The document analyzes flank wear characteristics of tungsten carbide tools when turning plain carbon steels. It finds that flank wear can be described by an equation similar to the one used for crater wear, but with two characteristic lines intersecting at around 1150K. Experiments measuring temperature and stress on the flank wear land support this, finding uniform distributions. The constants in the flank wear equation are affected by abrasives in the steels. Further investigation is needed to fully understand the contribution of abrasion to flank wear.
Tool wear and inclusion behaviour during turning of a calcium treated quenc...Lepuufu
1. The document analyzes tool wear and inclusion behavior during turning of a calcium-treated steel using coated carbide tools.
2. It finds that inclusions like MnS, mixed sulphides (Mn,Ca)S, and duplex calcium aluminates deform significantly in the flow zone near the tool. MnS deforms the most while mixed sulphides deform less.
3. The behavior and deformation of inclusions in the flow zone influences tool wear and formation of protective layers on the tool surface. Certain inclusions like mixed sulphides are more likely to form protective layers due to their deformation characteristics.
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Corrosion occurs via an electrochemical process involving an anode, cathode, and electrolyte. At the anode, metal atoms lose electrons and form positively charged ions, while at the cathode electrons are accepted. The electrolyte carries ions between the anode and cathode, enabling the flow of electrons. Proper surface preparation is critical for coating adhesion and longevity. It involves removing contaminants and increasing surface area via abrasive blasting or other methods. Abrasive blasting roughens the surface, forming a profile that improves adhesion through mechanical interlocking and chemical bonding between the coating and substrate.
This document contains a multiple choice exam for painting inspectors with 51 questions. The questions cover topics like measurement units, coating defects, abrasive blasting, corrosion, paint components, and testing equipment. An answer key is provided at the end to indicate the correct response for each question.
Effect of Modified AA5356 Filler on Corrosion Behavior of AA6061 Alloy GTA WeldsIJMER
1) The document examines the effect of modified AA5356 filler and grain refiners on the corrosion behavior of AA6061 alloy gas tungsten arc welds.
2) Dynamic polarization testing showed that welds made with 0.5% scandium-modified AA5356 filler using pulsed current welding had the highest pitting corrosion resistance.
3) Optical microscopy revealed that additions of grain refiners like scandium, zirconium, and tibor to the AA5356 filler reduced pit size and density in the fusion zone, improving corrosion resistance compared to unmodified AA5356 filler.
Fusion welding uses heat to melt materials that are then joined together as they solidify. Common fusion welding methods include arc, resistance, oxyfuel, and laser welding. Solid-state welding joins materials without melting using pressure and sometimes heat. Welding allows the production of parts that would be difficult or impossible to form as a single piece through other manufacturing methods. Inspection methods are used to evaluate welds and identify defects.
Tool wear and inclusion behaviour during turning of a calcium treated quenc...Lepuufu
1. The document analyzes tool wear and inclusion behavior during turning of a calcium-treated steel using coated carbide tools.
2. It finds that inclusions like MnS, mixed sulphides (Mn,Ca)S, and duplex calcium aluminates deform significantly in the flow zone near the tool. MnS deforms the most while mixed sulphides deform less.
3. The behavior and deformation of inclusions in the flow zone influences tool wear and formation of protective layers on the tool surface. Certain inclusions like mixed sulphides are more likely to form protective layers due to their deformation characteristics.
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Corrosion occurs via an electrochemical process involving an anode, cathode, and electrolyte. At the anode, metal atoms lose electrons and form positively charged ions, while at the cathode electrons are accepted. The electrolyte carries ions between the anode and cathode, enabling the flow of electrons. Proper surface preparation is critical for coating adhesion and longevity. It involves removing contaminants and increasing surface area via abrasive blasting or other methods. Abrasive blasting roughens the surface, forming a profile that improves adhesion through mechanical interlocking and chemical bonding between the coating and substrate.
This document contains a multiple choice exam for painting inspectors with 51 questions. The questions cover topics like measurement units, coating defects, abrasive blasting, corrosion, paint components, and testing equipment. An answer key is provided at the end to indicate the correct response for each question.
Effect of Modified AA5356 Filler on Corrosion Behavior of AA6061 Alloy GTA WeldsIJMER
1) The document examines the effect of modified AA5356 filler and grain refiners on the corrosion behavior of AA6061 alloy gas tungsten arc welds.
2) Dynamic polarization testing showed that welds made with 0.5% scandium-modified AA5356 filler using pulsed current welding had the highest pitting corrosion resistance.
3) Optical microscopy revealed that additions of grain refiners like scandium, zirconium, and tibor to the AA5356 filler reduced pit size and density in the fusion zone, improving corrosion resistance compared to unmodified AA5356 filler.
Fusion welding uses heat to melt materials that are then joined together as they solidify. Common fusion welding methods include arc, resistance, oxyfuel, and laser welding. Solid-state welding joins materials without melting using pressure and sometimes heat. Welding allows the production of parts that would be difficult or impossible to form as a single piece through other manufacturing methods. Inspection methods are used to evaluate welds and identify defects.
Wear performance of ceramic cutting tool materials when cutting steelLepuufu
The document summarizes the results of a study that tested the wear performance of various ceramic cutting tool materials when cutting steel. It found that alumina-based materials like alumina-zirconia (F) and alumina in submicron grain toughened by zirconia (G), as well as mixed-based alumina (Z), exhibited the best wear resistance when cutting steel at high speeds up to 11 m/s. These materials demonstrated tool lives between 180-300 seconds at the highest speed tested. In contrast, silicon nitride (S), sintered carbide (C), cubic boron nitride (B), and alumina reinforced with silicon carbide whiskers (W) showed
Introduction to stress corrosion cracking and nace material requirementsMahendra Prabhu S
Corrosion is one of the major areas of interest for Design / plant operator and maintenance personnel to keep the plant in good shape. The understanding of corrosion mechanism is important for the design engineers to tackle this problem by choosing right metallurgy / manufacturing methods and Inspection techniques. This presentation gives an overview about Sulfide stress corrosion in refining environment and the NACE MR0103 employed to control this phenomena.
Corrosion characteristics of al 0.91 mg-0.55si-1.12fe-0.39ca al-alloy aged at...eSAT Journals
Abstract The study of degradation of Al-0.91Mg-0.55Si-1.12Fe-0.39Ca aluminum-alloy is carried out under different state of microstructure. The reason for this work is to decide the impact of heat treatment on the microstructure and the corrosive consumption of Al-alloy in acid utilizing weight reduction system. Specimens were solution treated at 545 oC and artificially aged at 185 oC. The maximum hardness is found after aging for 12 hrs. They were immersed in 0.8 molar solution of sulfuric acid for 0.58 hrs, 1.08 hrs, 1.58, 2.08 hrs and 2.58 hrs. The corrosion rates were calculated for various immersion periods. The test work has uncovered that time and temperature assumes an imperative part in the precipitation transformation procedure of the Al-ally. The hardness increases due to formation of second phase particles of Mg2Si. In over-aging of the alloy, the growth of the precipitate particle takes place at the expense of smaller precipitate particles. The rate of corrosion is found lower in the artificially aged specimen. The corrosion rates are found stabilized after 2.08 hrs of immersion in H2SO4. The X-Ray Diffraction patterns are also analyzed in the range of 10-80⁰ which are showing peaks of aluminum solid solution and Mg2Si in the different patterns. Key Words: Corrosion rate, Aluminum alloys, aging of alloy, solutionizing, acid, weight reduction.
This document analyzes the hot corrosion behavior of laser melted GP1 stainless steel powder when exposed to a molten chloride and sulphide environment. The study found that the corrosion followed a parabolic rate law, with higher corrosion rates initially. Surface examination revealed pitting and scaling. Phase analysis identified oxides like Fe2O3 and Cr2O3 as well as other reaction products like NiFe2O4 and NiCr2O4, indicating the material underwent oxidation, chloridation and sulphidation during exposure. The results provide insight into corrosion mechanisms during additive manufacturing processes involving laser powder melting.
This document summarizes a study on the formability of various Indian stainless steel sheets formed under different stress conditions. Experimental work was conducted to determine the forming limit diagrams, microstructures, tensile properties, crystallographic textures and void characteristics of SS301, SS304, SS409M, SS430 and SSLN1 steel grades. Micrographs showed SS304 has a mixed grain structure while SS301 has coarse grains with carbides. Forming limit diagrams were plotted from strain measurements. Texture analysis was performed using X-ray diffraction. Void size, shape and spacing were analyzed from SEM images. Properties including yield strength, elongation and strain hardening exponent were calculated and correlated with formability.
