Ultrasonic-Vibration-Superimposed Face Turning of Aluminium Matrix Composite Components for Enhancing Friction-Surface Preconditioning
Aluminium matrix composites (AMCs) represent an important group of high-performance materials. Due to their specific strength and a high thermal conductivity, these composites have been considered for the large-scale production of brake discs. However, preconditioning the friction surfaces is necess...
| Main Authors: | , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2024-02-01
|
| Series: | Journal of Manufacturing and Materials Processing |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2504-4494/8/1/32 |
| _version_ | 1797297824200654848 |
|---|---|
| author | Patrick Eiselt Sarah Johanna Hirsch Ismail Ozdemir Andreas Nestler Thomas Grund Andreas Schubert Thomas Lampke |
| author_facet | Patrick Eiselt Sarah Johanna Hirsch Ismail Ozdemir Andreas Nestler Thomas Grund Andreas Schubert Thomas Lampke |
| author_sort | Patrick Eiselt |
| collection | DOAJ |
| description | Aluminium matrix composites (AMCs) represent an important group of high-performance materials. Due to their specific strength and a high thermal conductivity, these composites have been considered for the large-scale production of brake discs. However, preconditioning the friction surfaces is necessary to avoid severe wear of both the brake discs and the brake linings. This can be achieved through controlled friction against commercially available brake-lining materials and the formation of transfer or reactive layers (tribosurfaces). Homogeneous tribosurfaces allow for nearly wear-free brake systems under moderate brake conditions. In this work, preconditioning was carried out with a pin-on-disc tester, aiming for the fast creation of homogeneously formed and stable tribosurfaces. The influence of surface microedges perpendicular to the direction of friction on the machined AMC surfaces on the build-up speed and homogeneity of the tribosurfaces was investigated. The microedges were generated using ultrasonic-vibration-superimposed face turning. Thereby, the vibration direction corresponded to the direction of the passive force. For research purposes, the distance of the microedges was changed by varying the cutting speed and feed. The experiments were carried out using AMC disc specimens with a reinforcement content of a 35% volume proportion of silicon carbide particles. Machining was realised with CVD-diamond-tipped indexable inserts. The evaluation of the generated surfaces before and after preconditioning was achieved using 3D laser scanning microscopy and scanning electron microscopy. It was demonstrated that ultrasonic-vibration-superimposed face turning effectively generated microedges on the AMC surfaces. The results show that larger distances between the microedges enhanced the formation of stable tribosurfaces. Thus, the tribosystem’s steady state was reached quickly. Therefore, the benefits of AMC-friction-surface microstructuring on the generation of tribosurfaces under laboratory conditions were proven. These findings contribute to the development of high-performance AMC brake systems. |
| first_indexed | 2024-03-07T22:25:57Z |
| format | Article |
| id | doaj.art-a4e281effb0a4652b7f5857041c52582 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-07T22:25:57Z |
| publishDate | 2024-02-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-a4e281effb0a4652b7f5857041c525822024-02-23T15:22:54ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942024-02-01813210.3390/jmmp8010032Ultrasonic-Vibration-Superimposed Face Turning of Aluminium Matrix Composite Components for Enhancing Friction-Surface PreconditioningPatrick Eiselt0Sarah Johanna Hirsch1Ismail Ozdemir2Andreas Nestler3Thomas Grund4Andreas Schubert5Thomas Lampke6Micromanufacturing Technology, Institute for Machine Tools and Production Processes, Chemnitz University of Technology, Reichenhainer Str. 70, 09126 Chemnitz, GermanyMaterials and Surface Engineering, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Str. 73, 09125 Chemnitz, GermanyMaterials and Surface Engineering, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Str. 73, 09125 Chemnitz, GermanyMicromanufacturing Technology, Institute for Machine Tools and Production Processes, Chemnitz University of Technology, Reichenhainer Str. 70, 09126 Chemnitz, GermanyMaterials and Surface Engineering, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Str. 73, 09125 Chemnitz, GermanyMicromanufacturing Technology, Institute for Machine Tools and Production Processes, Chemnitz University of Technology, Reichenhainer Str. 70, 09126 Chemnitz, GermanyMaterials and Surface Engineering, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Str. 73, 09125 