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19 pages, 29727 KiB  
Review
A Review of Methods for Increasing the Durability of Hot Forging Tools
by Jan Turek and Jacek Cieślik
Materials 2025, 18(15), 3669; https://doi.org/10.3390/ma18153669 - 4 Aug 2025
Abstract
The article presents a comprehensive review of key issues and challenges related to enhancing the durability of hot forging tools. It discusses modern strategies aimed at increasing tool life, including modifications to tool materials, heat treatment, surface engineering, tool and die design, die [...] Read more.
The article presents a comprehensive review of key issues and challenges related to enhancing the durability of hot forging tools. It discusses modern strategies aimed at increasing tool life, including modifications to tool materials, heat treatment, surface engineering, tool and die design, die geometry, tribological conditions, and lubrication. The review is based on extensive literature data, including recent publications and the authors’ own research, which has been implemented under industrial conditions at the modern forging facility in Forge Plant “Glinik” (Poland). The study introduces original design and technological solutions, such as an innovative concept for manufacturing forging dies from alloy structural steels with welded impressions, replacing traditional hot-work tool steel dies. It also proposes a zonal hardfacing approach, which involves applying welds with different chemical compositions to specific surface zones of the die impressions, selected according to the dominant wear mechanisms in each zone. General guidelines for selecting hardfacing material compositions are also provided. Additionally, the article presents technological processes for die production and regeneration. The importance and application of computer simulations of forging processes are emphasized, particularly in predicting wear mechanisms and intensity, as well as in optimizing tool and forging geometry. Full article
(This article belongs to the Section Manufacturing Processes and Systems)
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31 pages, 1737 KiB  
Article
Trajectory Optimization for Autonomous Highway Driving Using Quintic Splines
by Wael A. Farag and Morsi M. Mahmoud
World Electr. Veh. J. 2025, 16(8), 434; https://doi.org/10.3390/wevj16080434 - 3 Aug 2025
Viewed by 39
Abstract
This paper introduces a robust and efficient Localized Spline-based Path-Planning (LSPP) algorithm designed to enhance autonomous vehicle navigation on highways. The LSPP approach prioritizes smooth maneuvering, obstacle avoidance, passenger comfort, and adherence to road constraints, including lane boundaries, through optimized trajectory generation using [...] Read more.
This paper introduces a robust and efficient Localized Spline-based Path-Planning (LSPP) algorithm designed to enhance autonomous vehicle navigation on highways. The LSPP approach prioritizes smooth maneuvering, obstacle avoidance, passenger comfort, and adherence to road constraints, including lane boundaries, through optimized trajectory generation using quintic spline functions and a dynamic speed profile. Leveraging real-time data from the vehicle’s sensor fusion module, the LSPP algorithm accurately interprets the positions of surrounding vehicles and obstacles, creating a safe, dynamically feasible path that is relayed to the Model Predictive Control (MPC) track-following module for precise execution. The theoretical distinction of LSPP lies in its modular integration of: (1) a finite state machine (FSM)-based decision-making layer that selects maneuver-specific goal states (e.g., keep lane, change lane left/right); (2) quintic spline optimization to generate smooth, jerk-minimized, and kinematically consistent trajectories; (3) a multi-objective cost evaluation framework that ranks competing paths according to safety, comfort, and efficiency; and (4) a closed-loop MPC controller to ensure real-time trajectory execution with robustness. Extensive simulations conducted in diverse highway scenarios and traffic conditions demonstrate LSPP’s effectiveness in delivering smooth, safe, and computationally efficient trajectories. Results show consistent improvements in lane-keeping accuracy, collision avoidance, enhanced materials wear performance, and planning responsiveness compared to traditional path-planning methods. These findings confirm LSPP’s potential as a practical and high-performance solution for autonomous highway driving. Full article
(This article belongs to the Special Issue Motion Planning and Control of Autonomous Vehicles)
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30 pages, 8223 KiB  
Article
Optimal Time–Jerk Trajectory Planning for Manipulators Based on a Constrained Multi-Objective Dream Optimization Algorithm
by Zhijun Wu, Fang Wang and Tingting Bao
Machines 2025, 13(8), 682; https://doi.org/10.3390/machines13080682 - 2 Aug 2025
Viewed by 281
Abstract
A multi-objective optimal trajectory planning method is proposed for manipulators in this paper to enhance motion efficiency and to reduce component wear while ensuring motion smoothness. The trajectory is initially interpolated in the joint space by using quintic non-uniform B-splines with virtual points, [...] Read more.
