| 1. |
- Golchin, Arash, et al.
(author)
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Effect of shaft roughness and pressure on friction of polymer bearings in water
- 2014
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In: Proceedings of the Institution of mechanical engineers. Part J, journal of engineering tribology. - : SAGE Publications. - 1350-6501 .- 2041-305X. ; 228:4, s. 371-381
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Journal article (peer-reviewed)abstract
- In this study, the frictional behavior of selected commercially available unfilled polymers, namely, polyether ether ketone, polytetrafluoroethylene, polyethylene terephthalate, and ultra-high molecular weight polyethylene against an Inconel shaft was investigated using a journal bearing test configuration in water-lubricated sliding contact. Dynamic friction curves were obtained for various shaft roughness values and polymer combinations. The results showed a significant influence of shaft surface roughness on running-in and steady state friction in water-lubricated conditions. Contact angle measurements revealed a significant increase in wettability of Inconel counterfaces. The X-ray photoelectron spectroscopy (XPS) analysis of the surfaces suggests formation of a reaction layer on worn Inconel surfaces when sliding against the polymers. The influences of counter surface roughness and load on frictional response of polymers were studied through intermittent tests by obtaining dynamic and breakaway friction maps for different polymer materials, shaft roughness values, and pressure combinations. In general, a trend of decreasing friction was obtained with increasing contact pressure; however, the materials' frictional responses to variations in counter surface roughness were different. These results indicate that although a reduced counter surface roughness may be beneficial for dynamic friction of polymers in all lubrication regimes, it can adversely affect the materials' breakaway friction response.
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| 2. |
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| 3. |
- Moghaddam, Pouria Valizadeh
(author)
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On the role of microstructure in wear of nanostructured carbide-free bainitic steels
- 2020
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Doctoral thesis (other academic/artistic)abstract
- The significance of steel production for the development of sustainable society and economy is immense. Today’s fast growing global economy poses an increasing demand for improving the properties of steel. The development of nanostructured carbide-free bainitic steel with an excellent combination of strength and toughness is an attempt to satisfy this global demand. During austempering, the precipitation of cementite can be suppressed by addition of approximately 1.5 wt% silicon and a duplex microstructure comprising of extremely fine aggregates of retained austenite and bainitic ferrite can be obtained. Owing to their excellent mechanical properties, these novel steels exhibit considerable potential to replace quenched and tempered bearing steel or pearlitic rail steel. In these applications, wear play a crucial role in determining the performance of the components. However, the majority of studies have been limited to mechanical properties of these steels but not much attention has been paid to their tribological behaviour. Notably, the role of retained austenite and bainitic ferrite on wear performance has not yet fully understood. Furthermore, machining process is an inevitable step in the manufacturing of metal products. During the machining, contact temperature can rise to several hundred degrees. However, high temperature tribological behaviour of these steels in conjunction with coated cutting tool has not yet been addressed. Therefore, the aim of the present research work is to gain a deeper understanding of the correlation between microstructure and tribological performance of carbide-free bainitic steels in various conditions.To achieve this aim, tribological behaviour of nanostructured carbide-free bainitic steels has been investigated under dry rolling/sliding, sliding and two-body abrasive wear conditions. A number of steel grades were austempered under a wide range of temperatures and durations to obtain different carbide-free bainitic microstructures. The results have been compared with that of quenched and tempered bearing steel. Moreover, high temperature tribological behaviour of carbide-free bainitic and 316L stainless steels during interaction with TiAlN PVD coating has also been studied under dry reciprocating sliding condition.The results show that a relatively higher retained austenite content and its stability enhance wear resistance under rolling/sliding condition. Moreover, wear performance of carbide-free bainitic steel has been found to be superior to that of the quenched and tempered bearing steel. However, under sliding condition, the effect of retained austenite on wear heavily depends on sliding speed. At low sliding speed and under adhesive-dominated wear condition, higher retained austenite content results in improved wear performance due to the higher work hardenability. In contrast, at high sliding speed where oxidative wear is dominant, a microstructure with the lowest content of retained austenite exhibits the highest wear resistance. The higher amount of bainitic ferrite provides a hard underlying substrate for a thin and mechanically stable compositional mixed layer and thereby enhances the wear resistance. The formation and microcracking of a brittle white etching layer of quenched and tempered steel is responsible for its inferior wear resistance. Under two-body abrasive wear conditions, higher retained austenite content leads to improved wear resistance. A microstructure providing an optimum combination of hardness and toughness shows the best abrasive wear resistance. During reciprocating sliding, the tribological response of carbide-free bainitic steel is altered with increasing temperature. Higher temperature results in severe material transfer from carbide-free bainitic steel to TiAlN coated cemented carbide. Furthermore, at elevatedtemperature, a porous oxide layer grows on the transferred materials and reduce friction coefficient.In summary, there is no simple and general relationship between microstructure and wear resistance. Depending upon the dominant wear mechanisms and operating conditions, retained austenite and bainitic ferrite affect the wear behaviour in radically different manners.
