Wear Characterization of Direct Steel–H20 Specimens Produced by Additive Manufacturing Techniques
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Quality assurance and health monitoring of rotating and sliding components are very significant in order to prevent the catastrophic failures. One of the inputs for this process is wear rate of the materials at different working conditions. An attempt has been made to use additive manufacturing technology for aerospace components since this process is bring down manufacturing time, cost effective and flexible for intricate shapes and contours. Before the actual manufacturing of the components, test specimens were manufactured using additive manufacturing route (Rapid prototype technique-RP) for wear characterizations study. Taguchi’s orthogonal array was used for wear test study to find out the parametric effects with less number of experiments. The loads, speeds and track diameters were varied for wear test study in RP produced test specimens. The most dominant parameter contributing to wear was found to be load and less significant was speed. The load under the combination of 15 N-200 rpm-35 mm track diameter gave volume loss of 0.3262 mm3 and speed gave volume loss of 0.05978 mm3 with the combination of 10 N-200 rpm-30 mm track diameter. The track diameter (which affects the sliding distance) has negligible effect on the wear, this may be because after a certain point the surfaces become smooth and also the wear particles from the pin deposit on the disc, and hence, the roughness is reduced and causes negligible wear further on. The load was very dominant because it increases contact area of surfaces and very high stresses at peaks and valleys of the surface finish are resulted in higher order of wear rates.
KeywordsAdditive manufacturing Taguchi’s orthogonal array Wear rate and wear co-efficient
Authors express their deep sense of gratitude to Mr. V Nagarajan, Scientist-G and Head, and NTAF for his approval of this study and his guidance throughout this work. Authors express their gratitude to Dr. Mohammed Haneef, Principal Ghousia College of Engineering (GCE) for his approval and encouragement. Authors express their thanks to Dr. C K Srinivas, Scientist-E, CMTI-Tumkur road, Bangalore for manufacturing of RP test specimens and interactions during the test. Authors are indebted to Mr. Md Tajuddin, the Technical Officer-E2 for his encouragement and support, and to Mr. Rajeev.G Senior Principal Scientist, Mr. Praveen Jinde Senior Scientist for their valuable suggestions and to Mr. Baburajan Thekkan for his support in photography. Our sincere thanks to Dr. C. Anandan, Chief Scientist and Head, Surface Engineering Department (SED), Dr. S.T. Aruna, Dr. J.N. Balaraju Scientists SED, NAL for their support. Authors are indebted to Mr. Muniprakash, Lab in charge, Wear testing Laboratory, SED for his constant guidance and support in carrying out the wear analysis. Authors express their thanks to Dr. Syed Babajan, HOD Mathematics, GCE for his encouragement and support throughout, and the department of mechanical engineering GCE for their motivation and guidance.
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