Wear Loss Research Articles

Mechanical and Durability Properties of Concrete with Volcanic Rock Additives

This study investigated the possibility of using basalt, diabase, and andesite natural stones instead of virgin fine aggregates. Substitution percentages varied between 10% and 40% according to the sand mass. The effect of basalt, diabase, and andesite addition on concrete performance was evaluated using strength and durability tests performed on the samples at the end of 7, 28, and 60 days. In addition, petrographic-mineralogical, X-ray diffraction (XRD), and scanning electron microscopy (SEM) analyses of basalt, diabase, and andesite stones were evaluated. The 60-day compressive strengths of the samples were 39% higher in samples with basalt additives, 35% higher in samples with diabase additives, and 37% higher in samples with andesite additives than in the control sample. At the end of 28 days, the water absorption rates of the samples with additives were 113.83%–55.81% less that of the control sample, on average, and the samples suffered 26%–52% less wear loss than the control sample. In addition, at the end of the freeze–thaw cycles, the compressive strengths of the samples with basalt, diabase, and andesite added were 67%, 63%, and 64% higher than that of the reference sample, respectively. The compressive strength values of samples exposed to the effect of sulfate for 180 days were examined, and samples with basalt, diabase, and andesite added had compressive strength values an average of 33.35%, 32.52%, and 32.80% higher than that of the reference sample, respectively. This study proves the usability of basalt, diabase, and andesite natural stones and their wastes as fine aggregate.

Effects of gradient nanostructures on the tribological properties and projectile abrasion during high-speed penetration in AerMet100 steel

To reduce the mass abrasion of AerMet100 ultra-high strength steel projectiles at increasing velocities, surface mechanical grinding treatment (SMGT) was employed to prepare a gradient nanostructure (GNS) on the AerMet100 surface. The microstructure of the GNS were investigated using scanning electron microscopy (SEM), X-ray diffraction (XRD), transmission electron microscopy (TEM), and nanoindentation. It was found that the gradient nano-crystal structure was successfully prepared, and the martensite plate width was reduced to about 30 nm. As the distance from the surface depth increased, the plate size gradually increased, with the depth of the grain refinement layer measuring approximately 300 μm. The microhardness of the GNS AerMet100 was 870 Hv0.025, which was approximately 40% higher than that of the AerMet100 substrate. Additionally, the hardness was observed to decrease with increasing GNS depth. The friction and wear behavior of coarse grained (CG) AerMet100 and GNS AerMet100 were investigated. The results showed that their friction coefficients were similar, but wear volumes of GNS AerMet100 were smaller than those of CG AerMet100, the wear mechanisms of two surfaces were predominantly abrasive and adhesive wear. Furthermore, the projectiles penetration test showed that the mass loss of GNS AerMet100 was significantly lower than that of CG AerMet100 under similar velocity condition. Within the velocity range of 1200–1750 m/s, the degree of erosion and wear loss of the CG AerMet100 and GNS AerMet100 projectile noses increased with increasing penetration velocity, and the wear mechanism was mainly abrasive wear.

Examining Vicker Hardness and Wear Volume Minimization in Composite Resin with Different Filler Dimensions via Scanning Topography

Aim: To compare the surface hardness of the nanohybrid resin composite with the other filler-containing resin composites. Material and Method: Abrasive wear properties of four types of resin composites: Harmonize (HM), Tetric N-Ceram (TNC), Filtek Z250 (Z250), and Filtek Z350 (Z350). Each composite had six 10 mm-diameter, 6 mm-thick cylindrical specimens for testing. The wear test involved subjecting the specimens to 800 cycles of abrasive wear under a 17 kg load. Surface hardness and weight loss were measured using a Vickers indenter micro-hardness tester after polishing. Surface morphology investigation was carried out using SEM on three specimens from each composite after the wear test. To identify significant differences in the wear characteristics of the resin composites, statistical analysis was conducted using one-way analysis of variance (ANOVA) and the Tukey HSD test (with α = 0.05). Results: The highest volumetric wear loss was observed in the Z350 XT nano-filled resin composite (71.19±2.49 mm3). The lowest was found in Z250 micro hybrid restorative material (36.33±1.57 mm3). The highest Vickers hardness was found in the Z250 micro-hybrid restorative material (111.24±2.1). Moreover, the lowest microhardness was found in tetric N ceram (TNC) (58.41±1.22). Conclusion: The wear resistance of micro-hybrid resin composite Z250 was found to be superior to that of other composite resins tested in the study.

