Wear最新文献

{"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":"Enhanced wear resistance of a die steel via modification of the M7C3 and M23C6 carbides","authors":"Xinyu Shen ,&nbsp;Mulan Peng ,&nbsp;Hao Fu ,&nbsp;Tongtao Wei ,&nbsp;Hong Wu ,&nbsp;Xiedong Huang ,&nbsp;Zulai Li ,&nbsp;Lu Li ,&nbsp;Ian Baker ,&nbsp;Quan Shan","doi":"10.1016/j.wear.2025.206106","DOIUrl":"10.1016/j.wear.2025.206106","url":null,"abstract":"<div><div>Large volume fractions of carbides in die steels are a crucial source of high wear resistance. However, the inherent brittleness of micrometer sized carbides reduces the toughness, and can cause embrittlement and even premature failure of die steels. In this work, Cr8Mo2VSi die steel, a typical cold work die steel, has been modified by both reducing the volume fraction and refining the M₇C₃ carbides. The modified Cr8Mo2VSi die steel was produced via a 0.8 wt% reduction of Cr and a 5 % increase in deformation during composition design and rolling process, respectively. Increased aging-induced precipitation of M₂₃C₆ carbides in Cr8Mo2VSi can balance the negative effects of the M₇C₃ carbides, thereby toughening the die steel and extending its fatigue life. Moreover, M₇C₃ carbides are prone to peeling during wear because of their inherent brittleness, the stacking faults present, and the low interfacial adhesion. The modified Cr8Mo2VSi die steel exhibited superior toughness and fatigue performance and high wear resistance not only due to the increased participation of M₂₃C₆ carbides, but also because of the increased number of high-angle grain boundaries resulting from increased deformation. This study aims to provide guidance for the toughening of die steels with high-carbide contents.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"576 ","pages":"Article 206106"},"PeriodicalIF":5.3,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143947286","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":"Binder jetting additive manufacturing of AISI M2 tool steel: Investigating the influence of sintering parameters on wear behavior","authors":"Amit Choudhari ,&nbsp;Abhishek Kumar ,&nbsp;Hong Liang ,&nbsp;Tushar Borkar","doi":"10.1016/j.wear.2025.206094","DOIUrl":"10.1016/j.wear.2025.206094","url":null,"abstract":"<div><div>Binder Jetting Additive Manufacturing (BJAM) offers significant potential for fabricating high-performance tooling materials, yet the behavior of AISI M2 tool steel processed via BJAM remains largely unexplored. This study bridges that gap by systematically investigating the effects of sintering temperatures (1270, 1280, and 1300 °C) and cooling methods (furnace, air, and water quenching) on the tribological performance of BJAM-processed M2 tool steel. Through advanced characterization techniques, including SEM/EDS mapping, Atomic Force Microscopy (AFM), and optical topography, the study examines microstructural evolution, tribological behavior, and carbide distribution (MC, M₆C, M₂C) and their role in wear resistance. Four dominant wear mechanisms, abrasive, adhesive, oxidative, and fatigue, are identified, each influencing the material's failure modes. MC carbides are primarily responsible for abrasive wear, M₆C promotes adhesion, oxidative wear results from elevated temperatures, and fatigue wear arises from microcracks at carbide-matrix interfaces. Key findings indicate that post-processing conditions significantly impact wear performance. Water-cooled samples sintered at 1270 °C for 60 min exhibit the lowest coefficient of friction and wear volume loss, which is attributed to finer microstructure, uniform carbide dispersion, and increased hardness, which reduces abrasive wear. Conversely, higher sintering temperatures lead to carbide coarsening, grain growth, and increased wear. This study establishes a direct correlation between BJAM processing parameters and tribological properties, demonstrating its viability for tooling applications. The findings provide a foundation for optimizing BJAM-processed M2 tool steel for improved wear resistance and industrial applicability.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"576 ","pages":"Article 206094"},"PeriodicalIF":5.3,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144084667","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":"Comparative analysis of surface morphology characteristics of abrasive belt wear in conventional and creep-feed grindings based on the Yolov8 algorithm","authors":"Youdong Zhang ,&nbsp;Duo Li ,&nbsp;Mingjun Ren ,&nbsp;Limin Zhu ,&nbsp;Yi He ,&nbsp;Xinquan Zhang","doi":"10.1016/j.wear.2025.206089","DOIUrl":"10.1016/j.wear.2025.206089","url":null,"abstract":"<div><div>Creep-feed belts grinding (CFBG) can improve processing efficiency while ensuring the surface quality of TC4 titanium alloy materials. However, the difficult-to-machine characteristics of titanium alloys and the single-layer abrasive nature of the abrasive belts accelerate belt wear. Meanwhile, grinding creates micron-level scratches on the surface, which can lead to localized stress concentration on the titanium alloy surface and significantly reduce the service performance of workpiece. Due to the randomness of the grain and the complexity of grinding process, which makes it a challenging problem to investigate the regularity and mechanism of the surface morphology characteristics with belt wear under different grinding forms. Therefore, this research proposes a surface topography evaluation method of titanium alloy based on YOLOv8 segmentation algorithm, and explores the regularity of surface topography after creep-feed/conventional abrasive belt (CBG) wear. Firstly, the YOLOv8 algorithm was used to segment the collected titanium alloy surface topography images. Accuracy of the algorithm is 0.85, Precision, Recall and F1 values are 0.85, 0.72, F1 and 0.78 respectively, which indicates that the algorithm performs relatively well. Secondly, the surface morphology characterization regularity was quantitatively characterized; with belt wear, the area ratio, perimeter ratio and depth of scratches in CBG gradually decreased, and the aspect ratio, fractal dimension and radius of curvature gradually increased; while in CFBG, the parameters all changed rapidly (decreasing/increasing) and the value then fluctuated within a range. Finally, a model of titanium alloy surface morphology molding in the whole life cycle of abrasive belts under different grinding methods was established.