When a train passes continuously over a section of the track, the track gradually moves away from the intended vertical and horizontal alignment with time and repeated use. Regular maintenance on the track, such as leveling, lifting, lining, and tamping, is necessary to maintain the optimal geometry of the track. Ballast is leveled and squeezed by hydraulic rams in tamping machines. The tamping is a process of ballast packing under railway tracks. In current system a set of tungsten carbide chips are attached either by welding or by coating on tamping tool tip made of EN24 steels. These tungsten carbide chips directly come in contact with the ballasts. After few tamping works, gradually these chips torn out and need to be replaced after certain period. Tungsten carbide is a costly material, therefore this research deals with replacement of tungsten carbide with silicon carbide (easily available cheaper) coating used for tamping tools tip. The study consists of microstructural

Mishra, Mamta, Pandey, Manas, Singh, Shruti, Srivastava, Sanjay, Kumar, Jitendra

Automobile Wheel Alignment and Wheel Balancing, Second Edition

R-59106/12/2025

With over thirty years of hands-on experience in designing, developing, and patenting products in the wheel alignment industry, the author brings invaluable expertise to the second edition of this essential guide. Perfectly suited for mechanics, technicians, engineers, and even vehicle owners, this book goes beyond the basics to offer a comprehensive understanding of wheel alignment and its critical role in vehicle performance. The importance of proper wheel alignment and balancing cannot be overstated—incorrect alignment leads to premature tire wear and reduced safety. This updated edition provides in-depth coverage on wheel alignment techniques for light vehicles, commercial trucks, and trailers, with clear illustrations to help readers recognize and address various types of tire wear. The book explores everything from the mechanics of alignment to the impact of air pressure and tire rotation on longevity. With the growing need for vehicle maintenance, this guide empowers

R., Mananathan

Wear Protection for Electrified Transmissions Using e-Fluids without Active Sulfur

04-18-03-0015

05/08/2025

In electrified drivetrains, lubricants are commonly in contact with the motor and other electrical components as well as the gears and bearings. Copper, present in these electrical components, is susceptible to corrosion by fluids containing active sulfur, which can lead to catastrophic failure of the unit. Lubricating fluids for electric vehicles (referred to as e-fluids) must not cause corrosion and must maintain high performance while having suitable electrical conductivity, material compatibility, and heat transfer properties. We describe a new formulation without active sulfur that has recently entered the market, which can protect against copper corrosion. We show that this e-fluid can provide suitable wear protection under field trial conditions, and that the e-fluid provides improved wear protection in bearing (FE-8) tests compared to a traditional extreme pressure axle fluid (API GL-4). Surface analysis (X-ray photoelectron spectroscopy) measurements of the component surfaces

Hopper, Elizabeth R., Williams, Megan S., Gahagan, Michael

Development of NOx Storage Catalyst and Investigation of Deterioration Mechanism for Small Powertrains

2024-32-0097

04/18/2025

In response to the evolving landscape of exhaust gas regulations for small powertrains, reducing NOx emission is increasingly important. This study deeply investigated the feasibility of a NOx storage catalyst (NSC) containing cerium oxide (CeO2) and barium oxide (BaO) for reducing NOx emission. The key functions, NOx storage and reduction performances were evaluated, and deterioration mechanisms were explored through performance evaluations and physical property analyses. The findings revealed a strong correlation between the size of CeO2 crystals and NOx storage performance at low temperature, such as those encountered during city driving conditions. Conversely, at high temperature, such as those during highway driving conditions, NOx storage performance correlated well with sulfur deposition, suggesting that the formation of barium sulfate (BaSO4) contributes to the deactivation. This experiment also showed a strong correlation between NOx reduction performance and BaSO4 formation

Nakano, Fumiya, Koito, Yusuke

Investigation on the Wear Regime of Plastic Gears Sliding Against Metal Gears

2024-32-0099

04/18/2025

The use of plastic gears has expanded due to their lightweight properties, low noise emission, and cost-effective manufacturing. For instance, in the transportation equipment industry, some metal gears are being replaced with plastic gears. To achieve further size and weight reduction, gears must be able to withstand higher loads without damage. Gears have various modes of damage. Since there are different types of wear, each with different factors, it is important to identify the factors and take appropriate countermeasures. In gear meshing, there are many factors that affect wear, so restricted-factor tests are required to confirm the effectiveness of countermeasures. The purpose of this study is to elucidate the wear regime in high-load gear meshing and then to establish a simplified evaluation method replicating the meshing of gears for wear resistance focusing on the relative sliding between the two surfaces of metal and plastic. In the evaluation, changes in wear morphology over

