Wear最新文献

{"title":"A visual analytical method for evaluating tool flank wear volumes of micro-milling cutters with AKAZE features matching: A preliminary study","authors":"Yu Zhang ,&nbsp;Shuaishuai Gao ,&nbsp;Xianyin Duan ,&nbsp;Kunpeng Zhu","doi":"10.1016/j.wear.2025.205739","DOIUrl":"10.1016/j.wear.2025.205739","url":null,"abstract":"<div><div>Tool wear is one of the most important factors restricting the development and application of micro-milling technology. In order to accurately evaluate the tool wear features in the micro-milling process, a visual analytical approach is proposed with multiple advanced image processing methods. Firstly, A theoretical model of tool wear volume considering the end concave angle is proposed, which is more descriptive of practical situations than the traditional one-dimensional parameters, the tool flank wear length. Secondly, the tool flank wear areas are accurately obtained of image segmentation with the Canny gradient operator, extraction with corner feature detection, and registration with Accelerated-KAZE (AKAZE) feature matching. Finally, the features of the tool flank wear are evaluated of correcting the integration areas with the Hough transformation, determining the parameters with scale conversion, and verifying the areas and volumes of the tool flank wear with experimental data and key quality metrics, Mean-Squared Error (MSE) and Multi-Scale Structural Similarity (MS-SSIM). The results demonstrate that the method presented effectively characterises the tool flank wear, giving a suitable approach for computer vision and image feature processing of tool wear monitoring during machining.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"564 ","pages":"Article 205739"},"PeriodicalIF":5.3,"publicationDate":"2025-01-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140750","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":"A new perspective on rail corrugation and its practical implications","authors":"Qinghua Guan ,&nbsp;Zefeng Wen ,&nbsp;Binbin Liu ,&nbsp;Hengyu Wang ,&nbsp;Shulin Liang","doi":"10.1016/j.wear.2025.205743","DOIUrl":"10.1016/j.wear.2025.205743","url":null,"abstract":"<div><div>To investigate the possible formation and evolution mechanisms of rail corrugation related to the resonances of wheel and rail, a wave approach is adopted to characterize the wave propagation and vibration behaviour of the track. Through the receptance coupling method, the interaction model of multiple wheels and track is established taking into account the P2 resonance and resonances due to the wave interaction, which is applied in combination with the wheel/rail rolling contact model and the Archard wear equation to demonstrate the formation and development of the rail corrugation in both low-speed metro and high-speed rail systems. The numerical results show that the resonances due to the wave interaction between adjacent wheels can lead to short-pitch corrugation with a wavelength of 20 mm–30 mm in the metro system and long wavelength corrugation of 110 mm–160 mm in the high-speed railway, which is supported by corresponding field measurements. It is also noted that the short-pitch corrugation in the metro and the long wavelength corrugation in the high-speed railway share the common frequency range of 550–700 Hz, which is explained from the perspective of the quasi-resonance phenomenon of the multiple wheels and track coupled system.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"564 ","pages":"Article 205743"},"PeriodicalIF":5.3,"publicationDate":"2025-01-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140751","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":"A feasible strategy to construct WC-Co-Cr/cu composite coating with good tribo-corrosion behavior and anti-fouling properties for marine applications","authors":"Zhenxin Qiao ,&nbsp;Rui Yang ,&nbsp;Yi Liu ,&nbsp;Xiaohua Feng ,&nbsp;Jing Huang ,&nbsp;Ye Tian ,&nbsp;Ping Zhou ,&nbsp;Hidetoshi Saitoh ,&nbsp;Xiaomei Liu ,&nbsp;Botao Zhang ,&nbsp;Hua Li","doi":"10.1016/j.wear.2025.205738","DOIUrl":"10.1016/j.wear.2025.205738","url":null,"abstract":"<div><div>Various protective coatings are applied to marine components to mitigate friction, wear, corrosion, and biofouling. However, these issues can arise simultaneously under certain operating conditions, posing significant challenges to the performance and durability of marine components. In this study, core-shell structured WC-Co-Cr/Cu powders were fabricated using electroless plating, and a high-velocity oxygen-fuel (HVOF) spraying technique was employed to deposit the WC-Co-Cr/Cu coating. The results demonstrated that the tribo-corrosion behavior of the WC-Co-Cr/Cu coating improved compared to that of the HVOF WC-10Co-4Cr coating, although there was a slight reduction in corrosion resistance. Additionally, the incorporation of Cu significantly reduced the adhesion rates of <em>Bacillus subtilis</em> and <em>Phaeodactylum tricornutum</em>, indicating that the WC-Co-Cr/Cu coating gained anti-biofouling properties from the presence of Cu. Overall, the development of this WC-Co-Cr/Cu coating presents a promising solution for marine components, providing enhanced tribo-corrosion performance and effective anti-biofouling properties.