A multi-objective optimal trajectory planning method is proposed for manipulators in this paper to enhance motion efficiency and to reduce component wear while ensuring motion smoothness. The trajectory is initially interpolated in the joint space by using quintic non-uniform B-splines with virtual points, achieving the C4 continuity of joint motion and satisfying dynamic, kinematic, geometric, synchronization, and boundary constraints. The interpolation reformulates the trajectory planning problem into an optimization problem, where the time intervals between desired adjacent waypoints serve as variables. Travelling time and the integral of the squared jerk along the entire trajectories comprise the multi-objective functions. A constrained multi-objective dream optimization algorithm is designed to solve the time–jerk optimal trajectory planning problem and generate Pareto solutions for optimized trajectories. Simulations conducted on 6-DOF manipulators validate the effectiveness and superiority of the proposed method in comparison with existing typical trajectory planning methods. Full article
(This article belongs to the Special Issue Cutting-Edge Automation in Robotic Machining)
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31 pages, 9769 KiB  
Review
Recent Advances of Hybrid Nanogenerators for Sustainable Ocean Energy Harvesting: Performance, Applications, and Challenges
by Enrique Delgado-Alvarado, Enrique A. Morales-Gonzalez, José Amir Gonzalez-Calderon, Ma. Cristina Irma Peréz-Peréz, Jesús Delgado-Maciel, Mariana G. Peña-Juarez, José Hernandez-Hernandez, Ernesto A. Elvira-Hernandez, Maximo A. Figueroa-Navarro and Agustin L. Herrera-May
Technologies 2025, 13(8), 336; https://doi.org/10.3390/technologies13080336 - 2 Aug 2025
Viewed by 311
Abstract
Ocean energy is an abundant, eco-friendly, and renewable energy resource that is useful for powering sensor networks connected to the maritime Internet of Things (MIoT). These sensor networks can be used to measure different marine environmental parameters that affect ocean infrastructure integrity and [...] Read more.
Ocean energy is an abundant, eco-friendly, and renewable energy resource that is useful for powering sensor networks connected to the maritime Internet of Things (MIoT). These sensor networks can be used to measure different marine environmental parameters that affect ocean infrastructure integrity and harm marine ecosystems. This ocean energy can be harnessed through hybrid nanogenerators that combine triboelectric nanogenerators, electromagnetic generators, piezoelectric nanogenerators, and pyroelectric generators. These nanogenerators have advantages such as high-power density, robust design, easy operating principle, and cost-effective fabrication. However, the performance of these nanogenerators can be affected by the wear of their main components, reduction of wave frequency and amplitude, extreme corrosion, and sea storms. To address these challenges, future research on hybrid nanogenerators must improve their mechanical strength, including materials and packages with anti-corrosion coatings. Herein, we present recent advances in the performance of different hybrid nanogenerators to harvest ocean energy, including various transduction mechanisms. Furthermore, this review reports potential applications of hybrid nanogenerators to power devices in marine infrastructure or serve as self-powered MIoT monitoring sensor networks. This review discusses key challenges that must be addressed to achieve the commercial success of these nanogenerators, regarding design strategies with advanced simulation models or digital twins. Also, these strategies must incorporate new materials that improve the performance, reliability, and integration of future nanogenerator array systems. Thus, optimized hybrid nanogenerators can represent a promising technology for ocean energy harvesting with application in the maritime industry. Full article
(This article belongs to the Special Issue Technological Advances in Science, Medicine, and Engineering 2024)
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22 pages, 29737 KiB  
Article
A Comparative Investigation of CFD Approaches for Oil–Air Two-Phase Flow in High-Speed Lubricated Rolling Bearings
by Ruifeng Zhao, Pengfei Zhou, Jianfeng Zhong, Duan Yang and Jie Ling
Machines 2025, 13(8), 678; https://doi.org/10.3390/machines13080678 - 1 Aug 2025
Viewed by 118
Abstract
Analyzing the two-phase flow behavior in bearing lubrication is crucial for understanding friction and wear mechanisms, optimizing lubrication design, and improving bearing operational efficiency and reliability. However, the complexity of oil–air two-phase flow in high-speed bearings poses significant research challenges. Currently, there is [...] Read more.
