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Research on tool wear mechanism of liquid nitrogen internal cooling machining

IF 5.3 1区工程技术

Wear Pub Date : 2025-04-02 DOI: 10.1016/j.wear.2025.206064

Yongquan Gan , Qiyu Han , Zhenhua Jiao , Liangliang Li , Hua Jia , Xianghua An

{"title":"Research on tool wear mechanism of liquid nitrogen internal cooling machining","authors":"Yongquan Gan , Qiyu Han , Zhenhua Jiao , Liangliang Li , Hua Jia , Xianghua An","doi":"10.1016/j.wear.2025.206064","DOIUrl":"10.1016/j.wear.2025.206064","url":null,"abstract":"<div><div>Due to its low temperature, high cooling efficiency, environmental friendliness, and other advantages, liquid nitrogen cooling machining is frequently employed in the processing of difficult-to-machine materials. Currently, liquid nitrogen cooling is most commonly performed using liquid nitrogen flood cooling. However, scholars hold differing views on the results of tool wear. This study uses Ti-6Al-2Zr-1Mo-1V titanium alloy as the subject to analyze tool life and wear mechanisms under four different cooling conditions: Dry cutting, Wet cutting (using cutting fluid), LN<sub>2</sub> flood cooling, and LN<sub>2</sub> internal cooling. The results demonstrate that although liquid nitrogen cooling does not exhibit a significant lubrication effect, internal cooling with liquid nitrogen provides more stable and efficient cooling, effectively inhibiting tool adhesion and oxidation wear. Additionally, it reduces the influence of the Leidenfrost effect, significantly improving tool life. Furthermore, it is shown that the method of applying liquid nitrogen as a cooling medium significantly impacts tool wear outcomes. Overall, liquid nitrogen internal cooling is a viable approach for enhancing tool life during the machining of difficult-to-machine materials.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"572 ","pages":"Article 206064"},"PeriodicalIF":5.3,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143777213","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}

引用次数: 0

Quick ultra-low friction in ceramics induced by high-strength nano surface film

IF 5.3 1区工程技术

Wear Pub Date : 2025-03-31 DOI: 10.1016/j.wear.2025.206061

Jinlu Li , Tianyi Sui , Haolin Li , Feifei Zhao , Xuan Bao , Guochen Ning , Yuan Zhang , Jingtao Wang , Bin Lin

{"title":"Quick ultra-low friction in ceramics induced by high-strength nano surface film","authors":"Jinlu Li , Tianyi Sui , Haolin Li , Feifei Zhao , Xuan Bao , Guochen Ning , Yuan Zhang , Jingtao Wang , Bin Lin","doi":"10.1016/j.wear.2025.206061","DOIUrl":"10.1016/j.wear.2025.206061","url":null,"abstract":"<div><div>Serious wear during running-in period significantly limited the application of ceramics in industry. With poor activity, ceramic contact surface is hard to be protected during friction. In this study, ceramics tribological properties are significantly enhanced and ultra-low friction is achieved in short time by formation of high-strength nano surface film. Copper nanoparticles with linear and cubic morphologies were synthesized and dispersed into water-based lubricants for silicon nitride ceramic friction pairs. A 1:1 mixture of copper nanoparticles with linear and cubic morphologies exhibits the best lubrication performance at an optimal concentration of 0.2 wt%. The result shows an 87.01 % reduction in the coefficient of friction, and a wear rate of 0.18 % of that obtained in the case of deionized water. High-strength protective film is found generated on the ceramic surface, which reduces wear and promotes the forming process of ultra-smooth surface to achieve ultra-low friction. Based on the characterization results, lubrication mechanism is elucidated, quick generation of surface film with high strength is the essential for reducing wear and running-in period.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"572 ","pages":"Article 206061"},"PeriodicalIF":5.3,"publicationDate":"2025-03-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143760604","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}

引用次数: 0

Investigation on fretting fatigue crack initiation of IN718 alloy in very high cycle regime

