abnormal wear patterns, potentially resulting in the premature failure of the gear train system. The study investigates the underlying mechanisms of gear wear evolution influenced by these defects and offers practical guidelines for the engineering, manufacturing, and maintenance of gear systems.

A comprehensive sliding wear prediction method for planetary roller screw mechanism

The thread-pairs wear has a significant role in the transmission accuracy, operational stability and service life of planetary roller screw mechanism (PRSM). Nevertheless, the previous literatures still lack the investigation on the wear evolution of roller, nut and screw. Hence, an accumulative wear depth (AWD) prediction model is proposed for PRSM with reciprocating motion. The presented model is validated by the measured wear phenomena of thread pairs and the experimental results in the literature. The equivalent sliding wear experiment of PRSM is designed and the sliding wear coefficient of PRSM material is obtained by the equivalent sliding wear experiment. Considering the thread profile error caused by AWD of roller, nut and screw, the load distribution (LD) and sliding velocities on screw-roller (SR) and nut-roller (NR) sides are calculated. More importantly, the interactions between the AWD, LD and sliding velocity are investigated. Furthermore, the effects of axial load on the AWD, sliding velocities in contact regions and load distribution coefficient are analyzed.

Initiation and evolution of interference wear and pitting for spur gears considering the concurrent effects of meshing impact and mixed lubrication

Extended tooth contact (ETC) leads to specific load paths, introduces periodic overload and lubrication degeneration. These disadvantages cause specific interference wear and pitting. This work proposes a wear-pitting prediction model incorporating ETC, dynamic motion, and mixed EHL to investigate coupling relations between these factors. The model predicts a MI-induced wear-pitting competition phenomenon, indicating that when the film load capacity is improved, an additional pitting streak emerges at 1.2 mm from the pinion tooth tip while the maximum wear depth decreases from 32.9 µm to 10.2 µm. Two endurance experiments under different working conditions are performed on the FZG test rig. The predicted wear distribution and pitting areas are consistent with the tested results.

Study on the dynamic evolution of friction and wear of polyurethane material for pipeline inspection gauge

The dynamic evolution in friction and wear can lead to interface failure and induce vibrations in pipeline inspection gauge. The friction behavior between polyurethane and X70 steel was evaluated with annular face contact under 0.042 to 0.07 MPa. The temperature increase was recorded using infrared cameras. Dynamic simulations of frictional heat and stress-strain were conducted using Abaqus software. The results indicate that in the initial stages, abrasive wear, stress (1.5 MPa), and frictional temperature rise (65 °C) of PU were observed in the inner-ring region at 0.056 MPa. The surface roughness (3.394 μm) of the PU became comparable to that of the steel ring (3.768 μm) due to abrasive wear. In the later stages, a higher frictional temperature (80 °C) and increased stress (3.8 MPa) were observed in the outer ring. Concurrently, Schallamach waves and ridge-like stripes indicative of stick-slip behavior emerged in the outer ring. The viscoelastic hysteresis effect is the fundamental cause of the dynamic evolution of the friction coefficient and wear. Frictional heat exacerbates the evolution of stick-slip behavior and increases fluctuations in the friction coefficient. The findings of this research can be utilized to analyze the causes of interface failure and vibration in pipeline inspection gauge.

Wear behavior and impact breakage characterization of PCD teeth of circular saw blades during high-speed sawing of hard aluminum alloy

Polycrystalline diamond (PCD) wear is a classic issue limiting the widespread use of PCD circular saw blades, impairing the final cost and productivity. However, previous studies have rarely focused on the wear of PCD layers of saw teeth considering the vibration effect. Hence, this study aimed to elucidate the wear behavior and impact breakage characteristics of PCD teeth in sawing hard aluminum alloys. Sawing experiments were conducted, while vibration signals and force signals were captured in real-time. Then, wear morphologies of different zones of the PCD tooth were finely characterized and studied by SEM. The results suggested that the main wear types of cutting edges are abrasion, chipping, and adhesion. The abrasive wear was found on the cutting edges, side edges, rake faces, and flank faces. Interestingly, the breakage in chipping zones is mostly marked by grain spalling and cleavage fracture due to binder strength limitations. Adhesive wear occurs in wear zones by EDS analysis. A schematic of the impact wear evolution mechanism is given to explore in detail the wear morphologies of PCD layers. The wear behavior and morphological characterization of the PCD layer are finely discussed considering impact load and sawing factors (e.g., adhesive chips). This study sheds insight into the wear behavior of PCD teeth and guides the design of PCD layers.