Chemnitz, GermanyAluminium matrix composites (AMCs) represent an important group of high-performance materials. Due to their specific strength and a high thermal conductivity, these composites have been considered for the large-scale production of brake discs. However, preconditioning the friction surfaces is necessary to avoid severe wear of both the brake discs and the brake linings. This can be achieved through controlled friction against commercially available brake-lining materials and the formation of transfer or reactive layers (tribosurfaces). Homogeneous tribosurfaces allow for nearly wear-free brake systems under moderate brake conditions. In this work, preconditioning was carried out with a pin-on-disc tester, aiming for the fast creation of homogeneously formed and stable tribosurfaces. The influence of surface microedges perpendicular to the direction of friction on the machined AMC surfaces on the build-up speed and homogeneity of the tribosurfaces was investigated. The microedges were generated using ultrasonic-vibration-superimposed face turning. Thereby, the vibration direction corresponded to the direction of the passive force. For research purposes, the distance of the microedges was changed by varying the cutting speed and feed. The experiments were carried out using AMC disc specimens with a reinforcement content of a 35% volume proportion of silicon carbide particles. Machining was realised with CVD-diamond-tipped indexable inserts. The evaluation of the generated surfaces before and after preconditioning was achieved using 3D laser scanning microscopy and scanning electron microscopy. It was demonstrated that ultrasonic-vibration-superimposed face turning effectively generated microedges on the AMC surfaces. The results show that larger distances between the microedges enhanced the formation of stable tribosurfaces. Thus, the tribosystem’s steady state was reached quickly. Therefore, the benefits of AMC-friction-surface microstructuring on the generation of tribosurfaces under laboratory conditions were proven. These findings contribute to the development of high-performance AMC brake systems.https://www.mdpi.com/2504-4494/8/1/32aluminium matrix compositebrake discpin-on-disc testpreconditioningsurface integritytool geometry |
| spellingShingle | Patrick Eiselt Sarah Johanna Hirsch Ismail Ozdemir Andreas Nestler Thomas Grund Andreas Schubert Thomas Lampke Ultrasonic-Vibration-Superimposed Face Turning of Aluminium Matrix Composite Components for Enhancing Friction-Surface Preconditioning Journal of Manufacturing and Materials Processing aluminium matrix composite brake disc pin-on-disc test preconditioning surface integrity tool geometry |
| title | Ultrasonic-Vibration-Superimposed Face Turning of Aluminium Matrix Composite Components for Enhancing Friction-Surface Preconditioning |
| title_full | Ultrasonic-Vibration-Superimposed Face Turning of Aluminium Matrix Composite Components for Enhancing Friction-Surface Preconditioning |
| title_fullStr | Ultrasonic-Vibration-Superimposed Face Turning of Aluminium Matrix Composite Components for Enhancing Friction-Surface Preconditioning |
| title_full_unstemmed | Ultrasonic-Vibration-Superimposed Face Turning of Aluminium Matrix Composite Components for Enhancing Friction-Surface Preconditioning |
| title_short | Ultrasonic-Vibration-Superimposed Face Turning of Aluminium Matrix Composite Components for Enhancing Friction-Surface Preconditioning |
| title_sort | ultrasonic vibration superimposed face turning of aluminium matrix composite components for enhancing friction surface preconditioning |
| topic | aluminium matrix composite brake disc pin-on-disc test preconditioning surface integrity tool geometry |
| url | https://www.mdpi.com/2504-4494/8/1/32 |
| work_keys_str_mv | AT patrickeiselt ultrasonicvibrationsuperimposedfaceturningofaluminiummatrixcompositecomponentsforenhancingfrictionsurfacepreconditioning AT sarahjohannahirsch ultrasonicvibrationsuperimposedfaceturningofaluminiummatrixcompositecomponentsforenhancingfrictionsurfacepreconditioning AT ismailozdemir ultrasonicvibrationsuperimposedfaceturningofaluminiummatrixcompositecomponentsforenhancingfrictionsurfacepreconditioning AT andreasnestler ultrasonicvibrationsuperimposedfaceturningofaluminiummatrixcompositecomponentsforenhancingfrictionsurfacepreconditioning AT thomasgrund ultrasonicvibrationsuperimposedfaceturningofaluminiummatrixcompositecomponentsforenhancingfrictionsurfacepreconditioning AT andreasschubert ultrasonicvibrationsuperimposedfaceturningofaluminiummatrixcompositecomponentsforenhancingfrictionsurfacepreconditioning AT thomaslampke ultrasonicvibrationsuperimposedfaceturningofaluminiummatrixcompositecomponentsforenhancingfrictionsurfacepreconditioning |