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"564 ","pages":"Article 205738"},"PeriodicalIF":5.3,"publicationDate":"2025-01-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143096714","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":"Solid-liquid composite lubricating coating based on thermally sprayed ceramic template: Tribological properties, lubrication and failure mechanism","authors":"Jialin He ,&nbsp;Nairu He ,&nbsp;Chunyan He ,&nbsp;Shuangjian Li ,&nbsp;Xiujuan Fan ,&nbsp;Chao Wang ,&nbsp;Mengyao Han ,&nbsp;Chunming Deng ,&nbsp;Jie Mao ,&nbsp;Xiaofeng Zhang","doi":"10.1016/j.wear.2025.205741","DOIUrl":"10.1016/j.wear.2025.205741","url":null,"abstract":"<div><div>In this study, a novel solid-liquid composite lubricating coating was prepared using the pores and micro-cracks of the thermally sprayed Al₂O₃/polyfluoroalkoxy coating, and the perfluoropolyether lubricating oil (PFPE) was incorporated into the coating as the liquid lubricating phase by vacuum thermal impregnation technology. The results indicate that PFPE encapsulated nanoscale Al₂O₃ and polyfluoroalkoxy abrasive debris, generating a lubrication protrusion structure at friction interfaces. The protrusion structure exhibits a high adhesion force (119 nN), thereby preventing crack propagation on the worn surface. A minimal friction coefficient of 0.07 is reached by creating a protrusion surface. This lowers the rate of wear by about 79 % compared to before oil immersion conditions and by about 99 % compared to Al₂O₃ coatings. Continuous consumption of PFPE, coupled with the accumulation of wear debris during sliding, gradually destroys the lubricating protrusion structures, ultimately leading to its failure.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"564 ","pages":"Article 205741"},"PeriodicalIF":5.3,"publicationDate":"2025-01-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143097238","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 damage and microstructure evolution of high-speed wheel steel under low slip ratios","authors":"Xiaotong Zhu ,&nbsp;Tai Peng ,&nbsp;Jun Hua ,&nbsp;Ruiming Ren ,&nbsp;Zhiqiu Huang ,&nbsp;Guanzhen Zhang","doi":"10.1016/j.wear.2025.205742","DOIUrl":"10.1016/j.wear.2025.205742","url":null,"abstract":"<div><div>A rolling wear test was carried out to investigate the wear damage and microstructure evolution of high-speed wheel steel under low slip ratios. The results indicate that in the initial stage of wear, the wear mechanism changes from oxidative and adhesive wear to fatigue wear with an increasing slip ratio. With an increasing number of wear cycles, the fatigue wear of the sample surface increases. Wear damage mainly depends on crack initiation and propagation on the surface and in the cross-section. Cracks mainly initiate and propagate at the interface between the deformed proeutectoid ferrite and pearlite under low tangential force. However, with increasing tangential force, cracks extend through the adjacent softer proeutectoid ferrite during propagation. In the cross-sectional direction, when proeutectoid ferrite is present near the crack tip, the crack preferentially propagates through the this ferrite or along the interface between proeutectoid ferrite and pearlite. As the slip ratio increases, the depth of the refined proeutectoid ferrite and pearlite and the degree of refinement increase; in addition, the depth of cementite bending and fracture increases, and the degree of cementite fragmentation becomes remarkable. On the worn surface, with increasing slip ratio and number of wear cycles, ferrite is refined into a fibrous microstructure and cementite is refined from short rods into particles until almost no cementite is observed.