Sliding abrasive wear when combining WEDM conditions and polishing treatment on H13 disks over 1045 carbon steel pins

Egea, Antonio J. Sánchez; Martynenko, Vitali; Simoncelli, Alejandro; Serrancolí, Gil; Krähmer, Daniel

doi:10.1007/s00170-021-07897-4

Cited by 7 publications

(7 citation statements)

References 46 publications

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“…It is also conceivable that pitting and fatigue cracks triggered fractures on the wear surface at 5 N (Supplementary Figure 10). Comparable wear mechanisms have previously been reported in pin-on-disk wear tests performed on different alloys (Ti-6Al-4V alloy and H13 tool steel) treated by the WEDM process (Kuriachen et al , 2018; Sánchez Egea et al , 2022). In addition, it is evident that the wear particles are more intense on the WEDM-treated surfaces compared with the untreated surfaces.…”

Section: Resultssupporting

confidence: 66%

“…This layer causes the alumina ball to slide more easily on the sample surface, which results in a decrease in the COF. It is also thought that the occurrence of an irregular structure on the WEDM-treated surface reduces the friction coefficient (Sánchez Egea et al , 2022). The COF obtained from the untreated Invar-36 surface is consistent with results obtained by Kanca (2022) who found the COF between Invar-36 and the alumina ball to be 0.43 at the sliding distance of 250 m under 20 N. In both the untreated and WEDM-treated samples, the COFs decreased with the increase of the applied load, which has been reported by previous researchers such as Tressia and Sinatora (2023).…”

Section: Resultsmentioning

confidence: 99%

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Investigation of the wear behavior of FeNi36 alloy cut by WEDM method under different loads

Ceritbinmez,

Kanca,

Tuna

et al. 2023

AEAT

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Purpose FeNi36 (Invar-36) alloy is widely used in the fabrication of molding tools in aerospace industries but there remains a need to improve its wear and friction performance due to its relatively low hardness. The formation of a heat affected zone (HAZ) on the surface of Invar-36 cut by wire electric discharge machining (WEDM) is promising to enhance its tribological properties. This study aims to investigate the tribological performance of WEDM-treated Invar-36 via a ball-on-disk tribometer in dry-sliding conditions. Design/methodology/approach The untreated and WEDM-treated Invar-36 surfaces were reciprocated against an alumina ball at a sliding velocity of 40 mm/s, a stroke length of 10 mm and a sliding duration of 125 min under loads of 5, 10 and 20 N. The worn surfaces were characterized using a 2D profilometry and a scanning electron microscope equipped with energy-dispersive spectroscopy. Findings The results showed that the WEDM-treated surface had a superior friction coefficient and wear resistance in comparison to the untreated surface, due to the grown HAZ. There was found to be a 9.3%–11.4% decrease in the friction coefficient and a 47%–57% reduction in the wear volume after the WEDM treatment. Both the untreated and WEDM-treated Invar-36 surfaces found abrasion and plastic deformation as the dominant wear mechanisms. Originality/value Previous works have not focused on the tribological performance of the WEDM-treated Invar-36 extensively used for molding tools in aerospace industries. Our findings provide compelling evidence that the WEDM treatment improved the wear and friction performance of Invar-36 alloy because of the grown HAZ.

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Section: Resultssupporting

confidence: 66%

Section: Resultsmentioning

confidence: 99%

Investigation of the wear behavior of FeNi36 alloy cut by WEDM method under different loads

Ceritbinmez,

Kanca,

Tuna

et al. 2023

AEAT

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“…In industry, parameters R a and R z are widely used to evaluate product quality. The parameters R sk and R ku can be complementary to the parameters R a and R z and allow the evaluation of the functional properties of the surface [53,54]. The tests were repeated three times and the standard deviation did not exceed 5%.…”

