Optimization of wear and cracks in roller contact under different coating and a range of loads and temperature with fixed speed using design expert (DOE) and finite element model

 
 
 
  • Abstract
  • Keywords
  • References
  • PDF
  • Abstract


    Superior coating technology and roller materials such as M50 steels (0.8C–4.2Cr–4.3Mo–1V wt. %) and (1.0C–2.0Cr–0.5Mo–1.0Mn– 0.5Si wt. %) are well recognized in modern technology. The aim is to present all the external and internal parameters that affect the rolling system by taking into consideration the microstructure importance in identifying the service life of such rolling technique. The most dangerous defects are the cracks and wear under high loading contact and temperature formed during the rolling process.

    Finite elements method was used to simulate rolling and to calculate the extensive wear in order to use DOE to optimize several conditions from coating to load and temperature. The analysis involved here used the steel rollers with and without coatings, which include titanium nitride (TiN), zirconium nitride (ZrN), and tungsten carbide (WC) under different temperature and loading conditions. Results showed that cracks propagation were limited to extreme load when using coating technology. Design Expert optimization confirmed that TiN and WC coatings would enhance the lifetime of rollers and inhibit cracks initiations and extensive wear that could results in severe plastic deformation.


  • Keywords


    Roller Contact; Wear; Cracks under Extreme Load; Temperature; Design of Experiment (DOE).

  • References


      [1] D. Das, A.K. Dutta, K.K. Ray, Sub-zero treatments of AISI D2 steel: part II. Wear behavior, Mater. Sci. Eng. A 527 (2010) 2194–2206. https://doi.org/10.1016/j.msea.2009.10.071.

      [2] D. Das, A.K. Dutta, K.K. Ray, Correlation of microstructure with wear behavior of deep cryogenically treated AISI D2 steel, Wear 267 (2009) 1371–1380. https://doi.org/10.1016/j.wear.2008.12.051.

      [3] G. Nehme, Monzer Al Esber, Finite. Proc. ASME. 52026; Mechanics of Solids, Structures, and Fluids, ASME: https://doi.org/10.1115/IMECE2018-86308.

      [4] G.E. Jia-shan, Y.A.N. Xian-guo, G.U.O. Hong, et al., Stochastic characteristics analysis on mechanical properties of W6Mo5Cr4V2 high-speed steel, Heat. Treat. Met. 40 (1) (2015) 198–200.

      [5] G. Nehme, “The importance of variable speeds under extreme pressure loading in molybdenum disulfide greases using four-ball wear tests”. Tribology Transactions 56 (2013), (6), 977–985. https://doi.org/10.1080/10402004.2013.816812.

      [6] E., Anders, B., Akesson, & E., Kabo, Wheel/railrollingcontactfatigue – Probe,predict,prevent. Wear (2013). 2–12.

      [7] G. Guetard, Formation of oxide under rolling contact fatigue. Tribology International (2015). 262–266 https://doi.org/10.1016/j.triboint.2015.11.030.

      [8] G. Nehme (2017), “Tribological behavior and wear prediction of molybdenum disulfide grease lubricated rolling bearings under variable loads and speeds via experimental and statistical approach”. Wear 376, 876–884. https://doi.org/10.1016/j.wear.2017.01.007.

      [9] G. Nehme, “Tribological and thermal characteristics of reduced phosphorus plain ZDDP oil in the presence of PTFE/FeF3/TiF3 under optimized extreme loading condition and a break in period”, Wear 301 (1-2), pp.747-752 https://doi.org/10.1016/j.wear.2012.11.034.

      [10] A. Myśliński, (2014). Thermoelastic rolling contact problems for multilayer. Nonlinear Analysis: Real World Applications, 619–631 https://doi.org/10.1016/j.nonrwa.2014.09.022.

      [11] Y.-Z. Lee, & S.-D. Oh, Friction and wear of the rotary compressor vane–roller surfaces. Wear, 440–746.

      [12] M.Nagentrau, A. Z. Tobi, M. I. Kamdi1, & M. Sambu1, Microstructure Analysis of Tungsten Carbide Hardfacing on Carbon Steel Blade . materials science and engineering , IOP(2014).


 

View

Download

Article ID: 31925
 
DOI: 10.14419/ijet.v11i1.31925




Copyright © 2012-2015 Science Publishing Corporation Inc. All rights reserved.