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The purpose of this study to identify and optimize the machining of polyvinyl butyral (PVB) material for industrial uses. The research is based on input machining parameters of rotary ultrasonic machining for better understand the output response surface roughness (SR) property of polyvinyl butyral (PVB) by using the Taguchi approach. The grey relational grade analysis (GRG) is also implemented to resolve the complex interrelationship of SR data for optimization and predicting and validate the results.

In experimental work, the input parameters, namely, concentration, abrasives, power rate, grit size, tool material and hydrofluoric (HF) acid has been selected. The experiment’s design was created using MINITAB Software; the L27 orthogonal array was selected for the experimentation. SR was examined with the GRG technique for process optimization. On the other hand, for single parameter optimization analysis of variance (ANOVA) has been used.

ANOVA optimization technique gives the best result on concentration (40%) of abrasive (Al2O3+SiC+B4C), power rate (40%), grit size (600), HF acid (1.5%) and tool material (D2 alloy) are the optimal parameters to provide the slightest degree of SR. GRG optimization of multi-response parameter setting: 40% concentration, SiC+B4C mixed abrasive slurry, 40% of power rating, 280 grit size, 0.5% HF acid and high-speed tool steel tool material gives better results. The SR of PVB glass material improved by 20% after grey relational analysis.

There are several practical applications in a variety of material processing sectors, including metallurgy, machinery, electronics and transportation. These real-world applications have produced substantial and discernible economic benefits.

The analytical and optimization results will be used in the various material processing sectors, including metallurgy, machinery, electronics and transportation.

The ANOVA and grey theory approaches offer the reader a primary picture of the machining research and process parameter optimization. Combined abrasive slurry of Al₂O3+SiC+B₄C with a high power-rating exhibits lower SR. Similarly, grit size is vital; larger grits produce better SR. Ra – 0. 611 m is the lowest SR value at the hole found in trial 25 after the experimentation.

This study aims to investigate the impact of titanium oxide (TiO₂) filler on the coefficient of friction (COF) and specific wear rate (SWR) in flax fiber reinforced epoxy composites (FFRCs) under abrasive wear conditions utilizing the Taguchi approach. The primary objective is to enhance wear resistance and promote the development of sustainable materials for various applications.

Epoxy/flax composites with varying TiO₂ filler content (0–8 wt%) are fabricated through the hand layup method. Subsequently, wear testing is conducted following ASTM G99-05 standards. The Taguchi design of experiments (DOE) and analysis of variance (ANOVA) are utilized for statistical analysis.

Results indicate a significant improvement in abrasive wear properties with the incorporation of TiO₂ filler. The COF is found to be most influenced by the normal load (55.19%), followed by grit size, wt% TiO₂ filler and sliding distance. SWR is found to be most influenced by the grit size (42.92%), followed by wt% TiO₂, normal load and sliding distance. Notably, the Taguchi model aligns well with experimental results, demonstrating its efficacy in predicting the abrasive wear behavior of FFRCs.

This research introduces a novel hybrid composite that combines TiO₂ filler and flax fibers, showcasing their potential to enhance the tribological properties of epoxy composites. The study offers valuable insights into optimizing abrasive wear test variables in natural fiber-reinforced composites using Taguchi DOE and ANOVA, crucial for improving the performance of sustainable materials in engineering applications.

The purpose of this paper is to investigate the effect of mullite on the mechanical properties and friction of carbon fiber (CF)-reinforced friction material.

CF-reinforced friction materials with varying content of mullite were fabricated by hot press molding, and then the tribological properties were tested on the MRH-3-type tribometer under ambient conditions with the ring-on-block configuration.

The experimental results indicated that the addition of mullite increased the density and compressive strength of friction material. However, the flexural strength of friction material decreased by 16% with the addition of 15 Wt.% mullite. The friction coefficient was proportional to the mullite content. Friction material with 12.5 Wt.% mullite showed the highest friction stability under different loads, whereas friction material with 10 Wt.% mullite exhibited the highest friction stability under different sliding speeds.

By boosting the resistance to deformation under load and increasing the specific heat capacity, mullite contributed significantly to the friction stability of the friction material.

This study aims to investigate the erosion wear rate of a stainless steel automobile exhaust manifold, both computationally and physically.

The experiment was performed on a motorcycle exhaust manifold as well as on a 3D model, created using SolidWorks 2022 CAD software. The analysis was later achieved using ANSYS 19.2 simulation software using Fluent – code.