Section: Measurement Of Surface Roughness Metricsmentioning

confidence: 99%

Corrosion Resistance and Surface Bioactivity of Ti6Al4V Alloy after Finish Turning under Ecological Cutting Conditions

et al. 2021

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The influence of cooling conditions and surface topography after finish turning of Ti6Al4V titanium alloy on corrosion resistance and surface bioactivity was analyzed. The samples were machined under dry and minimum quantity lubrication (MQL) conditions to obtain different surface roughness. The surface topographies of the processed samples were assessed and measured using an optical profilometer. The produced samples were subjected to electrochemical impedance spectroscopy (EIS) and corrosion potential tests (Ecorr) in the presence of simulated body fluid (SBF). The surface bioactivity of the samples was assessed on the basis of images from scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analysis. The inspection of the surfaces of samples after turning under dry and MQL conditions revealed unevenly distributed precipitation of hydroxyapatite compounds (Ca/P) with a molar ratio in the range of 1.73–1.97. Regardless of the cutting conditions and surface roughness, the highest values of Ecorr ~0 mV were recorded on day 7 of immersion in the SBF solution. The impedance characteristics showed that, compared to the MQL conditions, surfaces machined under dry conditions were characterized by greater resistance and the presence of a passive layer on the processed surface. The main novelty of the paper is the study of the effect of ecological machining conditions, namely, dry and MQL cutting on the corrosion resistance and surface bioactivity of Ti6Al4V titanium alloy after finish turning. The obtained research results have practical significance. They can be used by engineers during the development of technological processes for medical devices made of Ti6Al4V alloy to obtain favorable functional properties of these devices.

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“…These processes include not only the friction phenomena and the related abrasive and adhesive wear, fretting and oxidation, but also other processes, such as brittle cracking, adhesion, etc. The most common main destructive mechanisms include abrasive wear [ 3 , 4 ] and plastic deformation in warm forging [ 5 , 6 , 7 ] as well as plastic deformation in hot forging [ 8 , 9 ], thermo-mechanical cracking [ 10 , 11 , 12 ] and thermo-mechanical fatigue [ 13 , 14 ]. Among them, the most thoroughly analyzed is the wear mechanism, which occurs mostly in cold forging processes [ 15 , 16 ], but also in hot forging processes; although, despite common opinion, it is not a dominating destructive mechanism [ 17 ].…”

Section: Introductionmentioning

confidence: 99%

Increasing the Working Time of Forging Tools Used in the Industrial Process of Producing a Disk-Type Forging Assigned for a Gearbox through the Application of Hybrid Layers

Hawryluk,

Dudkiewicz,

Borowski

et al. 2024

Materials

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The article discusses the phenomena and destructive mechanisms occurring on the surface of 1.2344 steel dies used during the hot forging of disc-type forgings. Preliminary research has shown that gas nitriding alone, used so far, is insufficient due to the occurrence of destructive mechanisms other than abrasive wear, such as thermal and thermomechanical fatigue, which cause the average durability of such tools to be approximately 5000 forgings. Analyses were also carried out to assess the load on forging tools using numerical modeling (Forge 3.0NxT), which confirmed the occurrence of large and cyclically changing thermal and mechanical loads during the forging process. Therefore, in order to increase operational durability, it was decided to use two types of hybrid layers, differing in the PVD coating used: TiCrAlN and CrN, and then subjected to gas nitriding (GN). The obtained results showed that, depending on the area of the tool and the current working conditions, the applied PVD coatings protect the surface layer of the tool against the dominant destructive mechanisms. In both cases, the strength increased to the level of 7000 forgings, the tools could continue to work, and globally, slightly better results were obtained for the GN+TiCrAlN layer. The CrN-type layer protects the tool more against thermal fatigue, while the TiCrAlN layer is more resistant to abrasive wear. In areas where the hybrid layer was worn, a decrease in hardness was observed from 1300 HV to 600–700 HV, and in places of intense material flow (front—point 2 and tool bridge—point 9) the hardness dropped to below 400 HV, which may indicate local tempering of the material. Moreover, the research has shown that each process and tool should be analyzed individually, and the areas in the tool where particular destructive mechanisms dominate should be identified, so as to further protect the forging tool by using appropriate protective coatings in these areas.

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Sliding abrasive wear when combining WEDM conditions and polishing treatment on H13 disks over 1045 carbon steel pins

Cited by 7 publications

References 46 publications

Investigation of the wear behavior of FeNi36 alloy cut by WEDM method under different loads

Investigation of the wear behavior of FeNi36 alloy cut by WEDM method under different loads

Corrosion Resistance and Surface Bioactivity of Ti6Al4V Alloy after Finish Turning under Ecological Cutting Conditions

Increasing the Working Time of Forging Tools Used in the Industrial Process of Producing a Disk-Type Forging Assigned for a Gearbox through the Application of Hybrid Layers

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