Analyzing the two-phase flow behavior in bearing lubrication is crucial for understanding friction and wear mechanisms, optimizing lubrication design, and improving bearing operational efficiency and reliability. However, the complexity of oil–air two-phase flow in high-speed bearings poses significant research challenges. Currently, there is a lack of comparative studies employing different simulation strategies to address this issue, leaving a gap in evidence-based guidance for selecting appropriate simulation approaches in practical applications. This study begins with a comparative analysis between experimental and simulation results to validate the reliability of the adopted simulation approach. Subsequently, a comparative evaluation of different simulation methods is conducted to provide a scientific basis for relevant decision-making. Evaluated from three dimensions—adaptability to rotational speed conditions, research focuses (oil distribution and power loss), and computational economy—the findings reveal that FVM excels at medium-to-high speeds, accurately predicting continuous oil film distribution and power loss, while MPS, leveraging its meshless Lagrangian characteristics, demonstrates superior capability in describing physical phenomena under extreme conditions, albeit with higher computational costs. Economically, FVM, supported by mature software ecosystems and parallel computing optimization, is more suitable for industrial design applications, whereas MPS, being more reliant on high-performance hardware, is better suited for academic research and customized scenarios. The study further proposes that future research could adopt an FVM-MPS coupled approach to balance efficiency and precision, offering a new paradigm for multi-scale lubrication analysis in bearings. Full article
(This article belongs to the Section Machine Design and Theory)
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27 pages, 8070 KiB  
Article
Study on Solid-Liquid Two-Phase Flow and Wear Characteristics in Multistage Centrifugal Pumps Based on the Euler-Lagrange Approach
by Zhengyin Yang, Yandong Gu, Yingrui Zhang and Zhuoqing Yan
Water 2025, 17(15), 2271; https://doi.org/10.3390/w17152271 - 30 Jul 2025
Viewed by 195
Abstract
Multistage centrifugal pumps, owing to their high head characteristics, are commonly applied in domains like subsea resource exploitation and groundwater extraction. However, the wear of flow passage components caused by solid particles in the fluid severely threatens equipment lifespan and system safety. To [...] Read more.