Selective oxidation induced wear degradation in cemented carbides

Understanding the wear micro-mechanisms of metallic binders is a prerequisite to designing durable cemented carbides for drilling applications. Here we studied the oxidational wear behaviors of WC-based composites encompassing particularly the CoAl binder (α phase, comprised of 5.7 wt% Al and bal. Co) and the CoFeAl binder (B2 phase) with same Al content. Unlike the oxidation of Co in the CoAl, selective oxidation of Al occurred unexpectedly in the CoFeAl, which weakened the binder integrity and aggravated the wear losses. Such unique behavior was rationalized computationally, where the Al2O3 formation was attributed to the low energy barrier to Al diffusion in the B2 structure. These findings could lay a useful basis for future development of robust cemented carbides.

Effect of Ultrasonic Impact on the Organization and Friction Wear Performance of AZ31B Magnesium Alloy Micro-Arc Oxidation Composite Coating

To enhance the frictional wear performance of AZ31B magnesium alloy, a nanocrystalline layer was prepared by ultrasonic impact (UI) treatment on magnesium alloy samples, and the effects of different ultrasonic impact times (5 min, 10 min, and 15 min) on the organization and wear resistance of the composite coating were studied. The findings revealed that the maximum thickness of the composite coating was about 50 μm after 10 min of impact time, which was approximately 15 μm higher than that of the MAO coating. The elemental composition of the composite coating was mainly Mg, O, and Si elements, and the phase structure of the coating, mainly MgO and Mg2SiO4, was the same before and after UI. The microhardness value gradually decreased in a gradient with the increasing distance from the sample surface. The coating had a lower average coefficient of friction (0.18) and lower wear loss (1.56 mg) for the 15 min impact time. Moreover, a small amount of abrasive and adhesive wear served as the primary modes of wear.

Enhanced mechanical and wear properties of aluminium-based composites reinforced with a unique blend of granite particles and boron carbide for sustainable material recycling

In this study, a two-step stir casting technique was employed to fabricate composites using scrap aluminium cans (SAC) as matrix and a unique blend of Granite Particles (GP) and boron carbide (B4C) as reinforcements. Mono and hybrid composites were developed to evaluate the effects of the GP-B4C on the microstructure, mechanical properties, wear characteristics, and fracture behaviour of the composites. The microstructural characterization of the composites revealed that the incorporation of reinforcement into the aluminium matrix led to a refined grain structure with distinct interfaces. Both mono and hybrid composites exhibited improved hardness, with the hybrid composite showing a significant increase of 15.74 % in macro hardness and 16.33 % in microhardness compared to the base material. The mono composite demonstrates the highest ultimate tensile strength of 218 MPa, followed by the hybrid composite with a strength of 192 MPa. The improved mechanical properties of the mono composite are attributed to the reduction in grain size and the enhanced interfacial bonding between the reinforcement and the matrix. Although the hybrid composite exhibited more porosities, it shows the maximum ultimate compressive strength of 1124 MPa. The tensile fractured surfaces displayed dimples, cleavage facets, transgranular cracks, and river line markings. The wear loss of the mono composite decreased by 11.2 %, while that of the hybrid composite decreased by an impressive 28 % compared to their parent base matrix. The worn surface exhibits a combination of abrasive, adhesive, and delamination wear mechanisms.

