Wear最新文献

{"title":"Enhancing the wear resistance of polycrystalline diamond tools in Cf/SiC machining via ion implantation","authors":"Jiaming Jiang,&nbsp;Wenxiang Zhao,&nbsp;Lijing Xie","doi":"10.1016/j.wear.2025.206099","DOIUrl":"10.1016/j.wear.2025.206099","url":null,"abstract":"<div><div>Machining carbon fiber-reinforced silicon carbide (Cf/SiC) composites is hindered by rapid tool wear, even with the hardest available polycrystalline diamond (PCD) tools. This study explores ion implantation to enhance the wear resistance of PCD tools. The effects of ion type, energy, and dose on the surface morphology, chemical composition, and microstructure of PCD materials were investigated. Tool wear tests were conducted to assess the performance of ion-implanted tools. The results show that hydrogen-ion-implanted tools exhibit the best wear resistance, increasing tool life by 18.7 %. Hydrogen ion implantation induces the amorphous layer with high sp³ content on the diamond surface, and induces a large number of defects such as dislocation and even nanocrystals inside the binder cobalt. The amorphous layer reduces grain anisotropy, mitigating cleavage wear, while dislocation and fine-grain strengthening of the binder cobalt help reduce intergranular wear of the diamond grains.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206099"},"PeriodicalIF":5.3,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143891160","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Adapting a scaled twin-disc device for tread braking investigations based on an ad-hoc thermal similitude model","authors":"Matteo Magelli,&nbsp;Rosario Pagano,&nbsp;Nicolò Zampieri","doi":"10.1016/j.wear.2025.206105","DOIUrl":"10.1016/j.wear.2025.206105","url":null,"abstract":"<div><div>The present paper shows the design of a scaled tread braking system to be included in a scaled twin-disc system, to carry out thermomechanical investigations on wheel and shoe materials. The test bench consists of two discs, pressed against each other, simulating the wheel-rail contact. A pneumatic cylinder pushes scaled brake shoes against the wheel tread surface, and a fan-nozzle device improves convection cooling. As a major novelty, both systems are designed to comply with a new thermal scaling method, that is specifically identified to obtain the same temperature field on the scaled twin-disc as for a full-scale system. The paper thoroughly describes the mathematical background of the new thermal scaling method, which is then preliminarily validated with finite element thermal models for both the brake block and wheel. The greatest advantage of the final twin-disc configuration is that it allows to carry out investigations of wheel-rail wear phenomena as well as studies on the thermomechanical interaction between wheels and brake shoes, while adhering to scaling rules that corroborate the validity of the experimental results.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206105"},"PeriodicalIF":5.3,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143881746","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Research on node-improved energy dissipation wear model for fretting fatigue prediction in railway press-fit shaft","authors":"Hang Wang ,&nbsp;Lijun Zhang ,&nbsp;Weijian Zhang ,&nbsp;Hongtao Li ,&nbsp;Hong Chi ,&nbsp;Kai Yang ,&nbsp;Jixu Zhou ,&nbsp;Li Ai","doi":"10.1016/j.wear.2025.206104","DOIUrl":"10.1016/j.wear.2025.206104","url":null,"abstract":"<div><div>As a key component of the traveling system of high-speed trains, the axle is crucial for its safe operation. The current research on the fretting wear and fatigue development of shafts suffers from the problems of low local simulation accuracy of the wear model and the lack of detection and validation methods for the dynamic expansion of wear and fatigue. To this end, this study firstly proposes a new node-improved form of energy dissipation wear model, which is more sensitive to the contact behavior of the asperity body in the overfilled region and the energy transfer process; it exhibits wear prediction results that are closer to the actual situation than the traditional model and improves the prediction accuracy of the corresponding relationship between the cycle time and the wear fatigue crack extension. Secondly, the acoustic emission deep learning detection and validation method of shaft wear fatigue under dynamic rotation is developed; 75,480 wear fatigue signal time-frequency map datasets are established with shaft dynamic rotation experiments, and the convolutional self-encoder and multi-head attention mechanism recognition and detection network are trained. The recognition accuracy of the wear fatigue damage stage reaches 87.4 %. This study shows that the node-improved energy dissipation model combined with acoustic emission dynamic rotation wear fatigue detection can accurately assess the effect of shaft fretting wear on fatigue development.