Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Geometrically Derived Designs
Subtractive manufacturing processes are usually accompanied by the occurrence of tiny flakes and swarf, which later on cause severe wear and damage, especially in moving components such as rolling or sliding bearings, pistons, etc. However, up until now, such detrimental effects have hardly been inv...
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-09-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/6/5/100 |
| _version_ | 1827649699882991616 |
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| author | Patrick Brag Volker Piotter Klaus Plewa Alexander Klein Mirko Herzfeldt Sascha Umbach |
| author_facet | Patrick Brag Volker Piotter Klaus Plewa Alexander Klein Mirko Herzfeldt Sascha Umbach |
| author_sort | Patrick Brag |
| collection | DOAJ |
| description | Subtractive manufacturing processes are usually accompanied by the occurrence of tiny flakes and swarf, which later on cause severe wear and damage, especially in moving components such as rolling or sliding bearings, pistons, etc. However, up until now, such detrimental effects have hardly been investigated. One reason is the lack of a definition of a typical design of debris particle. Therefore, the main goal of the project described in this paper was to elaborate a draft that defines standardized test particles. It had to be evaluated whether test particles could be adequately reproduced and whether they would reveal significant damage potential. Taking into account future mass fabrication, Micro Powder Injection Molding (MicroPIM) was chosen as a production method. Five different 3D designs of geometrically defined test particles were developed. The maximum size of each design was 1167 mm in green state; however, all samples shrank in size during sintering. Specially tailored feedstocks containing 42CrMo4 steel powders were used and the related molding, debinding and sintering procedures were developed. All particle geometries and related mold inserts were developed using a commercial software routine for the layout of runner systems, gate locations and ejector positions. The damage potential of the test particles was evaluated based on trials using journal bearing and shift valve test rigs. Although only a moderate degree of damage potential could be ascertained up until now, it can be expected that the artificial swarf will enable standardized wear test procedures to be developed. |
| first_indexed | 2024-03-09T20:02:20Z |
| format | Article |
| id | doaj.art-df2ec364c83d43dbbef4e25a04cd3175 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-09T20:02:20Z |
| publishDate | 2022-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-df2ec364c83d43dbbef4e25a04cd31752023-11-24T00:42:13ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942022-09-016510010.3390/jmmp6050100Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Geometrically Derived DesignsPatrick Brag0Volker Piotter1Klaus Plewa2Alexander Klein3Mirko Herzfeldt4Sascha Umbach5Department of Ultraclean Technology and Micromanufacturing, Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Nobelstrasse 12, 70569 Stuttgart, GermanyInstitute for Applied Materials (IAM-WK), Karlsruhe Institute of Technology (KIT), Hermann-von Helmholtz-Platz 1, 76344 Eggenstein-Leopoldshafen, GermanyInstitute for Applied Materials (IAM-WK), Karlsruhe Institute of Technology (KIT), Hermann-von Helmholtz-Platz 1, 76344 Eggenstein-Leopoldshafen, GermanyInstitute for Applied Materials (IAM-WK), Karlsruhe Institute of Technology (KIT), Hermann-von Helmholtz-Platz 1, 76344 Eggenstein-Leopoldshafen, GermanyAuE Kassel GmbH, Heinrich-Hertz-Str. 52, 34123 Kassel, GermanyDepartment of Machine Elements and Engineering Design (iaf), University of Kassel, Mönchebergstr. 7, 34125 Kassel, GermanySubtractive manufacturing processes are usually accompanied by the occurrence of tiny flakes and swarf, which later on cause severe wear and damage, especially in moving components such as rolling or sliding bearings, pistons, etc. However, up until now, such detrimental effects have hardly been investigated. One reason is the lack of a definition of a typical design of debris particle. Therefore, the main goal of the project described in this paper was to elaborate a draft that defines standardized test particles. It had to be evaluated whether test particles could be adequately reproduced and whether they would reveal significant damage potential. Taking into account future mass fabrication, Micro Powder Injection Molding (MicroPIM) was chosen as a production method. Five different 3D designs of geometrically defined test particles were developed. The maximum size of each design was 1167 mm in green state; however, all samples shrank in size during sintering. Specially tailored feedstocks containing 42CrMo4 steel powders were used and the related molding, debinding and sintering procedures were developed. All particle geometries and related mold inserts were developed using a commercial software routine for the layout of runner systems, gate locations and ejector positions. The damage potential of the test particles was evaluated based on trials using journal bearing and shift valve test rigs. Although only a moderate degree of damage potential could be ascertained up until now, it can be expected that the artificial swarf will enable standardized wear test procedures to be developed.https://www.mdpi.com/2504-4494/6/5/100MicroPIMparticleshape characterizationdamagetribologybearing |
| spellingShingle | Patrick Brag Volker Piotter Klaus Plewa Alexander Klein Mirko Herzfeldt Sascha Umbach Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Geometrically Derived Designs Journal of Manufacturing and Materials Processing MicroPIM particle shape characterization damage tribology bearing |
| title | Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Geometrically Derived Designs |
| title_full | Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Geometrically Derived Designs |
| title_fullStr | Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Geometrically Derived Designs |
| title_full_unstemmed | Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Geometrically Derived Designs |
| title_short | Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Geometrically Derived Designs |
| title_sort | development and production of artificial test swarf to examine wear behavior of running engine components geometrically derived designs |
| topic | MicroPIM particle shape characterization damage tribology bearing |
| url | https://www.mdpi.com/2504-4494/6/5/100 |
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