The gross slip fretting corrosion mechanisms of biomedical ceramic-metal couples

Fretting corrosion in taper joints is of concern since the mid-1970s. Thus, different metallic and ceramic material combinations have been tested and used clinically. While the stem is typically made of Ti-alloy the head materials can vary and may consist of CoCrMo-base alloys, alumina- or zirconia-based ceramics, and materials that rely on surface engineering. Based on retrieval analysis as to the acting mechanisms in real taper joints we tested some of these material combinations under gross slip fretting corrosion as one of the failure mechanisms at ultra-mild wear rates. We found that the main submechanisms for the generation of the tribomaterial (or 3rd-body) – which remains in contact and provides boundary lubrication – are microploughing, microcutting, and mechanical mixing, while the wear loss is brought about by the ejection of metal ions (and wear particles) and predominantly governed by the balance between tribocorrosion and triboxidation. We also showed that topography plays a major role under these circumstances. On the basis of ultra-mild wear gross-slip fretting corrosion experiments we demonstrated that non-self-mating combinations of Ti6Al4V against CoCr29Mo6 or zirconia-toughened alumina (ZTA) ceramic show a smaller wear loss provided that the reaction products can act as boundary lubricants. In addition, the material properties of bodies, counterbodies and the interfacial medium are also governed by the topographies in contact and their capability to act as reservoir for the tribomaterial. Hence, the fluted Ti6Al4V worked best against polished ZTA under these specific test conditions.

Investigation of 1-octanethiol capped ZnS nanoparticles as lubricant additives and tribological behavior of oil-based nanolubricant

1-Octanethiol (OT) capped ZnS nanoparticles (OT-ZnS) as lubricating oil additives were investigated by tribological tests including wear tests and rheological measurements. The wear tests were performed on lubrication states using a custom design wear test device consisting of a rotating pin on a cylinder geometry. A rotating 1.2379 cylinder (steel counterpart) and a stationary C40 pin were used as a pair of test material for the wear test. The stationary pin was pressed against a rotating cylinder under lubrication conditions. It was observed that the synthesized OT-ZnS NP effectively improved the lubrication performance of 10W engine oil and the surface properties of the test materials. The addition of OT-ZnS NPs to the 10W base oil increased its viscosity and decreased the contact angle (CA) values. The results showed that the wear loss and the wear scar dimensions were both the lowest, while 0.0125 (wt.%) of OT-ZnS NPs were treated with the base oil. The mass loss of the pins was reduced to more than 6.3%. The wear reduction was observed at about 27% and the length of wear scar in the minor axis was reduced to 11.4% when a load of 100 kg was applied. The images of wear scars showed that the OT-ZnS NPs additives could prevent severe contact with the interacting surfaces. OT-ZnS NPs partially filled on the grooves and adhered on the wear scar surfaces and promote tribofilm formation, thereby it improve the tribological performance of 10W base oil, especially under extreme pressure conditions. Sulfide film (sulfuration layer) adhered to the wear scar surfaces and decrease the wear.

Investigation on Microstructure, Hardness, Wear behavior and Fracture Surface Analysis of Strontium (Sr) and Calcium (Ca) Content A357 Modified Alloy by Statistical Technique

The aluminum alloy are extensively used in several industrial applications. Stir casting is one of the most frequently accepted methods. In the present investigation, how the microstructure, mechanical and wear mechanics of A357 alloy were impacted by the presence of Sr/Ca was investigated. The outcomes revealed that addition of elements (Sr/Ca) enhance the microstructural features. Uniform dispersal of particulates (Sr/ Ca) in Al357 alloy and also the modified structure of silicon (Si) were observed. Hardness of modified alloy was evaluated by using hardness tester. A result reveals that hardness of modified alloy was improved by increasing in the Sr/Ca content. The wear rate of modified alloy was evaluated by using Pin and Disc wear test rig. Test trials were conducted according to Taguchi technique. L27 array was implemented for evaluation of data. The effect of varying parameters (factors) on wear loss and COF were analyzed using ANOVA (Analysis of Variance) method. ANOVA outcomes shown that, the Sr/Ca content has a better significant impact on wear behavior and COF of the modified alloy. A wear fractography result shows the internal fracture structure of a wornout surface which was studied by SEM analysis.

Radiographic signs of occlusal trauma are associated with marginal bone loss: a retrospective clinical study.