This document reviews additive manufacturing research on cermets. Several powder-based AM processes have been used to produce cermets, including selective laser sintering/melting, laser engineering net shaping, direct laser deposition, and binder jet 3D printing. Research has focused on optimizing process parameters to produce dense, crack-free cermet components and evaluating properties like density and hardness. Key findings include that SLS/SLM of WC-Co is most widely studied and parameters like laser power, scan speed, layer thickness influence microstructure and properties of final parts.
The document summarizes research characterizing the forming behavior of aluminum alloy AA5754 at elevated temperatures. Key findings from tensile and forming tests are:
1) Yield strength, strain hardening exponent, and flow stress decrease with increasing temperature, while elongation increases.
2) Warm forming from 100-250°C improves formability over room temperature forming.
3) A test setup was developed to evaluate forming limits at elevated temperatures up to 250°C.
This document provides guidelines for laboratory immersion corrosion testing of metals, including recommended procedures, factors that influence test results, specimen preparation, test conditions, and reporting of data. It describes an apparatus consisting of a flask, condenser, temperature control, and specimen support system. The size and shape of specimens can vary but should have a large surface-to-mass ratio and small edge-to-total area ratio to provide more uniform results. All pertinent test details must be recorded to allow proper interpretation and comparison of results.
Chip flow and notch wear mechanisms during the machining of high austenitic s...Lepuufu
This document discusses notch wear mechanisms during the machining of high austenitic stainless steels. Special step-turning tests were conducted on four stainless steel alloys to study the degree of work hardening ahead of the tool and the side flow of work material at the depth of cut line. Microhardness measurements and SEM analysis showed severe localized shear and chip side flow interacting strongly with the tool, leading to notch wear initiation. Notch wear was found to be most sensitive to cutting parameters for the alloy with the highest nickel content, and increased with feed and depth of cut. Hardness was highest in the side flow region, indicating work hardening affects notch wear progression.
This document discusses various types of wear mechanisms that can occur in machines. It defines 11 main types of wear: adhesive, abrasive, erosion, polishing, contact fatigue, corrosive, electro-corrosive, fretting, electrical discharge, cavitation, and false brinelling wear. For each type of wear, it describes the wear process and provides recommendations for both mechanical and lubricant-based prevention methods. Microscopic analysis of wear debris is also discussed as a way to determine the specific type of wear that occurred.
NACE is the corrosion engineer institute. As now, material corrosion exist in our daily life, no matter in the industry application or usual commercial product. They all suffer corrosion impact. As one of member valve industry, I would like to introduce NACE and its related code in upstream and downstream area for stimulating more idea and opponent for make our working environment safe and green.
The document summarizes a study that investigated the corrosion behavior of annealed 2205 duplex stainless steel in sulphuric acid environments. Potentiodynamic polarization tests were conducted on annealed and untreated 2205 duplex stainless steel samples in 0.1M and 3M sulphuric acid. The results showed that the annealed samples exhibited lower corrosion resistance than the untreated samples in both acid environments, indicating that annealing heat treatment reduces the corrosion resistance of 2205 duplex stainless steel in sulphuric acid.
The document summarizes a study on increasing the salt fog corrosion resistance of plasma nitrided AISI 4340 steel through a pulsed plasma post-oxidation process. Key findings:
1) Post-oxidation treatment produces an oxidized layer on the nitrided surface that fills and seals pores, improving corrosion resistance.
2) Samples post-oxidized for 15 minutes showed the best corrosion performance when exposed to salt fog, with only 1/16 as much red rust as nitrided samples alone.
3) X-ray diffraction analysis found the oxidized layer consisted mainly of magnetite iron oxide, which provides high corrosion resistance.
Effect of deep cryogenic treatment on surface integrity and dimensional stabi...eSAT Journals
Deep cryogenic treatment of D2 tool steel at -1930°C following conventional heat treatment improves surface roughness and hardness slightly. Microstructural analysis shows more uniform precipitation of fine secondary carbides in cryogenically treated samples. Dimensional testing of navy C-rings reveals that while size distortion is similar, shape distortion increases more after deep cryogenic treatment compared to conventional heat treatment alone. The higher distortion is attributed to section sensitivity of D2 tool steel and incomplete relief of thermal stresses induced during deep cryogenic processing.
Types 316, 316L, 317, and 317L are molybdenum-bearing austenitic stainless steels that offer improved corrosion resistance and strength over conventional chromium-nickel steels. They have higher resistance to pitting, crevice corrosion, and various chemicals. Types 317 and 317L contain more molybdenum than Types 316 and 316L, providing better corrosion performance. The low-carbon grades 316L and 317L are more resistant to intergranular corrosion. These alloys are fabricated into sheet, strip, and plate and offer good formability while maintaining corrosion resistance and strength at elevated temperatures.
This document summarizes friction stir welding (FSW), including its working principle, microstructure analysis, tool design, process parameters, advantages, challenges, and applications. FSW is a solid state welding technique that uses a rotating tool to generate frictional heat and mechanically deform aluminum alloys below their melting point. It produces high quality welds with improved mechanical properties compared to fusion welding. Main applications are in shipbuilding, aerospace, and automotive industries.
Friction stir welding is a solid state joining process that was invented in 1991. It involves a non-consumable rotating tool that is plunged into metal materials to join them. Frictional heat generated by the tool plasticizes the materials without melting them. As the tool traverses along the weld line, it forges the plasticized materials behind the tool to form a joint. Compared to fusion welding, friction stir welding produces joints with lower heat input and narrow heat affected zones. It can weld a variety of materials, including aluminum alloys, copper alloys, magnesium alloys, and plastics.
Influence of Carbon in Iron on Characteristics of Surface Modification by EDM...drboon
1) Experiments were conducted using a titanium electrode to modify the surface of carbon steel, pure iron, and cast iron through electric discharge machining (EDM) in liquid nitrogen.
2) Analysis showed that titanium nitride (TiN) and titanium carbonitride (TiCN) layers were formed on the carbon steel and cast iron surfaces. Hardness measurements found the modified layers to have a hardness over 1000 HV.
3) Examination of the pure iron samples found a TiN layer was also formed, though it was softer with a hardness of 600-800 HV, likely due to the lack of carbon in pure iron to react with titanium.
Influence of Carbon in Iron on Characteristics of Surface Modification by EDM...drboon
Many surface modification technologies have been proposed and carried out practically by CVD, PVD et.al. Carbonized layer has been made using EDM method. In this paper, to make the nitride layer by EDM some new trials were carried out using a titanium electrode in liquid nitrogen. Experiments were carried out on carbon steel (S45C), pure iron and cast iron. TiN can be obtained on EDMed surface. Moreover, TiCN can be found on cast iron and steel (S45C) by XRD investigation. To confirm the fabrication mechanisms of modified layer on the steel, the following experimental factors were investigated by EDS.
Constant-amplitude fatigue tests were carried out in air and artificial seawater on T-shaped welded steel joints to compare fatigue behavior between the two environments. Tests investigated the effects of weld profile, stress relieving, stress ratio, cathodic protection, and overprotection. Fatigue lifetime was shorter in seawater than air. Crack initiation typically began near weld toes and results were compared to design curves for welded joints.
Wear performance of ceramic cutting tool materials when cutting steelLepuufu
The document summarizes the results of a study that tested the wear performance of various ceramic cutting tool materials when cutting steel. It found that alumina-based materials like alumina-zirconia (F) and alumina in submicron grain toughened by zirconia (G), as well as mixed-based alumina (Z), exhibited the best wear resistance when cutting steel at high speeds up to 11 m/s. These materials demonstrated tool lives between 180-300 seconds at the highest speed tested. In contrast, silicon nitride (S), sintered carbide (C), cubic boron nitride (B), and alumina reinforced with silicon carbide whiskers (W) showed
Introduction to stress corrosion cracking and nace material requirementsMahendra Prabhu S
Corrosion is one of the major areas of interest for Design / plant operator and maintenance personnel to keep the plant in good shape. The understanding of corrosion mechanism is important for the design engineers to tackle this problem by choosing right metallurgy / manufacturing methods and Inspection techniques. This presentation gives an overview about Sulfide stress corrosion in refining environment and the NACE MR0103 employed to control this phenomena.