IF 5.3 1区工程技术

Wear Pub Date : 2025-03-27 DOI: 10.1016/j.wear.2025.206059

Jian Wang , Zhiyong Huang , Zheting Jia , Mintao Bian , Ziren Yang , Haoyu He

{"title":"Investigation on fretting fatigue crack initiation of IN718 alloy in very high cycle regime","authors":"Jian Wang , Zhiyong Huang , Zheting Jia , Mintao Bian , Ziren Yang , Haoyu He","doi":"10.1016/j.wear.2025.206059","DOIUrl":"10.1016/j.wear.2025.206059","url":null,"abstract":"<div><div>The objective is to investigate the characteristic of crack initiation in Inconel 718 alloy (IN718) under very high cycle fretting fatigue (VHCFF) conditions. Experimental data and microscopic analysis were used to examine the fatigue performance and microstructure of IN718 at room temperature (RT) and 650 °C. Additionally, a crystal plastic finite element model (CPFEM) was developed to simulate fretting contact, and a multiaxial fatigue damage parameter was established by considering parameters such as the total dislocation density, grain elastic modulus, and equivalent grain size. The findings indicate that the depth of fretting wear increases with the number of fatigue cycles for the same level of cyclic loads. However, when different orders of magnitude of fatigue cyclic loads are applied, the axial load becomes the determining factor in fretting wear. The crack initiation is primarily attributed to the cleavage fracture of relatively large facets. Crack initiation is likely to take place in grains exhibiting a higher Schmid factor in the activated slip system, a larger equivalent grain size, and a reduced elastic modulus.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"572 ","pages":"Article 206059"},"PeriodicalIF":5.3,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747823","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}

引用次数: 0

Elucidating wear evolution and its impact on material removal via modeling for curved surface belt grinding with pyramid-structured abrasives

IF 5.3 1区工程技术

Wear Pub Date : 2025-03-27 DOI: 10.1016/j.wear.2025.206060

Xiaoyu Zhao , Lai Zou , Wenxi Wang , Yilin Mu , Yingjie Liu , Chao Wang

引用次数: 0

Tribological properties of C/Si-Ni-C composites fabricated by reaction melt infiltration with Si-Ni alloy at lower temperature

IF 5.3 1区工程技术

Wear Pub Date : 2025-03-26 DOI: 10.1016/j.wear.2025.206053

Wei Zhang , Yangjie Han , Qianhui Qin , Yiming Chen , Song Li , Rong Xue , Yuke Zeng , Jiping Wang , Zhichao Xiao , Hongyan Xia

{"title":"Tribological properties of C/Si-Ni-C composites fabricated by reaction melt infiltration with Si-Ni alloy at lower temperature","authors":"Wei Zhang , Yangjie Han , Qianhui Qin , Yiming Chen , Song Li , Rong Xue , Yuke Zeng , Jiping Wang , Zhichao Xiao , Hongyan Xia","doi":"10.1016/j.wear.2025.206053","DOIUrl":"10.1016/j.wear.2025.206053","url":null,"abstract":"<div><div>Carbon fiber-reinforced carbon and silicon carbide dual matrix composites (C/C-SiC) are widely used for braking materials owing to their low density, as well as excellent thermal, mechanical, and tribological properties. However, the presence of residual silicon and the high processing temperatures can adversely affect the fibers, leading to a degradation in the composite's performance. This study proposes a novel approach that utilizes Si-Ni alloy instead of pure Si as the melt for preparing C/Si-Ni-C composites through reaction melt infiltration at a lower temperature. The introduced NiSi and NiSi<sub>2</sub> phases effectively replace some of the brittle phases, such as SiC and C, thereby enhancing the overall performance of the composites. The mechanical, thermal and tribological properties of the C/Si-Ni-C composite are investigated and compared with those of composites prepared using pure Si. The results indicate that the thermal conductivity of C/Si-Ni-C reaches 49.38 W/m·K, which is 62 % higher than that of pure Si. Additionally, the wear rate is significantly reduced to 0.77 × 10<sup>−5</sup> mm<sup>3</sup> N<sup>−1</sup>m<sup>−1</sup>, showing a 75 % decrease compared to pure Si when tested under a sliding speed of 0.50 m/s and a load of 30 N. The coefficient of friction of C/Si-Ni-C composites remains stable and can be adjusted. Furthermore, the prepared C/Si-Ni-C composites exhibit anisotropic properties when the steel ball slides perpendicular to or parallel to the fiber alignment.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"572 ","pages":"Article 206053"},"PeriodicalIF":5.3,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747726","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}

引用次数: 0

Impact of dissolved oxygen concentration on the coupling damage between fretting wear and corrosion on zirconium alloy cladding tube in high temperature pressurized water