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| 4. |
- Ukonsaari, Jan, et al.
(author)
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Tribological studies on an eal lubricated bearing bronze - Steel pair under reciprocating sliding conditions
- 2008
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In: Tribologia. - 0780-2285. ; 27:1, s. 3-18
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Journal article (peer-reviewed)abstract
- Boundary lubricated journal bearings are found in various applications involving oscillatory sliding conditions. Environmental adaptation of hydraulic systems includes the introduction of synthetic esters. These new environmentally adapted lubricants (EALs) have shown very good boundary lubrication performance but also condition sensitivity. This study examines an oil lubricated bronze pin on hardened steel configuration in a reciprocating friction and wear test machine. Three synthetic esters were tested with a 1 mm stroke length. Results were compared with those for a mineral oil. The tribological performance with synthetic ester lubricant can, under certain conditions, be very good. SEM-EDS and XRD surface sensitive studies indicate the formation of a soft, copper enriched outer contact layer. The layer's nature and contact mechanisms clearly affect the performance of the different lubricants.
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| 5. |
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| 6. |
- Deng, Liang, 1986-, et al.
(author)
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Development of a Tribological Test Programme Based on Press Hardening Simulations
- 2017
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In: Tribology letters. - : Springer. - 1023-8883 .- 1573-2711. ; 65:2
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Journal article (peer-reviewed)abstract
- Press hardening is widely utilized to form ultra-high-strength steels characterized by a high strength-to-weight ratio for automotive components. Press hardening processes include heating boron–manganese steels to austenite phase, forming the steels at a high temperature, and cooling the formed blanks until the martensite phase is reached . However, press hardening processes lead to severe contact conditions between the blank and the tools including contact pressure, relative sliding, and high temperatures, which result in tool wear and increased maintenance cost. The contact conditions that occur in the stamping tool are difficult to study on site. Additionally, simplified tests, such as pin on disc and ball on disc, are insufficient to reproduce press hardening conditions in laboratory environments . The aim of this study includes developing a tribological test with press hardening conditions in which tool steel pins continuously slide on fresh and hot boron–manganese steel strips. The test programme mimics press hardening conditions with respect to sliding distance, sliding velocity, contact pressure, and surface temperature that were studied based on finite element (FE) simulations of a press hardening experiment. Furthermore, a FE simulation of the tribological test is established and it provides contact temperature in the pin tip with a high accuracy. A tribological test is used to study friction and mass loss with variational pressures and velocities that represented typically variational contact conditions in the press hardening. The tribological test is also used to obtain correlations between the tribological behaviours and process parameters in press hardening including pressure and sliding velocity.
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| 7. |
- Deng, Liang, 1986-, et al.
(author)
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Experimental Evaluation of Galling Under Press Hardening Conditions
- 2018
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In: Tribology letters. - : Springer. - 1023-8883 .- 1573-2711. ; 66:3
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Journal article (peer-reviewed)abstract
- Severe adhesion, also referred to as galling, is a critical problem in press hardening, especially in stamping tools used for hot forming of Al–Si-coated ultra-high strength steel. Galling is known to develop rapidly on the tool surface and it negatively affects the quality of the formed products. Earlier research on this topic has focused on the galling initiation. However, studies on the galling development during extended sliding and the corresponding quantitative measurement still lack depth. In the present study, a tribological test is established to study the galling development under press hardening conditions. The tribological test set-up aims to simulate extended sliding between the Al–Si-coated boron steels and the tool die material. The contact conditions in the interface are studied by a numerical model of the tribological test. The friction coefficients and material transfer are discussed taking into account the variation of the different test conditions. Using the results from the tribological tests, the galling simulation is performed in the numerical model. A geometry-updated sample based on the galling (transferred material build-up) height is simulated and the consequent pressure fluctuation is obtained in the numerical model. This contributes to the explanation of the severe transferred material accumulation during the test.