Multistage centrifugal pumps, owing to their high head characteristics, are commonly applied in domains like subsea resource exploitation and groundwater extraction. However, the wear of flow passage components caused by solid particles in the fluid severely threatens equipment lifespan and system safety. To investigate the influence of solid-liquid two-phase flow on pump performance and wear, this study conducted numerical simulations of the solid-liquid two-phase flow within multistage centrifugal pumps based on the Euler–Lagrange approach and the Tabakoff wear model. The simulation results showed good agreement with experimental data. Under the design operating condition, compared to the clear water condition, the efficiency under the solid-liquid two-phase flow condition decreased by 1.64%, and the head coefficient decreased by 0.13. As the flow rate increases, particle momentum increases, the particle Stokes number increases, inertial forces are enhanced, and the coupling effect with the fluid weakens, leading to an increased impact intensity on flow passage components. This results in a gradual increase in the wear area of the impeller front shroud, back shroud, pressure side, and the peripheral casing. Under the same flow rate condition, when particles enter the pump chamber of a subsequent stage from a preceding stage, the fluid, after being rectified by the return guide vane, exhibits a more uniform flow pattern and reduced turbulence intensity. The particle Stokes number in the subsequent stage is smaller than that in the preceding stage, weakening inertial effects and enhancing the coupling effect with the fluid. This leads to a reduced impact intensity on flow passage components, resulting in a smaller wear area of these components in the subsequent stage compared to the preceding stage. This research offers critical theoretical foundations and practical guidelines for developing wear-resistant multistage centrifugal pumps in solid-liquid two-phase flow applications, with direct implications for extending service life and optimizing hydraulic performance. Full article
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20 pages, 5568 KiB  
Article
Dynamic Wear Modeling and Experimental Verification of Guide Cone in Passive Compliant Connectors Based on the Archard Model
by Yuanping He, Bowen Wang, Feifei Zhao, Xingfu Hong, Liang Fang, Weihao Xu, Ming Liao and Fujing Tian
Polymers 2025, 17(15), 2091; https://doi.org/10.3390/polym17152091 - 30 Jul 2025
Viewed by 230
Abstract
To address the wear life prediction challenge of Guide Cones in passive compliant connectors under dynamic loads within specialized equipment, this study proposes a dynamic wear modeling and life assessment method based on the improved Archard model. Through integrated theoretical modeling, finite element [...] Read more.
To address the wear life prediction challenge of Guide Cones in passive compliant connectors under dynamic loads within specialized equipment, this study proposes a dynamic wear modeling and life assessment method based on the improved Archard model. Through integrated theoretical modeling, finite element simulation, and experimental validation, we establish a bidirectional coupling framework analyzing dynamic contact mechanics and wear evolution. By developing phased contact state identification criteria and geometric constraints, a transient load calculation model is established, revealing dynamic load characteristics with peak contact forces reaching 206.34 N. A dynamic contact stress integration algorithm is proposed by combining Archard’s theory with ABAQUS finite element simulation and ALE adaptive meshing technology, enabling real-time iterative updates of wear morphology and contact stress. This approach constructs an exponential model correlating cumulative wear depth with docking cycles (R2 = 0.997). Prototype experiments demonstrate a mean absolute percentage error (MAPE) of 14.6% between simulated and measured wear depths, confirming model validity. With a critical wear threshold of 0.8 mm, the predicted service life reaches 45,270 cycles, meeting 50-year operational requirements (safety margin: 50.9%). This research provides theoretical frameworks and engineering guidelines for wear-resistant design, material selection, and life evaluation in high-reliability automatic docking systems. Full article
(This article belongs to the Section Polymer Processing and Engineering)
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16 pages, 3664 KiB  
Article
Wave Prediction Error Compensation and PTO Optimization Control Method for Improving the WEC Power Quality
by Tianlong Lan, Jiarui Wang, Luliang He, Peng Qian, Dahai Zhang and Bo Feng
Energies 2025, 18(15), 4043; https://doi.org/10.3390/en18154043 - 29 Jul 2025
Viewed by 173
Abstract
Reliable wave prediction plays a significant role in wave energy converter (WEC) research, but there are still prediction errors that would increase the uncertainty for the power grid and reduce the power quality. The efficiency and stability of the power take-off (PTO) system [...] Read more.