Corrosion characteristics of al 0.91 mg-0.55si-1.12fe-0.39ca al-alloy aged at...eSAT Journals
Abstract The study of degradation of Al-0.91Mg-0.55Si-1.12Fe-0.39Ca aluminum-alloy is carried out under different state of microstructure. The reason for this work is to decide the impact of heat treatment on the microstructure and the corrosive consumption of Al-alloy in acid utilizing weight reduction system. Specimens were solution treated at 545 oC and artificially aged at 185 oC. The maximum hardness is found after aging for 12 hrs. They were immersed in 0.8 molar solution of sulfuric acid for 0.58 hrs, 1.08 hrs, 1.58, 2.08 hrs and 2.58 hrs. The corrosion rates were calculated for various immersion periods. The test work has uncovered that time and temperature assumes an imperative part in the precipitation transformation procedure of the Al-ally. The hardness increases due to formation of second phase particles of Mg2Si. In over-aging of the alloy, the growth of the precipitate particle takes place at the expense of smaller precipitate particles. The rate of corrosion is found lower in the artificially aged specimen. The corrosion rates are found stabilized after 2.08 hrs of immersion in H2SO4. The X-Ray Diffraction patterns are also analyzed in the range of 10-80⁰ which are showing peaks of aluminum solid solution and Mg2Si in the different patterns. Key Words: Corrosion rate, Aluminum alloys, aging of alloy, solutionizing, acid, weight reduction.
This document analyzes the hot corrosion behavior of laser melted GP1 stainless steel powder when exposed to a molten chloride and sulphide environment. The study found that the corrosion followed a parabolic rate law, with higher corrosion rates initially. Surface examination revealed pitting and scaling. Phase analysis identified oxides like Fe2O3 and Cr2O3 as well as other reaction products like NiFe2O4 and NiCr2O4, indicating the material underwent oxidation, chloridation and sulphidation during exposure. The results provide insight into corrosion mechanisms during additive manufacturing processes involving laser powder melting.
This document summarizes a study on the formability of various Indian stainless steel sheets formed under different stress conditions. Experimental work was conducted to determine the forming limit diagrams, microstructures, tensile properties, crystallographic textures and void characteristics of SS301, SS304, SS409M, SS430 and SSLN1 steel grades. Micrographs showed SS304 has a mixed grain structure while SS301 has coarse grains with carbides. Forming limit diagrams were plotted from strain measurements. Texture analysis was performed using X-ray diffraction. Void size, shape and spacing were analyzed from SEM images. Properties including yield strength, elongation and strain hardening exponent were calculated and correlated with formability.
This document reviews additive manufacturing research on cermets. Several powder-based AM processes have been used to produce cermets, including selective laser sintering/melting, laser engineering net shaping, direct laser deposition, and binder jet 3D printing. Research has focused on optimizing process parameters to produce dense, crack-free cermet components and evaluating properties like density and hardness. Key findings include that SLS/SLM of WC-Co is most widely studied and parameters like laser power, scan speed, layer thickness influence microstructure and properties of final parts.
The document summarizes research characterizing the forming behavior of aluminum alloy AA5754 at elevated temperatures. Key findings from tensile and forming tests are:
1) Yield strength, strain hardening exponent, and flow stress decrease with increasing temperature, while elongation increases.
2) Warm forming from 100-250°C improves formability over room temperature forming.
3) A test setup was developed to evaluate forming limits at elevated temperatures up to 250°C.
This document provides guidelines for laboratory immersion corrosion testing of metals, including recommended procedures, factors that influence test results, specimen preparation, test conditions, and reporting of data. It describes an apparatus consisting of a flask, condenser, temperature control, and specimen support system. The size and shape of specimens can vary but should have a large surface-to-mass ratio and small edge-to-total area ratio to provide more uniform results. All pertinent test details must be recorded to allow proper interpretation and comparison of results.
Chip flow and notch wear mechanisms during the machining of high austenitic s...Lepuufu
This document discusses notch wear mechanisms during the machining of high austenitic stainless steels. Special step-turning tests were conducted on four stainless steel alloys to study the degree of work hardening ahead of the tool and the side flow of work material at the depth of cut line. Microhardness measurements and SEM analysis showed severe localized shear and chip side flow interacting strongly with the tool, leading to notch wear initiation. Notch wear was found to be most sensitive to cutting parameters for the alloy with the highest nickel content, and increased with feed and depth of cut. Hardness was highest in the side flow region, indicating work hardening affects notch wear progression.
This document discusses various types of wear mechanisms that can occur in machines. It defines 11 main types of wear: adhesive, abrasive, erosion, polishing, contact fatigue, corrosive, electro-corrosive, fretting, electrical discharge, cavitation, and false brinelling wear. For each type of wear, it describes the wear process and provides recommendations for both mechanical and lubricant-based prevention methods. Microscopic analysis of wear debris is also discussed as a way to determine the specific type of wear that occurred.
NACE is the corrosion engineer institute. As now, material corrosion exist in our daily life, no matter in the industry application or usual commercial product. They all suffer corrosion impact. As one of member valve industry, I would like to introduce NACE and its related code in upstream and downstream area for stimulating more idea and opponent for make our working environment safe and green.
The document summarizes a study that investigated the corrosion behavior of annealed 2205 duplex stainless steel in sulphuric acid environments. Potentiodynamic polarization tests were conducted on annealed and untreated 2205 duplex stainless steel samples in 0.1M and 3M sulphuric acid. The results showed that the annealed samples exhibited lower corrosion resistance than the untreated samples in both acid environments, indicating that annealing heat treatment reduces the corrosion resistance of 2205 duplex stainless steel in sulphuric acid.
The document summarizes a study on increasing the salt fog corrosion resistance of plasma nitrided AISI 4340 steel through a pulsed plasma post-oxidation process. Key findings:
1) Post-oxidation treatment produces an oxidized layer on the nitrided surface that fills and seals pores, improving corrosion resistance.
2) Samples post-oxidized for 15 minutes showed the best corrosion performance when exposed to salt fog, with only 1/16 as much red rust as nitrided samples alone.
3) X-ray diffraction analysis found the oxidized layer consisted mainly of magnetite iron oxide, which provides high corrosion resistance.
Effect of deep cryogenic treatment on surface integrity and dimensional stabi...eSAT Journals
Deep cryogenic treatment of D2 tool steel at -1930°C following conventional heat treatment improves surface roughness and hardness slightly. Microstructural analysis shows more uniform precipitation of fine secondary carbides in cryogenically treated samples. Dimensional testing of navy C-rings reveals that while size distortion is similar, shape distortion increases more after deep cryogenic treatment compared to conventional heat treatment alone. The higher distortion is attributed to section sensitivity of D2 tool steel and incomplete relief of thermal stresses induced during deep cryogenic processing.
Types 316, 316L, 317, and 317L are molybdenum-bearing austenitic stainless steels that offer improved corrosion resistance and strength over conventional chromium-nickel steels. They have higher resistance to pitting, crevice corrosion, and various chemicals. Types 317 and 317L contain more molybdenum than Types 316 and 316L, providing better corrosion performance. The low-carbon grades 316L and 317L are more resistant to intergranular corrosion. These alloys are fabricated into sheet, strip, and plate and offer good formability while maintaining corrosion resistance and strength at elevated temperatures.
This document summarizes friction stir welding (FSW), including its working principle, microstructure analysis, tool design, process parameters, advantages, challenges, and applications. FSW is a solid state welding technique that uses a rotating tool to generate frictional heat and mechanically deform aluminum alloys below their melting point. It produces high quality welds with improved mechanical properties compared to fusion welding. Main applications are in shipbuilding, aerospace, and automotive industries.
Friction stir welding is a solid state joining process that was invented in 1991. It involves a non-consumable rotating tool that is plunged into metal materials to join them. Frictional heat generated by the tool plasticizes the materials without melting them. As the tool traverses along the weld line, it forges the plasticized materials behind the tool to form a joint. Compared to fusion welding, friction stir welding produces joints with lower heat input and narrow heat affected zones. It can weld a variety of materials, including aluminum alloys, copper alloys, magnesium alloys, and plastics.
Influence of Carbon in Iron on Characteristics of Surface Modification by EDM...drboon
1) Experiments were conducted using a titanium electrode to modify the surface of carbon steel, pure iron, and cast iron through electric discharge machining (EDM) in liquid nitrogen.
2) Analysis showed that titanium nitride (TiN) and titanium carbonitride (TiCN) layers were formed on the carbon steel and cast iron surfaces. Hardness measurements found the modified layers to have a hardness over 1000 HV.
3) Examination of the pure iron samples found a TiN layer was also formed, though it was softer with a hardness of 600-800 HV, likely due to the lack of carbon in pure iron to react with titanium.