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"564 ","pages":"Article 205742"},"PeriodicalIF":5.3,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140640","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":"Anti-wear behaviors of nanofluids at the micro-textured tool/chip interface of CBN tools with electromagnetic field effects","authors":"Kedong Zhang ,&nbsp;Mingjing Jiang ,&nbsp;Haishan Li ,&nbsp;Xuhong Guo ,&nbsp;Yayun Liu ,&nbsp;Chuanyang Wang","doi":"10.1016/j.wear.2025.205735","DOIUrl":"10.1016/j.wear.2025.205735","url":null,"abstract":"<div><div>The micro-texture fabricated on the cubic boron nitride (CBN) tool surface is an established method for enhancing the penetration ability of nanofluids into the tool/chip interface. However, achieving efficient and continuous cooling lubrication at the micro-textured tool/chip interface continues to pose significant challenges. In this study, we employed an external magnetic field to enhance the permeability of nanofluids, while also taking into account the effects of electroosmosis. The turning experiments conducted on superalloys using micro-textured CBN tools (named TSN) have validated the effectiveness of the proposed method. By increasing the magnetic field intensity to 1200 Gs and integrating an electroosmotic accelerator into Fe₃O₄ nanofluids, the anti-wear properties of TSN were enhanced. This enhancement resulted in a reduction of cutting force by approximately 18 %, a decrease in cutting temperature by 9.1 %, and a reduction in surface roughness of machined workpiece by 43.04 %. Finally, the mechanism was discussed.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"564 ","pages":"Article 205735"},"PeriodicalIF":5.3,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143096716","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":"Enhancing tribological performance of CBN materials by Fe3O4 nanofluid and wedge-shaped micro-texture considering electroosmosis effect","authors":"Haishan Li ,&nbsp;Kedong Zhang ,&nbsp;Yayun Liu ,&nbsp;Tongshun Liu ,&nbsp;Xuhong Guo ,&nbsp;Youqiang Xing","doi":"10.1016/j.wear.2025.205737","DOIUrl":"10.1016/j.wear.2025.205737","url":null,"abstract":"<div><div>Nanofluid as cooling and lubrication medium at the micro-textured contact interface is common. It is a promising approach to employ electroosmosis effect to improve the infiltration of nanofluid into the micro-textured interface, thereby enhancing the tribological performance. In this study, the effects of Fe₃O₄ nanofluids with different surfactant additions on the friction and wear performance of micro-textured specimens were investigated through ball-on-disc friction experiments under self-excited electric fields. Results showed that micro-textured specimens combined with 0.5 vol% sodium lauriminodipropionate (SLI) surfactant exhibited the lowest friction temperature, smallest average friction coefficient, and least ball wear. Moreover, CBN specimen wear was significantly reduced. Combining capillary electroosmosis experiments and tribological test results revealed the penetration mechanism of Fe₃O₄ nanofluids.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"564 ","pages":"Article 205737"},"PeriodicalIF":5.3,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143096713","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":"Inspired articular structure for enhancing high-temperature abrasibility of as-sprayed YSZ/BN-polyester sealing coating","authors":"Shuang Yu ,&nbsp;Shuqi Wang ,&nbsp;Yaming Wang ,&nbsp;Zhiyun Ye ,&nbsp;Guoliang Chen ,&nbsp;Qiang Zhao ,&nbsp;Yang Li ,&nbsp;Dawei Ren ,&nbsp;Yongchun Zou ,&nbsp;Jiahu Ouyang ,&nbsp;Dechang Jia ,&nbsp;Yu Zhou","doi":"10.1016/j.wear.2024.205730","DOIUrl":"10.1016/j.wear.2024.205730","url":null,"abstract":"<div><div>Designing and preparing engineering abradable seal coatings (ASCs) with excellent abrasibility and adequate mechanical stability at extremely high temperatures is exceptionally challenging. Inspired by the unique structural features of articulation, we designed a YSZ/BN-polyester coating with polyester to form a cancellous-like structure and a smooth “glaze” layer to form a cartilage-like structure-combined, the two formed an ASC with improved abrasibility at both room temperature and a high temperature of 1000 °C. The cancellous-like structure in the YSZ/BN-polyester coating effectively reduced the number of spalling pits caused by stress concentration and brittle fracture, which contributed to a reduction in the coefficient of friction (COF, 0.33) at room temperature. At 1000 °C, the wear debris rich in <em>h</em>-BN and B₂O₃ produced by the oxidation of <em>h</em>-BN compressed to form a cartilage-like smooth “glaze” layer. Moreover, B₂O₃, as a “sintering agent”, improved the stability of the cartilage-like structure and caused “healing”, which effectively reduced the COF (0.22) and its fluctuation amplitude at 1000 °C. The cartilage-like structure helped to improve the mechanical stability of the coating, which further extended the service durability of the YSZ/BN-polyester sealing coating. Thus, the YSZ/BN-polyester coating with an articulation-mimicking structure demonstrates significant promise for the development of a high-temperature ASC system.