Reliable wave prediction plays a significant role in wave energy converter (WEC) research, but there are still prediction errors that would increase the uncertainty for the power grid and reduce the power quality. The efficiency and stability of the power take-off (PTO) system are also important research topics in WEC applications. In order to solve the above-mentioned problems, this paper presents a model predictive control (MPC) method composed of a prediction error compensation controller and a PTO optimization controller. This work aims to address the limitations of existing wave prediction methods and improve the efficiency and stability of hydraulic PTO systems in WECs. By controlling the charging and discharging of the accumulator, the power quality is enhanced by reducing grid frequency fluctuations and voltage flicker through prediction error compensation. In addition, an efficient and stable hydraulic PTO system can be obtained by keeping the operation pressure of the hydraulic motor at the optimal range. Thus, smoother power output minimizes grid-balancing penalties and storage wear, and stable hydraulic pressure extends PTO component lifespan. Finally, comparative numerical simulation studies are provided to show the efficacy of the proposed method. The results validate that the dual-controller MPC framework reduces power deviations by 74.3% and increases average power generation by 31% compared to the traditional method. Full article
(This article belongs to the Section A3: Wind, Wave and Tidal Energy)
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14 pages, 2969 KiB  
Article
ANSYS-Based Modeling and Simulation of Electrostatic Oil-Line Sensor
by Ruochen Liu, Ge Cai, Jianzhong Sun and Lanchun Zhang
Sensors 2025, 25(15), 4669; https://doi.org/10.3390/s25154669 - 28 Jul 2025
Viewed by 197
Abstract
Mechanical components are more difficult to detect at the initial state of failure. To solve this problem, this paper models and simulates the characteristics of an electrostatic oil-line sensor (OLS) wear particles carried in the lubricating oil path are detected. In this study, [...] Read more.
Mechanical components are more difficult to detect at the initial state of failure. To solve this problem, this paper models and simulates the characteristics of an electrostatic oil-line sensor (OLS) wear particles carried in the lubricating oil path are detected. In this study, an OLS that monitors the charge in an oil line using the principle of electrostatic induction is modeled and simulated. The sensor characteristics are simulated and tested using finite element simulation. The sensor efficiency, spatial sensitivity, and length-to-diameter ratio are simulated based on the point charges at different locations. The simulation results show that the sensitivity exhibits different trends when the point charge is inside and outside the probe. The length-to-diameter ratio is proportional to the sensor efficiency, the spatial sensitivity distribution law of multiple charges is consistent with that of a point charge, and the relative deviation rate between the mathematically calculated values and the simulated values is less than 3% under the same conditions. In conclusion, the finite element simulation results of the electrostatic oil line sensor constructed in this study are consistent with the theoretical model calculations and can be used in future mechanical fault diagnosis. Full article
(This article belongs to the Section Electronic Sensors)
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22 pages, 6823 KiB  
Article
Design Optimization of Valve Assemblies in Downhole Rod Pumps to Enhance Operational Reliability in Oil Production
by Seitzhan Zaurbekov, Kadyrzhan Zaurbekov, Doszhan Balgayev, Galina Boiko, Ertis Aksholakov, Roman V. Klyuev and Nikita V. Martyushev
Energies 2025, 18(15), 3976; https://doi.org/10.3390/en18153976 - 25 Jul 2025
Viewed by 273
Abstract
This study focuses on the optimization of valve assemblies in downhole rod pumping units (DRPUs), which remain the predominant artificial lift technology in oil production worldwide. The research addresses the critical issue of premature failures in DRPUs caused by leakage in valve pairs, [...] Read more.