Yamamoto, Jimpei, Suzuki, Takaharu, Ako, Natsuki, Iwasaki, Shinya, Kurita, Hirotaka

Compatibility between Stability and Curving Ability of Railway Vehicles Using Conventional and Unconventional Bogie Frame Models

02-18-03-0014

04/09/2025

This article analyses the fundamental curving mechanics in the context of conditions of perfect steering off-flanging and on-flanging. Then conventional, radial, and asymmetric suspension bogie frame models are presented, and expressions of overall bending stiffness kb and overall shear stiffness ks of each model are derived to formulate the uniform equations of motion on a tangent and circular track. A 4 degree of freedom steady-state curving model is formulated, and performance indices such as stability, curving, and several parameters including angle of attack, tread wear index, and off-flanging performance are investigated for different bogie frame configurations. The compatibility between stability and curving is analyzed concerning those configurations and compared. The critical parameters influencing hunting stability and curving ability are evaluated, and a trade-off between them is analyzed. For the verification, the damped natural frequencies and mean square acceleration

Sharma, Rakesh Chandmal, Sharma, Sunil Kumar, Palli, Srihari, Rallabandi, Sivasankara Raju, Sharma, Neeraj

Fiber Computer Allows Apparel to Run Apps and Understand the Wearer

TBMG-52877

04/01/2025

What if the clothes you wear could care for your health?

Spectral Estimation to Quantify Road/Track Surface Degradation

2025-01-8252

04/01/2025

Track testing methods are utilized in the automotive industry for emissions and fuel economy certification. These track tests are performed on smooth road surfaces which deteriorate over time due to wear and weather effects, hence warranting regular track repaves. The study focuses on the impact of repaving on track quality and surface degradation due to weather effects. 1D surface profiles and 2D surface images at different spatial frequencies were measured at different times over a span of two years using various devices to study the repave and degradation effects. Data from coastdown tests was also collected over a span of two years and is used to demonstrate the impact of track degradation and repaving on road load characterization parameters that are used for vehicle certification tests. Kernel density estimation and non-parametric spectral estimation methods are used to visualize the characteristic features of the track at different times. In the pre-processing stage, outliers

Singh, Yuvraj, Jayakumar, Adithya, Rizzoni, Giorgio

Advanced Aftertreatment System Meeting Future HD CNVII Legislation II

2025-01-8478

04/01/2025

With the increasing clarity of the CNVII emission legislation, it is foreseeable that CNVII will further tighten the emission limits of major pollutants such as Nitrogen Oxide (NOx), Nitrous Oxide (N2O) and Particulate Number (PN). Together with the implementation of stage IV fuel consumption legislation in July 2025, which requires engine fuel consumption reduction or thermal efficiency improvement, it will lead to further deterioration of its pollutant emissions and reduction of exhaust temperature, posing greater challenges to the After-Treatment System (ATS) in terms of NOx removal, particularly during engine cold start and N2O formation suppression. This study is an extension of our earlier investigation [1], and a novel copper-based corrugated SCR (Full Body-CuSCR, FB-CuSCR) technology was successfully applied. The results based on a modified CNVI medium duty engine indicated excellent dynamic response of the FB-CuSCR technology over cordierite which helped to improve the

Wang, Yan, Fu, Guangxia, Chen, Shuyue, Aberg, Andreas, Jiang, Shuiyan, Zhang, Jun

A Suspension Model Based on Semi-Recursive Method and Data-Driven Compliance Characteristics

