Significance of Dimple Parameters on the Friction of Sliding Surfaces Investigated by Orthogonal Experiments

Surface texturing has proven to be an effective method to improve tribological performance of sliding surfaces. The pattern of microdimples is the most popular surface texture because it is supposed to obtain additional hydrodynamic pressure easily.

In order to evaluate the significance of the dimple parameters, including dimple diameter, depth, and area ratio, to the frictional performance, the dimple patterns with dimple diameter from 50 to 300 μm, dimple depth from 5 to 20 μm, and area ratio from 5 to 20% were manufactured on chromium-coated specimens by through-mask electrochemical micromachining. Experiments were designed using an L ₁₆ (4 ⁵ ) orthogonal array, which contained the above three factors and four levels for each factor. The frictional tests on the above-textured specimens against the specimens of cast iron with oil lubrication were carried out under the contact pressures of 0.2 and 1 MPa and sliding velocities of 0.1 s and 0.5 m/s.

The range analysis showed that the optimum dimple pattern was that with dimple diameter of 100–200 μm, dimple depth of 5–10 μm, and area ratio of 5%, which induced the friction reduction up to 77.6% compared to that of untextured surfaces.

Both the range analysis and analysis of variance suggested that dimple area ratio is the most important parameter influencing friction coefficient under the test condition of this research.     

凹坑织构对石墨材料水润滑性能的影响

为提高核主泵屏蔽电机用水润滑石墨轴承的摩擦润滑性能,采用高速雕铣机在石墨试样表面加工不同形状、深度和面积占有率的凹坑织构,通过水润滑条件下的销盘摩擦试验,测试分析凹坑织构结构参数对石墨材料水润滑性能的影响。结果表明：在水润滑条件下凹坑织构具有一定的减摩效果,随着转速的增加,凹坑织构的动压效应增强,石墨试样摩擦因数减小;随着载荷的增加,石墨试样摩擦因数减小;随着凹坑深径比、面积占有率的增加,石墨试样摩擦因数均呈现先减小后增大的变化趋势,当凹坑深径比为0.5、凹坑面积占有率为3%左右时,石墨试样摩擦因数最小;相较三角形凹坑织构,正方形凹坑和圆形凹坑织构的减摩效果更好。     

Metal flow prediction during sheet-metal punching process using the finite element method

In this study, part springback and metal flow caused by punch penetration into a sheet was investigated by punching circular test specimens with concentric circular tools. Strain gauges were bonded on the upper surface of the specimens at radial distances varying from 2 mm to 10 mm from the cutting edge of the punch. The experiments were used to validate a finite element model (FEM) valid for numerical simulation of sheet-metal punching processes. Damage and crack propagation were taken into account by means of an elastoplastic constitutive law. The main difficulty encountered in simulating this operation is describing the behaviour of the sheet continuously from the beginning of the operation up to the total rupture. The choice of a behaviour law is crucial, since each successive step in the whole process has to be described accurately. In this investigation, an elastoplastic behaviour law coupled with damage was retained to describe the progressive damage accumulation in the workpieces. During the analysis, the initiation of a crack is assumed to occur at any point in the structure where the damage reaches its critical value D _c . The crack propagation is simulated by the propagation of a completely damaged area. This is taken into account in the FEM by a decrease in the stiffness of the broken elements. The numerical results obtained by the simulation were compared with the experimental ones in order to verify the validity of the proposed FEM.     

Preliminary investigation of the effect of dimple size on friction in line contacts

The scale of surface texture is becoming an important issue of surface texture design, particularly for the condition of low speed and high load. Experiments were carried out to investigate the effect of dimple size on friction under line contact condition. The patterns of dimples distributed as square array were fabricated on the surface of brass disks. Each pattern has the same area density of 7%, the same depth over diameter ratio h/d of 0.03, and dimple diameter d varying from 20 to 60 μm. The frictional tests of the brass disk sliding against a stationary cylindrical surface of bearing roller were conducted. It was found that the pattern with dimple diameter of 20 μm presented the effect of friction reduction. For the further understanding of the effect of dimple size under line contact condition, numerical simulations were also carried out to evaluate the hydrodynamic pressure within the contact of cylindrical and plane surfaces. The effects of dimple size and radius of the cylinder on the load carrying capacity were evaluated and discussed.     

