Search Results (177)

Due to the random factors that influence grinding stability, hardness distribution appears in inhomogeneity at different locations on the hardened layer in grind-hardening technology. It may affect the wear resistance of parts. Therefore, in order to explore the influence mechanism of hardness homogeneity on the wear resistance comprehensively, grind-hardening and friction experiments on AISI 1045 steel are carried out. Then, the causes of inhomogeneous hardness distribution are analyzed, and the influence of hardness homogeneity on wear resistance is also discussed. Combining the Archard wear model, the wear process of the hardened layer is simulated for analyzing the effect of contact stress distribution and action range on material loss in the worn area and finally realizing the prediction of the wear depth. The results show that the difference in microstructure distribution caused by the nonlinear variation in grinding force is the fundamental reason for the hardness inhomogeneity of the hardened layer. The hardness homogeneity results in the wear resistance of the cut-out end being superior to that of cut-in end. Additionally, the error between the predictive and the experimental value of the wear depth with different parameters is between 3.6% and 11.3%, thereby verifying the effectiveness of the theoretical research. Full article

Shape memory alloy (SMA) materials are valued for their shape memory effect, superelasticity, and biocompatibility, making them an ideal choice for applications in biomedical, aerospace, and actuator fields. Nickel–titanium (NiTi) SMA is a promising biomedical material. It is widely used in the manufacture of biomedical instruments, devices, implants, and surgical tools. However, its complex thermo-mechanical behavior and poor machinability pose challenges for conventional machining. To manufacture high-quality nitinol parts, traditional machining processes are being replaced by advanced machining technologies. Electric discharge machining (EDM) is an advanced machining technique whose mechanism of material removal involves erosion caused by plasma formation and spark generation. It has proven effective for processing difficult-to-machine materials. This review summarizes EDM and its variants, including hybrid EDM, with a focus on machining NiTi-SMA materials for biomedical, aerospace, microelectromechanical systems, and automotive applications, and systematically explores key factors such as process parameters, material removal mechanisms, surface integrity, tool wear, and optimization strategies. This review begins with an introduction to nitinol (i.e., NiTi-SMA) and its variants, followed by an in-depth discussion of plasma formation, spark generation mechanisms, and other key aspects of EDM. It then provides a detailed analysis of notable past research on the machining of NiTi SMA materials using EDM and its variants. This paper concludes with insights into future research directions, aiming to advance EDM-based machining of SMA materials and serve as a valuable resource for researchers and engineers in the field. Full article

The high hardness and toughness of AISI 4130 alloy present significant challenges during machining, including excessive cutting forces, rapid tool wear, and poor surface finish control. To address these issues, this study combines numerical simulation with turning experiments to systematically investigate the effects of tool geometry and cutting parameters on cutting force, temperature, and surface roughness. Through Deform-3D finite element modeling, one-factor, and orthogonal simulation tests, it was found that the optimal tool geometric combination (λs = 2°, κ_r = 99°, γ₀ = 5°) reduces the cutting forces by 21.86% as compared to the baseline parameters. Experimental validation showed that the agreement between simulated and measured cutting forces was 86.73%–87.8%, with simulated values being 10%–13.27% higher due to idealized boundary conditions. Surface morphological analysis by Bruker Contour Elite K shows that the surface roughness of the workpiece decreases with an increasing cutting speed and increases with an increasing feed rate and depth of cut. The above studies provide a certain research basis for optimizing the tool angle and improving the cutting efficiency. Full article

Surface texturing involves creating micro-channels, micro-dimples, micro-grooving, and other surface modifications. To do this, laser and micromachining are employed on the substrate surface in addition to other methods. The surface characteristics of the Arboblend V2 Nature biodegradable polymers with laser texturing, hexagonal and square patterns, and four and six passes are shown in this study. Regardless of the texture type, Arboblend V2 Nature’s hydrophilic surface (a contact angle of less than 90°) was demonstrated by the results of the wettability test. The underlying material’s wear behavior changed as a result of the LST surface modification. The COF values increased only after six passes with both textures. On the topographical side, Arboblend V2 Nature (square and hexagonal) shows a consistent X-axis expansion in the hexagonal geometry and a considerable amount of variability in the square geometry, especially at six passes, where the Y-axis (higher depths) is more compressed. According to the results, since textured surfaces are practicable, non-biodegradable polymers from a variety of industries can be substituted. Full article