IF 5.3 1区工程技术

Wear Pub Date : 2025-03-26 DOI: 10.1016/j.wear.2025.206058

Shuji Wang , Yusheng Zhang , Hongliang Ming , Jiazhen Wang , Jianqiu Wang , En-Hou Han

引用次数: 0

Tribological properties of oil palm fiber-derived graphene coatings on piston ring; influence of hydrogen flow rate during CVD process

IF 5.3 1区工程技术

Wear Pub Date : 2025-03-25 DOI: 10.1016/j.wear.2025.206054

Raied Mehtab , Nurin Wahidah Binti Mohd Zulkifli , Mohd Faizul Bin Mohd Sabri , Ardian Morina , Mohd Fadzli Bin Abdollah , Hilmi Bin Amiruddin , Syahrullail Bin Samion , Mohamad Firdaus bin Saharudin

{"title":"Tribological properties of oil palm fiber-derived graphene coatings on piston ring; influence of hydrogen flow rate during CVD process","authors":"Raied Mehtab , Nurin Wahidah Binti Mohd Zulkifli , Mohd Faizul Bin Mohd Sabri , Ardian Morina , Mohd Fadzli Bin Abdollah , Hilmi Bin Amiruddin , Syahrullail Bin Samion , Mohamad Firdaus bin Saharudin","doi":"10.1016/j.wear.2025.206054","DOIUrl":"10.1016/j.wear.2025.206054","url":null,"abstract":"<div><div>This study aims to investigate the influence of varying hydrogen flow rates on the tribological properties of graphene-coated piston rings developed via chemical vapor deposition (CVD) with oil palm fiber as precursor. Graphene was derived from oil palm fiber and polystyrene with varying Hydrogen (H<sub>2</sub>) flow rate in the CVD process i. e, 200, 400, 600 and 800 sccm and deposited on piston rings. The tribological tests were conducted using a high-frequency reciprocating rig (HFRR) according to ASTM G181 – 11 engineering standards. The load of 10N was kept constant for each test and the test was performed till 300m sliding distance was attained. Among all four hydrogen flow rates, it was observed that graphene-coated piston ring developed with 600 sccm and 800 sccm hydrogen flow rates show enhanced tribological properties when derived from 100 wt% of oil palm fiber and polystyrene respectively. The coated piston ring results were compared with non-coated commercially used piston rings and it was found that the coefficient of friction and wear rate of 600 sccm oil palm fiber based graphene coated piston ring was reduced by 20 % and 70 % respectively as compared to uncoated piston ring.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"572 ","pages":"Article 206054"},"PeriodicalIF":5.3,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747725","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}

引用次数: 0

Sustainable and efficient cooling in titanium milling for dental applications: A study on supercritical CO2 + MQL with focus on tool wear and surface topography

IF 5.3 1区工程技术

Wear Pub Date : 2025-03-24 DOI: 10.1016/j.wear.2025.206051

Armin Siahsarani , Amir Alinaghizadeh , Bahman Azarhoushang , Masuod Bayat , Robert Bösinger

{"title":"Sustainable and efficient cooling in titanium milling for dental applications: A study on supercritical CO2 + MQL with focus on tool wear and surface topography","authors":"Armin Siahsarani , Amir Alinaghizadeh , Bahman Azarhoushang , Masuod Bayat , Robert Bösinger","doi":"10.1016/j.wear.2025.206051","DOIUrl":"10.1016/j.wear.2025.206051","url":null,"abstract":"<div><div>Titanium alloys, commonly used in dental implants due to their biocompatibility and mechanical properties, pose significant machining challenges. Their low thermal conductivity leads to elevated cutting temperatures, accelerated tool wear, and compromised surface integrity. This study investigates the application of supercritical carbon dioxide (scCO<sub>2</sub>) combined with minimum quantity lubrication (MQL) as an advanced cooling and lubrication strategy for milling titanium dental implant bridges, comparing its performance with conventional emulsion-based flood cooling. Milling experiments on dental geometries under varying cutting parameters evaluated tool wear, surface integrity, and material removal rates. The results reveal that the scCO<sub>2</sub> + MQL approach significantly reduces tool wear, improves surface quality, and enhances material removal rates compared to emulsion cooling. Specifically, tool flank wear decreased by over 190 %, while material removal rates increased by approximately 68 % during extended milling operations. These findings underscore the potential of scCO<sub>2</sub> + MQL to improve precision, efficiency, and sustainability in the manufacturing of dental implants.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"572 ","pages":"Article 206051"},"PeriodicalIF":5.3,"publicationDate":"2025-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143735064","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