Measurement of the surface roughness of wood based materials used in furniture manufacture

The objective of this work was to evaluate surface quality of wood based materials used to manufacture furniture units in Singapore. Various type commercially produced composite panels including particleboard, medium density fibreboard (MDF), plywood in addition to ten different solid wood species which are commonly used in furniture production were considered for the experiments. A stylus type profilometer and 3D image analyzer were employed to determine surface roughness of the samples. Medium density fibreboard (MDF) samples resulted in the smoothest surface with an across the sandmark average roughness (R_a) value of 5.07 μm, while corresponding value for plywood specimens was 8.09 μm among the composite panel samples. In the case of solid wood samples, measurements taken along and across the sandmark from the surface of the specimens measured by the stylus type profilometer, balau had the roughest surface with an R_a value of 9.85 μm across the sandmark followed by beech and walnut. Pine specimens along with ash, cherry and nyatoh resulted in relatively smooth surface values. Correlation between measurements taken by two different methods, namely stylus and 3D scanning showed a good agreement with each other. Based on the findings in this work it appears that both methods can be successfully used to evaluate and to get objective numerical values on surface quality of these samples so that such initial data can be used as quality control tool to have more effective further manufacturing steps in furniture production.     

Numerical investigation of an axi-symmetric laminar jet impinging on a dimpled surface under uniform heat flux using a finite element method

The purpose of this study is to numerically investigate heat transfer and flow field in a semi-confined axi-symmetric laminar air jet impinging on a concave surface, or dimple, with uniform heat flux. A commercial software package relying on the finite element method was used for the simulation, and mesh convergence was examined in order to minimize computational cost. Jet impingement on a flat plate was used as a baseline reference case, and flat plate results were validated against previously published experimental data with good agreement. The effects of various parameters involved in dimple impingement -such as Reynolds number (Re) between 100–1,400; jet-to-plate spacing (H/D_j) ranging from 2 to 6 jet diameters; dimple depths (d/D_d) of 0.1, 0.15, and 0.2; and the ratio of jet diameter and dimple projected diameter (D_j/D_d) from 0.25 to 1—were all studied. Comparisons show that heat transfer reduction occurs in the presence of dimples because of the larger impingement area, which results in less momentum flux. The dimple curvature lifts the post-impinging fluid and creates a backflow, instead of allowing it to maintain contact with the surface, as is the case with flat plate impingement.     

Numerical investigation of surface topography and residual stress after abrasive water jet sequential peening (AWJSP)

Abstract

This article reveals the formation mechanism of surface topography and the formation and coupling mechanism of residual stress field (RSF) after abrasive water jet sequential peening (AWJSP) that can sequential peening on the material surface at a certain distance interval, and proposes a mathematical model of surface dimple characteristic verified by simulation results. In addition, the influences of shot velocity v₀, shot radius R and the distance between the center of adjacent shots D_C on surface topography and RSF were also investigated. Results show the surface dimple forms resulting from the material plastic strain, and the residual stress (RS) is mainly induced by the unrecovered elastic strain resulting from the hindering of plastic strain. Decreasing v₀, R or D_C can decrease the surface roughness R_t, while increasing v₀ and R is beneficial to induce a large and deep compressive RS layer. D_C influences the whole distribution of compressive RS layer directly.     

Flow characteristics along and above dimpled surfaces with three different dimple depths within a channel

The effects of dimples in altering time-averaged flow behavior occur mostly within one-half of one dimple print diameter from the surface, and the dimples within the arrays periodically eject a primary vortex pair from each dimple, which exists in conjunction with edge vortex pairs that form along the spanwise edges of staggered dimples regardless of three dimple depths. As the dimple depth increases, deeper dimples eject stronger primary vortex pairs, with hig her levels of turbulence transport due to larger deficits of time-averaged, normalized total pressure and streamw ise velocity as the surfaces with deeper dimples are approached. Primary vortex pair ejection frequencies range about 7–9 Hz, and edge vortex pair oscillation frequencies range about 5–7 Hz forR _eH =20,000, regardless of dimple depths.     

Metal-ceramic bond mechanism of the Co-Cr alloy denture with original rough surface produced by selective laser melting