Tyre wear is a major contributor to global microplastic pollution, affecting air, soil, water, and wildlife as well as human health. In the European Union (EU), the latest Euro 7 regulation foresees the introduction of tyre abrasion limits covering all tyre categories, referring to two testing methods (convoy on road or laboratory drum) developed by the United Nations (UN) Economic Commission for Europe (UNECE) World Forum for Harmonization of Vehicle Regulations (WP.29). In this study, we applied the convoy method adopted by the UNECE Working Group on Noise and Tyres (GRBP) as part of the UN Regulation 117 on tyre performance parameters. The method has been developed by the Task Force on Tyre Abrasion (TFTA) of the UNECE and involves vehicles driving on public roads for about 8000 km. Candidate and reference tyres are fitted in a convoy of up to four vehicles, and an abrasion index for each candidate tyre is determined as a ratio of the abrasion of the candidate and reference tyres. In our tests, in addition to the abrasion rate, we measured the tread depth reduction and defined a service life index (i.e., total mileage potential) without the need of a different methodology. The results from six summer and nine winter C1 class passenger car tyres of various sizes showed a wide range of abrasion rates and service life values. We also compared our results with values reported in the literature and on websites. The conclusions of this study are expected to support the ongoing discussion on limit setting for C1 tyres and the definition of a service life index. Full article

Despite local and national road authorities striving to provide motorists with a durable and safe infrastructure environment, one in six UK roads are currently classed as being in poor condition. In terms of safety, Department for Transport statistics report high numbers of road incidents; 29,711 killed or seriously injured in 2023, representing little change compared to 2022. As such, reported in this paper is research aimed at developing artificial geopolymer cement mortar-based aggregate as a cost/environmentally attractive alternative to calcined bauxite for high friction surfacing applications. Work was undertaken in two distinct phases. In the first, the performance of alkali silicate-based geopolymers comprising a range of industrial wastes as binder materials was assessed using modified versions of standardized polished stone value and micro-Deval tests. In phase two, selected mixes were assessed for resistance to simulated wear by exposing test specimens to 20,000-wheel passes on an accelerated road test machine. Performance was further investigated using a dynamic friction test method developed by the Indiana Department of Transportation. Despite commercially sourced calcined bauxite aggregates exhibiting the highest performance levels, the findings from this preliminary research were generally positive, with acceptable levels of performance noted for manufactured geopolymer-based aggregates. For instance, in accordance with recommended levels of performance prescribed in BBA/HAPPAS standards, this included attainment of polished stone values higher than 65 and, following accelerated road testing, average texture depths greater than 1.1 mm. It is recognized that further research is needed to investigate geopolymer binder systems and blends of aggregate types, as well as artificial aggregate manufacturing procedures. Full article

Due to the insufficient durability (wear resistance) of guides made of 50SiCr4 steel tempered to a hardness of 400 HB, 14 variants of the yarn guide manufacturing process were developed. The ring spinner yarn guides were manufactured from three types of steel, from Al99.5% and its alloys, as well as from porcelain, Al₂O₃ sinter, and WC 94% + Co 6% tungsten carbide. The unit manufacturing cost and six manufacturing quality criteria were used as evaluation criteria: four parameters of the geometric structure of the surface and the maximum surface hardness, as well as the depth of hardening of the surface layer. The presented variants were then evaluated against the seven criteria, determining a set of optimal solutions in the Pareto sense. This set consisted of 12 variants. A distance function was then used to select the best manufacturing process variant, corresponding to the smallest value of the distance function. In this study, this is the process variant for which the semi-finished product is a drawn bar ø6 mm of C45 steel tempered to a hardness of 350 HB with a glazed porcelain insert. The alternative process, with a slightly higher distance function value, is the variant with the Al₂O₃ ceramic sinter insert. Full article