Work in animal models has implicated excessive occlusal forces and occlusal trauma as co-destructive factors for periodontitis. The main aim of the present study was to make a radiographic assessment of the effects of excessive occlusal forces i.e. occlusal/incisal tooth wear (TW), widening of the periodontal space (PDLw), and the presence of a mandibular torus (TM), on interproximal marginal bone loss (MBL) in a large series of patients. A secondary aim was to evaluate the statistical correlation between the parameters in specific two teeth and those of 12 teeth for MBL and six teeth for TW within the same individual. A total of 1950 full-mouth radiographic surveys were analyzed retrospectively. MBL was quantified relative to the root length ("Schei's ruler technique"). In addition, TW and PDL widening of the periodontal space were assessed, as well as the presence of TM. Odds ratio and logistic regression analysis were used to determine the association between occlusal trauma and MBL. The correlation of the measured parameters between the values for specific teeth and the whole dentition was evaluated from data from the first 400 radiographs. Teeth 41 and 33 showed the best correlation to the whole dentition: 0.85 for MBL, 0.83 for PDLw, and 0.97 for TW. The results of a logistic regression analysis with age as an independent variable, revealed a significant association between bone loss and both tooth wear (OR=2.767) and bone loss and PDLw (OR=2.585). TW is positively correlated to both PDLw and MBL. No correlation was found between the presence of TM and MBL.

Polydopamine-modified polysulfone/silica double-walled heat-resistant microcapsules efficiently improve the tribological properties of polyamides

The tribological properties of nylon 6 (PA6) play an important role in regulating the energy consumption, component integrity, and reliability of construction machinery. In order to improve the tribological properties of polyamide, by using high temperature resistant green lubricant ionic liquid (IL) lubricant as core material and polysulfone (PSF) and SiO2 hybrid system as wall materials, double-walled IL@PSF/SiO2 self-lubricating microcapsules with high core content has been prepared. By exploring different emulsifiers and different agitation rates, the degree of encapsulation of an ionic liquid (IL) has been improved and the optimal synthesis conditions for microcapsules have been determined. And the core content was as high as 68 wt% The introduction of SiO2 in the wall material increased the thermal softening temperature of the microcapsules up to 400 °C. The friction coefficient and specific wear loss of a PA6 composite containing 10 wt% IL-loaded microcapsules were reduced by 82% and 87.9% comparing with pure PA6, respectively. The self-lubrication mechanism has been investigated by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and atomic force microscope (AFM), and the results showed the formation of a uniform, continuous, and thin boundary lubricating film on the wear surface to be the main reason for the improved tribological performance.

Inoculation mechanism and strengthening effect of V-based multi-element multiphase inoculant on high chromium cast iron

High chromium cast iron (HCCI) has been widely used as an antiwear material in the industry. Adding inoculants is an effective way to improve the microstructure and mechanical properties of HCCI. In this paper, a new multi-element V-Fe-Ti-Nb-C-Zr-B ribbon inoculant was prepared by the melt-spinning method, and the effect of inoculant addition on the microstructure and mechanical properties of HCCI was studied. The results show that the inoculant consists of V(Fe, M) matrix, V0.89Ti0.11C0.50-, V2C-, VC1−x-, and V3B2-type multiphase nanocrystalline. Adding inoculant to molten HCCI alters the morphology and size of M7C3 carbide, and the possible inoculation mechanism to the as-cast alloy is: the V(Fe, M) matrix melts first, and then the exposed nanograins are dispersed in the melt; The atoms on the particle surface diffuse into the melt, reducing the nanoparticle size; During pouring, the primary M7C3 carbide, austenite, and the eutectic M7C3 carbide nucleate and grow with these nanoparticles as the cores. After inoculation, the grain size of the as-cast and heat-treated HCCI alloy decreased by 39.8 % and 69.1 %, respectively. The combined effect of solution strengthening and fine grain strengthening increased the hardness of as-cast and heat-treated HCCI alloy by 4.1 % and 6.9 %, respectively. Finally, the impact toughness of the heat-treated HCCI alloy increased by 26.8 %, the friction coefficient decreased by 13.5 %, and the wear loss decreased by 21.1 %.

