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Article
Publication date: 14 December 2020

Lawrance G., P. Sam Paul and Varadarajan A.S.

In the internal turning process, tool life and work piece quality are greatly influenced by the generation of heat in the cutting zone. During machining, cutting fluids…

Abstract

Purpose

In the internal turning process, tool life and work piece quality are greatly influenced by the generation of heat in the cutting zone. During machining, cutting fluids are applied at the cutting zones to reduce heat generation and enhance tribological properties. However, in the boring process, cutting fluids cannot be applied at cutting zone properly, and wastage of cutting fluid is a threat to the ecology and personnel health. Hence, application of semisolid lubricant in the boring process is considered as an innovative technique for temperature reduction in cutting zone because of its eco-friendly system, which also has a higher ability of biodegradability. This paper aims to study the influence of semisolid lubricants comprising of grease,graphite, aluminium oxide in different composition applied at a tool–chip,tool–work interface using a semisolid lubricant applicator applied with varying pressure.

Design/methodology/approach

In the present study, the cutting performance during boring of AISI4340 steel is enhanced through the application of semisolid lubricant with different composition of grease, graphite and aluminium oxide applied at tool-work and tool-chip interface with varying pressure using semisolid lubricant applicator.

Findings

The results show that use of semisolid lubricant like grease, graphite and nano aluminium oxide at tool-chip interface with maximum pressure reduces cutting temperature, tool vibration, cutting force and surface roughness.

Originality/value

Reduce cutting temperature, tool vibration, cutting force and surface roughness.

Details

World Journal of Engineering, vol. 18 no. 3
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 1 December 1999

M. Alagar and V. Mohan

Different percentages of calcium and lithium stearate greases were prepared using dimethyldi‐2‐ethyl‐1‐hexoxysilane and dimethyldi‐1‐dodecoxysilane as base oils by open…

Abstract

Different percentages of calcium and lithium stearate greases were prepared using dimethyldi‐2‐ethyl‐1‐hexoxysilane and dimethyldi‐1‐dodecoxysilane as base oils by open kettle process and then were characterised. The performance of different greases has been studied by determining their apparent viscosity, consistency, dropping point, oxidation stability, anti‐wear characteristics and moisture resistance. These properties are compared with those of tetra‐2‐ethyl‐1‐hexoxysilane and polydimethylsiloxane greases. Lithium stearate thickened greases exhibit better lubrication and heat resistance properties than those of calcium stearate and can be used for extreme temperature conditions in the range between –70°C and +220°C for automotive ball joints, aircrafts, antifriction, ball bearings etc.

Details

Industrial Lubrication and Tribology, vol. 51 no. 6
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 8 June 2015

TS Kiran, M Prasannakumar, S Basavarajappa and BM Viswanatha

The purpose of the paper is to study the dry sliding wear behavior of as-cast and heat-treated zinc-aluminum (ZA-27) alloy, reinforced with silicon carbide and graphite…

Abstract

Purpose

The purpose of the paper is to study the dry sliding wear behavior of as-cast and heat-treated zinc-aluminum (ZA-27) alloy, reinforced with silicon carbide and graphite particles.

Design/methodology/approach

The alloy and composite samples were prepared with stir casting technique. Heat treatment was carried out for samples at a temperature of 370°C followed by quenching in water at room temperature. Subsequently, the heat-treated samples were aged at 180°C and quenched in water at room temperature. The wear tests were carried using pin-on-disc apparatus at room temperature at different applied loads, sliding speed and sliding distance.

Findings

The wear volume loss of as-cast samples was more compared with heat treated samples. Composites exhibited improved wear resistance than base alloy.

Originality/value

Hybrid metal matrix composites with heat treatment has exhibited superior wear behavior in dry sliding conditions.

Details

Industrial Lubrication and Tribology, vol. 67 no. 4
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 1 April 2006

Jaroslav Mackerle

To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources…

4651

Abstract

Purpose

To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources which can help them to be up‐to‐date.

Design/methodology/approach

A range of published (1996‐2005) works, which aims to provide theoretical as well as practical information on the material processing namely bulk material forming. Bulk deformation processes used in practice change the shape of the workpiece by plastic deformations under forces applied by tools and dies.