This study investigates the evolution laws and prediction models of anti-skid and wear-resistant performance for asphalt pavements during the operation period. Using a combination of indoor accelerated wear tests and field detection, mixed specimens are prepared with SBS modified asphalt, limestone, and basalt aggregates. Through accelerated wear tests of different durations, the structural depth and friction coefficient are measured. Combined with the field data from the G56 K2319 section of the Hangrui Expressway, the decay laws of anti-skid performance are analyzed, and prediction models are established. The results show that the anti-skid performance of basalt mixtures is superior to that of limestone. The deepened structure technology significantly enhances the performance of basalt but has a negative impact on the pendulum value of limestone. The influence degrees of wear duration, aggregate type, and deepened structure state on structural depth and pendulum value vary. The initial structural depth of basalt mixtures (0.85 mm) is 11.8% higher than that of limestone (0.76 mm). The longitudinal pendulum value of basalt (44) is 10% higher than that of limestone (40), while the transverse pendulum value of limestone (50) is 4.2% higher than that of basalt (48). After 21 h of wear, the structural depth of basalt (0.68 mm) is 4.6% higher than that of limestone (0.65 mm), with a decay rate 23.6% lower. The pendulum value of basalt remains above 50, while limestone’s longitudinal pendulum value drops to 36 (10% lower than its initial value), even below the unmodified state. The influence order for structural depth is deepened structure state > wear duration > aggregate type, and for lateral pendulum value, it is wear duration > deepened structure state > aggregate type. There is a significant linear relationship between structural depth/pendulum value and wear duration, and the prediction models are reliable. The indoor accelerated wear of 44.5 h is equivalent to the field operation wear of 3 years. The research findings provide a theoretical basis for the evaluation of anti-skid performance, maintenance decision-making, and material optimization of asphalt pavements. Full article

This study investigates the interplay between infill structure and surface texture in Fused Deposition Modeling (FDM)-printed polymer specimens and their combined influence on tribological and mechanical performance. Unlike previous works that focus on single-variable analysis, this work offers a comparative evaluation of Shore D hardness and coefficient of friction (COF) for PLA and Iglidur materials, incorporating diverse infill patterns. The results reveal that specific combinations (e.g., grid infill with 90% density) optimize hardness and minimize friction, offering practical insights for design optimization in functional parts. Our aim is to provide design insights for enhanced wear resistance and hardness through tailored structural configurations. Carbon Fiber-reinforced PLA (PLA CF), aramid fiber-reinforced Acrylonitrile Styrene Acrylate (Kevlar), and Iglidur I180-BL tribofilament. Disc specimens were fabricated with gyroid infill densities ranging from 10% to 100%. Experimental methodologies included Ball-on-Disc tests conducted under dry sliding conditions (5 N normal load, 150 mm/s sliding speed) to assess friction and wear characteristics. These tribological evaluations were complemented by profilometric and microscopic analyses and Shore D hardness testing. The results show that Iglidur I180-BL achieved the lowest friction coefficients (0.141–0.190) and negligible wear, while PLA specimens with 90% infill demonstrated a polishing-type wear with minimal material loss and a friction coefficient (COF) of ~0.108. In contrast, PLA CF and Kevlar exhibited higher wear depths (up to 154 µm for Kevlar) and abrasive mechanisms due to fiber detachment. Shore hardness values increased with infill density, with PLA reaching a maximum of 82.7 Shore D. These findings highlight the critical interplay between infill architecture and surface patterning and offer actionable guidelines for the functional design of durable FDM components in load-bearing or sliding applications. Full article

Background: Attachments are essential components in clear aligner therapy, enhancing retention and improving the predictability of tooth movements. Mechanical and wear properties of the composite resins used for attachment reproduction are critical to maintaining their integrity and shape over time. This study aimed to evaluate and compare the mechanical properties, thermal behavior, and wear performance of the hybrid composite Aligner Connect (AC) and the flowable resin (Connect Flow, CF). Methods: Twenty samples (ten AC and ten CF) were reproduced. All specimens underwent differential scanning calorimetry (DSC), combustion analysis, flat instrumented indentation, compression stress relaxation tests, and tribological analysis. A 3D wear profile reconstruction was performed to assess wear surfaces. Results: DSC and combustion analyses revealed distinct thermal transitions, with CF showing significantly lower Tg values (103.8 °C/81.4 °C) than AC (110.8 °C/89.6 °C) and lower residual mass after combustion (23% vs. 61%), reflecting reduced filler content and greater polymer mobility. AC exhibited superior mechanical properties, with higher maximum load (585.9 ± 22.36 N) and elastic modulus (231.5 ± 9.1 MPa) than CF (290.2 ± 5.52 N; 156 ± 10.5 MPa). Stress relaxation decrease was less pronounced in AC (18 ± 4%) than in CF (20 ± 4%). AC also showed a significantly higher friction coefficient (0.62 ± 0.060) than CF (0.55 ± 0.095), along with greater wear volume (0.012 ± 0.0055 mm³ vs. 0.0070 ± 0.0083 mm³) and maximum depth (36.88 ± 3.642 µm vs. 17.91 ± 3.387 µm). Surface roughness before wear was higher for AC (Ra, 0.577 ± 0.035 µm; Rt, 4.369 ± 0.521 µm) than for CF (Ra, 0.337 ± 0.070 µm; Rt, 2.862 ± 0.549 µm). After wear tests, roughness values converged (Ra, 0.247 ± 0.036 µm for AC; Ra, 0.236 ± 0.019 µm for CF) indicating smoothened and similar surfaces for both composites. Conclusions: The hybrid nanocomposite demonstrated greater properties in terms of stiffness, load-bearing capacity, and structural integrity when compared with flowable resin. Its use may ensure more durable attachment integrity and improved aligner–tooth interface performance over time. Full article