Investigation on the machining performance of copper-based diamond ultra-thin dicing blades manufactured by fused deposition modeling and sintering (FDMS)

Utilizing FDMS technology to manufacture ultra-thin diamond blades can enhance its machining performance. In this study, the machinability of ultrathin diamond blades manufactured by FDMS on a variety of materials, including ferrite magnets, synthetic sapphire, ceramic, and cemented carbide, was investigated. This study examined the fragmentation characteristics, chipping size, and surface morphology of the machined surfaces with the ultra-thin diamond blades. Experimental results showed that ultrathin diamond blades for dicing ferrite magnets and sapphire produced larger chipping sizes than the other two materials; while because of high aluminum content, alumina ceramics have a smoother dicing surface among other materials, the surface roughness of the alumina measuring surface reached 13.6 nm. On the other hand, as a result of the reinforcement of cobalt on the matrix properties and the wetting effect on the interface between matrix and diamond particles, the wear resistance and sharpness of the blade are improved, and the wear loss of the blade is only 0.011 g. Even though diamond blades for various materials produce different machining results, FDMS diamond blades can improve the machining performance of processed materials, the machined surface quality, and the exposure of diamond particles on the blades. In summary, this study affirms that FDMS improves diamond blade machining performance, promoting the industrialization of FDMS for the production of ultra-thin diamond blades.

The Effect of Ceramic Oxide Type on Compressive Strength and Abrasive Wear Behavior in Different Ceramic Oxide Reinforced Al2024 Composites

In this study, particulate tungsten trioxide (WO3), Neodymium oxide (Nd2O3), zirconium oxide(ZrO2) and aluminum oxide (Al2O3) ceramics were separately reinforced at 10% weight ratio into 2024aluminum matrix material by powder metallurgy method. Abrasive wear and compression strength testswere carried out on the composite samples. According to the data obtained, the type of ceramic oxidereinforcement in the composite structure was compared according to the wear behavior and compressivestrength. As a result of the abrasive wear tests carried, the lowest wear loss amount was obtained from theAl2O3 reinforced composite, while the highest wear loss value was obtained from the WO3 reinforcedsample. Looking at the compressive strengths, it was seen that the highest compressive stress was obtainedfrom the Al2O3 reinforced composite, while the lowest compressive stress value was obtained from theNd2O3 reinforced sample. It was understood that the hardness values of the ceramic oxides doped into theAl2024 matrix directly affect the wear loss and compressive strength values of the composite structures. Itwas concluded that WO3, Nd2O3, ZrO2 and Al2O3 reinforcement elements in the form of particles dopedinto the Al2024 matrix improve the mechanical properties of the composite structure.

Wear, corrosion and oxidation characteristics of consolidated and laser remelted high entropy alloys manufactured via powder metallurgy

High entropy alloys have promising wear, oxidation, and corrosion properties compared to conventional alloys and superalloys. In the present study, CrCuFeNiAl0.5 and CrCuFeNiAl0.5Si0.5 alloys were prepared using a traditional powder metallurgy process and then remelted the surfaces via laser. The laser remelting (LR) process gains a denser and more homogeneous surface to alloys. Pressureless consolidated and laser-remelted specimens were subjected to wear, corrosion, and oxidation tests. In the wear tests, it was observed that the wear resistance of Si-containing samples was better due to higher hardness. However, the laser remelting process has mostly increased rather than reduced wear losses. The less volume loss of laser-melted samples was attributed to the almost pure Cu in its content. There is little difference among all samples in electrochemical corrosion measurements. The formation of a fragile passivation layer was observed in potentiodynamic polarization curves of CrCuFeNiAl0.5Si0.5 and LR-CrCuFeNiAl0.5Si0.5 alloys. The alloy with the best corrosion resistance is CrCuFeNiAl0.5Si0.5, whose icorr value is 0.936 × 10−6 A/cm2. After high-temperature oxidation tests, the CrCuFeNiAl0.5 alloy exhibited the worst oxidation performance due to not forming a protective oxide layer on the surface, while LR enabled the protective oxide scale in a short oxidation time. The presence of Si in this alloy relatively enhances the oxidation resistance. The best oxidation performance was observed in LR-CrCuFeNiAl0.5Si0.5 due to the forming of a protective Al2O3 layer during the oxidation tests.