Influence of Carbon in Iron on Characteristics of Surface Modification by EDM...drboon
Many surface modification technologies have been proposed and carried out practically by CVD, PVD et.al. Carbonized layer has been made using EDM method. In this paper, to make the nitride layer by EDM some new trials were carried out using a titanium electrode in liquid nitrogen. Experiments were carried out on carbon steel (S45C), pure iron and cast iron. TiN can be obtained on EDMed surface. Moreover, TiCN can be found on cast iron and steel (S45C) by XRD investigation. To confirm the fabrication mechanisms of modified layer on the steel, the following experimental factors were investigated by EDS.
Constant-amplitude fatigue tests were carried out in air and artificial seawater on T-shaped welded steel joints to compare fatigue behavior between the two environments. Tests investigated the effects of weld profile, stress relieving, stress ratio, cathodic protection, and overprotection. Fatigue lifetime was shorter in seawater than air. Crack initiation typically began near weld toes and results were compared to design curves for welded joints.
Literature Review on Tribological behaviour of Nitronic-SteelDeepuDavid1
The document discusses the tribological behavior of nitronic steel under cavitation erosion, solid particle erosion, and sliding erosion conditions. It aims to study these behaviors in hydro turbine blades and other nitronic steel products. The document describes the experimental setup used to test nitronic steel samples against cavitation erosion in a vibratory setup and solid particle erosion using an air jet erosion tester. It analyzes the microstructure, mechanical properties, and erosion behavior of the as-received and heat treated nitronic steel samples and compares it to 316L stainless steel. The results show that cavitation erosion resistance increases with finer grain size, and the as-received steel with the finest grain size exhibited the best erosion resistance among the samples tested.
1) The document examines how extremely mild abrasive processing through lapping can raise the fatigue strength of titanium by over 55%.
2) Lapping introduces compressive residual stresses and higher hardness near the surface of titanium specimens, which helps prevent fatigue crack formation and growth.
3) Fatigue cracks in lapped titanium specimens only originated from the edges of specimens, whereas cracks in chemically polished specimens could originate from slip bands on the surface or edges. Rounding off specimen edges was important for improving fatigue strength.
IRJET - Parametric Optimization of Gas Tungsten Arc Welding for Austenitic St...IRJET Journal
This document discusses optimizing gas tungsten arc welding (GTAW) parameters for joining austenitic stainless steel J4 and brass C21000 using the Taguchi method. Three welding parameters were selected - groove angle, preheat temperature, and welding current. Experiments were conducted using an L9 orthogonal array with the parameters set at three levels each. Microstructural analysis of the welds was performed to evaluate depth of penetration on the stainless steel side as the objective function for the Taguchi analysis. Analysis of variance (ANOVA) was also conducted on the response data using MINITAB software. The goal of the study was to determine optimal welding parameters to produce a sound weld between the dissimilar metals
Mechanism of Fracture in Friction Stir Processed Aluminium AlloyDr. Amarjeet Singh
Aluminium alloys are used for important
applications in reducing the weight of the component and
structure particularly associated with transport, marine,
and aerospace fields. Grain refinement by scandium (Sc)
addition can eliminate the casting defects and increase the
resistance to hot tearing for high strength aluminium alloys.
FSP for cast aluminium alloys have been focused and it has
great advantages including solid state microstructural
evolution, altering mechanical properties by optimizing
process parameters. These parameters are tool rotational
speeds (720, and 1000 rpm), traverse speeds (80, and 70
mm/min), and axial compressive force at 15 kN, etc. The
mechanical properties had been evaluated on FSPed
aluminium alloy with different microstructural conditions.
Fracture properties of aluminium alloys are very important
for industrial applications. Tensile and fracture toughness
properties were correlated to microstructural and
fractographic features of the aluminium alloys need to
explore their essential failure mechanisms.
Effect of nitrogen on crevice corrosion and repassivationFerRy P. RAzi
1. The document investigates the effect of nitrogen content on the crevice corrosion and repassivation behavior of austenitic stainless steels.
2. Tests found that increasing nitrogen content decreases corrosion spots, corrosion loss, and maximum corrosion depth during crevice corrosion. Nitrogen stimulates passivation and suppresses crevice corrosion.
3. Surface analysis showed the presence of nitrogen as nitrides and NH3 in the passive film and crevice corrosion areas, which contributes to improved corrosion resistance.
surface characteristics and electrochemical impedance investigation of spark-...mohammad fazel
This document summarizes a study that investigated the surface characteristics of oxide films formed on Ti-6Al-4V alloy by spark anodization in H2SO4/H3PO4 electrolyte at different voltages. The results showed that increasing the anodization voltage increased the pore diameter and porosity of the oxide layer. Higher voltages also produced thicker oxide layers and rougher surfaces. Analysis found the layers incorporated elements from the electrolyte and consisted of crystalline anatase. Electrochemical testing indicated the impedance behavior was affected by the space charge region, inner compact layer and outer porous layer, and that corrosion resistance decreased with higher voltages.
Experience in In-Situ Repair Welding of Steam Turbine Shrouds and Blades by S...RAMASUBBU VELAYUTHAM
1. Cracking was observed in steam turbine shrouds and blades during maintenance inspections at nuclear power plants in India. Replacing the cracked components was impractical, so an in-situ weld repair procedure was developed.
2. The procedure used gas tungsten arc welding and an austenitic stainless steel filler wire. Three different filler wires were evaluated and ER 316L was selected. Localized post-weld heat treatment was also conducted.
3. The repaired turbine components have performed satisfactorily for over three years, demonstrating the effectiveness of the developed in-situ weld repair procedure.
This document discusses different types of joining processes used to assemble components. It begins by introducing solid phase welding processes which join components without melting them through techniques like pressure. It then discusses different criteria for classifying joining processes, such as whether they use a filler material and whether the filler is the same or different from the parent material. The document goes on to explain principles of solid phase welding, including factors like surface deformation and contamination, and diffusion. It also covers principles of fusion welding processes, which do involve melting material at the joint.
This document summarizes an experiment that examined the effect of zinc content on the cold rolling textures of cast aluminum alloys. Aluminum alloys with 0, 1, 10, 30, and 60% zinc by weight were cast and samples from each alloy were cold rolled to elongations of 75% and 90%. The textures were analyzed using x-ray diffraction and orientation distribution functions to determine the volumes of key texture components. Preliminary results found a reduction in the copper component and fluctuations in the brass and S components with increasing zinc that suggest zinc may decrease the stacking fault energy of aluminum alloys.
Study and CFD Analysis on Different Test Plate Specimens with Different Nozzl...IRJET Journal
This document discusses the simulation and analysis of thermal striping phenomenon, which occurs due to the mixing of hot and cold fluid streams in nuclear reactor cores. Thermal striping can cause thermal fatigue damage to reactor structures. The study involves experimentally simulating thermal striping using a water jet test setup with different nozzle designs. Temperature fluctuations are measured and input into computational fluid dynamics (CFD) analysis. CFD results are compared to experimental data. Power spectral density analysis is performed on copper, steel, and brass materials to determine their suitability for use in reactor cores, depending on whether fluctuations remain within 0.1-10 Hz. The objectives are to predict fluctuations, study nozzle and material effects, and develop thermal striping models for
Investigation on the Creep Behaviour of Friction Stir Processed Al Ni Composi...ijtsrd
Indentation creep experiments were carried out on friction stirred Aluminum Nickel composite. The samples were cut from Al Ni plate which was undergone by friction stir processing. The specimen was polished by different polishing methods to reveal the macro and micro structure of the material. The macro structure contains two zones base metal zone and friction stirred zone . Creep tests were carried out on both friction stirred and base metal region of test specimen at different temperatures with different loads. It was found that there was a significant difference between the creep rates of friction stirred region and that of base metal region when tested under various conditions. The Activation energy determined was found to in the range of 45KJ Mole to 55KJ Mole at lower temperatures. Based on these results it can be concluded that the operative mechanism is the dislocation creep. But at higher temperature the Activation energy was found to be in the range of 140KJ Mole to 170KJ Mole so the operative mechanism for creep is diffusion creep. Samples were metallographic ally prepared and the microstructures were studied under optical and scanning electron microscope. Results of the experiments were discussed. Marripally Ravikumar "Investigation on the Creep Behaviour of Friction Stir Processed Al-Ni Composite Material" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-5 | Issue-1 , December 2020, URL: https://www.ijtsrd.com/papers/ijtsrd38145.pdf Paper URL : https://www.ijtsrd.com/engineering/mechanical-engineering/38145/investigation-on-the-creep-behaviour-of-friction-stir-processed-alni-composite-material/marripally-ravikumar
Study of Pitting Corrosion Behavior of FSW weldments of AA6101- T6 Aluminium ...IJERA Editor
Friction Stir Welding (FSW) is a promising solid state joining process widely used generally for Al alloys,
especially in aerospace, marine and automobile applications. In present work, the microstructure and corrosion
behavior of friction stir welded AA6101 T6 Al alloy is studied. The friction stir welding was carried using
vertical milling machine with different tool rotational speeds and welding speeds. The microstructure at weld
nugget or stir zone (SN), thermo-mechanically affected zone (TMAZ), heat affected zone (HAZ) and base metal
were observed using optical microscopy. The corrosion tests of base alloy and welded joints were carried out in
3.5% NaCl solution at temperature of 30º C. Corrosion rate and emf were determined using cyclic polarization
measurement.