The analysis of solid particle erosion in the exhaust manifold revealed that erosion wear is concentrated predominantly at the extrados of the manifold, with the most significant wear occurring at the lowermost bend. The erosion wear rate increases with larger particulate sizes and varies among bends, with negligible wear observed in straight pipes. The SEM analysis further confirmed surface degradation, with rugged textures, pits and grooves indicating abrasive wear. Spine-like structures and fractured soot particles suggest erosive and abrasive forces caused by high-speed contact of exhaust gas compounds. Energy dispersive X-ray spectroscopy revealed significant carbon abundance, indicating carbonaceous compounds from fuel combustion, along with notable amounts of oxygen and iron, typical of oxidized metallic constituents. The discrete phase modeling (DPM) analysis highlighted peak particulate matter deposition at the first bend exit, with maximum concentrations observed at specific angles. This deposition is influenced by centrifugal force, leading to increased PM concentration at outer bend walls. Velocity magnitude contours showed asymmetrical flow profiles, with high turbulence levels and secondary flow induced by centrifugal effects in bend areas. Dynamic pressure contours revealed varying pressures at intrados and extrados, with maximum pressure observed at the intrados of the manifold’s bends. These findings provide valuable insights into erosion wear, particulate dispersion and flow dynamics within the exhaust manifold.

The study investigated an automobile exhaust manifold model using ANSYS Fluent code and DPM to analyze erosion wear rate phenomena and its various constituents. This analysis was conducted in comparison with a physically eroded sample. The study offers insights into the mechanism underlying the exhaust manifold of an automobile.

The purpose of this paper is to improve the mechanical and tribological properties of Si₃N₄ ceramics and to make the application of Si₃N₄ ceramics as tribological materials more extensive.

Si₃N₄-based composite ceramics (SN-2L) containing nitrogen-doped graphene quantum dots (N-GQDs) were prepared by hot press sintering process through adding 2 Wt.% nanolignin as precursor to the Si₃N₄ matrix, and the dry friction and wear behaviors of Si₃N₄-based composite against TC4 disc were performed at the different loads by using pin-on-disc tester.

The friction coefficients and wear rates of SN-2L composite against TC4 were significantly lower than those of the single-phase Si₃N₄ against TC4 at the load range from 15 to 45 N. At higher load of 45 N, SN-2L/TC4 pair presented the lowest friction coefficient of 0.25, and the wear rates of the pins and discs were as low as 1.76 × 10⁻⁶ and 2.59 × 10⁻⁴mm³/N·m. The low friction and wear behavior could be attributed to the detachment of N-GQDs from the ceramic matrix to the worn surface at the load of 30 N or higher, and then an effective lubricating film containing N-GQDs, SiO₂, TiO₂ and Al₂SiO₅ formed in the worn surface. While, at the same test condition, the friction coefficient of the single-phase Si₃N₄ against TC4 was at a range from 0.45 to 0.58. The spalling and cracking morphology formed on the worn surface of single-phase Si3N4, and the wear mechanism was mainly dominated by adhesive and abrasive wear.

Overall, a high-performance green ceramic composite was prepared, and the composite had a good potential for application in engineering tribology fields (such as aerospace bearings).

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0161/

This paper aims to enhance lubrication performance of the pitcher plant–like textured surface with various parameters.

A pitcher plant–like structure surface is fabricated on the copper alloy, and the lubrication performance of the pitcher plant–like structure with various parameters is evaluated. In addition, the pressure distribution and oil film load capacity of the pitcher plant–like surface are simulated based on Navier–Stokes equations.

When the direction of motion aligns with the pitcher plant–like structure, the friction coefficient remains lower than that of the nontextured surface, and it exhibits a decreasing trend with the increasing of the texture width and spacing distance; the lowest friction coefficient (0.04) is achieved with B = 0.3 mm, L = 1.0 mm and θ = 45°, marking a 75% reduction compared to the nontextured surface. Simulation results demonstrate that with the increase in texture width and spacing distance, the oil film load-bearing capacity demonstrates an increasing trend.

Bionic pitcher plants are prepared on the copper alloy to improve the lubrication performance and wear resistance.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-04-2024-0119/

This study aims to investigate the influences of Al₂O₃ mass fraction on the corrosive wear and electrochemical behaviors of FeAl–xAl₂O₃ coatings.

FeAl–xAl₂O₃ coatings were prepared on S355 steel by laser cladding to improve its corrosive wear and electrochemical properties.