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206104"},"PeriodicalIF":5.3,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143881747","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of multi directional forging-induced grain refinement and subsequent aging on tribological performance of Cu-Ni-Si-Cr alloys in electrical contact sliding conditions","authors":"Harun Yanar ,&nbsp;Abdulkadir Coskun","doi":"10.1016/j.wear.2025.206100","DOIUrl":"10.1016/j.wear.2025.206100","url":null,"abstract":"<div><div>This study examines the effect of deformation-induced grain refinement on the tribological behavior of CuNi2SiCr alloys under electrical current-carrying contact conditions of 0A, 5A, 15A, and 25A. The results demonstrate that the formation of an ultrafine-grained (UFG) structure in the matrix enhanced the wear resistance of the alloy in all test conditions. The improvement in wear resistance is more pronounced under electrical contact sliding conditions. With the formation of the UFG structure, the wear volume loss decreased by 18 % compared to the coarse-grained (CG) sample under currentless conditions. The decrease seen in volumetric loss is achieved as 27 %, 42 %, and 67 % for conditions of 5A, 15A, and 25A, respectively. Additionally, as the intensity of electric current increases, the average friction coefficient value of the samples rises, exhibiting significant fluctuations during the steady-state period of rubbing with increasing electric current intensity. Furthermore, the dominant wear mechanism depends on the level of electrical current intensity. While adhesive, abrasive, and oxidative wear mechanisms are operative for coarse (CG) and UFGed CuNi2SiCr samples at low-intensity electrical current conditions, arc-induced erosion, oxidative, and severe abrasive-based wear are more active at higher current intensities for both samples.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206100"},"PeriodicalIF":5.3,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143881748","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of process parameters on the wear characteristics and lapping performance of SLS-fabricated polyamide tools","authors":"Dawid Zieliński ,&nbsp;Sisay Workineh Agebo ,&nbsp;Mariusz Deja","doi":"10.1016/j.wear.2025.206093","DOIUrl":"10.1016/j.wear.2025.206093","url":null,"abstract":"<div><div>Nowadays, additive manufacturing (AM) offers new possibilities in the production of tools for various finishing processes, such as grinding, lapping, and polishing. In this study, the effect of different lapping parameters was investigated on the wear characteristics and lapping performance of SLS printed polyamide tools. In accordance with the PS/DK 2³ experimental design, machining of Al₂O₃ ceramic materials have been conducted on one-sided lapping setup, in which crucial process input factors, such as unit pressure <em>p</em>, velocity <em>v,</em> and machining time <em>t,</em> were considered at upper (+) and lower (−) two different levels. Technological effects related to the material loss of Al₂O₃ ceramic samples, as well as their surface quality based on 2D (Ra, Wa) and 3D (Sa, Sq) roughness and waviness parameters, were analyzed. The experimental results indicated a noticeable influence of the lapping input parameters on the analyzed machining effects, as well as on the shape profile and wear value of the polyamide lapping wheels abrasive segments. Moreover, considering the result of the statistical analysis, mathematical models are developed for the technological effects related to the values of mass material loss <em>Δm</em>, linear material loss <em>Δh</em>, and surface height parameter roughness Ra, in the form of linear regression equations. The developed mathematical models can be used to precisely predict the values of the output variables within the specified range of variation of the parametric settings.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206093"},"PeriodicalIF":5.3,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143891313","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Innovative small-scale testing to investigate thermo-mechanical damage in tread-braked railway wheel steel paired with various types of cast iron","authors":"Lorenzo Ghidini ,&nbsp;Franco Zanardi ,&nbsp;Angelo Mazzù ,&nbsp;Michela Faccoli","doi":"10.1016/j.wear.2025.206102","DOIUrl":"10.1016/j.wear.2025.206102","url":null,"abstract":"<div><div>This study investigates the thermo-mechanical damage to wheel steel caused by the use of different types of grey cast iron as brake materials. Both untreated and austempered specimens of cast iron were tested to evaluate their wear behaviour and frictional properties under controlled conditions employing an innovative small-scale testing rig called “4-contact machine”. The experiments measured temperature on the specimens' contact surface, wear, friction coefficient and power developed. An in-depth metallographic analysis of all wheel samples was also conducted to determine the impact on wheel steel integrity. Significant findings include the formation of a martensitic transfer layer on the