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The purpose objective of this study is to identify the friction coefficient and friction effect in electromagnetic upsetting (EMU) high-speed forming process.

Based on numerical simulation and upsetting experiment of 2A10 aluminum alloy bar, the friction coefficient between contact surfaces is obtained by combining the fitting displacement distribution function and the electromagnetic-mechanical coupling numerical model, and the influence of friction effect is analyzed.

The maximum impact velocity and acceleration during EMU are 13.9 m/s and −3.3 × 106 m/s², respectively, and the maximum strain rate is 7700 s⁻¹. The functional distribution relationship between friction coefficient combination (FS, FD) and characteristic parameters [upper diameter (D1) and middle diameter (D2)] is established. The values of FS and FD are 0.1402 and 0.0931, respectively, and the maximum relative error is 2.39%. By analyzing the distribution of equivalent stress and strain, it is found that plastic deformation has obvious zoning characteristics and there is serious failure concentration in the strong shear zone.

Friction coefficient significantly affects stress or strain distributions in material forming process, but it is difficult to obtain friction coefficients through experimental tests in the high-speed forming process. In this paper, a multi-field coupling numerical model is proposed to determine friction coefficients and applied to the electromagnetic impact loading process (a high-speed forming process).

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0154/

This study aims to establish a thermally coupled two-dimensional orthogonal cutting model to further improve the modeling process for systematic evaluation of material damage, stiffness degradation, equivalent plastic strain and other material properties, along with cutting temperature distribution and cutting forces. This enhances modeling efficiency and accuracy.

A two-dimensional orthogonal cutting thermo-mechanical coupled finite element model is established in this study. The tanh material constitutive model is used to simulate the mechanical properties of the material. Velocity-dependent friction model between the workpiece and the tool is considered. Material characteristics such as material damage, stiffness degradation, equivalent plastic strain and temperature field during cutting are evaluated through computation. Contact pressure and shear stress on the tool surface are extracted for friction analysis.

Speed-dependent friction models predict cutting force errors as low as 8.6%. The prediction errors of various friction models increase with increasing cutting forces and depths of cut, and simulation results tend to be higher than experimental data.

The current research results provide insights into understanding and controlling tool-chip friction in metal cutting, offering practical recommendations for friction modeling and machining simulation work.

The originality of this research is guaranteed, as it has not been previously published in any journal or publication.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0162/

The purpose of this study is to investigate the sealing performance of different deep groove mechanical seals by considering the changing law of dynamic pressure effect and temperature gradient caused by high speed and high pressure.

A thermohydrodynamic lubrication model (THD) of the mechanical seal was constructed and solved using the commercial software FLUENT. The pressure and temperature distributions of the fluid under different groove types, as well as the sealing performance under different pressures, rotational speeds and sealing gaps, are obtained.

The annular groove (AG) can effectively reduce the temperature, and the T-type spiral groove (STG) can effectively inhibit the leakage. The increase of pressure and rotational speed leads to the enhancement of dynamic pressure effect and the increase of leakage, while the sealing gap increases and the leakage increases while taking away more heat. The choice of groove type is very important to the impact of sealing performance.

In consideration of the beneficial effect of deep grooves on cooling performance, the viscous temperature equation and the impact of the thermodynamic lubrication model are evaluated in conjunction with the sealing performance of four distinct groove types. This approach provides a theoretical basis for the optimal design of mechanical seals.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0184/

To improve the thermal performance of base fluid, nanoparticles of three types are dispersed in the base fluid. A novel theory of non-Fourier heat transfer is used for design and development of models. The thermal performance of sample fluids is compared to determine which types of combination of nanoparticles are the best for an optimized enhancement in thermal performance of fluids. This article aims to: (i) investigate the impact of nanoparticles on thermal performance; and (ii) implement the Galerkin finite element method (GFEM) to thermal problems.

The mathematical models are developed using novel non-Fourier heat flux theory, conservation laws of computational fluid dynamics (CFD) and no-slip thermal boundary conditions. The models are approximated using thermal boundary layer approximations, and transformed models are solved numerically using GFEM. A grid-sensitivity test is performed. The accuracy, correction and stability of solutions is ensured. The numerical method adopted for the calculations is validated with published data. Quantities of engineering interest, i.e. wall shear stress, wall mass flow rate and wall heat flux, are calculated and examined versus emerging rheological parameters and thermal relaxation time.

The thermal relaxation time measures the ability of a fluid to restore its original thermal state, called thermal equilibrium and therefore, simulations have shown that the thermal relaxation time associated with a mono nanofluid has the most substantial effect on the temperature of fluid, whereas a ternary nanofluid has the smallest thermal relaxation time. A ternary nanofluid has a wider thermal boundary thickness in comparison with base and di- and mono nanofluids. The wall heat flux (in the case of the ternary nanofluids) has the most significant value compared with the wall shear stresses for the mono and hybrid nanofluids. The wall heat and mass fluxes have the highest values for the case of non-Fourier heat and mass diffusion compared to the case of Fourier heat and mass transfer.

An extensive literature review reveals that no study has considered thermal and concentration memory effects on transport mechanisms in fluids of cross-rheological liquid using novel theory of heat and mass [presented by Cattaneo (Cattaneo, 1958) and Christov (Christov, 2009)] so far. Moreover, the finite element method for coupled and nonlinear CFD problems has not been implemented so far. To the best of the authors’ knowledge for the first time, the dynamics of wall heat flow rate and mass flow rate under simultaneous effects of thermal and solute relaxation times, Ohmic dissipation and first-order chemical reactions are studied.

This study aims to understand the influence of raceway surface topography on the temperature rise characteristics of silicon nitride (Si₃N₄) full ceramic ball bearing and improve its service life.