This study focuses on the optimization of valve assemblies in downhole rod pumping units (DRPUs), which remain the predominant artificial lift technology in oil production worldwide. The research addresses the critical issue of premature failures in DRPUs caused by leakage in valve pairs, i.e., a problem that accounts for approximately 15% of all failures, as identified in a statistical analysis of the 2022 operational data from the Uzen oilfield in Kazakhstan. The leakage is primarily attributed to the accumulation of mechanical impurities and paraffin deposits between the valve ball and seat, leading to concentrated surface wear and compromised sealing. To mitigate this issue, a novel valve assembly design was developed featuring a flow turbulizer positioned beneath the valve seat. The turbulizer generates controlled vortex motion in the fluid flow, which increases the rotational frequency of the valve ball during operation. This motion promotes more uniform wear across the contact surfaces and reduces the risk of localized degradation. The turbulizers were manufactured using additive FDM technology, and several design variants were tested in a full-scale laboratory setup simulating downhole conditions. Experimental results revealed that the most effective configuration was a spiral plate turbulizer with a 7.5 mm width, installed without axis deviation from the vertical, which achieved the highest ball rotation frequency and enhanced lapping effect between the ball and the seat. Subsequent field trials using valves with duralumin-based turbulizers demonstrated increased operational lifespans compared to standard valves, confirming the viability of the proposed solution. However, cases of abrasive wear were observed under conditions of high mechanical impurity concentration, indicating the need for more durable materials. To address this, the study recommends transitioning to 316 L stainless steel for turbulizer fabrication due to its superior tensile strength, corrosion resistance, and wear resistance. Implementing this design improvement can significantly reduce maintenance intervals, improve pump reliability, and lower operating costs in mature oilfields with high water cut and solid content. The findings of this research contribute to the broader efforts in petroleum engineering to enhance the longevity and performance of artificial lift systems through targeted mechanical design improvements and material innovation. Full article
(This article belongs to the Special Issue Petroleum and Natural Gas Engineering)
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17 pages, 6623 KiB  
Article
Numerical Study on Flow Field Optimization and Wear Mitigation Strategies for 600 MW Pulverized Coal Boilers
by Lijun Sun, Miao Wang, Peian Chong, Yunhao Shao and Lei Deng
Energies 2025, 18(15), 3947; https://doi.org/10.3390/en18153947 - 24 Jul 2025
Viewed by 165
Abstract
To compensate for the instability of renewable energy sources during China’s energy transition, large thermal power plants must provide critical operational flexibility, primarily through deep peaking. To investigate the combustion performance and wear and tear of a 600 MW pulverized coal boiler under [...] Read more.
To compensate for the instability of renewable energy sources during China’s energy transition, large thermal power plants must provide critical operational flexibility, primarily through deep peaking. To investigate the combustion performance and wear and tear of a 600 MW pulverized coal boiler under deep peaking, the gas–solid flow characteristics and distributions of flue gas temperature, wall heat flux, and wall wear rate in a 600 MW tangentially fired pulverized coal boiler under variable loads (353 MW, 431 MW, 519 MW, and 600 MW) are investigated in this study employing computational fluid dynamics numerical simulation method. Results demonstrate that increasing the boiler load significantly amplifies gas velocity, wall heat flux, and wall wear rate. The maximum gas velocity in the furnace rises from 20.9 m·s−1 (353 MW) to 37.6 m·s−1 (600 MW), with tangential airflow forming a low-velocity central zone and high-velocity peripheral regions. Meanwhile, the tangential circle diameter expands by ~15% as the load increases. The flue gas temperature distribution exhibits a “low-high-low” profile along the furnace height. As the load increases from 353 MW to 600 MW, the primary combustion zone’s peak temperature rises from 1750 K to 1980 K, accompanied by a ~30% expansion in the coverage area of the high-temperature zone. Wall heat flux correlates strongly with temperature distribution, peaking at 2.29 × 105 W·m−2 (353 MW) and 2.75 × 105 W·m−2 (600 MW) in the primary combustion zone. Wear analysis highlights severe erosion in the economizer due to elevated flue gas velocities, with wall wear rates escalating from 3.29 × 10−7 kg·m−2·s−1 (353 MW) to 1.23 × 10−5 kg·m−2·s−1 (600 MW), representing a 40-fold increase under full-load conditions. Mitigation strategies, including ash removal optimization, anti-wear covers, and thermal spray coatings, are proposed to enhance operational safety. This work provides critical insights into flow field optimization and wear management for large-scale coal-fired boilers under flexible load operation. Full article
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16 pages, 3807 KiB  
Article
Optimization of Machining Efficiency of Aluminum Honeycomb Structures by Hybrid Milling Assisted by Longitudinal Ultrasonic Vibrations
by Oussama Beldi, Tarik Zarrouk, Ahmed Abbadi, Mohammed Nouari, Mohammed Abbadi, Jamal-Eddine Salhi and Mohammed Barboucha
Processes 2025, 13(8), 2348; https://doi.org/10.3390/pr13082348 - 23 Jul 2025
Viewed by 306
Abstract
The use of aluminum honeycomb structures is fast expanding in advanced sectors such as the aeronautics, aerospace, marine, and automotive industries. However, processing these structures represents a major challenge for producing parts that meet the strict standards. To address this issue, an innovative [...] Read more.