Findings

Provides information about each source, indicating what can be found there. Listed references contain journal papers, conference proceedings and theses/dissertations on the subject.

Research limitations/implications

It is an exhaustive list of papers (1,693 references are listed) but some papers may be omitted. The emphasis is to present papers written in English language. Sheet material forming processes are not included.

Practical implications

A very useful source of information for theoretical and practical researchers in computational material forming as well as in academia or for those who have recently obtained a position in this field.

Originality/value

There are not many bibliographies published in this field of engineering. This paper offers help to experts and individuals interested in computational analyses and simulations of material forming processes.

Details

Engineering Computations, vol. 23 no. 3
Type: Research Article
ISSN: 0264-4401

Keywords

Article
Publication date: 16 September 2013

S. Venkat Prasat and R. Subramanian

The purpose of this paper is to explore the use of fly ash and graphite particles as low cost reinforcing materials for improved wear resistance, enhanced mechanical…

Abstract

Purpose

The purpose of this paper is to explore the use of fly ash and graphite particles as low cost reinforcing materials for improved wear resistance, enhanced mechanical properties and reduction in density of hybrid composites.

Design/methodology/approach

The AlSi10Mg/fly ash/graphite (Al/FA/Gr) hybrid composite was synthesised by stir casting method. The dry sliding wear and friction behaviour of hybrid composites were studied using pin-on-disc machine by varying parameters like load and weight fraction of fly ash, and compared with the base metal alloy and aluminium-graphite composite. The tests were conducted with a constant sliding speed of 2 m/s and sliding distance of 2,400 m.

Findings

The hybrid composites exhibit higher hardness, higher tensile strength and lower density when compared to unreinforced alloy and aluminium-graphite composite. The incorporation of fly ash and graphite particles as reinforcements caused a reduction in the wear rate and coefficient of friction (COF) of the hybrid composites. The improvement in the tribological characteristics occured due to the load carrying capacity of hard fly ash particles and the formation of a lubricating film of graphite between the sliding interfaces. The wear rates and COF of unreinforced aluminium alloy and composites increase with an increase in the applied normal load. The wear rates and COF of hybrid composites decrease with an increase in the fly ash content. 9 wt.% fly ash and 3 wt.% graphite reinforced hybrid composite exhibited the highest wear resistance and lowest COF at all applied loads. Abrasive wear and delamination were dominant in the mild wear regime of aluminium alloy and composites. Due to subsurface deformation and crack propagation, plate-like wear debris were generated during delamination wear. In the severe wear regime, the dominant wear mechanism was adhesive wear with formation of transfer layers.

Practical implications

It is expected that these findings will contribute towards the development of lightweight and low cost aluminium products with improved tribological and mechanical properties.

Originality/value

The wear and friction data have been made available in this article for the use of Al/FA/Gr hybrid composites in tribological applications.

Details

Industrial Lubrication and Tribology, vol. 65 no. 6
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 8 June 2015

Amit Sharma, Manish Garg and Satnam Singh

The purpose of this paper is to develop hybrid aluminum metal matrix composite by stir casting process, reinforced with graphite and hard boron carbide particles to…

Abstract

Purpose

The purpose of this paper is to develop hybrid aluminum metal matrix composite by stir casting process, reinforced with graphite and hard boron carbide particles to enhance the wear resistance. An attempt is made to optimize the wear (weight loss) and coefficient of friction (COF) by considering three factors, i.e. normal load, track diameter and sliding speed which were varied at three different levels.

Design/methodology/approach

The effect of graphite and boron carbide on microhardness was studied by adding them in varying percentages. After determining the best combination of hybrid reinforcements, optimization of wear (weight loss) and COF was carried out at various levels of considered factors. Taguchi design of experiments was used using the software “Minitab 16.1”. ANOVA was used to analyze the effect of various parameters on wear and COF. To validate the results, mathematical modeling was carried out in terms of regression equations and results obtained by regression equations.

Findings

The results revealed that the lower weight percentage of graphite (3 per cent) and boron carbide (1 per cent) significantly improved microhardness of developed composites. Results of ANOVA revealed that normal load was the main contributing factor for wear and COF. The results obtained by regression equations and confirmatory tests were within the results obtained by ANOVA.

