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Frictional sliding contact problems between laterally graded orthotropic half-planes and a flat rigid stamp are investigated. The presented study aims at guiding engineering applications in the prediction of the contact response of orthotropic laterally graded members.

The solution procedure is based on a finite element (FE) approach which is conducted with an efficient FE analysis software ANSYS. The spatial gradations of the orthotropic stiffness constants through the horizontal axis are enabled utilizing the homogeneous FE approach. The Augmented Lagrangian contact algorithm is used as an iterative non-linear solution method in the contact analysis.

The accuracy of the proposed FE solution method is approved by using the comparisons of the results with those computed using an analytical technique. The prominent results indicate that the surface contact stresses can be mitigated upon increasing the degree of orthotropy and positive lateral gradations.

One can infer from the literature survey that, the contact mechanics analysis of orthotropic laterally graded materials has not been investigated so far. In this study, an FE method-based computational solution procedure for the aforementioned problem is addressed. The presented study aims at guiding engineering applications in the prediction of the contact response of orthotropic laterally graded members. Additionally, this study provides some useful points related to computational contact mechanics analysis of orthotropic structures.

Titanium alloy has the excellent performance and been widely utilized in aeroengine and airframe manufacture. However, improving the understanding of all aspects of titanium alloy is necessary. The purpose of this paper is to investigate the tribological properties of two typical titanium alloys against tungsten carbide under dry friction.

Reciprocating ball-disc friction tests were carried out at room temperature in different loading without lubricant to investigate the friction properties of TA19/WC-Co and TC18/WC-Co friction pairs. The influence of the load on the friction coefficient and friction force was analyzed. The worn surfaces of TA19 and TC18 specimens were observed by the digital microscopy and scanning electron microscopy (SEM). And the wear mechanism was discussed.

The results show that the friction coefficients decreased with the increase in the normal load. However, the reduction in the friction coefficient for the TC18 alloy was less than that for the TA19 alloy. The dynamic friction forces with time were not quite coincident with the variation trend of the friction coefficients during the sliding friction. The results observed by the SEM and EDS revealed that several grooving were the main type of frictional wear causing the surfaces of the TA19 and TC18 alloys.

It is shown in the paper that the tribological property of TA19 alloy was better than that of TC18 when sliding against tungsten carbide under the dry friction conditions. The main types of damage to the TA19/WC-Co friction pair were the ploughing, the delamination fatigue associate with abrasive wear and some diffusive wear. The ploughing and abrasion were the main wear mechanisms for the surface of TC18 alloy.

The paper considers a plane joint or interface element suitable for implementation into a standard non‐linear finite element code. Sliding of the joint is assumed to be governed by Coulomb friction, with a non‐associated flow rule and no cohesion. The constitutive equations are formulated in a manner appropriate for a backward difference discretization in time along the path of loading. It is shown that the backward difference assumption can lead to an explicit formulation in which no essential distinction need be drawn between opening and closing of the joint and sliding when the joint is closed. However, an inherent limitation of the dilatant Coulomb model becomes evident; the final formulation is internally consistent but does not describe reversed shear displacement in a physically reasonable way. Explicit equations for the consistent tangent stiffness and for the corrector step (or return algorithm) of the standard Newton—Raphson iterative algorithm are given. The equations have been implemented as a user element in the finite element code ABAQUS, and illustrative examples are given.

A finite element model for numerical simulation of non‐steady but continuous chip formation under orthogonal cutting conditions is described. The problem is treated as coupled thermo‐mechanical. A velocity approach has been adopted for the proposed solution. The computational algorithm takes care of dynamic contact conditions and makes use of an automatic remeshing procedure. The results of simulation yield complete history of chip initiation and growth as well as distributions of strain rate, strain, stress and temperature. The paper includes a detailed presentation of computational results for an illustrative case.

The purpose of this paper is to compare the performance of implicit and explicit integration schemes for simulating the metal rolling process using commercial software packages ANSYS™ and LS-DYNA™.

For the industrial application of finite element method, the time discretization is one of the most important factors that determine the stability and efficiency of the analysis. An iterative approach, which is unconditionally stable in linear analyses, is the obvious choice for a quasi-static problem such as metal rolling. However, this approach may be challenging in achieving convergence with non-linear material behavior and complicated contact conditions. Therefore, a non-iterative method is usually adopted, in order to achieve computational accuracy through very small time steps. Models using both methods were constructed and compared for computational efficiency.

The results indicate that the explicit method yields higher levels of efficiency compared to the implicit method as model complexity increases. Furthermore, the implicit method displayed instabilities and numerical difficulties in certain load conditions further disfavoring the solver’s performance.