Sliding Friction and Wear Behavior of Flash-Welded U75V Steel Joints in Air and Water Environments

U75V high-strength steel has been widely used to improve the service life of high-speed rails. Considering the consecutive cold and wet condition of the Sichuan–Tibet highway, water plays an important role in the wear process of U75V welded joints. In this study, we investigated the wear behaviors of flash-butt-welded U75V joints in dry air and water environments using a ball-on-disk sliding wear tester. The worn surfaces were tested using optical microscopy, scanning electron microscopy, and energy dispersive X-ray spectroscopy. The cross-sectional profiles of the wear scar were tested using a wear volume tester. The results show that the U75V welded joint has a lower wear resistance than the base metal owing to its nonuniform structure and exhibits a high friction coefficient (0.64) and wear loss (0.21 mm3) in dry air. Water exerts a lubricating function on the fretting wear of U75V welded joints and reduces the friction coefficient (0.36) and wear loss (0.15 mm3). Furthermore, abrasive wear and micropitting are predominant in water environment, accompanied by the formation of a protective-oxide layer on the surface. In contrast, microcutting and microcracking are the dominant wear mechanisms of U75V welded joints in dry air.

An Investigation to the Abrasive Wear in Pipes Used for Oil Industry

The work reported in this study focusing on the abrasive wear behavior for three types of pipes used in oil industries (Carbone steel, Alloy steel and Stainless steel) using a wear apparatus for dry and wet tests, manufactured according to ASTM G65. Silica sand with hardness (1000-1100) HV was used as abrasive material. The abrasive wear of these pipes has been measured experimentally by measuring the wear rate for each case under different sliding speeds, applied loads, and sand conditions (dry or wet). All tests have been conducted using sand of particle size (200-425) µm, ambient temperature of 34.5 °C and humidity 22% (Lab conditions).The results show that the material loss due to abrasive wear increased monotonically with the applied load at constant sliding speed and constant grit size due to increasing depth of penetration in both dry and wet sand which agrees with Archard´s equation. Sliding speed show insignificant effect on the wear loss of metals at constant load and constant grit size in both dry and wet sand. Wet sand results show higher wear losses than dry sand (20-70) % due to micro abrasion – corrosion wear and high slurry concentration.

Prediction of Disc Cutter Wear Considering the Argillization Effect

When a tunnel boring machine (TBM) excavates in the mudstone layer, the slacking mudstone will be formed under the action of the disc cutter due to the argillization effect. Therefore, the cutter wear mechanism differs significantly from that in the hard rock layer, and the hazard of flat wear increases rapidly. To predict the cutter wear in the mudstone, a novel prediction model based on the “mixture lubrication-cavity expansion” theory is established in the present study, which takes the argillization effect into consideration. Initially, the cutter wear mechanism in the mudstone was revealed by the mixture lubrication theory. Then a modified cavity expansion model was proposed and the thickness of the slacking mudstone in the rock was determined. Subsequently, according to the force acting on the disc cutter, the motion of disc cutter during the rock breakage process, and the critical condition for flat wear, formulas for the normal and flat wear of a disc cutter considering the argillization effect were derived. Finally, the proposed model was employed to predict the wear loss of a disc cutter in a tunnel project in Chongqing. The effectiveness of the proposed model was verified. It was found that the force acting on the disc cutter is borne by the slacking mudstone and the cutter simultaneously. In the modified cavity expansion model, the zone of the rock beneath the cutter is divided into the core zone (0 ≤ r ≤ T/2), argillization zone (T/2 ≤ r ≤ ra), plastic zone (ra ≤ r ≤ rp), and elastic zone (r ≥ rp). The stress caused by the cutter is equal to the stress at the argillization zone. The argillization effect can reduce the wear loss to some extent due to the mixture lubrication, however, it aggravates the risk of flat wear. This study will enrich the understanding of the cutter wear mechanism during the tunneling. Furthermore, it will provide some references for the design of the TBM and the scheme of the tunneling project.