This document summarizes research on oxide dispersion strengthened (ODS) steels. It discusses how nanoscale oxide particles are controlled through dissociation and precipitation during mechanical alloying and annealing. It examines the crystalline structure and coherency of oxide particles with the ferritic matrix. The document also reviews the development of 9Cr and 12Cr ODS martensitic and ferritic steels, including their manufacturing processes, mechanical properties, and performance under irradiation. Al-added high chromium ODS steels designed for corrosion resistance in lead-bismuth coolant systems are also discussed.
Comparative Study on the High-Stress Abrasive Wear Behaviour of Zinc and Copp...IRJET Journal
This document presents a comparative study on the abrasive wear behavior of zinc-based and copper-based alloys. Pin-on-disc tests were conducted on samples of the two alloys under varying loads and sliding distances. The zinc-based alloy exhibited higher wear rates and friction coefficients than the copper-based alloy. Microstructural analysis found the zinc alloy had a dendritic structure with intermetallic phases, while the copper alloy contained copper and intermetallic compounds. Temperature and friction increased with load and sliding time for both alloys, with the zinc alloy experiencing higher temperatures and friction. The copper alloy showed better wear resistance overall.
In the material testing laboratory, a Charpy impact test was performed on three different types (hot,cold,and steel alloy)of steels testing each variety at four different temperatures (32°C(RT), 100°C,0°C and -22°C ). From results (shown below), we determined that the a transition is from ductile failures to brittle failures
Parte 2 relatório do comportamentode usinagem em brocas helicoidais de aço rá...Lepuufu
A empresa anunciou um novo produto revolucionário que usa tecnologia de ponta para fornecer uma experiência aprimorada para os clientes. O produto será lançado no próximo trimestre e espera-se que gere receita significativa. Os investidores estão animados com o potencial do novo produto para impulsionar o crescimento da empresa.
The behaviour of materials in machining the influence of small tellurium ad...Lepuufu
The behaviour of materials in machining - the influence of small tellurium additions on the microstructure and machining behaviour of low carbon free cutting steels
Specific reduction of toxic side effectsof adriamycin by induction of metallo...Lepuufu
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help protect against developing mental illness and improve symptoms for those who already have a condition.
Inclusion modification of steels the theoryLepuufu
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms.
Effect of machining on high strength low-alloy steelsLepuufu
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help boost feelings of calmness, happiness and focus.
Bismuth alloyed steels with improved machinabilityLepuufu
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise boosts blood flow, releases endorphins, and promotes changes in the brain which help enhance one's emotional well-being and mental clarity.
About bismuth in incut 200 a new series of free-machining steelsLepuufu
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms.
Historical analysis of metal cutting shows that metal removal rates have been increasing in the course of the century, predicated by the advancement in tool materials but the steel design has lagged behind. This paper examines the mechanisms of chip formation and tool wear as a function of cutting speed in metal cutting. Chemical wear is identified as the dominant mechanism of tool wear at high cutting speeds caused by temperature rise due to shear localisation in the primary and secondary shear zones of chip. Shear localisation in the primary shear zone is shown to be influenced by both microstructural parameters, i.e. matrix hardening and second phase particles, and metal cutting variables, i.e. cutting speed (strain rate) and feed (pressure).
Influence of tellurium addition on drilling of microalloyed steel (din 38mns6)Lepuufu
This study evaluated the influence of tellurium content and minimum quantity lubrication (MQL) flow rate on drilling performance when drilling microalloyed steel. Two grades of steel were tested, one with high tellurium content and one with low tellurium content. Drilling tests were conducted using two cutting speeds, two feed rates, two drill geometries, and two MQL flow rates. Statistical analysis showed that tellurium content most significantly impacted performance, doubling drill life for the high tellurium steel. MQL flow rate had the lowest influence, with a higher flow only reducing life 9%. Addition of tellurium improved machinability by reducing forces during chip formation.
Desenvolvimento de aço com usinabilidade melhoria para moldes para plástico d...Lepuufu
A fabricação de moldes de grande porte exige a produção na aciaria de lingotes de
dimensões acima do usual. De forma a garantir a polibilidade do produto acabado, o material
não pode apresentar forte segregação, nível elevado de inclusões não metálicas ou
porosidades. Para tanto, é necessária a obtenção de reduzidos teores de enxofre e a execução
de elevada deformação mecânica no processo de conformação, principalmente em se
tratando de grandes lingotes. Contudo, a redução do teor de enxofre prejudica a
usinabilidade o que, sem outras alterações, encarece a fabricação do molde. Neste trabalho, é
apresentada a tecnologia de fabricação do bloco para o maior molde já produzido com aço
manufaturado no Brasil no qual o teor de enxofre foi reduzido abaixo de 50 ppm e a
usinabilidade foi mantida através da modificação da morfologia das inclusões através da
desoxidação por cálcio.
Cutting of hardened steel is a topic of high interest for toda 's industrial production and scientific research.
Machine parts consisting of hardened steel are high peiormance components which are often loaded
near their physical limits. The functional behavior of machined parts is decisively influenced by the fine
finishing process which represents the last step in the process chain and can as well be undertaken by
cutting as grinding. An overview of the mechanisms of chip removal in hard cutting and the thermomechanical
influence of the work area is presented. Furthermore, several models of chip removal in hard
turning are introduced and discussed summarizing the metallurgical fundamentals and giving an overview
on stress and temperature distributions in the work area. Boundary conditions for hard cutting as e.g.
machine tools, cutting materials and others are subject to discussion to determine the achievable
workpiece quality and economic efficiency of hard cutting processes in comparison with grinding.
Surface residual stresses in machined austenitic stainless steelLepuufu
Surface residual stresses due to turning operations in AISI 304 type stainless steel were studied as a function of machining speed, feed rate,
depth of cut, and tool geometry and coating. Residual stress tensors were determined using X-ray diffraction technique. The effects of turning
conditions and tool on the residual stresses were discussed in terms of mechanically and thermally induced non-homogeneous plastic
deformation of the surface layers of the workpiece.
This presentation was provided by Steph Pollock of The American Psychological Association’s Journals Program, and Damita Snow, of The American Society of Civil Engineers (ASCE), for the initial session of NISO's 2024 Training Series "DEIA in the Scholarly Landscape." Session One: 'Setting Expectations: a DEIA Primer,' was held June 6, 2024.
it describes the bony anatomy including the femoral head , acetabulum, labrum . also discusses the capsule , ligaments . muscle that act on the hip joint and the range of motion are outlined. factors affecting hip joint stability and weight transmission through the joint are summarized.
How to Build a Module in Odoo 17 Using the Scaffold MethodCeline George
Odoo provides an option for creating a module by using a single line command. By using this command the user can make a whole structure of a module. It is very easy for a beginner to make a module. There is no need to make each file manually. This slide will show how to create a module using the scaffold method.
How to Add Chatter in the odoo 17 ERP ModuleCeline George
In Odoo, the chatter is like a chat tool that helps you work together on records. You can leave notes and track things, making it easier to talk with your team and partners. Inside chatter, all communication history, activity, and changes will be displayed.
A review of the growth of the Israel Genealogy Research Association Database Collection for the last 12 months. Our collection is now passed the 3 million mark and still growing. See which archives have contributed the most. See the different types of records we have, and which years have had records added. You can also see what we have for the future.
The simplified electron and muon model, Oscillating Spacetime: The Foundation...RitikBhardwaj56
Discover the Simplified Electron and Muon Model: A New Wave-Based Approach to Understanding Particles delves into a groundbreaking theory that presents electrons and muons as rotating soliton waves within oscillating spacetime. Geared towards students, researchers, and science buffs, this book breaks down complex ideas into simple explanations. It covers topics such as electron waves, temporal dynamics, and the implications of this model on particle physics. With clear illustrations and easy-to-follow explanations, readers will gain a new outlook on the universe's fundamental nature.