The porcelain fracture caused by low metal-ceramic bond strength is a critical issue in porcelain fused to metal（PFM） restorations. Surface roughening methods, such as sand blasting, acid etching and alkaline degreasing for the metal matrix are used to increase bond strength. However, the metal matrix of PFM processed by selective laser melting（SLM） has natural rough surface. To explore the effect of the original roughness on metal-ceramic bond strength, two groups of specimen are fabricated by SLM. One group of specimen surface is polished smooth while another group remains the original rough surface. The dental porcelain is fused to the specimens＇ surfaces according to the ISO 9693：1999 standard. To gain the bond strength, a three-point bending test is carried out and X ray energy spectrum analysis（EDS）, scanning electron microscope（SEM） are used to show fracture mode. The results show that the mean bond strength is 116.5 16 MPa of the group with rough surface（Ra= 17.2）, and the fracture mode is cohesive. However, when the surface is smooth （Ra =3.8）, the mean bond strength is 74.5 MPa _＋ 5 MPa and the fracture mode is mixed. The original surface with prominent structures formed by the partly melted powder particles, not only increases surface roughness but also significantly improves the bond strength by forming strong mechanical lock effect. Statistical analysis （Student＇s t-test） demonstrates a significant difference （p〈0.05） of the mean value of bond strength between the two groups. The experiments indicate the natural rough surface can enhance the metal-ceramic bond strength to over four times the minimum value （25 MPa） of the ISO 9693：1999 standard. It is found that the natural rough surface of SLM-made PFM can eliminate the porcelain collapse defect produced by traditional casting method in PFM restorations.     

Predicting surface roughness of hardened AISI 1040 based on cutting parameters using neural networks and multiple regression

In this study, models for predicting the surface roughness of AISI 1040 steel material using artificial neural networks (ANN) and multiple regression (MRM) are developed. The models are optimized using cutting parameters as input and corresponding surface roughness values as output. Cutting parameters considered in this study include cutting speed, feed rate, depth of cut, and nose radius. Surface roughness is characterized by the mean (R _a) and total (R _t) of the recorded roughness values at different locations on the surface. A total of 81 different experiments were performed, each with a different setting of the cutting parameters, and the corresponding R _a and R _t values for each case are measured. Input–output pairs obtained through these 81 experiments are used to train an ANN is achieved at the 200,00th epoch. Mean squared error of 0.002917120% achieved using the developed ANN outperforms error rates reported in earlier studies and can also be considered admissible for real-time deployment of the developed ANN algorithm for robust prediction of the surface roughness in industrial settings.     

Characteristics of flow past a circular cylinder with a rectangular groove

In the present study, features of the flow past a circular cylinder with single longitudinal groove pattern placed on its surface were investigated. Six different rectangular groove sizes were tested for angular position of the groove from the forward stagnation point of the circular cylinder within 0°≤θ≤150°. The particle image velocimetry (PIV) technique were employed to measure flow field downstream of the cylinder immersed in a uniform flow field with the Reynolds number, Re=5000. Time-averaged flow data such as vorticity, 〈ω〉 streamline, 〈Ψ〉, streamwise, 〈u′u′〉 and transverse, 〈v′v′〉 Reynolds normal stresses, turbulent kinetic energy, TKE and RMS of streamwise, u_rms and transverse, v_rms velocity components were obtained from PIV data to demonstrate flow features. Moreover, frequency of Karman vortex shedding was explored using single point spectral analysis. It is concluded that presence of the groove on a cylinder surface significantly affects the near wake flow structure and turbulence statistics. Karman vortex shedding frequency, f_k strongly depends on the groove size. Moreover, the shear layer instability is induced on the grooved side with additional frequencies.     

Measurement of various properties of Southern pine and aspen as function of heat treatment

The objective of this study was to investigate the influence of heat treatment parameters, namely temperature and exposure time on surface roughness, shear strength, hardness and density of Southern pine (Pinus echinata) and aspen (Populus grandidentata) samples. The specimens were exposed to two different temperature levels of 120–200 °C for time spans of 2–8 h. A stylus type portable profilometer was employed to evaluate the surface characteristics of the samples by taking measurements across the grain orientation. Average roughness (R_a), mean peak-to-valley height (R_z) and maximum roughness (R_max) were used to evaluate surface roughness of the samples exposed to various heat treatment schedules. Comten testing unit was also used to determine shear strength and Janka hardness of the control and heat treated specimens. Based on the results of this study Southern pine samples had more enhanced surface quality but lower hardness values than those of aspen specimens with increased temperature and time of heat treatment schedules. It was found that heat treatment adversely affected hardness and shear strength properties of all types of samples. Reduction in shear strength values of Southern pine and aspen samples ranged from 23.31% to 68.59% and from 4.67% to 48.55%, respectively as compared to those of control samples. It appears that influence of heat treatment on all properties of the samples was more pronounced with increasing temperature and exposure time.     