wheel samples’ surface, resulting from the high temperature and pressure during braking. This layer, being harder than the unaltered wheel steel, highlights the thermo-mechanical stress imposed on the wheel. Austempered cast iron brake samples showed superior performance with reduced wear and lower friction coefficients compared to untreated samples. The results emphasize the need for improved brake materials to mitigate thermo-mechanical damage to wheels, enhancing both safety and longevity of railway brake systems. This research contributes to the development of more resilient brake materials, providing valuable insights for the railway industry in optimizing material selection for enhanced operational efficiency and reduced maintenance costs. These advantages are particularly notable compared to composite materials, as austempered cast iron offers comparable or superior performance without the higher costs or vehicle modifications required for composites, all while maintaining its eco-friendly nature.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206102"},"PeriodicalIF":5.3,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143881745","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimization of sanding application parameters based on the wheel-rail adhesion restoration effect and surface damage","authors":"Shuyue Zhang ,&nbsp;Lubing Shi ,&nbsp;Xinxin Song ,&nbsp;Chao Wang ,&nbsp;Haohao Ding ,&nbsp;Junjun Ding ,&nbsp;Jun Guo ,&nbsp;Zhongrong Zhou ,&nbsp;Roger Lewis ,&nbsp;Wenjian Wang","doi":"10.1016/j.wear.2025.206077","DOIUrl":"10.1016/j.wear.2025.206077","url":null,"abstract":"<div><div>Sanding with hard particles is an effective method to improve wheel-rail adhesion under low-adhesion conditions. However, the lack of unified standards for sanding parameters necessitates further investigation into their optimization. This study examined the effects of sanding application parameters on adhesion restoration and surface damage using a twin-disc wheel-rail rolling contact testing machine. The results showed that particle distribution density as the most critical factor influencing adhesion restoration, outweighing the effects of particle size and material. With the increase in particle distribution density, the wheel-rail adhesion coefficient (adhesion restoration amplitude), wear rate and material damage increased sharply at first and then stabilized after surpassing a threshold (approximately 0.607 g/m). Additionally, the restoration duration (adhesion coefficient remained in a proper amplitude) increased almost linearly with an increase in particle distribution density. The influence of particle size on adhesion restoration amplitude depended on particle distribution density, affecting the sensitivity of the adhesion coefficient to density changes. While Alumina exhibited better adhesion restoration effect (restoration amplitude and duration) than Silica sand, it resulted in significantly greater surface damage. Furthermore, to facilitate field applications, an empirical equation was developed to evaluate adhesion restoration amplitude. Based on this equation, a graded control strategy for sanding amounts (0.6–2.2 kg/min) was proposed, related to train operating speeds ranging from 20 to 120 km/h.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206077"},"PeriodicalIF":5.3,"publicationDate":"2025-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143887204","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of Mo2B5 coating on diamond graphitization and cutting performance of Fe-based diamond composites","authors":"Xinyue Mao ,&nbsp;Qingnan Meng ,&nbsp;Mu Yuan ,&nbsp;Sifan Wang ,&nbsp;Shiyin Huang ,&nbsp;Yuting Qiu","doi":"10.1016/j.wear.2025.206097","DOIUrl":"10.1016/j.wear.2025.206097","url":null,"abstract":"<div><div>The bottleneck of iron-based diamond composites lies in the fact that iron is highly susceptible to catalyzing diamond graphitization, which leads to premature diamond detachment, thus affecting work efficiency. In this paper, a transition metal boride (Mo₂B₅) is coated on the diamond surface. During the sintering process of the composites, the Mo₂B₅ coating and Fe undergo a series of chemical reactions to build up an interfacial layer for inhibiting diamond graphitization. The wear performance of the Fe-based matrix diamond composites was examined by wear tests with grinding wheels. The results show that introducing the interfacial layer greatly reduces the degree of interfacial amorphous carbon by isolating the direct contact between the diamond and the Fe-based matrix. The decrease in the degree of interface graphitization promotes the interfacial bonding of diamond with the matrix, resulting in a 59 % increase in the abrasive ratio of the composites. This study introduces a novel coating and method for interfacial modification of metal matrix diamond composites, and the mechanism of its influence on the amorphous carbon content of the interface and wear performance of the composites is thoroughly investigated.