Design and Analysis of Fixed-Segment Carrier at Carbon Thrust Bearing

Abstract: This thesis work aimed to provide a design and analysis of fixed segment carrier at carbon thrust bearing. With increased the bearing efficiency and reduced the frictional loss and wear resistance. Thrust bearings plays vital role in submersible pumps. Thrust bearings are fixed bottom of the submersible pumps so total thrust or axial load acting on the thrust collar. Thrust collar are manufacturing with resin mixed carbon and casting material and the segments are manufacturing with casting material and stainless steel material. Two types of materials combines to manufacture the segment carrier. The materials hardness and density properties are different from on materials to another material. If suddenly power cut is happen the total load acting on thrust collar. The collar under heavy load carbon surface and segment carrier surface are scratched or damaged the carbon surface. This type of damages are affecting submersible pump. Submersible pumps are fixed with maximum 900 feet under the boar well but this damages are happen we spend more money to lifting the pump from well and also time is wasted. Segment carrier segment surface and thrust pad surface in between micron level film thickness. If the loose segment carrier the loose segment will tilt under the load and vibration of pump. The thrust collar surface is scratched with thrust collar is not rotate because the thrust collar is fitted with rotating shaft with key way. In this study the segment carrier were made with same materials and the hardness of the materials is same and making process are compared to normal bearing were reduced. The segment carrier is made with stainless steel 410 material. The materials are bought a rod or using pattern with investment casting. After the materials is after completing machining process will goes to hardening and materials surface will go to grinding process. The segment surfaces are grinded and achieve the required surface finish. The surface finish techniques are available no of methods. Triondur coating system is more effective than other process. The grinded segment carrier surfaces are goes to next process of lapping. Here the surface is lapped and get required level of surface roughness. In this process the surface roughness is get required level. Because the lapping coating ratio is high the material removal and surface roughness is get more level like 0.2 micron. The diamond powder coating using 100 CRT is lapping process to achieve the required surface finish. The main purpose of the study is to reduce the bearing damages and frictional loss and wear loss and pump damages. And increase the pump life and reduce the raw materials usage

Simulation based analysis to study the effect of compression ring crown height in ring liner assembly on the performance of four stroke petrol engine

Among different piston rings of an Internal Combustion Engine (IC), the top compression ring-liner assembly shared a momentous amount of the total frictional losses, particularly at the Top Dead Center (TDC) and Bottom Dead Center (BDC) where boundary lubrication subsists. In the present study, the lubrication mechanism in piston ring cylinder liner conjunction for top compression ring using one dimensional Reynolds equation assuming axisymmetric contact was studied. The hydrodynamic and mixed lubrication regimes were taken during the study. Gumbel boundary conditions were used for Reynolds equation solution. For boundary pressure calculation, first, combustion chamber pressure variation was determined, then, interring pressure was calculated assuming orifice volume method by solving mass flow rate through crevice volumes using Runge-Kutta 4th order method. The Reynolds equation was solved using finite difference method. Whole solution process was repeated for different engine speed and crown height of top compression ring to study the effect of them in wear and power loss. First, the solution was found for 3000, 5000 and 7500 RPM keeping constant crown height of 10 µm. Average power loss was found to be increased with the increasing engine speed. There was increased in oil film thickness around mid-stroke with the increased engine speed, but there was no significant change in film thickness with the engine speed at the TDC and BDC positions. Then, the solution was again repeated for different RPM varying the crown height. The compression ring with lower crown height showed the better wear performance by increasing the minimum film thickness in critical zones of engine cycle for all RPM. The crown height of 5,7 and 9 µm gave the minimum power loss (77.89, 163.47 and 297.33 W) for 3000, 5000 and 7500 rpm. Moreover, the power loss in the range of 5-9 µm had no significant differences.