The study is motivated by the application of dry finish milling for post-build processing of additive Ti6Al4V blanks, since the use of neither lubricant nor coolants has been attracting increasing attention due to its environmental benefits, non-toxicity, and the elimination of the need for additional cleaning processes. For end mills, wear patterns were investigated upon finish milling of the SLM Ti6Al4V samples under various machining conditions (by varying the values of radial depth of cut and feed values at a constant level of axial depth of cut and cutting speed). When using all the applied milling modes, the identical tool wear mechanism was revealed. Built-up edges mainly developed on the leading surfaces, increasing the surface roughness on the SLM Ti6Al4V samples but protecting the cutting edges. However, abrasive wear was mainly characteristic of the flank surfaces that accelerated peeling of the protective coatings and increased wear of the end mills. The following milling parameters have been established as being close to rational ones: Vc = 60 m/min, Vf = 400 mm/min, a_p = 4 mm, and a_e = 0.4 mm. They affected the surface roughness of the SLM Ti6Al4V samples in the following way: max cutting thickness—8 μm; built-up edge at rake surface—50 ± 3 μm; max wear of flank surface—15 ± 1 μm; maximum adherence of workpiece. Mode III provided the maximum MRR value and negligible wear of the end mill, but its main disadvantage was the high average surface roughness on the SLM Ti6Al4V sample. Mode II was characterized by both the lowest average surface roughness and the lowest wear of the end mill, as well as an insufficient MRR value. Since these two modes differed only in their feed rates, their values should be optimized in the range from 200 to 400 mm/min. Full article

This study explores the machinability of Incoloy 800HT (high temperature) under a sustainable lubrication approach, employing a twin-nozzle minimum quantity lubrication (MQL) system with groundnut oil as a green cutting fluid. The evaluation focuses on key performance indicators, including surface roughness, tool flank wear, power consumption, carbon emissions, and chip morphology. Groundnut oil, a biodegradable and nontoxic lubricant, was chosen to enhance environmental compatibility while maintaining effective cutting performance. The Taguchi L₁₆ orthogonal array (three factors and four levels) was utilized to conduct experimental trials to analyze machining characteristics. The best surface quality (surface roughness, Ra = 0.514 µm) was obtained at the lowest depth of cut (0.2 mm), modest feed (0.1 mm/rev), and moderate cutting speed (160 m/min). The higher ranges of flank wear are found under higher cutting speed conditions (320 and 240 m/min), while lower wear values (<0.09 mm) were observed under lower speed conditions (80 and 160 m/min). An entropy-integrated multi-response optimization using the MOORA (multi-objective optimization based on ratio analysis) method was employed to identify optimal machining parameters, considering the trade-offs among multiple conflicting objectives. The entropy method was used to assign weights to each response. The obtained optimal conditions are as follows: cutting speed = 160 m/min, feed = 0.1 mm/rev, and depth of cut = 0.2 mm. Optimized outcomes suggest that this green machining strategy offers a viable alternative for sustainable manufacturing of difficult-to-machine alloys like Incoloy 800 HT. Full article