How to Manage Your Lost Opportunities in Odoo 17 CRMCeline George
Odoo 17 CRM allows us to track why we lose sales opportunities with "Lost Reasons." This helps analyze our sales process and identify areas for improvement. Here's how to configure lost reasons in Odoo 17 CRM
2. 8ull. Japan Soc. of Prec. Engg., Vol, 22, No. 4 (Dec. 1988)
r, Received 29th August, 1986 in Japanese
and 21st December, 1987 in English
** Faculty of Engineering, Kitani
Institute of Technology: 165 Koen-cho'
Kitani 090
*** Faculty of Engineering, Tokyo Inst!-
tute of Technology; 2-12-1 Ohokayana'
Meguro-ku, TokYo 152
Analytical Prediction of Flank Wear of Carbide Tools
in Turning Plain Carbon Steels (Part 1)x
- Characteristic Equation of FIank Wear
-
Takeaki KITAGAWAi' Katsuhiro MAEKAWA,'-
Takahiro SHIRAKASHI *i'* and Eiji USUI
t**
Flank wear characteristics of tungsten carbide tools in turning
plain carbon steels lrithout a built-up edge have been investigated by
neasuring temperature, norEal stress and vear rate on the flank wear
land. The crater wear characteristic equation which was derived fron an
adhesive wear model is able to describe the flank near as well'
Horever, the characteristic equation for flank wear consists of two
characteristic lines with different gradient which intersect at the
critical tempelature of around 1,150 K. Both lines are affected by
abrasives in the steels. This abrasion effect could be taken into
account by changing the constants involved in the wear characteristic
equation. On the other hand, an abrasive type wear equation could be
dirived so as to have the same expression as our wear equation'
Observation of the vear particles by Uehara et al'' honeve!' appears to
exclude the possibitity of this wear model.
Key words: cutting tool life, flank lrear, itear Eechanism' wear
characteristic equation, lrear test' abrasion
1. t ntrod uction
The vear nechanism of tungsten
carbide tools is dorninated by adheslon
and/or abrasion in continuous rnachining of
plain carbon steels vithout a built-up
"ag".
It is exPected, howeve!, that
adhesive ltear plays an important role
whereas abrasion by hard particles in
sceels, such as carbides and oxides like
SiOz or AlzOa, plays an auxiliary role'
Because of extreoely high pressure and
temDeratule on the tool/chiP contact
f""el) nutual diffusion of constitutive
atoms could easily occur at the interface
under practical cutting conditions '
Fioru this Point of view, discussions
of the crater vear have been made through
an adhesive wear nodeI, so ihat a wear
characteristic equation vhich invo lves
only two constants to be det,einined by
.*plri.ent has been proposedl' In this
pup"t
""
focus ort the flank vear in vhich
the temperature is experienced to be lower
than that of cratel wear, and investigate
the wear characteristics.
2. Discussion of Flank wear Mechanism
Fig. 1 dePicts the crater vear
characteristics of tungsten carbide tools
in nachining plain carbon steels, vhich
have already been rePorted in Reference
(l). The straight line in the figure is
vrlE[en as
dIl (1)
ヽ
1
/
■
ot
一
/
′
︲
ヽ
、=CexP
having been used for the analytical
orediJrion ot crater wear3) Here W is the
wear .roluoe per unit area of the worn
surafce, L the ltear distance, ot the
normal sttess on the worn surface, 0t the
absolute temPerature' and C and I are
characteristic constants dePending on the
combination of the tool aod uork
rnaterials. Eq. (1) well describes the
experimental results in the higher
temperature range, but is not conPatible
enough with those in the lor.'er temperature
range. The higher teoPerature range or
Fig. 1 contains nost of the clate! wear
reiults under plactical cutting conditions
of carbon steel s L'ith tungsten carblde
too1s. On the contrary, flank teoperature
is lower thao that on the rake face' This
oakes iE impossible to emPloy Eq' (1) for
the prediction of flank wear. Furthernore
the experirnenlaL points are not scaLtered
around the straight line, but the higher
the percentage of carbon content is, the
more the points are deviated froo the
1ine. Note that experiEental erlors are
3. work mate rial
a O.46ZC, tempered
o o.35Zc, lempe red
o O.25ZC, tcmpe red
o 0. 15ZC, lempe red
o 0.152C, annea 1ed
Too 1; carbide P20
(0,var,6,6, 15, 15,0.5)
Depth of cut i 2 o).n
-
Cutting fluid; dry
Takpaki KITACAWA, Katsuhrro MAEKAwA, Takahiro SHIRAKASHI and Eijt USUI
'10
e
1.0
0. 01
I /At K-r
Fig.l Crater wear characteristic of
carbide P20 for different plain
catbon steels.
exaggerated in the lower temperature range
because of using a logarithnic scale for
the ordinate.
Eq. (1) was based on an adhesive wea!
modelJ) On the other hand, it has been
pointed out that abrasive wear by hard
particl.es dispersed in carbon steels are
rnoie dorninant in the lower temperature
range?) This inplies that abrasive vear
might cause the- disagreemeot nentioned
above. As a matter of fact according to
Rabinowiczf) a characteristic equation of
abrasive wear is given by
dtir = K
j! dL e)Hr
where K is a constant depending on the
shape and size of abr:asive particles and
Hr is the hardness of a harder material
(i.e. a cuting tool). Then introducing the
same tempelatute effects as those in
Reference (1):
/Az / Bz
H'=A1 exp ( . J,K =Brexp[-
" J (3)
"t/ "t/
into Eq. (2), r.re obtain
being a sioilar expression to Eq. (1).
conbining Eq. (1) vith Eq. (4), the total
lrear rate may be given by
og dL
If the constants in the right-hand terBs
have different specific values, Eq. (5)
could describe the wear characteristics
Iike Fig. 6 which have a folded charac-
teristic 1ine.
However this idea is excluded by
observation of lrear particles. It is
vell-knorn'n that since stress states on the
rake face are very sevele1) nominal contact
area is nearly equal to the real one, and
developed plastic deforrnation like viscous
flow takes place ln the contact layers
owing to thermal softening, Under these
circuEstances, if abrasive wear is
predoEinant, wear particles caused by hard
particles on the chip surface scratching a
neakened diffused layer on the rake face
must be identified. According ro the
experinent by Uehara et al!) however, no
such large wear debris is discovered,
neither in flank vear nor in crater vear,
but only tiny r.'ear particles of 0.1.!1 uE
are observed.
Hence if abrasion doDinates the near
in the lower ternperature range of Fig. I
which is described by a sinilar wear
characteristic equation to Eq. (l), it is
a matter of discussion hov to exDlain the
difference in the constants of Eq. (l)
from those in the higher tenpeiature
range. Moreover consideration should be
given to the contribution of abrasive wear
to Eq. (1) because meaningfully different
qtear rates can be seen not onlv in the
louer temperature range but also in the
higher te&peraLure range, when compared
wrLh the cases beLween nore hard second
phase inclusions (0.462C steel) and less
inclusions (0.l5Zc steel). The first
question rf ill be answered in Section 3
fron the viewpoint of different Detallog-
raphy of diffused layers on the worn
surface in the lower and highe!
teDPerature ranges, respectively. The
second problen will experinentally be
investigated in Section 4 so that the
effect of abrasive wear appeats both in
the higher and lower temperature ranges,
resulting in the change of the
characteristic constants of Eq. (1).
3. Experimental Investigation of Flank
Wear C ha racteristics
It is foreseen fron the discussion so
that the wear characteristic equation
holds for flank wear as welI, but the
ヽ
、
′
′
P
一
鈍
′
↑
ヽ
PX+
ヽ
、
1
ノ
上
ot
た
ヽpXeC〓
〒
Z
Σ
”
日
︵口
0
一
じ
︶
ヽ
〓
0
ヽ
、
′
/
だ
一
〇t
一
/
1
ヽ
dW'
r
ヽ
ノ
a
´︱
os dL
= Cr exp
4. ヽ
Z C Si Mn P S Cu Ni Cr Al
0.46ZC steel 0.46 0.23 0,72 0.026 0.016 0.01 0.01 0.01 0.020
0.47ZC steel 0.4フ 0.21 0。 フ4 0.022 0.017 0.01 0.02 0.10 0.025
0.25%C steel 0.25 0.24 0.51 0.020 0.022 0.01 0.03 0.02 0.020
Analytical Prediction of Flank Wear of Carbide Tools
in Turning Plain Carbon Steels (Part 1)
Table 1 chenical conposition of work oaterials.
appropriateness is to be experinentally
exaoined. 411 the experiments were
perforEed in senri-orthogonal turning of an
outer surface of plain carbon steeLs
(Ol50",2OO x 300 nn) with a carbide P20
grade cutting tool. Table 1 shows chemical
composition of the steels to be cut. The
tool geonetry was set in (0,0'6,6'
15,15,0.5), tool shank dimensions 30x30
om and its overhang 30 nn, which allosed a
stable cutting state vithout tool
v ibra t ion.