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| 8. |
- Deng, Liang, et al.
(author)
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Implementation of wear models for stamping tools under press hardening conditions based on laboratory tests
- 2014
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In: Advanced Materials Research. - 1022-6680 .- 1662-8985. ; 1063, s. 339-342
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Journal article (peer-reviewed)abstract
- Tool wear occurring in press hardening processes receives insufficient attention since its corresponding measurements and full-scale experiments are complicated and expensive. This paper presents a study of tool wear in press hardening based on laboratory experiments and FE-simulations. Two experimental laboratory setups depending on the contact conditions in press hardening build the base for the wear models implemented in the FE-simulation to predict wear depths. The highest wear depth is found at the radius of the stamping tool and the discrepancies in wear predictions based on the two different laboratory test setups are analyzed.
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| 9. |
- Deng, Liang, 1986-, et al.
(author)
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Numerical investigation of galling in a press hardening experiment with AlSi-coated workpieces
- 2019
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In: Engineering Failure Analysis. - : Elsevier. - 1350-6307 .- 1873-1961. ; 99, s. 85-96
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Journal article (peer-reviewed)abstract
- Press hardened steels are commonly used as a lightweight choice for manufacturing car components because of the high ratio of strength to weight. The use of ultra-high-strength steels for the design of lightweight vehicles contributes to the reduction of emissions of carbon dioxide while maintaining passenger safety. Stamping tools used in press hardening processes suffer harsh contact conditionsin terms of dramatic temperature changes, cyclic loadings, and complex interactions between coatings and oxidation. In mass production, tool wear is an inevitable problem that increases maintenance costs. Severe adhesive wear, also called galling, substantially occurs in the stamping tool used against Al—Si-coated workpieces. The galling that takes place during press hardening not only degrades the production quality but also shortens the service life of the tool. In order to properly arrange tool maintenance and minimize galling through adjusting process parameters, engineers need to know when and where galling occurs, based on modelling of the galling in press hardening simulations. In order to implement a galling simulation for press hardening, a modified Archard wear model is employed in the present study, which is a contact-mechanics-based model. The specific wear rate in the model is calibrated by the quantitative galling measurements of a high-temperature tribometer test. The tribological test is designed to mimic the press hardening conditions, where the correlations between galling and process parameters such as temperature, pressure, and sliding distance are outlined. The galling simulation is implemented in a full-scale press hardening experiment, and the predicted galling is validated in terms of severe galling positions and galling profiles. The galling profile evolution is correlated to variations in the contact conditions. Uncertainties in the numerical model, such as the choice of penalty scaling factor and friction coefficient, are analysed with a parameter study and discussed. This study demonstrates finite element (FE) simulations involving galling prediction in press hardening so as to improve product development and production efficiency.
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| 10. |
- Deng, Liang, et al.
(author)
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Numerical study of contact conditions in press hardening for tool wear simulation
- 2017
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In: International Journal of Material Forming. - : Springer. - 1960-6206 .- 1960-6214. ; 10:5, s. 717-727
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Journal article (peer-reviewed)abstract
- In the press hardening industry, industrial and academic efforts are being directed toward predicting tool wear to realize an economical manufacturing process. Tool wear in press hardening is a tribological response to contact conditions such as pressure and sliding motion. However, these contact conditions are difficult to measure in-situ. Furthermore, press hardening involves high temperatures, and this increases the complexity of the tribo system. The present work investigated the contact conditions of press hardening with a commercial FE code (LS-DYNA) as a base for tool wear simulation. A press hardening experiment was established in industrial environments and evaluated through FE simulations. The numerical model was set up so as to approximate the manufacturing conditions as closely as possible, and the sensitivity with respect to the friction coefficients was examined. The influence of numerical factors such as the penalty value and mesh size on the contact conditions is discussed. The implementation of a modified Archard’s wear model in the FE simulation proved the possibility of tool wear simulation in press hardening. Finally, a comparison between the tool wear simulation and the measured wear depth is presented.
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