Comparison of the implicit and explicit procedures for time stepping was applied in 3D finite element analysis of the plate rolling process in order to evaluate and quantify the computational efficiency.

This study aims to carry out an investigation of design approaches that should be used for the design of unconventional, innovative transmission system for construction yards to privilege a smooth behaviour efficiency, and the use of innovative production techniques. Results are quite surprising, as with a proper method it is possible to demonstrate that a cycloidal drive with Wolfrom topology should be an interesting solution for the proposed application.

With a functional approach, also considering materials and specifications related to the investigated application, it is possible to demonstrate that possible optimal solutions should be quite different respect to the ones that can be suggested with a conventional approach. In particular for proposed applications constraints related to encumbrances, the choice of new material has led to the innovative unconventional choice of a Wolfrom cycloidal speed reducer.

Provided solution is innovative respect current state of the art for machine currently used in construction yards: in terms of adopted transmission layout; in terms of chosen materials, resulting in an innovative solution.

Current research has strong implications on the adoption of polimeric materials for the construction of reliable transmission for harsh industrial environment as the proposed case study (concrete mixer for construction yard).

Proposed transmission system is absolutely original and innovative respect current state of art also considering proposed materials and consequently production methods. This is an example of transmission designed to be built with polymeric materials by optimizing chosen topology respect to chosen material.

The purpose of this paper is to present, an optimization problem based on the imperialistic competitive algorithm (ICA) approach for optimizing the needle velocity and variation of needle acceleration in a link drive mechanism of a sewing machine. The optimal geometry of the link drive has been achieved using a non-linear optimization procedure.

As an important study in this case, the authors might refer to a previous work in which they introduced the possibility of replacing the slider-crank mechanism, that is typically used in sewing machines, with a link drive mechanism. The authors regenerate the optimization problem by modifying the objective function and follow a novel optimization method based on the ICA to overcome the drawbacks of that work. In addition, further modification of the objective function with respect to the variation of needle acceleration is applied to assure smooth movement of the needle during sewing process.

The results showed a significant improvement with respect to the optimization of needle velocity and variation of needle acceleration in comparison to that previous work. This clearly justifies the efficiency and reliability of the optimization formulation based on the ICA approach.

Needle temperature is considered as an effective parameter on sewing process efficiency and stitch quality. Needle heat generated during sewing process is directly related to needle velocity in penetration zone which in turn depends on the needle driver mechanism of sewing machine. According to literature survey, few researches have focussed to design a driver mechanism of the sewing machine to reduce the generated needle heat. This mechanism has the ability of reducing the penetration velocity of the needle without affecting sewing speed which consequently can reduce the needle heat generated during needle penetration. The work here is novel regarding implementation of optimization algorithm for this mechanism.

This study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304 (SS-304) (Ni-Cr alloys).

Machining of Ni-Cr-based alloys is very challenging as these exhibit lower thermal conductivity and rapid work hardening. So, these cannot be machined dry, and a suitable cutting fluid has to be used. To improve the thermal conductivity of cutting fluid, multi-walled carbon nanotubes (MWCNTs) were added to the soybean oil and used with MQL. This study attempts to compare tool wear of coated carbide inserts during face milling of Inconel-625 and SS-304 under dry, flooded and NMQL conditions. The machining performance of both materials, i.e. Inconel-625 and SS-304, has been compared on the basis of tool wear behavior evaluated using scanning electron microscopy-energy dispersive spectroscopy.

The results indicate higher tool wear and lower tool life during machining of Inconel-625 as compared to SS-304. Machining of Inconel-625 exhibited non-consistent tool wear behavior. The tool failure modes experienced during dry machining are discrete fracture, cracks, etc., which are completely eliminated with the use of NMQL machining. In addition, less adhesion wear and abrasion marks are noticed as compared to dry and flooded machining, thereby enhancing the tool life.

Inconel-625 and SS-304 have specific applications in aircraft and aerospace industry, where sculptured surfaces of the turbine blades are machined. The results of current investigation will provide a rich data base for effective machining of both materials under variety of machining conditions.

The literature review indicated that majority of research work on MQL machining has been carried out to explore machining of Ni-Cr alloys such as Inconel 718, Inconel 800, AISI4340, AISI316, AISI1040, AISI430, titanium alloys, hardened steel alloys and Al alloys. Few researchers have explored the suitability of nanofluids and vegetable oil-based cutting fluids in metal cutting operation. However, no literature is available on face milling using nanoparticle-based MQL during machining Inconel-625 and SS-304. Therefore, experimental investigation was conducted to examine the machining performance of NMQL during face milling of Inconel-625 and SS-304 by using soybean oil (vegetable oil) with MWCNTs to achieve ecofriendly machining.