Originality/value

To the best of the author’s knowledge, very less work has been reported on optimization of wear and COF using hybrid reinforcement particles of graphite and boron carbide.

Details

Industrial Lubrication and Tribology, vol. 67 no. 4
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 3 February 2021

S. Sarath and P. Sam Paul

A new cutting tool is always well-defined and sharp at the onset of the metal cutting process and gradually losses these properties as the machining process advances…

Abstract

Purpose

A new cutting tool is always well-defined and sharp at the onset of the metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of the service period of the cutting tool while machining. It is significant to provide a corresponding real-time varying damping to control this chatter, which directly influences accuracy and quality of productivity. This paper aims to review the literature related to the application of smart fluid to control vibration in metal cutting and also focused on the challenges involved in the implementation of active control system during machining process.

Design/methodology/approach

Smart dampers, which are used as semi-active and active dampers in metal cutting, were reviewed and the research studies carried out in the field of the magnetorheological (MR) damper were concentrated. In smart materials, MR fluids possess some disadvantages because of their sedimentation of iron particles, leakage and slow response time. To overcome these drawbacks, new MR materials such as MR foam, MR elastomers, MR gels and MR plastomers have been recommended and suggested. This review intents to throw light into available literature which exclusively deals with controlling chatter in metal cutting with the help of MR damping methods.

Findings

Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration. In the past, many researchers have attempted to implement MR damper in metal cutting to control vibration and were successful. Various methods with the help of MR fluid are illustrated.

Research limitations/implications

A new cutting tool is always well-defined and sharp at the onset of metal cutting process and gradually losses these properties as the machining process advances. Similarly, at the beginning of the machining process, amplitude of tool vibrations is considerably low and it increases gradually and peaks at the end of service period of cutting tool while machining. Application of MR damper along with the working methodology in metal cutting is presented, challenges met are analyzed and a scope for development is reviewed.

Practical implications

This study provides corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity. Using an MR damper popularly known for its semi-active damping characteristics is very adaptable and flexible in controlling chatter by providing damping to real-time amplitudes of tool vibration.

Social implications

This study attempts to implement smart damper in metal cutting to control vibrations.

Originality/value

It is significant to provide corresponding real-time varying damping to control tool vibration which directly influences accuracy and quality of productivity.

Details

World Journal of Engineering, vol. 18 no. 3
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 18 October 2019

Rahul S.G. and Sharmila A.

The purpose of this study is to present a comprehensive review of the fundamental concepts and terminologies pertaining to different types of aluminium metal matrix…

Abstract

Purpose

The purpose of this study is to present a comprehensive review of the fundamental concepts and terminologies pertaining to different types of aluminium metal matrix composites, their joining techniques and challenges, friction stir welding (FSW) process, post-welding characterizations and basic control theory of FSW, followed by the discussions on the research reports in these areas.

Design/methodology/approach

Joining of aluminium metal matrix composites (Al-MMC) poses many challenges. These materials have their demanding applications in versatile domains, and hence it is essential to understand their weldability and material characteristics. FSW is a feasible choice for joining of Al-MMC over the fusion welding because of the formation of narrow heat affected zone and minimizing the formation of intermetallic compounds at weld interface. The goal in FSW is to generate enough thermal energy by friction between the workpiece and rotating tool. Heat energy is generated by mechanical interaction because of the difference in velocity between the workpiece and rotating tool. In the present work, a detailed survey is done on the above topics and an organised conceptual context is presented. A complete discussion on significance of FSW process parameters, control schemes, parameter optimization and weld quality monitoring are presented, along with the analysis on relation between the interdependent parameters.

Findings

Results from the study present the research gaps in the FSW studies for joining of the aluminium-based metal matrix composites, and they highlight further scope of studies pertaining to this domain.

Originality/value

It is observed that the survey done on FSW of Al-MMCs and their control theory give an insight into the fundamental concepts pertaining to this research area to enhance interdisciplinary technology exploration.

Details

World Journal of Engineering, vol. 16 no. 6
Type: Research Article
ISSN: 1708-5284

Keywords

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