The wear measurement of journal bearing coatings that are poor reflectors using ultrasound analytical signals

IF 5.3 1区工程技术

Wear Pub Date : 2025-03-24 DOI: 10.1016/j.wear.2025.206052

Liqun Wu , Ion Palamarciuc , Rizwan Bajwa , Yi Zhang , Rob Dwyer-Joyce

{"title":"The wear measurement of journal bearing coatings that are poor reflectors using ultrasound analytical signals","authors":"Liqun Wu , Ion Palamarciuc , Rizwan Bajwa , Yi Zhang , Rob Dwyer-Joyce","doi":"10.1016/j.wear.2025.206052","DOIUrl":"10.1016/j.wear.2025.206052","url":null,"abstract":"<div><div>In journal bearings, the soft coatings are designed to facilitate running in and served as a low friction sacrificial layer in case of lubricant starvation. Ultrasound methods have shown the feasibility for in-situ monitoring of the coatings acoustically dissimilar to the bearing shell substrate. However, some coating materials, notably bronze alloys, always show a low acoustic reflection at coating-substrate interface. This paper proposes a “Reflection Package” analysis method based on Hilbert transform and analytical signal to measure the thickness and wear of coatings with low acoustic reflection interface. Finite element simulations were performed to study ultrasound behaviour in this case. For experimental validation, the journal bearing shells with 250 μm bronze-lead alloy (Cu-Pb) coating were subjected to ultrasound inspection under various conditions, including dry-running, excessive dry-running and in-situ condition. The wear depth was obtained by comparing the thickness before and after operation and the dynamic wear progression was demonstrated for these in-situ tests. Compared to microscopic results from sectioned bearings, ultrasound results were generally accurate to within ±15 μm. This study provides a method for measuring bearing wear during real-time operation, especially when the acoustic impedance of the coating is similar to that of the bearing steel. It broadens the ultrasound wear measurement of various materials and has the potential to be applied to the safety monitoring of rotating components in important or inaccessible structures.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"572 ","pages":"Article 206052"},"PeriodicalIF":5.3,"publicationDate":"2025-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143704756","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}

引用次数: 0

Prediction of tool wearability distribution considering friction and energy characteristics of the cutting process

IF 5.3 1区工程技术

Wear Pub Date : 2025-03-24 DOI: 10.1016/j.wear.2025.206028

Jiyang Ma, Yongchuan Lin, Debin Lai, Hao Wei, Zangjian Liu

{"title":"Prediction of tool wearability distribution considering friction and energy characteristics of the cutting process","authors":"Jiyang Ma, Yongchuan Lin, Debin Lai, Hao Wei, Zangjian Liu","doi":"10.1016/j.wear.2025.206028","DOIUrl":"10.1016/j.wear.2025.206028","url":null,"abstract":"<div><div>The accurate assessment of tool wear characteristics is of paramount significance in digital manufacturing, as it directly influences machining efficiency, precision, and energy consumption. This study investigated the wearability distribution of cemented carbide tools during high-performance iron-based material machining by examining the friction and energy characteristics present in the tool-chip interaction. Initially, an analysis of the energy transfer and cumulative distribution within the tool-workpiece system was conducted, leading to the proposal of a wear mechanism that is deeply coupled with the diffusion heat energy density and friction energy power density. Subsequently, the correlation between the cumulative energy damage density and wear characteristics in various regions of the rake face is investigated, and the load distribution was calculated, considering bond damage. The findings revealed the presence of a third body layer during the bond damage process, and its viscoelastic properties significantly impacted the load distribution and damage behavior. A comprehensive wearability distribution model for the rake face was developed by leveraging insights obtained from the coupling mechanism and load characteristics. The model highlights substantial variations in the abrasive distribution across different locations on the rake face. The experimental results corroborate the general applicability and effectiveness of the proposed method, offering theoretical guidance for enhancing digital manufacturing processes.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"572 ","pages":"Article 206028"},"PeriodicalIF":5.3,"publicationDate":"2025-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143725376","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}

引用次数: 0