A special tool was used fo! oeasuring
flank tenperature. The tool consists of
tlro carbide tip Parts' between then is
held a Pt-wire (010 um) which is wrapped
vith a quartz glass tube (050 um) for
insulation. Fig. 2 shows the construction
and principle of the measurement. As soon
as t;rning begins a thermocouPle is formed
between the Pt-wire and sork nacerial'
Changing the exit position of the nire, it
is possible to measure the temPerature
anylrhere on the flank weal land. A worn
tool
"ith
artificial wear land initially
ground to -0.5 deg at the side clearaoce
iaae "as
used for the neasurement after
being pre-oachined enough to develop flank
r4'ear: Fig. 3 shovs the distribution of
flank temperature obtained by the use of
︾
J
︼
づ
一
。
●
。
。
日
o
■
1200
1150
1100
1050
1000
950
0 0.5 1.0 1.5 2.O
Distance ,-s, ,-f , lc nm
Fig.3 Temperature dist!ibution on' tool
f ace.
Work; 0.462C stee1, Tool; carbide
P2O (0,0,6,6,15,15'0.5)
'
cutting
speed; I .67 a/s, Feed; 0.26 nm/rev,
Depth of cut; 2 mm, Cutting fluid;
dry.
︾
Ч
o
0
,
っ
0
0
︼
①
O
F
O
い
Iflsulating material
Fig.2 Set-up for measur ing
flank vear 1and.
0246
cutting sPeed V n/s
Fig.4 Relation betr^teen temperature
center of flank weai and
speed.
Cutting conditions are the
those in Pig- 3.
8
at the
cutt rng
sane as
_::二 :Hpt:::l'vI[::メηh, 1[[│:4mlm
a-Worn tool' I's=2.2 uun, t"=1 '4 nuu
Vg; width of flank wear land_-.9!{
鷺:]E:釜 pby_
thernocouple
:'CCき (♂
vr=: , ii"nt wear land
carbidc riP
Se tp late
Insu Lat ing
Iflsulating
os‐ Cs‐
0 -10° 15°
② 0 5
0 0 15
● 0 25
o 10 15
0 46スC
a O.46Zc ste€ I f=0.2
nn/:ev
O 0.252c s teel f=0.2
f; feed
os; side rake angle
Cs; side cut t ing edge
anSle
VB; sidlh of flank lrear
land (=0.6 mo)
telnperature on
5. 266 Takeaki KITAGAWA, Katsuhiro MAEKAWA, Takahiro SHIRAKASHI and Eiii USUI
the special tool. For compa!ison,
tenperature on the rake face of a sharp
tool is also shown. The attached figure
tells the difference among the individual
distribution curves. For the eidth of
flank wear land VB=0.4 @, the flank
tenperature 06 is found to be unifornly
distribured over the wear land. A similai
distribution vas obtained for changing Vg,
cutting speed and feed. Since 0g i;
regarded as a uniforql distribution, we
represent ef neasured at the center of the
wear land as the flank temperature. Fig. 4
shons how this Bf is affected by changing
work marerial and cutting conditions,
In terms of nornal stress on the
flank rdear 1and, it was difficult
precisely to measure the distribution in
the direction of the irear rridth by using a
divided tool6) because of the narrow width
of less than 0.6 nm. Accordinq to
preliminary rests and an analyiical
result ]) however, the oornal stress i.s
considered almost to be uniformly
distributed in the direction of the weai
vidth except in the vicinity of the
cutting edge. Hence assumiog the uniforn
distribution in rhe dilection of the
cutting edge as vel1, we measured the nean
stress by means of conparing cutting
forces between a sharp tool and a worn
tool having a!tificial wear on the
clearance facel) fig. 5 shows the effects
of cutting speed, feed and Lridth of wear
land on the mean normal stress 6-r. lt isfound from the figure that -5 d'ecreases
with increasing these paranerers. The
ざ
1
0.1 0.15 0.2 0.26
Feed f mn/rev
Fig.5 (b) Influence of feed.
滞錯垂鎌誓琲憮手
pf;宅
Ivalue is Only 1/5∼ 1/6 of the shear stress
::lili:il]:lilil::型 iI[lili:::i:ll;
area I:; ι[11lcli:[edr];e dw/dL per unit
#=十 静 ⑥
[1:reclttilgth[if』iaril:e f]ξle fFtt Tw::
”
“
目
∽
∽
0
ヽ
0
∽
”
自
ぽ
∽
∽日
あ
I 1.5 2 3 4
Cutting speed V m/s
(a) Influence of curting speed.
Fig.5 Experimental result of nean nornal
stress on flank wear land.
Cutting conditions are the same as
those in Fig. 3.
琴憂]菱
8::: い \● 0.8
0 1.0
0 46ZC steel
Cut ting speed;3.33 m/s
0 0.4 1… ミ」子、
0 0.6 1 ヽ ^`く0、
:乳 :0●
6疑面
・
N=Feed; 0.2 rm/rev | ―-0-- 0.25%C steel
VB=0.6 1mll
6. Work material Feed
o0 46π C ―- 0 26 mm/rcv
o0 46%C ―- 0 2
o0 25ZC ―- 0 2
Tool, Carbidc P20
(0,0,6,6,15,15,0 5)
Depth Of cut, 2 mm
wiath of wcar land;
VB‐ 0 6 Fun
cutting Fluid, d
“
ω磁 品亜:
fi17-ひヾ●_ピ噂里
ヽ
ヽ
An6lytical Prediction of Flank Wear of Carbide Tools
in Turning Plain Carbon Steels (Part l)
,
Z
目
N 日
︵口
●
Ч
O
︶
ヽ
〓
0
つ
0
1
1。
●
0
.
[,
Z
,
N
ε
︵い
0
口
o
︶
ヽ
〓
も
7.0 8.0 9.0
t /ot K
10.0 '10-q
(a) Conparison vith crater lrear.
by the same characteristics as crate!
wear, if the flank temPeratule goes uP !o
the higher teEperature range in case of
high speed Eachining. As to crater wear ln
which the experimental points doninate the
higher tenperature lange, the situation is
vice ve r sa.
In addition to the observation that a
wear chaiacteristic equation fike Eq. (1)
can be applied to the lower temperatule
range, it is further found from Fig. 6 (a)
tbat there seems to exist a significant
difference in flank wear !ates between the
trro sorts of the steels, because more
accurate experiments can be performed at
the lorrer temperature range as can be seen
in Fig. 6 (b). This Point will be
discussed in Section 4. Froro the viewpoint
of wear analysis or tool life prediction,
such a difference in the wear rates does
not introduce large errors in prediction
if a wear equation correspondent to the
broken line of Fig. 6 (a) is enployed'
This will be a subject of Pat 2.
It was pointed out in Section 2 that
the characteristic line in the louer
tenperature range of Fig. 6 was not caused
by abrasive wear, which is based on the
observation of vear particles:) Next the
explanation should be given to the
question why the gradient of the line is
different from that in the higher
tempeiature range, According to a static
diffusion experinent for the coulbination
between catbon steels and tungsten
carbides by Narutaki and Yanane f) not only
WC gtains disappear but also a fragile
Fe-l.l-Co carbide cornpund starts to form at
temperatures above 1,200 K. Moreover rhe
less carbon is contained in steels and
also the higher the temperature is, the
more cooplex conpound is produced. One of
the authorsr0) has perforned a sirnilar
diffusion experiment for: the cornbination
ot 0.467,C steel and a carbide P20 which
were used in the machining experiment,
confir(0ing Lhat the temPeratures at lthich
the comPlex compound apPeared were more
than 1.120.'. I,i7O K (1/O =8.59 xl0-a
1/K), This ternperature corresponds to the
critical temperature at which the two
characteristic lines intersect in Fig' 6'
though the agreenent is good -beyond
expectation since the concentratlon ot
diffused atoms and the vacancy density in
the actual chip are different from those
in the static diffusion exPeriment' Hence
such a different state of the diffused
layers between loter and higher
temperature ranges in Fig. 6 seems to
explain the difference in the wear
characteristic constants of Eq. (1).