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206089"},"PeriodicalIF":5.3,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143899923","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":"Analysis the surface integrity taking into account the tool wear stage in the multi-axis torus milling of a Ni-based superalloy using the active cutting edge segment change technique and new approach for machining aircraft engine blades","authors":"Michał Gdula ,&nbsp;Andrzej Nowotnik ,&nbsp;Grażyna Mrówka-Nowotnik","doi":"10.1016/j.wear.2025.206095","DOIUrl":"10.1016/j.wear.2025.206095","url":null,"abstract":"<div><div>This study aims to comprehensively investigate the state of the technological surface layer taking into account the tool wear stage in multi-axis torus milling of a Ni-based superalloy using the author's active cutting edge segment change (ACESC) technique. A mathematical model of the distance between tool paths as a function of the angle of inclination of the tool axis in relation to the active cutting edge segment change technique is established. Addition, a theoretical model of flank wear width is established, taking into account the elastic recovery effect of the material, with an average prediction error of 10 %. Analysis of the surface morphology revealed a scratch with a curved outline, arranged according to the surface velocity vector as a function of the tool rotation angle. This is the result of micro-chipping and adhesion of chips to the cutting edge of the round insert. At the same time, it has been observed that in the boundary zone of adjacent machining marks, adhesion occurs after the elastic recovery of the material. The deformation of the material grains and the distribution of residual stresses depend significantly on the stage of tool wear and the angle of inclination of the tool axis. Based on the results, a new approach for multi-axis torus milling of aircraft engine blades was proposed.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206095"},"PeriodicalIF":5.3,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143899926","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":"Evaluating tool wear mechanisms, hole integrity and drilling performance of indexable and solid carbide tools on GFRP-Steel stacked composite","authors":"Sana Ehsan ,&nbsp;Muhammad Umer Latif Malik ,&nbsp;Muhammad Faisal Shahzad ,&nbsp;Muhammad Asad Ali ,&nbsp;Muhammad Umar Farooq ,&nbsp;Saqib Anwar","doi":"10.1016/j.wear.2025.206096","DOIUrl":"10.1016/j.wear.2025.206096","url":null,"abstract":"<div><div>Engineers are exploring GFRP-steel hybrid materials for various applications due to their superior mechanical properties with lightweight. However, machining these materials poses significant challenges due to mismatch leading towards accelerated tool wear and compromised surface quality. Therefore, the present study reports a comprehensive analysis of drilling GFRP-steel stacked composite using indexable inserts and solid carbide drills in dry conditions. The experiments were designed by varying key process parameters such as feed rate (10–20 mm/min) and spindle speed (2400–4800 rpm). While, five significant response variables of this study were investigated as surface roughness (Ra in μm), tool wear (TW in μm), diametric error (DE in μm), delamination factor (Fd) and drilling temperature (Td in °C). Key findings revealed that indexable drill exhibited superior TW due to its robust design and efficient cutting-edge geometry, reducing localized stress and heat. TW significantly increased by increasing the feed rate and spindle speed. SEM analysis of solid carbide drills and the indexable inserts revealing grooves, adhesion, and coating delamination at higher spindle speed and feed rate, but lower for indexable inserts. Roughness analysis highlighted that indexable inserts resulted reduced Ra of 0.09 μm at 10 mm/min feed rate and 3600 rpm spindle speed compared to the solid carbide drill (Ra 1.28 μm). The indexable drill ensured better accuracy with a minimum DE of 10.33 μm compared to 42.94 μm for the solid carbide drill, attributed to enhanced chip evacuation and reduced thermal stress. Delamination control was more effective at 10 mm/min feed and 3600 rpm spindle speed, minimizing material separation, whereas higher settings (20 mm/min, 4800 rpm) amplified delamination. The indexable inserts maintained consistently lower drilling temperatures, with the solid carbide drill reaching a peak of 482 °C due to higher frictional heat generation, underscoring its superior thermal stability and wear resistance.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"576 ","pages":"Article 206096"},"PeriodicalIF":5.3,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144072364","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}