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"564 ","pages":"Article 205730"},"PeriodicalIF":5.3,"publicationDate":"2025-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143141039","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":"Surface preparation and wear mechanism of high-strength microtextured aluminum alloys using combined cutting and ultrasonic rolling process","authors":"Xiao Yu ,&nbsp;Youqiang Wang ,&nbsp;Chengyong Wang ,&nbsp;Ping Zhang","doi":"10.1016/j.wear.2025.205734","DOIUrl":"10.1016/j.wear.2025.205734","url":null,"abstract":"<div><div>Cutting processes can form microtextures with alternating peaks and valleys on the surface, while ultrasonic rolling can cause material flow from peaks to valleys and bring about plastic deformation strengthening, which avoids the reduction in surface strength associated with microstructures processed by material removal. This study utilizes a combined approach of cutting and ultrasonic rolling process (CURP) to create high-strength, wear-resistant microtextured surfaces on aluminum alloys. The research investigates the principles of point contact wear on microtextured surfaces. Models were developed for the contact area between cutting roughness peaks and the rolling element to analyze the shape of the contact area and the forces acting on the rolling element under different processing parameters. Experiments were conducted with single and multiple passes of ultrasonic rolling under different cutting parameters to establish the relationship between indentation size and processing parameters. Friction and wear experiments were performed to explore the wear mechanisms on surfaces with microtexturing. The results revealed that the length of the indentation is positively correlated with the cutting feed rate. At the same indentation depth, a larger feed rate results in a longer indentation length. As the angle φ between the rolling direction and the cutting mark decreases, single indentations shift from symmetrically distributed along the midline of the rolling to one side. When the feed rate is high and the overlap rate is low, the roller-burnished surface exhibits a uniformly distributed sector-shaped pit area. However, with an overlap rate of 25 %, sector-shaped pits disappear under smaller feed rates. Microtextured surfaces are less prone to microcracks and material peeling abrasion under light loading conditions. With an increase in contact stress during heavy loading, surfaces with higher degrees of work hardening, such as the CURP specimens, become more susceptible to material peeling.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"564 ","pages":"Article 205734"},"PeriodicalIF":5.3,"publicationDate":"2025-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143096711","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":"Molecule-dependent abnormal wear of GCr15 ball-ball contact: Morphological, chemical, and structural characterization","authors":"Huajie Tang ,&nbsp;Xinchun Chen ,&nbsp;Chunhui Zhao ,&nbsp;Daoxin Su ,&nbsp;Jinshan Pan ,&nbsp;Jianlin Sun","doi":"10.1016/j.wear.2024.205723","DOIUrl":"10.1016/j.wear.2024.205723","url":null,"abstract":"<div><div>Abnormal wear has always been a common concern in engineering lubrication, which sometimes depends on the lubrication. The present work aimed to elucidate the formation mechanism of abnormal non-circular wear scar of GCr15 ball-ball contact in the presence of dibutyl phosphite (DBPI). A detailed characterization of morphology, composition, and structure was performed. The results show that the abnormal wear depended on the chemical reactivity of DBPI, structure and size of wear products. Importantly, wear products exhibited a flocculent structure at the macroscale and had a capsule structure with metal debris encapsulated into an amorphous shell at the microscale. The redeposition of wear products formed a multilayered tribofilm, containing a metal-debris-dominated layer and multiple organic-dominated amorphous layers. The total thickness of tribofilm can be up to 268 nm. Fe₃(PO_<em>x</em>)₂, FePO_<em>x</em>, Fe[DBPI]₂, and Fe[DBPI]₃ were the principal composition of tribofilm. The present work elucidates the molecule-dependent abnormal wear of ball-ball contact, which will have wide potential for the additives design and the corresponding lubrication mechanism research.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"564 ","pages":"Article 205723"},"PeriodicalIF":5.3,"publicationDate":"2025-01-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143096710","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}