The purpose of this study is to identify an innovative solution for the power transmission gearbox of concrete mixers, according to the specifications provided by the company.

A tailored systematic design approach (inspired to the German systematic framework) has been adopted to comprehensively gather the company specifications and perform in-depth design space explorations. Subsequently, an iterative embodiment design approach has been followed to identify the size of the components for the preferred concept, by using acknowledged mechanical design procedures and finite element analysis tools.

An innovative cycloidal gearbox has been developed, by merging the kinematics underpinning the classical cycloidal drives and the Wolfrom planetary gearbox. The resulting concept provides high reduction rates with a very high overload capacity.

The main limitation of the studies is the absence of in-depth evaluations usually performed in the detail design phase. However, this limitation is a direct consequence of the company specifications, which only asked to find a preferred concept and to perform preliminary evaluations. Accordingly, the subsequent design optimization are intended to be performed by the company’s staff.

The present paper shows an original design approach, opportunely tailored to the design of innovative gearboxes. It can be conveniently adapted and reused by designers involved in similar tasks. Moreover, the designed cycloidal gearbox paves the way for important innovations in the field of concrete mixers, allowing to design more robust and compact devices.

Additive manufacturing (AM) is a promising alternative to the conventional production methods (i.e., machining), providing the developers with great geometrical and topological freedom during the design and immediate prototyping customizability. However, frictional characteristics of the AM surfaces are yet to be fully explored, making the control and manufacturing of precise assembly manufactured mechanisms (i.e., robots) challenging. The purpose of this paper is to understand the tribological behavior of fused deposition modeling (FDM) manufactured surfaces and test the accuracy of existing mathematical models such as Amontons–Coulomb, Tabor–Bowden, and variations of Hertz Contact model against empirical data.

Conventional frictional models Amontons–Coulomb and Tabor–Bowden are developed for the parabolic surface topography of FDM surfaces using variations of Hertz contact models. Experiments are implemented to measure the friction between two flat FDM surfaces at different speeds, normal forces, and surface configuration, including the relative direction of printing stripes and sliding direction and the surface area. The global maximum measured force is considered as static friction, and the average of the local maxima during the stick-slip phase is assumed as kinematic friction. Spectral analysis has been used to inspect the relationship between the chaos of vertical wobbling versus sliding speed.

It is observed that the friction between the two FDM planes is linearly proportional to the normal force. However, in contrast to the viscous frictional model (i.e., Stribeck), the friction reduces asymptotically at higher speeds, which can be attributed to the transition from harmonic to normal chaotic vibrations. The phase shift is investigated through spectral analysis; dominant frequencies are presented at different pulling speeds, normal forces, and surface areas. It is hypothesized that higher speeds lead to smaller dwell-time, reducing creep and adhesive friction consequently. Furthermore, no monotonic relationship between surface area and friction force is observed.

Due to the high number of experimental parameters, the research is implemented for a limited range of surface areas, which should be expanded in future research. Furthermore, the pulling position of the jaws is different from the sliding distance of the surfaces due to the compliance involved in the contact and the pulling cable. This issue could be alleviated using a non-contact position measurement method such as LASER or image processing. Another major issue of the experiments is the planar orientation of the pulling object with respect to the sliding direction and occasional swinging in the tangential plane.

Given the results of this study, one can predict the frictional behavior of FDM manufactured surfaces at different normal forces, sliding speeds, and surface configurations. This will help to have better predictive and model-based control algorithms for fully AM manufactured mechanisms and optimization of the assembly manufactured systems. By adjusting the clearances and printing direction, one can reduce or moderate the frictional forces to minimize stick-slip or optimize energy efficiency in FDM manufactured joints. Knowing the harmonic to chaotic phase shift at higher sliding speeds, one can apply certain speed control algorithms to sustain optimal mechanical performance.

In this study, theoretical tribological models are developed for the specific topography of the FDM manufactured surfaces. Experiments have been implemented for an extensive range of boundary conditions, including normal force, sliding speed, and contact configuration. Frictional behavior between flat square FDM surfaces is studied and measured using a Zwick tensile machine. Spectral analysis, auto-correlation, and other methods have been developed to study the oscillations during the stick-slip phase, finding local maxima (kinematic friction) and dominant periodicity of the friction force versus sliding distance. Precise static and kinematic frictional coefficients are provided for different contact configurations and sliding directions.