Understanding the tribological aspects of machining processes are essential for increasing the dimensional accuracy and surface integrity of products, as well as gaining a better control of tool wear, chip handling and power consumption. The objective of this investigation is to develop numerical models that accurately predict the chip formation and stress profiles in the work-piece during orthogonal metal cutting using the explicit finite-element method (FEM). In our simulations, a damage material model was utilized to capture the work-piece chip separation behavior and the simultaneous breakage of the chip into multiple fragments. In the simulation, the rigid steel cutter of different rake angles was moved at different velocities against a stationary aluminum work-piece at constant friction for a cutting depth of 1 mm. Overall, the results indicate that the explicit FEM is a powerful tool for simulating metal cutting and discontinuous chip formation. The rake angle had a significant effect on the formation of chip during metal cutting. The formation of discontinuous chip along the contact interface was hypothesized to be due to the internal crack initiation and propagation in front of the tool and above the cutting edge, rather than from the free surface.
Various surface textures, characterised in terms of roughness parameters using an optical profilometer, were produced on the steel plates. Sliding experiments were conducted on the prepared hard steel plate using a soft Al-Mg alloy pin under both dry and lubricated conditions. The contact surfaces were examined using SEM to study the transfer layer formation on the plate surface and damage on the pin surface. Results showed that among the surface roughness parameters, the coefficient of friction and transfer layer formation are strongly controlled by a roughness parameter, namely mean slope of the profile, Δa, regardless of the surface textures.
The study explored the viability of using waste plastic oil (PO) as an alternative lubricant to petroleum-based lubricants in industrial settings. To enhance the lubrication performance of the PO, this study incorporated cost-efficient, oleic acid-modified, graphene nano platelets [GNP (f)] and hexagonal boron nitride [hBN (f)] nano solid lubricant additives into the PO in various concentrations, forming functionalized nano lubricants. The PO and its functionalized nano lubricant’s rheological, dispersion stability, thermal degradation, friction, and wear performance were investigated. Results manifest that incorporating GNP (f) and hBN (f) into the PO significantly enhanced the viscosity and dispersion stability. In addition, it was seen that GNP (f) and hBN (f) nano lubricants lowered the coefficient of friction (COF) by 53% and 63.63% respectively, compared to the PO. However, the GNP (f) and hBN (f) nano lubricants demonstrated a 3.16% decrease and a 50.08% increase in wear volume relative to the PO. Overall, the GNP (f) and hBN (f) nano lubricants displayed a synergistic friction behavior, while they exhibited an antagonistic behavior pertaining to the wear volume. The study elucidated the mechanisms underlying friction and wear performance of the nano lubricants.
In recent years, significant academic and industrial research and development has explored novel methods of creating green and environmentally friendly materials for commercial applications. Natural fibers offer the potential to develop lower cost products with better performance, sustainability, and renewability characteristics than traditional materials, particularly in the automotive industry. In this respect, natural fiber reinforced polymer composites have emerged as an environmentally friendly and cost-effective option to synthetic fiber reinforced composites. Hence, in this study, a review of the tribological behavior of natural fiber reinforced polymer composites has been undertaken to better understand their usability for various automotive applications.
In the present investigation, various kinds of textures (undirectional, 8-ground, and random,) were attained on a set of steel plate surfaces. The roughness of the textures was varied using different grits of emery papers or polishing powders. Pins made of pure magnesium were then slid against the steel plates at various numbers of cycles (1, 2, 6, 10 and 20) using an inclined pin-on-plate sliding apparatus. In the experiments, it was observed that the coefficient of friction and the formation of a transfer layer depended on the die surface textures under both dry and lubricated conditions. The coefficient of friction increased with number of cycles under dry conditions for all of the textures studied. Under lubricated conditions, however, the coefficient of friction decreased for unidirectional and 8-ground surfaces and increased for random surfaces with the number of cycles. A stick-slip phenomenon was observed under both dry and lubricated conditions. Occurrence of the stick slip behavior depended on the surface texture, the load and the number of cycles. The variation in the coefficient of friction under both dry and lubrication conditions was attributed to changes in the texture of the surfaces during sliding.
Surface texture influences friction during sliding contact conditions. In the present investigation, the effect of surface texture of soft materials on friction during sliding against hard materials was studied using an inclined scratch testing system. In the experiments steel balls were slid against aluminum alloy flats of different surface textures and roughness. The surface textures were classified into unidirectional, 8-ground and random. Analysis of the experimental data showed that the friction depends on the softer materials surface texture under both dry and lubricated conditions. The results were also compared with aluminum alloy slid against steel flats of different surface textures and roughness. From the experiments, it can be inferred that the surface textures of both harder and softer materials are important in controlling frictional behavior.
Surface texture influences friction during sliding. In the present investigation, experiments were conducted using an inclined pin-on-plate apparatus to study the tribological response of metals and polymers during sliding against various surface textures. In the experiments, metals (Pb and Sn) and polymers (PP and PVC) were used for the pin and hardened steel was used for the plate. Experiments were conducted under both dry and lubricated conditions in an ambient environment. Two surface parameters of the steel plates — roughness and texture — were varied in the experiments. Using scanning electron microscope images, the surfaces of both the plate and pin materials were examined to determine the transfer layer formation on the plate and the wear of the pins. Based on the experimental results, it was observed that the transfer layer formation and the coefficient of friction were controlled by the surface texture of the plates. Moreover, both polymers and metals exhibited similar frictional responses, but the metals had a significantly larger variation in friction with surface texture.
Tribological properties during rock cutting under extremely high pressure and high temperature (HPHT) conditions are important in deep mining and drilling operations. In the present investigation, a rock fragmentation process is simulated during mechanical cutting of rock using an explicit finite element code, LS-DYNA. In the simulations, a rigid steel cutting tool of different rake angles was moved at different velocities against a stationary rock material. Rock material properties have been incorporated using an advanced damage constitute material model. In addition, the friction factors at the cutting tool–rock interface were varied in the contact model. The variation of cutting forces, stresses and rock fragment morphology have been investigated. Overall, the results indicate that the explicit finite element model is a powerful tool for simulating rock cutting and the fragmentation process. More specifically, the separation of rock fragments from the rock slab was accurately predicted using the numerical model. The rake angle was found to have significant influence on the fragment morphology during rock cutting. Moreover, the cutting forces and the discontinuous fragmentation process were strongly influenced by the friction and cutting velocity.
Graphene oxide (GO) aerogels were discovered as lightweight, highly porous materials with exceptional mechanical, electrical, and thermal properties. These properties make them suitable for a wide range of advanced applications. This paper discusses GO aerogel synthesis processes, characterization, mechanical properties, applications, and future directions. The synthesis methods discussed include hydrothermal reduction, chemical reduction, crosslinking methods, and 3D printing, with major emphasis on their effects on the aerogel’s structural and functional attributes. A detailed analysis of mechanical characterization techniques is elaborated upon, along with highlighting the effects of parameters such as porosity, crosslinking, and graphene concentration on mechanical strength, elasticity, and stability. Research has been carried out to find GO aerogel applications in various sectors, such as energy storage, environmental remediation, sensors, and thermal management, showcasing their versatility and potential. Additionally, the combination of nanoparticles and doping strategies to improve specific properties is addressed. The review concludes by identifying current challenges in scalability, brittleness, and property optimization and proposes future directions for synthesis innovations. This work will be helpful for researchers and engineers exploring new possibilities for GO aerogels in both academic and industrial areas.
