Wear最新文献

{"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}

{"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":"Towards understanding wear mechanisms of parallel ultrasonic vibration-assisted cutting for titanium alloy","authors":"Wei Cai ,&nbsp;Yupeng Long ,&nbsp;Hongxiang Yin ,&nbsp;Shun Jia ,&nbsp;Kee-hung Lai","doi":"10.1016/j.wear.2025.206092","DOIUrl":"10.1016/j.wear.2025.206092","url":null,"abstract":"<div><div>High tool wear often occurs in titanium alloy (Ti-6Al-4V) machining, which greatly affects part quality and productivity. Parallel Ultrasonic Vibration-assisted Cutting (PUVC) is as the most potential cutting method for machining titanium alloy, Ti-6Al-4V is selected as the machining material in this work for experimental study to reveal the wear mechanism of PUVC. First, the concept and separation characteristics of PUVC are described. Then the characteristics of PUVC (two tools, cutting mode, feed direction, and tool utilization) are experimentally investigated for their influence on tool wear patterns. The experimental results show that cutting efficiency can be improved although increasing the number of tools leads to increased wear. Shared cutting surface (SCS) mode of PUVC reduces tool wear while non-shared cutting surface (NCS) mode increases tool wear. Reverse cutting of PUVC reduces temperature by improving heat dissipation and chip flow and reduces tool wear with insignificant notch wear. In addition, PUVC allows simultaneous machining using both cutting edges of the tool, improving tool utilization and reducing wear. This study is instructive in exploring new titanium alloy machining methods in extending tool life.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"574 ","pages":"Article 206092"},"PeriodicalIF":5.3,"publicationDate":"2025-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143899924","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}