The arithmetic average height S_a, skewness S_sk and kurtosis S_ku in the three-dimensional surface roughness parameters are used to quantitatively characterize the surface topography of the raceway after superfinishing. The bearing life testing machine is used to test the Si₃N₄ full ceramic ball bearing using polytetrafluoroethylene (PTFE) cage under dry friction conditions, and the self-lubricating full ceramic ball bearing heat generation model is established.

With the decrease of S_a and S_sk on the raceway surface and the increase of S_ku, the average height of the raceway surface decreases, and the peaks and valleys tend to be symmetrically distributed on the average surface, and the surface texture becomes tighter. This kind of raceway surface topography is beneficial to form a thin and uniform filamentous PTFE transfer film with a wide coverage area on the raceway surface based on consuming less cage materials and improving the temperature rise characteristics of hot isostatic pressing silicon nitride full ceramic ball bearings.

The research results provide a theoretical basis for the reasonable selection of Si₃N₄ ring raceway processing technology and have important significance for improving the working characteristics and service life of Si₃N₄ full ceramic ball bearings under dry friction conditions.

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/

This study aims to promote the anti-disturbance and tracking accuracy performance of the servo systems, in which a modified active disturbance rejection control (MADRC) scheme is proposed.

An adaptive radial basis function (ARBF) neural network is utilized to estimate and compensate dominant friction torque disturbance, and a parallel high-gain extended state observer (PHESO) is employed to further compensate residual and other uncertain disturbances. This parallel compensation structure reduces the burden of single ESO and improves the response speed of permanent magnet synchronous motor (PMSM) to hybrid disturbances. Moreover, the sliding mode control (SMC) rate is introduced to design an adaptive update law of ARBF.

Simulation and experimental results show that as compared to conventional ADRC and SMC algorithms, the position tracking error is only 2.3% and the average estimation error of the total disturbances is only 1.4% in the proposed MADRC algorithm.

The disturbance parallel estimation structure proposed in MADRC algorithm is proved to significantly improve the performance of anti-disturbance and tracking accuracy.

The purpose of the paper is to analyse the performances of closures and compressibility corrections classically used in turbulence models when applied to highly-compressible turbulent boundary layers (TBLs) over flat plates.

A direct numerical simulation (DNS) database of TBLs, covering a wide range of thermodynamic conditions, is presented and exploited to perform a priori analyses of classical and recent closures for turbulent models. The results are systematically compared to the “exact” terms computed from DNS.

The few compressibility corrections available in the literature are not found to capture DNS data much better than the uncorrected original models, especially at the highest Mach numbers. Turbulent mass and heat fluxes are shown not to follow the classical gradient diffusion model, which was shown instead to provide acceptable results for modelling the vibrational turbulent heat flux.

The main originality of the present paper resides in the DNS database on which the a priori tests are conducted. The database contains some high-enthalpy simulations at large Mach numbers, allowing to test the performances of the turbulence models in the presence of both chemical dissociation and vibrational relaxation processes.

Given the current friction and wear challenges faced by automobile parts and bearings, this study aims to identify a novel texture for creating anti-friction and wear-resistant surfaces. This includes detailing the preparation process with the objective of mitigating friction and wear in working conditions.

Femtosecond laser technology was used to create a mango-shaped texture on the surface of GCr15 bearing steel. The optimized processing technology of the texture surface was obtained through adjusting the laser scanning speed. The tribological behavior of the laser-textured surface was investigated using a reciprocating tribometer.

The friction coefficient of the mango-shaped texture surface is 25% lower than that of the conventional surface, this can be attributed to the reduced contact area between the friction ball and the micro-textured surface, leading to stress concentration at the extrusion edge and a larger stress distribution area on the contact part of the ball and disk compared to the conventional surface and the function of the micro-texture in storing wear chips during the sliding process, thereby reducing secondary wear.

The mango-shaped textured surface in this study demonstrates effective solutions for some of the friction and wear issues, offering significant benefits for equipment operation under light load conditions.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-04-2024-0127/

The purpose of this study is two-fold. First, it aims to differentiate the response of a stretching jet encountering a quadratic air resistance from the classical jet shape formed in a frictionless medium. Second, it investigates how the resulting jet forms with and without air resistance, seeking evidence that supports the similarity flows frequently studied for stretching/moving thin bodies under the boundary layer approximation.

This study extends the established electrohydrodynamic stretching jet theory, used to model electrospinning or jet printing in the absence of air resistance, to encompass the impact of the retarding force on the jet stretching in both the cone and final regimes before it impinges on a substrate.

A close examination of the nonlinear governing equations reveals that the jet rapidly thins near the nozzle because of the combined action of viscous and electrical forces. In this region, the exponentially decaying jet receives further support from the air resistance, resulting in a closer alignment with the observed experimental jet. This exponential decay, accelerated by the inversely quadratic speed of the liquid particles, serves as clear evidence for the existence of a similarity flow over an exponentially stretching sheet. Furthermore, in the final regime, the jet stretching exhibits an algebraic decay in the absence of air friction, while with air resistance, it decays exponentially to reach a limiting speed. In the former case, a square root dependence of the stretching jet speed leads to the emergence of a similarity flow over a thin stretching jet, while in the latter case, a Sakiadis’ similarity flow appears over a continuously moving flat surface.

The analysis goes beyond jet hydrodynamics, delving into the interplay of electrostatic forces (including Coulomb’s law) and quadratic air drag, drawing upon experimental data on glycerol liquid presented in earlier publications.

Finally, the asymptotic behavior of the stretching jet under the combined influence of electrostatic pull and its electric currents because of bulk conduction and surface convection is validated through a comprehensive numerical simulation of the nonlinear system.