Review of oxidational wear: Part I: The origins of oxidational wear

This is the first part of a two-part in-depth review of the oxidational wear of metals. It discusses the parallelism between the formation of an oxide film for dry contact conditions and of other surface films for lubricated contacct. Wear modes are unified into two major classes of mild and severe wear, including both lubricated both dry and conditions. Oxidational wear is a mechanism of mild wear in which protective oxide films are formed at the real areas of contact (during the time of a contact) at the contact temperature, T_cc. When the oxide reaches a critical thickness ξ, usually 1 to 3 μm, the oxide breaks up and eventually appears as wear particles. These oxides are preferentially formed on plateaux, which alternately carry the load - as they reach their critical thickness - and are removed. Temperature is important in determining the structure of the oxide film present, which in turn affects the wear properties of the sliding interfaces. Hence, this part of the review concludes with a thorough treatment of the thermal aspects involved during the sliding of a typical laboratory simulation of the oxidational wear of steel specimens without lubrication. This treatment shows how the general surface temperature (T_s) and the division of heat (?)_at the interface can be calculated and used, in conjunction with the measured wear rate (w), to give information about a possible surface model consisting of N contracts on the (thermally expanded) operative plateau, the height of the plateau being identical to the critical oxide film thickness (ξ) mentioned above.Part II outlines recent research to determine the oxidational constant, ie the activation energy and the Arrhenius constant, relevant to oxidational wear. It is found that the Arrhenius constant for oxidational wear is different from that for static oxidation tests. Some typical values of N, ξ and T_c are calculated from oxidational wear experiments. A new oxidational wear theory designed to take into account the oxide growth which occurs at the general surface temperature, T_s (where T_s < T_c) , whilst operation plateau is out-of-contact. This theory is most relevant to weat at elevated temperatures, where it is not permissible to assume that out-of-contact oxidation is negligible. After a brief review of the small amount of work done on the effects of partial oxygen pressures on oxidational wear, Part II concludes with a discussion of the possible connection between the general oxidational wear theory for dry contacts and the wear which occurs at lubricated contacts.     

Surface finish of bulk metallic glass using sequential abrasive jet polishing and annealing processes

Surface finish plays an important role in product quality due to its direct effects on product appearance. Hence, improvement of the surface finish is an essential requirement in industrial products. In an attempt to improve the surface finish of bulk metallic glass (BMG) material, several common methods have been used, such as milling, grinding, and lapping. However, the BMG surface finish has not yet been significantly improved by using these methods. Therefore, this paper proposes sequential abrasive jet polishing (AJP) and annealing processes that can considerably improve the BMG surface finish. In addition, this paper also takes into account optimal parameters for the AJP and annealing processes based on the Taguchi’s L ₁₈ and L ₈ orthogonal array experimental results, respectively. The experimental results show that using optimal AJP parameters, the surface roughness (R _a) of the ground specimens can be significantly improved from 0.675 to 0.016 μm. After the AJP process, the surface roughness (R _a) of the polished specimens can be further improved from 5.7 to 2 nm within an area of 5?×?5 μm by using optimal annealing parameters.     

SAR Remote Sensing of Buried Faults: Implications for Groundwater Exploration in the Western Desert of Egypt

The hydrological setting of a desert plain area located in Egypt, west of Aswan city, is still not well understood, and thus, its groundwater potential remains largely unknown. Images from the ALOS/PALSAR L-band sensor have been used to detect and delineate the subsurface structures in this area. Linear, elliptical and circular polarization transformations were applied to the ALOS/PALSAR full polarimetric data by changing the orientation angle (??°) and elliptical angle (??°). The circular polarization (?? = 0° and ?? = 45°) proved to be the best transformation for revealing buried faults in various strike directions, which have not been reported in the last version of the official geologic map of this area. Such derived circular polarization images were further enhanced by applying the Optimal Polarization Contrast Enhancement method. The moisture content (? _S ) of the study sites was generally low, with an average of roughly 0.01%. The average Root Mean Square Height (h_RMS) of the surface roughness was also low with 0.01 cm across all sites. The relative dielectric constant (?? _r ) of the sand in the study area produced a very low value of 3.04. The effects of ? _S , ?? _r and h_RMS on the radar backscattered signals turned out to be very low, thus providing, optimal conditions for L-band to penetrate relatively deeply. Moreover, 21 GPR profiles were acquired using 270 MHz shielded antennas to validate the radar remote sensing results. These GPR profiles reveal obvious offsets in the subsurface stratigraphy suggesting that such highly fractured zones are possibly favorable zones for groundwater accumulation.     