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206097"},"PeriodicalIF":5.3,"publicationDate":"2025-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143878994","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Wear modelling and experimental research on diamond coated tool ultrasonic longitudinal-torsional vibration grinding and polishing of SiCp/Al composites","authors":"Zhong Cheng,&nbsp;Daohui Xiang,&nbsp;Jun Zhang,&nbsp;Chaosheng Song,&nbsp;Yanqin Li,&nbsp;Guofu Gao,&nbsp;Jinglin Tong,&nbsp;Xiaobin Cui,&nbsp;Bo Zhao","doi":"10.1016/j.wear.2025.206098","DOIUrl":"10.1016/j.wear.2025.206098","url":null,"abstract":"<div><div>The substantial discrepancy in cutting properties between the Al matrix and SiC particles within the aluminum-based silicon carbide (SiCp/Al) composition results in severe tool wear during machining operations. This significantly affects the surface quality of the workpiece. Texture boron-doped micro and nano diamond-coated tools are prepared in this paper to study such problems. The tools are then used to conduct sliding friction experiments and ultrasonic longitudinal-torsional vibration, abrasion and polishing machining experiments on SiCp/Al with a volume fraction of 45 %. A tool wear model has been established based on the wear delamination theory. The sliding friction experiment has yielded an average friction coefficient of 0.22 between diamond-coated tools and SiCp/Al, which reduces the coefficient of friction by 57.7 % compared with cemented carbide tools. Furthermore, the surface quality of the wear marks is significantly improved. The tool wear under different machining parameters is analyzed by ultrasonic longitudinal-torsional vibration grinding and polishing experiments, and the validity of the wear model is verified with a maximum error value of 19.3 %. In comparison with conventional machining methodologies, ultrasonic longitudinal-torsional vibration machining has been demonstrated to enhance machining efficiency, improve the surface quality of the workpiece, prolong the service life of the tool, and reduce the cutting force by a maximum of 48.75 %. Concurrently, it has been observed to augment the cutting force of diamond-coated tools during standard operation.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206098"},"PeriodicalIF":5.3,"publicationDate":"2025-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143877255","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Halogen-free ionic liquid as metalworking fluid: Impact on tool wear and surface roughness in machining of Ti6Al4V alloys","authors":"Arun Kumar Bambam ,&nbsp;Marella Pavan Kalyan ,&nbsp;Abinash Pradhan ,&nbsp;Kishor Kumar Gajrani","doi":"10.1016/j.wear.2025.206088","DOIUrl":"10.1016/j.wear.2025.206088","url":null,"abstract":"<div><div>Titanium alloys are known for their poor thermal conductivity. During dry machining of titanium alloy, significant heat is generated, which has detrimental effect on the quality of machined components and longevity of cutting tools. Therefore, metalworking fluids (MWFs) are employed during machining. Vegetable oils are currently recognised as a viable environmentally friendly alternative to petroleum based MWFs owing to their biodegradability, renewability, low toxicity, and efficient lubricating qualities. However, they are also known for poor oxidation stability and inadequate performance at low temperatures. Halogen-free ionic liquids (HF-IL) are evolves as potential additive to MWFs due to its distinct properties such as high thermal stability and oxidation stability. This work compares the effect of varying concentration of phosphonium based HF-IL in canola oil on its thermos-physical properties such as wettability and thermal conductivity. It was found that the addition of HF-IL in canola oil improves the MWFs spreadability by 40<span><math><mrow><mo>−</mo></mrow></math></span>45 % by compared to pure canola oil. Further, machining experiments were conducted under three different environments; dry, canola oil and phosphonium based HF-IL blended with canola oil at varying feeds. Machining responses such as cutting temperature, tool flank and rake wear, machined surface roughness and chip morphology were analysed. The findings demonstrated that the use of HF-IL as additives led to drop in cutting temperature by 68<span><math><mrow><mo>−</mo></mrow></math></span>93 % and reduction in surface roughness by 24<span><math><mrow><mo>−</mo></mrow></math></span>61 % at different feeds compared to dry machining. Furthermore, scanning electron microscopy and energy dispersive spectroscopy examinations elucidated the wear mechanism on tools under different machining environments. HF-IL environment showed the lowest tool flank and rake wear. These data corroborate the effectiveness of HF-IL as MWFs additive to improve tool life and surface finish.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206088"},"PeriodicalIF":5.3,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143874044","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}