Response surface test simulation of locking system reliability considering kinematic pair wear evolution

The concentrated load endured by the locking system during the weapon mounting and release procedures may lead to mechanical wear in hinges and kinematic pairs, thereby influencing the functional reliability of the weapon rack mechanism system. This study aims to investigate the impact of kinematic pair wear evolution on the reliability of the locking system. Firstly, a rigid-flexible coupling multi-body dynamics model of the locking system was established to simulate the dynamic behaviors of the rack under different loading conditions. Moreover, the wear amounts of the main kinematic pairs were precisely calculated by the Archard wear model to provide data support for the subsequent reliability analysis. Subsequently, the response surface method was employed to design the orthogonal experiments for the reliability analysis of the locking system, and the reliability degradation law of the locking system within the design lifespan was obtained through the Monte Carlo method simulation. The research findings indicate that the wear of kinematic pairs has a significant effect on the motion function and accuracy of the mechanism. The motion reliability of the mechanism can be maintained above 99% within the design lifespan. Nevertheless, when the usage time exceeds twice the design lifespan, the reliability drops significantly to approximately 85%, and the influence degrees of different wear positions on the reliability were obtained through the sensitivity analysis. The research results not only provide a scientific basis for the optimal design of the locking system but also offer a novel perspective and method for the reliability assessment and maintenance strategy of the weapon rack locking system.

Multi-objective optimization design of rail grinding profile in Curve Section of Subway based on wear Evolution and representative worn profile

Curve rail grinding has always been one of the key points of subway maintenance and repair. The appropriate grinding can effectively reduce wear. A multi-objective optimization design method for grinding profiles in curved sections is proposed. Firstly, representative grinding profiles are selected as the initial population using the dynamic time regularization algorithm (DTW). Then, the optimal design range is determined based on wear characterization analysis, and mathematical expressions of wheel profiles are chosen as design variables to establish a parametric model. Next, the prediction model considering the evolution of wheel wear is incorporated into the multi-objective function, and objective function adaptive weight adjustment coefficient factors are introduced to establish the multi-objective optimization model for wheel profiles. The Latin hypercubic sampling method is employed to establish the RBF agent model for simulation calculation, and the optimization design of wheel profiles is carried out using the TS-NSGA-II multi-objective algorithm.

Research on dynamic and wear prediction models of compound planetary transmission systems

Under high speeds and heavy loads, gear tooth surfaces will be worn, which will lead to accidents. The current wear prediction model is not comprehensive, but the wear prediction model that considers the temperature field and dynamic response can provide more accurate gear wear fault early warning than previous methods. Therefore, according to the Archard model, the discrete wear prediction model of the tooth surface is deduced in this paper, and the wear evolution trend of the tooth surface is predicted and analyzed in each operation stage. The tooth surface temperature field was simulated by the finite-element method, and the tooth surface wear prediction model was improved considering its influence on materials. In addition, the dynamic model of the compound planetary transmission system was established, and the wear prediction model was improved again by using its nonlinear meshing force. Finally, the tooth wear prediction model under the interaction of the dynamic response and temperature field was obtained. A wear measurement method based on duplicate adhesive film was proposed. The wear evolution trend along the tooth length direction and the tooth width direction were measured, and the accuracy of the wear prediction model was verified. The results show that the wear depth along the tooth width direction is larger in the middle part and smaller on both sides under the influence of temperature. After the interference of the dynamic response, the wear depth along the tooth rectangle fluctuates, which is very similar to the results of the theoretical prediction model. It provides a theoretical basis for the early warning of gear health status in practical engineering.

