Effect of Micro-Dimple Geometry on the Tribological Characteristics of Textured Surfaces

Ali, Saood; Kurniawan, Rendi; Xu, Ming; Ahmed, Farooq; Danish, Mohd; Aslantaş, Kubilay

doi:10.3390/lubricants10120328

Cited by 7 publications

(4 citation statements)

References 33 publications

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“…Ali et al 35 investigated the tribological properties of Al 6061 cylindrical work specimen using micro dimple patterns developed by dual frequency vibration method and observed that the dimple patterns aided in providing an additional hydrodynamic lift effect which in turn improved the frictional characteristics. Moreover, the specific wear rate was observed to be significantly reduced as compared to the non-textured surfaces.…”

Section: Introductionmentioning

confidence: 99%

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

George

Sahu

Dhanish

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Machinability of Ti-6Al-4V, despite its numerous applications, is challenging owing to its poor thermal conductivity, severe chemical affinity and strain hardening characteristics. Although various coating techniques and expensive lubrication strategies have been tried, a significant improvement in tool life characteristics are yet to be achieved. Hence this work aims at suggesting a novel cost-effective and ecofriendly tool treatment technique by exploring the impact of a dual combination of an AlSi-10Mg coating developed by an emerging pre-conditioning technique with the incorporation of micro-textures on tool face to observe significant improvements in tool life and machinability characteristics of the alloy. It was analyzed from the results that while the micro-textures played a vital role in reducing the severe contact stress and machining temperature due to its improved heat transfer by convection, AlSi-10Mg film effectively shielded the cutting edges of the tool by providing a dampening effect along the edges, thereby ensuring improved tool life and enhanced machinability characteristics at the same time. The proposed tool combination was observed to be successful in significantly reducing the flank wear by 35%, 43% and 30% where 75, 253, and 371 µm were observed at 80, 100, and 120 m/min as compared to 117, 449, and 531 µm in the case of uncoated non-textured tool at the same operating conditions. Surface roughness of Ti-6Al-4V also reduced by 25%, 34%, and 37% where 1394, 1168, and 872 nm as compared to plain tool where 1840, 1770, and 1370 nm were recorded. Moreover, average chip curl diameter was observed to be 2.62, 3.36, and 6.49 mm as compared to chips generated by uncoated tools which recorded values of 4.33, 11.9, and 18.87 mm at 80, 100, and 120 m/min respectively.

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Section: Introductionmentioning

confidence: 99%

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

George

Sahu

Dhanish

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…Rough-surfaced channels have a higher thermal-hydraulic efficiency than turbulence inserts [38]. The technologies are well studied and proven on existing equipment to produce rough surfaces, such as plastic deformation [39] or the cutting of material [40,41].…”

Section: Introductionmentioning

confidence: 99%

Numerical and Experimental Study of Heat Transfer in Pyrolysis Reactor Heat Exchange Channels with Different Hemispherical Protrusion Geometries

Kolenchukov,

Bashmur,

Kurashkin

et al. 2023

Energies

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One of the most effective technologies for recycling organic waste is its thermal destruction by pyrolysis methods to produce valuable products such as hydrogen and mixtures containing hydrogen. Increasing the thermal power of the flow helps to reduce the formation of secondary reactions, making the non-condensable hydrocarbon gas in the pyrolysis process cleaner, which simplifies further technology for the production of hydrogen and hydrogen-containing mixtures. In addition, the economic viability of pyrolysis depends on the energy costs required to decompose the organic feedstock. Using passive intensifiers in the form of discrete rough surfaces in heat exchanging channels is a widely used method of increasing heat transfer. This paper presents the results of numerical and experimental studies of heat transfer and hydraulic resistance in a channel with and without hemispherical protrusions applied to the heat transfer surface. The investigations were carried out for a reactor channel 150 mm long and 31 mm in diameter, with a constant pitch of the protrusions along the channels of 20 mm and protrusion heights h of 1 to 4 mm for 419 ≤ Re ≤ 2795. Compared to a smooth channel, a channel with protrusions increases heat transfer by an average of 2.23 times. By comparing the heat exchange parameters and the hydraulic resistance of the heat exchange channels, it was determined that h = 2 mm and 838 < Re < 1223 is the combination of parameters providing the best energetic mode of reactor operation. In general, an increase in h and coolant flow rate resulted in an uneven increase in heat transfer intensity. However, as h increases, the dead zone effect behind the protrusions increases and the rough channel working area decreases. Furthermore, increasing Re > 1223 is not advisable due to the increased cost of maintaining high coolant velocity and the reduced heat transfer capacity of the channel.

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“…The influences of surface textures have been frequently investigated with the aim of friction and wear reduction in boundary and mixed lubrication regimes. Ali et al [4] explored the use of textured surfaces in high-load boundary lubrication conditions. Textured surfaces reduced friction and contributed to the creation of an extra hydrodynamic lift effect.…”

Section: Introductionmentioning

confidence: 99%

The Effect of Steel Electropolishing on the Tribological Behavior of a Steel–Bronze Pair in the Mixed and Boundary Lubrication Regimes

Mašović,

Miler,

Čular

et al. 2023

Lubricants

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Electropolishing at high current densities without agitation of the electrolyte results in a pitting phenomenon that produces dimple-like surface features. Although pitting is unfavorable in the electropolishing process, its effect on surface modification, such as surface texturing, has not been thoroughly investigated. Surface topography and chemical composition analyses of electropolished steel revealed surface pits and an oxide surface layer, indicating the presence of surface texture and coating. The resulting surface is characterized by negative skewness and high kurtosis values. The tribological behavior of the electropolished steel-bronze pair is investigated by evaluating coefficients of friction and bronze wear using sliding tests conducted in mixed and boundary lubrication regimes. The results are compared to those of the ground steel-bronze pair. In the mixed and upper range of the boundary lubrication regime, coefficients of friction reduction up to 30% and shorter running-in phases are observed for electropolished steel (electropolished steel μavg = 0.019 vs. ground steel μavg = 0.028). In contrast, the coefficient of friction increased in the lower range of boundary lubrication regime by 50% (electropolished steel μavg = 0.098 vs. ground steel μavg = 0.065). Electropolishing, as a cost- and time-effective method applicable to complex geometries, presents an alternative method for achieving surface modifications aimed at friction reduction and improved tribological behavior for non-conformal contacts in the boundary and mixed lubrication regimes.

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Effect of Micro-Dimple Geometry on the Tribological Characteristics of Textured Surfaces

Cited by 7 publications

References 33 publications

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

Numerical and Experimental Study of Heat Transfer in Pyrolysis Reactor Heat Exchange Channels with Different Hemispherical Protrusion Geometries

The Effect of Steel Electropolishing on the Tribological Behavior of a Steel–Bronze Pair in the Mixed and Boundary Lubrication Regimes

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