The use of aluminum honeycomb structures is fast expanding in advanced sectors such as the aeronautics, aerospace, marine, and automotive industries. However, processing these structures represents a major challenge for producing parts that meet the strict standards. To address this issue, an innovative manufacturing method using longitudinal ultrasonic vibration-assisted cutting, combined with a CDZ10 hybrid cutting tool, was developed to optimize the efficiency of traditional machining processes. To this end, a 3D numerical model was developed using the finite element method and Abaqus/Explicit 2017 software to simulate the complex interactions among the cutting tool and the thin walls of the structures. This model was validated by experimental tests, allowing the study of the influence of milling conditions such as feed rate, cutting angle, and vibration amplitude. The numerical results revealed that the hybrid technology significantly reduces the cutting force components, with a decrease ranging from 10% to 42%. In addition, it improves cutting quality by reducing plastic deformation and cell wall tearing, which prevents the formation of chips clumps on the tool edges, thus avoiding early wear of the tool. These outcomes offer new insights into optimizing industrial processes, particularly in fields with stringent precision and performance demands, like the aerospace sector. Full article
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20 pages, 3625 KiB  
Article
Improvement in the Corrosion and Wear Resistance of ZrO2-Ag Coatings on 316LVM Stainless Steel Under Tribocorrosive Conditions
by Willian Aperador and Giovany Orozco-Hernández
Coatings 2025, 15(8), 862; https://doi.org/10.3390/coatings15080862 - 22 Jul 2025
Viewed by 334
Abstract
This study investigates the development of silver (Ag)-doped zirconia (ZrO2) coatings deposited on 316LVM stainless steel via the unbalanced magnetron sputtering technique. The oxygen content in the Ar/O2 gas mixture was systematically varied (12.5%, 25%, 37.5%, and 50%) to assess [...] Read more.
This study investigates the development of silver (Ag)-doped zirconia (ZrO2) coatings deposited on 316LVM stainless steel via the unbalanced magnetron sputtering technique. The oxygen content in the Ar/O2 gas mixture was systematically varied (12.5%, 25%, 37.5%, and 50%) to assess its influence on the resulting coating properties. In response to the growing demand for biomedical implants with improved durability and biocompatibility, the objective was to develop coatings that enhance both wear and corrosion resistance in physiological environments. The effects of silver incorporation and oxygen concentration on the structural, tribological, and electrochemical behavior of the coatings were systematically analyzed. X-ray diffraction (XRD) was employed to identify crystalline phases, while atomic force microscopy (AFM) was used to characterize surface topography prior to wear testing. Wear resistance was evaluated using a ball-on-plane tribometer under simulated prosthetic motion, applying a 5 N load with a bone pin as the counter body. Corrosion resistance was assessed through electrochemical impedance spectroscopy (EIS) in a physiological solution. Additionally, tribocorrosive performance was investigated by coupling tribological and electrochemical tests in Ringer’s lactate solution, simulating dynamic in vivo contact conditions. The results demonstrate that Ag doping, combined with increased oxygen content in the sputtering atmosphere, significantly improves both wear and corrosion resistance. Notably, the ZrO2-Ag coating deposited with 50% O2 exhibited the lowest wear volume (0.086 mm3) and a minimum coefficient of friction (0.0043) under a 5 N load. This same coating also displayed superior electrochemical performance, with the highest charge transfer resistance (38.83 kΩ·cm2) and the lowest corrosion current density (3.32 × 10−8 A/cm2). These findings confirm the high structural integrity and outstanding tribocorrosive behavior of the coating, highlighting its potential for application in biomedical implant technology. Full article
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21 pages, 8433 KiB  
Article
Development of an Advanced Wear Simulation Model for a Racing Slick Tire Under Dynamic Acceleration Loading
by Alfonse Ly, Christopher Yoon, Joseph Caruana, Omar Ibrahim, Oliver Goy, Moustafa El-Gindy and Zeinab El-Sayegh
Machines 2025, 13(8), 635; https://doi.org/10.3390/machines13080635 - 22 Jul 2025
Viewed by 528
Abstract
This study investigates the development of a tire wear model using finite element techniques. Experimental testing was conducted using the Hoosier R25B slick tire mounted onto a Mustang Dynamometer (MD-AWD-500) in the Automotive Center of Excellence, Oshawa, Ontario, Canada. A general acceleration/deceleration procedure [...] Read more.