Calculation and Analysis of TVMS Considering Profile Shifts and Surface Wear Evolution Process of Spur Gear

Profile shift is a highly effective technique for optimizing the performance of spur gear transmission systems. However, tooth surface wear is inevitable during gear meshing due to inadequate lubrication and long-term operation. Both profile shift and tooth surface wear (TSW) can impact the meshing characteristics by altering the involute tooth profile. In this study, a tooth stiffness model of spur gears that incorporates profile shift, TSW, tooth deformation, tooth contact deformation, fillet-foundation deformation, and gear body structure coupling is established. This model efficiently and accurately determines the time-varying mesh stiffness (TVMS). Additionally, an improved wear depth prediction method for spur gears is developed, which takes into consideration the mutually prime teeth numbers and more accurately reflects actual gear meshing conditions. Results show that consideration of the mutual prime of teeth numbers will have a certain impact on the TSW process. Furthermore, the finite element method (FEM) is employed to accurately verify the values of TVMS and load sharing ratio (LSR) of profile-shifted gears and worn gears. This study quantitatively analyzes the effect of profile shift on the surface wear process, which suggests that gear profile shift can partially alleviate the negative effects of TSW. The contribution of this study provides valuable insights into the design and maintenance of spur gear systems.

Influence of drilling technology on wear evolution of impregnated diamond bits

Diamond exposed on the surface of an impregnated diamond bit (IDB) is the key to breaking rock. The exposure conditions of the diamond affect the drilling efficiency and life of the bit. However, scant attention has been directed towards investigating the diamond exposure mechanism of IDBs, particularly under varying drilling process conditions. In this study, drilling experiments were conducted on granite under rotary and rotary-percussive drilling conditions using a self-developed drilling test platform. The evolution of diamond emergence on the surface of the IDB under two drilling technology conditions was evaluated; the typical characteristics of diamond wear and their causes were discussed. The results indicate that under rotary drilling conditions, the primary evolution process of diamond on a slippery IDB surface follows the sequence of Emerging→Whole→Blunt (Flat). The exposed diamond tends to be predominantly blunt and fractured, and a slippery IDB cannot be resharpened by increasing the weight-on-bit. The evolution process of a diamond under rotary-percussive drilling conditions encompasses Emerging→Whole→Fractured→Pull out, and the diamond on the surface of the bit is primarily fractured. Diamond emerges from the matrix in the form of points, lines, and planes, with different emergence states affecting its wear and failure modes. The main form of wear in diamonds is mechanical wear, which is dominated by abrasive and fatigue wear. The proportion of fractured diamonds was notably higher under rotary-percussive conditions than in rotary drilling conditions. The tail of the diamond under rotary-percussive drilling conditions was shorter than that under rotary drilling conditions. The impact effect in rotary-percussive drilling enhances the bit-rock contact, facilitating matrix wear and diamond emergence. These results provide valuable insight for optimizing the IDB design and refining drilling technology.

Dynamic analysis of spindle-bearing system considering bearing wear evolution

Dynamic analysis of spindle-bearing system considering bearing wear evolution

Cloud maps highlighting dynamic characteristics of surface signal to improve time-varying wear evaluation accuracy

This paper proposes a high accuracy time-varying wear evolution method with cloud maps highlighting dynamic characteristics of surface signal. Firstly, the cloud map method is established by arrangement of measured data, thus time-varying wear evolution process is visualized on a series of plane figures for preliminary qualitative analysis. Then, high accuracy recognition of time-varying wear states is realized by cloud map shape parameters, including kurtosis and 1-D kernel density function highlighting distribution information of surface signal. The relative recognition degree by cloud map shape parameters are higher than those of friction coefficient, Root-Mean-Square (RMS) deviation and fractal dimension. Finally, high accuracy time-varying wear life prediction is realized by cloud map size growing speed highlighting waviness information of surface signal. The relative prediction error is reduced from more than 20% to less than 10% compared with friction coefficient and roughness.

Research on the Wear Evolution Behavior of 20CrMnTi Alloy Steel under Different Loading Conditions

Abstract 20CrMnTi alloy steel has excellent surface hardness and good wear resistance, making it widely used in the preparation of key components of various high-speed and high-load gearboxes, such as gear, rack, and bearing. However, the existence of friction and wear behavior in service leads to various damage behaviors, which seriously affects its service stability and effective life. Based on experimental research and numerical simulation technology, this study reveals the damage evolution law of 20CrMnTi low carbon alloy steel under different wear load conditions. It is shown that the increase of wear load and time duration will obviously lead to the increase of contact stress and deformation of the material surface, and eventually lead to an increase in wear degree. The research findings provide experimental support and theoretical guidance for effectively predicting the damage law in actual service.