Investigation of wire electrical discharge machining characteristics of Al6063/SiCp composites

In this investigation, the effect of wire electrical discharge machining (WEDM) parameters such as pulse-on time (T _ON), pulse-off time (T _OFF), gap voltage (V) and wire feed (F) on material removal rate (MRR) and surface roughness (R _a) in metal matrix composites (MMCs) consisting of aluminium alloy (Al6063) and silicon carbide (SiC_p) is discussed. The Al6063 is reinforced with SiC_p in the form of particles with 5%, 10% and 15% volume fractions. The experiments are carried out as per design of experiments approach using L₉ orthogonal array. The results were analysed using analysis of variance and response graphs. The results are also compared with the results obtained for unreinforced Al6063. From this study, it is found that different combinations of WEDM process parameters are required to achieve higher MRR and lower R _a for Al6063 and composites. Generally, it is found that the increase in volume percentage of SiC resulted in decreased MRR and increased R _a. Regression equations are developed based on the experimental data for the prediction of output parameters for Al6063 and composites. The results from this study will be useful for manufacturing engineers to select appropriate WEDM process parameters to machine MMCs of Al6063 reinforced with SiC_p at various proportions.     

A manufacturable converter for E 01 ↔ H 01 modes in circular waveguides

A manufacturable converter for E ₀₁ ? H ₀₁ modes in circular waveguides is described. The converter is based on a cylinder with the anisotropic surface conduction along helical lines. The cylinder mates two different-diameter waveguides and ensures power transmission of the incoming mode to the outgoing mode.     

Simulation of piston ring tribology with surface texturing for internal combustion engines

Design of piston rings is a very crucial subject in the field of internal combustion engines. In the present paper, a numerical model is created using the Navier–Stokes equations. Fluid–structure interaction analysis is performed in order to calculate the structural integrity of the ring for several engine operational conditions and texturing patterns. This paper illustrates the hydrodynamic friction force under various surface artificial texturing in terms of spherical and rectangular microdimples. Piston ring stress analysis is also investigated due to gas leakage. Results show a substantial reduction of the friction using rectangular texturing and less reduction using spherical texturing. The rectangular microdimple parameters were considered to obtain a better friction reduction with the following configurations: H_d = 4 µm, ρ_τ = 0.61, λ = 20 and s = 0.004. Each rectangular texture cell is defined by the dimple depth, H_d; the texture density, ρ_τ; the dimple aspect ratio, λ; and the relative dimple depth, s. Copyright © 2014 John Wiley & Sons, Ltd.     

Applicability of ultrasonic technique for evaluation of elastic plastic fracture toughness of high manganese steel at low temperatures

A study on the evaluation of elastic-plastic fracture toughness, J_IC, by ultrasonic technique is described for a newly developed high manganese steel at low temperature. In order to see the applicability of the ultrasonic technique based on pulse echo method at low temperature, special attention was paid to detect change point of ultrasonic echo due to the onset of stable crack growth. The J_IC values are evaluated by the ultrasonic method (which needs single specimen) and by stretched zone method (which needs several specimens) for compact tension (CT) specimens and three-point bend (3PB) specimens. The temperature dependence of these J_IC values of theCT specimens by the ultrasonic method show almost the same values to 3PB specimens over the temperature range tested. The J_IC values of 3PB specimens by the stretched zone method show slightly higher values than those of theCT specimens at low temperature. The J_IC values evaluated by the ultrasonic method give more conservative values than those evaluated by the stretched zone method for bothCT and 3PB specimens.     

The effect of manufacturing variables on the corrosion resistance of a super duplex stainless steel

Recent in-service failures of super duplex stainless steel (SDSS) components have revealed the important role of manufacturing variables on the corrosion behaviour of the material. These variables include surface condition, heat treatment and cold work. The effect of all three variables on the corrosion behaviour of an example SDSS was investigated using electrochemical techniques, tensile testing and microscopic observations. The role of surface condition was investigated by characterising the topography of specimens using the surface roughness parameter, R _a, then measuring the critical pitting temperature. The results showed that R _a on its own is not sufficient to characterise the effect of surface condition on corrosion resistance. The effect of heat treatment on pitting potential was pronounced as a result of the intermetallic phases precipitated. Plastic deformation caused by cold work affected the pitting potential of the material, although the effects varied with increasing cold work; certain plastic strain levels caused reduced resistance, whilst others caused little change compared with the solution-annealed specimens. Hydrogen embrittlement increased with increasing cold work. The main conclusion is that the interactions between corrosive environments and SDSS components containing one or more of these manufacturing variables must be considered if reductions in service life are to be avoided.