This study investigates the development of a tire wear model using finite element techniques. Experimental testing was conducted using the Hoosier R25B slick tire mounted onto a Mustang Dynamometer (MD-AWD-500) in the Automotive Center of Excellence, Oshawa, Ontario, Canada. A general acceleration/deceleration procedure was performed until the battery was completely exhausted. A high-fidelity finite element tire model using Virtual Performance Solution by ESI Group, a part of Keysight Technologies, was developed, incorporating highly detailed material testing and constitutive modeling to simulate the tire’s complex mechanical behavior. In conjunction with a finite element model, Archard’s wear theory is implemented algorithmically to determine the wear and volume loss rate of the tire during its acceleration and deceleration procedures. A novel application using a modified wear theory incorporates the temperature dependence of tread hardness to measure tire wear. Experimental tests show that the tire loses 3.10 g of mass within 45 min of testing. The results from the developed finite element model for tire wear suggest a high correlation to experimental values. This study demonstrates the simulated model’s capability to predict wear patterns, ability to quantify tire degradation under dynamic loading conditions and provides valuable insights for optimizing performance and wear estimation. Full article
(This article belongs to the Special Issue Advanced Technologies in Vehicle Interior Noise Control)
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16 pages, 5442 KiB  
Communication
Analysis of the Impact of Frog Wear on the Wheel–Rail Dynamic Performance in Turnout Zones of Urban Rail Transit Lines
by Yanlei Li, Dongliang Zeng, Xiuqi Wei, Xiaoyu Hu and Kaiyun Wang
Lubricants 2025, 13(7), 317; https://doi.org/10.3390/lubricants13070317 - 20 Jul 2025
Viewed by 319
Abstract
To investigate how severe wear at No. 12 turnout frogs in an urban rail transit line operating at speeds over 120 km/h on the dynamic performance of the vehicle, a vehicle–frog coupled dynamic model was established by employing the 2021 version of SIMPACK [...] Read more.
To investigate how severe wear at No. 12 turnout frogs in an urban rail transit line operating at speeds over 120 km/h on the dynamic performance of the vehicle, a vehicle–frog coupled dynamic model was established by employing the 2021 version of SIMPACK software. Profiles of No. 12 alloy steel frogs and metro wheel rims were measured to simulate wheel–rail interactions as the vehicle traverses the turnout, using both brand-new and worn frog conditions. The experimental results indicate that increased service life deepens frog wear, raises equivalent conicity, and intensifies wheel–rail forces. When a vehicle passes through the frog serviced for over 17 months at the speed of 120 km/h, the maximum derailment coefficient, lateral acceleration of the car body, and lateral and vertical wheel–rail forces increased by 0.14, 0.17 m/s2, 9.52 kN, and 105.76 kN, respectively. The maximum contact patch area grew by 35.73%, while peak contact pressure rose by 236 MPa. To prevent dynamic indicators from exceeding safety thresholds and ensure train operational safety, it is recommended that the frog maintenance cycle be limited to 12 to 16 months. Full article
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