The average coefficients of friction and wear rates of FeAl–xAl₂O₃ coatings are decreased with the Al₂O₃ mass fraction, and the Al₂O₃ plays a positive role in the corrosion wear resistance. Moreover, the charge transfer resistance of FeAl–xAl₂O₃ coatings is increased with the Al₂O₃ mass fraction, showing the FeAl–15%Al₂O₃ coating has the best corrosion resistance. The findings show the corrosion resistance of FeAl–15%Al₂O₃ coating is the highest among the three kinds of coatings.

Al₂O₃ was first added into FeAl coatings to further improve its corrosive wear and electrochemical properties by laser cladding.

This paper aims to study the tribological characteristics of the electrical contact system under different displacement amplitudes.

First, the risk frequency of real nuclear safety distributed control system (DCS) equipment is evaluated. Subsequently, a reciprocating friction test device which is characterized by a ball-on-flat configuration is established, and a series of current-carrying tribological tests are carried out at this risk frequency.

At risk frequency and larger displacement amplitude, the friction coefficient visibly rises. The reliability of the electrical contact system declines as amplitude increases. The wear morphology analysis shows that the wear rate increases significantly and the degree of interface wear intensifies at a larger amplitude. The wear area occupied by the third body layer increases sharply, and the appearance of plateaus on the surface leads to the increase of friction coefficient and contact resistance. EDS analysis suggests that oxygen elements progressively arise in the third layer as a result of increased air exposure brought on by larger displacement amplitude.

Results are significant for recognizing the tribological properties of electrical connectors in nuclear power control systems.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2024-0098/

Liquid-assisted laser surface texturing technology was used to create composite microtextures on triangular guide rail surfaces to enhance their tribological properties.

Numerical simulations were used to investigate the impact of various microtextures on fluid dynamic lubrication. Reciprocating friction and wear tests, followed by mechanistic analysis, examined the combined tribological effects of microtextured surfaces and lubricants.

The numerical simulation outcomes reveal a significant augmentation in the influence of fluid dynamic pressure due to composite microtextures, consequently amplifying the load-bearing capacity of the oil film. The average friction coefficient of composite microtextured samples was approximately 0.136 in reciprocating pin-on-disk friction tests, representing approximately 17% decrease compared to polished samples. Triangular guide rails with composite microtextures demonstrated the lowest average coefficient under conditions of high-speed and heavy-loading in the reciprocating friction and wear tests. Additionally, the presence of composite microtextures was found to promote the formation of adsorbed and friction films during friction, potentially contributing to the enhancement of tribological properties.

Triangular guide rails face high friction and wear, limiting their stability in demanding applications like machine tool guideways. This paper proposes a novel approach for steel triangular guide rails, involving composite microtexturing, numerical fluid simulations, liquid-assisted laser surface texturing and friction-wear testing. By implementing composite microtextures, the method aims to reduce friction coefficients and extend guideway service life, thereby saving energy and reducing maintenance costs. Enhancing the antifriction and antiwear properties of machine tool guideways is crucial for improving performance and longevity.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0183/

The purpose of this paper is to examine the mechanical characteristics and optimization of wear parameters of hybrid (TiO₂ + Y₂O₃) nanoparticles with Al matrix using squeeze casting technique.

The hybrid aluminium matrix nanocomposites (HAMNCs) were fabricated with varying concentrations of titanium oxide (TiO₂) and yttrium oxide (Y₂O₃), from 2.5 to 10 Wt.% in 2.5 Wt.% increments. Dry sliding wear test variables were optimized using the Taguchi method.

The introduction of hybrid nanoparticles in the aluminium (Al) matrix was evenly distributed in contrast to the base matrix. HAMNC6 (5 Wt.% TiO₂ + 5 Wt.% Y₂O₃) reported the maximum enhancement in mechanical properties (tensile strength, flexural strength, impact strength and density) and decrease in porosity% and elongation% among other HAMNCs. The results showed that the optimal combination of parameters to achieve the lowest wear rate was A3B3C1, or 15 N load, 1.5 m/s sliding velocity and 200 m sliding distance. The sliding distance showed the greatest effect on the dry sliding wear rate of HAMNC6 followed by applied load and sliding velocity. The fractured surfaces of the tensile sample showed traces of cracking as well as substantial craters with fine dimples and the wear worn surfaces were caused by abrasion, cracks and delamination of HAMNC6.

Squeeze-cast Al-reinforced hybrid (TiO₂+Y₂O₃) nanoparticles have been investigated for their impact on mechanical properties and optimization of wear parameters.