Friction leads to substantial energy losses and wear in mechanical systems. This study explores the tribological potential of the high-temperature superconductor precursor Y₂BaCuO₅ (Y211), synthesized via chemical co-precipitation, as a novel additive to PAO6 base oil. A 0.3 wt.% Y211/PAO6 lubricant (CD) was formulated using ultrasonic dispersion. Tribological performance was evaluated using a custom end-face tribometer (steel-on-iron) under varying loads (100–500 N) and speeds (300–500 rpm), comparing CD to neat PAO6. The results indicate that the Y211 additive consistently reduced the coefficient of friction (COF) relative to neat PAO6, maintaining a stable value around ~0.1. However, its effectiveness was strongly load-dependent: a significant friction reduction was observed at 100 N, while the benefit diminished at higher loads (>200 N), with the COF peaking around 200 N. Rotational speed exerted minimal influence. Compared with neat PAO6, the inclusion of 0.3 wt.% Y211 resulted in a reduction in the coefficient of friction by approximately 50% under low-load conditions (100 N), with COF values decreasing from 0.1 to 0.045. Wear depth measurements also revealed a reduction of over 30%, supporting the additive’s anti-wear efficacy. Y211 demonstrates potential as a friction-reducing additive, particularly under low loads, but its high-load performance limitations warrant further optimization and mechanistic studies. This highlights a novel tribological application for Y211. The objective of this study is to evaluate the tribological effectiveness of Y₂BaCuO₅ (Y211) as a lubricant additive, investigate its load-dependent friction behavior, and explore its feasibility as a multifunctional additive leveraging its superconductive precursor structure. Full article

The vibration and noise of friction pairs are severe when cutting titanium alloy with cemented carbide tools, and the surface micro-texture can significantly reduce noise and friction. Therefore, it is very important to clarify the correlation mechanism between friction noise and friction force for processing quality control. Consequently, investigating the underlying mechanisms that link friction noise and friction is of considerable importance. This study focuses on the friction and wear acoustic signals generated by micro-textured cemented carbide–titanium alloy. A friction testing platform specifically designed for the micro-textured cemented carbide grinding of titanium alloy has been established. Acoustic sensors are employed to capture the acoustic signals, while ultra-depth-of-field microscopy and scanning electron microscopy are utilized for surface analysis. A novel approach utilizing the dung beetle algorithm (DBO) is proposed to optimize the parameters of variational mode decomposition (VMD), which is subsequently combined with wavelet packet threshold denoising (WPT) to enhance the quality of the original signal. Continuous wavelet transform (CWT) is applied for time–frequency analysis, facilitating a discussion on the underlying mechanisms of micro-texture. Additionally, features are extracted from the time domain, frequency domain, wavelet packet, and entropy. The Relief-F algorithm is employed to identify 19 significant features, leading to the development of a hybrid model that integrates Bayesian optimization (BO) and Transformer-LSTM for predicting friction. Experimental results indicate that the model achieves an R² value of 0.9835, a root mean square error (RMSE) of 0.2271, a mean absolute error (MAE) of 0.1880, and a mean bias error (MBE) of 0.1410 on the test dataset. The predictive performance and stability of this model are markedly superior to those of the BO-LSTM, LSTM–Attention, and CNN–LSTM–Attention models. This research presents a robust methodology for predicting friction in the context of friction and wear of cemented carbide–titanium alloys. Full article

Aiming at the engineering problems of the severe wear and limited service life of mandrels during the hole extrusion strengthening of critical aerospace components, this study proposes a surface modification strategy for mandrels based on the anti-friction mechanism of micro-textures. Based on the Lame stress equation and the Mises yield criterion, a plastic strengthening stress distribution model of the hole wall was developed. Integrating Bowden’s adhesive friction theory, a parameterized numerical model was constructed to investigate the influence of micro-texture morphology on interfacial friction and wear behavior. An elastic–plastic contact model for micro-textured mandrels during hole extrusion strengthening was established using ANSYS. The effects of key parameters such as the micro-texture depth and area ratio on the contact pressure field, friction stress distribution, and strengthening performance were quantitatively analyzed. The results show that a circular micro-texture with a depth of 50 μm and an area ratio of 20% can reduce the fluctuation and peak value of the contact pressure by 41.0% and 29.7%, respectively, and decrease the average friction stress by 8.1%. The interfacial wear resistance and the uniformity of the residual compressive stress distribution on the hole wall are significantly enhanced, providing tribological insight and surface optimization guidance for improving the anti-wear performance and extending the service life of mandrels. Full article