4. contribution of Abrasive wear
0.02
7.0
t /€t K
(b) lnfluence of cutting speed V, feed
f, side rake angle crs, side cutting
edge angle Cs and width of flank
wear land VB.
Fig.6 Flank wear characteristic of carbide
P20 when cutting Plain carbon
steels.
mechanism: even the flank uear in vhich
the experioental points mainly occuPy the
lowe! teoPeratule range can be described
work nalerial; 0.462C sleel
O V=3. 33 m/s , f=0 2 nur/rev
'
os= 0 rad , Cs=0.262 rad,
vB=O.2 - 0.8 nm
a V=3.33 n/s, vB-o.6 nm,
0s= O rad , Cs=0.262 rad ,
f=0. I - 0. 26 il.n/rcv
AvB=0.6 nllll, f =0.2 nm/rev,
0s= 0 r:td, Cs=O.262 r3d,
V-].67 - 4.17 m/s
O v=2.5 n/s' f=0.2 nm/rcv
'
vB=O.6 ffr ,
os= -0.175 - 0 rad
'Cs‐ 0 087 - 0 436 rad
7. 258 Takeaki KITAGAWA, Katsuhiro MAEKAWA, Takahiro SHIRAKASHI and Eiii USUI
It may be concluded fron above
discussion that an adhesive vear mechanism
is still dominant over flank wear. Then
the effect of abrasive particles on the
wear characteristic equation (1) should
experimentally be examined. Since it is
difficult to mix and melt plenty of A12O:
particles in a steel natrix lrithout
changing its property, the following
technique was eutployed for conveniencers
sake: a unique V-shaped groove, the
surface width of which was 5 rDm, was
machined in the direction of the center
axis of a O.47ZC steel bar ({200 uun) as
shown in Fig. 7. lte groove was next
filled wfuh a mixture of bond containins
plastic glue (202), iron povder (802) anJ
AlzO3 powder ('l ,000 vt.ppn for the whole
steel !od) as an abrasive. We used tvo
kinds of parricle size of AlzOt with
diaEeter of 105., 149 pn and 53 tu74 ]ln, The
compressive fracture strength of the
mixture after solidificarion was lOO., 120
MPa. When turning an outer surface of this
steel bar, plenty of A1203 par:ticles in
the groove instantaDeously, once per
rotation, sciatch the diffused layer on
the worn surface which has been fonned
during cutting of the other steel natrix
part. Since the cutting distance on the
groove is 1/126 of the periphery of the
bar, the flank tenperature haidly drops
during cutting of the gr:oove part which
does not contain the mixturelD The
pressure on the flank wear land Eay be
mole or less decreased. A large drop
probably does not take place because the
state of contact betqeen the wear land and
rnachined surface is elastic as qras sho$n
in Reference (7). ttrese facts may allow us
to use the temperature and notBal stress
during cutting of the steel natrix part
for the discussi.on of the
""",characteristics.
In the case of tur:ning the steel lrith
a groove, it was inevitable that chipping
of the cutting edge occurred durins
cutting Lhe groove. part. As a result. the
flank wear rate rdas meaningfully different
between cutting the plain steel bar and
cutting the steel with a groove filled
only with the nixture of steel powder and
bond plastics. Therefore we evaluated the
diffeience in the wear rate between
turning the steel containing only steel
powder and bond plastics and turning that
added A1203, and then superinposed it on
fne uear rate in continuous turning of the
bar without a groove. Fig. g is the result
snowrng rhe effect of the abrasive
particles on the wear characteristic
diagran.'t The char:acte!istic lines are
translated paral1el to the axes bv the
addition of rhe hard particles. Ttris
Fig.7 Set-up for abrasion vear resE.
'10-e
1.0
0
→
z日
ヽE
︵●
●
Ч
O
︶
ヽ
〓
一
0.01
8.0 9.0 10.0
1/Of K・
Fig.8 wear characterist■ c curve
effect of abrasion wear due
particles.
Work, 0.47ZC steel, Too l,
P20 (-5,-6,5,6,15,15,0.4),
cut, 2 mll, Feed: 0.2 mln/rev,
fluid; dry.
11 .0 'l o-r
showing
to A1203
carbide
Depth of
Cutting
,r T'he carbide tool used in the exDerinent
of Fig. 8 is a p20 grade produced bv a
Eool nanufacturer. As the chemical
composition of p20 had been alteled, the
old one used in Figs. I and 6 was not
obtainable. This is the reason why the
position of the characteristic linenithout Al zOr in Fig. g does not
coincide wirh that in Figs. 1 and 6.
Binding agent
Steel powder
AI20 3 Ponder
o WithOut A1203
0 A1203
105ヽ 149口 n,1000
0 A1203 Vt・ ppn
53∼ 7411m,1000 wt ppn
Width of flank vear
land; 0.6
V・ 3 33m/s
V=2.5 m/s
V‐ 1.25
ミ m/S
8. An6lytical Prediction of Flank Wear of Carbide Tools
in Tr-rrning Plain Carbon Steels (Psrt l)
suBgests that the abrasion effect could be
identified with the apparent difference in
the characteri.stic constants of Eq. (1).
As a eatter of fact, the difference in the
lower tenperatule lange of Fig.6 is so
sinilar to that of Fig. 8 rhar the
abrasion effect by hard palticles in
perlite should cause the di.fferent
characteristic constants. Note. that the
result of Fig. 8 is not direct
verification of the ablasion effect by
hard particles in the stee1, because A12O:
particles vele not uniforoly dispersed
over the steel rod but concentrated in a
groove with steel powder and bond
plastics.
5, conclusions
Flank rrear of tungsten carbide tools
in turning plain carbon steels at stable
cutting conditions I'ithout a built-up edge
has experiDentally been analysed and the
results obtained are as follovs:
(1) Flank lrear can be described by the
sat0e characteristic equation for crater
dt,l - / r
-=UexP{--}
ordl vtl
vhich is based on an adhesive wear model.
(2) Flank lrear consists of tuo
characteristic lines at the critical
telrperature of around ef'1'150 K despite
changing calbon content of lhe steels to
be cut, width of wear land and cutting
conditions. The folded characteristic line
is attributed to che fact that netallo-
graphic changes, such as genelation of
couplex carbide conpounds and disapPear-
ance of I,lC grains, take place in the tool
material at higher temperatures loore than
of=1 ,l50 K.
(3) Clater wear also obeys the same
characte!istic equation as that for flank
wear. The experiDental points for c!ater
wear usually 1ie on the line in the higher
teoperature range, whereas those for flank
wear are usually distributed around the
Iine in the lower tenperature lange.
(4) The effect of abrasive particles
dispersed in steels is correlated tith the
change in the constants of the sear
chalacteristic equation both in the higher
and lower tenperature ranges. The
influence is more ploninant in the lorter
tex0peratule range accompanied by a slight
difference in dw/ (ord],) depending on
changing carbon content of the steels to
be cut.
Acknow ledgements
T'tre authors vish to thank Messrs.
A.Kubo and Y.saeki, Kitani Institute of
Technology, for their dedicated assistance
to the experiruent. Thanks are also
extended to Sholra Denko Inc. for the
preparation of Alz0 r Powder.
References
l) T.Kitagawa, T.shirakashi and E.Usui:
J.JSPE, 42, 12 (1976) 1178. (in
J apanes e)
2) E.Usui, T,shirakashi and T.Kitagawa:
ibid., 43, 1O (1977) 1211 . (in
Japanese)
3) H. Takeyana and R.Murata: ibid., 27, 1
( 1961 ) 33. (in Japanese)
4) E.Rabinor,ricz, L.A.Dunn and P.G.Russel:
Wear, 4, ( 1961 ) 345.
5) K.Uehara, It.Takeshita, K.Nishina and
M.sakurai: Ploc. 2nd ICPE, TokYo
'(1976) 203.
6) S.Kato, K.Yauraguchi and M,Yanada:
J.JSME, 37, 298 (1971) 1228. (in
Japanes e)
7) E. Usui, T. Kit agawa
'
K,Maeka!'a,
T.Obikalta and T. Shirakashi: J.JSPE'
48, 9 (1982) 123'l ' (in JaPanese)
8) M,Okoshi and T.sata: ibid., 23, I
(1957) 404. (in Japanese)
9) N.Narutaki and Y'Yarnane: Proc. znd
ICPE, Tokyo, (1976) 190.
10) T.Kitagawa: Ph.D Thesis, Tokyo
Institute of Technology' (1978) 143.
(in Japanese)
11) T. Shirakashi, T.Ihara and E.Usui:
Proc, Annual Meetiog JsPE, SPring,
( 1986) 599. (in Japanese)