2025-01-8282

04/01/2025

Many methods have been proposed to accurately compute a vehicle’s dynamic response in real-time. The semi-recursive method, which models using relative coordinates rather than dependent coordinates, has been proven to be real-time capable and sufficiently accurate for kinematics. However, not only kinematics but also the compliance characteristics of the suspension significantly impact a vehicle’s dynamic response. These compliance characteristics are mainly caused by bushings, which are installed at joints to reduce vibration and wear. As a result, using relative or joint coordinates fails to account for the effects of bushings, leading to a lack of compliance characteristics in suspension and vehicle models developed with the semi-recursive method. In this research, we propose a data-driven approach to model the compliance characteristics of a double wishbone suspension using the semi-recursive method. First, we create a kinematic double wishbone suspension model using both the semi

Zhang, Hanwen, Duan, Yupeng, Zhang, Yunqing, Wu, Jinglai

Three-Body Abrasive Wear Surface Characterization of Military Diesel Engine Piston Rings and Cylinder Bores

2025-01-8346

04/01/2025

Two 50-hr engine dynamometer tests were conducted on 12-cylinder diesel military engines with differing piston ring sets. Engine A exhibited more than double the oil consumption over engine B. An investigation was conducted to explain why the oil consumption differed by employing several posttest analytical techniques including cylinder bore geometry measurements, surface metrology, wear characterization, and chemical analysis on the piston rings and cylinder wall coatings. The 3D colormaps of cylinder bore deformation showed uneven volumetric deformation through the piston stroke instead of 2D plane deformation. It was found that the primary reason of high oil consumption was direct loss of sealing between the piston, piston ring and cylinder bore due to predominately abrasive wear, three-body abrasive wear and bore polishing. Furthermore, the compromised sealing of the combustion chamber led to blow-by. Carbon deposits, corrosive byproducts, surface abrasives, loss of desired surface

Thrush, Steven, Chen, Aijie, Foley, Michael, Sebeck, Katherine, Boufakhreddine, Ziad

WITHDRAWAL NOTICE

2025-01-8278.01

04/01/2025

Combine HD Map Information to Enhance Road Topology Reasoning by Offline Supervised Training and on-Line Ensemble Learning

2025-01-8021

04/01/2025

Topology reasoning plays a crucial role in understanding complex driving scenarios and facilitating downstream planning, yet the process of perception is inevitably affected by weather, traffic obstacles and worn lane markings on road surface. Combine pre-produced High-definition maps (HDMaps), and other type of map information to the perception network can effectively enhance perception robustness, but this on-line fused information often requires a real-time connection to website servers. We are exploring the possibility to compress the information of offline maps into a network model and integrate it with the existing perception model. We designed a topology prediction module based on graph attention neural network and an information fusion module based on ensemble learning. The module, which was pre-trained on offline high-precision map data, when used online, inputs the structured road element information output by the existing perception module to output the road topology, and

Kuang, Quanyu, Rui, Zhang, Zhang, Song, Yixuan, Gao

Comparative Evaluation of Untextured and Textured Surfaces for Wear, Wettability and Friction Characteristics

2025-01-8331

04/01/2025

Reduction of frictional losses by changing the surface roughness in the form of surface textures has been reported as an effective method in reducing friction in the boundary regime of lubrication. Laser-based micro texturing has been mostly used to create these texture patterns and it is reported that it can reduce the frictional resistance by ~20-50%. However, the use of laser-based techniques for texture preparation led to residual thermal stress and micro cracks on the surfaces. Hence, the current study emphasizes using conventional micromachining on piston material (Al alloy Al4032) to overcome this limitation. Three variations of semi-hemispherical geometries were prepared on the surface of Al alloy with dimple depths of 15, 20 and 40 μm and dimple diameters of 90, 120 and 240 μm. Prepared textured surfaces with untextured surfaces are compared in terms of wear, wettability, and friction characteristics based on Stribeck curve behaviors. Results of this investigation demonstrated

Sahu, Vikas Kumar, Shukla, Pravesh Chandra, Gangopadhyay, Soumya

Tire Wear Life Prediction Using Machine Learning Technique

2025-01-8757

04/01/2025

As global warming and environmental problems are becoming more serious, tires are required to achieve a high level of performance trade-offs, such as low rolling resistance, wet braking performance, driving stability, and ride comfort, while minimizing wear, noise, and weight. However, predicting tire wear life, which is influenced by both vehicle and tire characteristics, is technically challenging so practical prediction method has long been awaited. Therefore, we propose an experimental-based tire wear life prediction method using measured tire characteristics and the wear volume formula of polymer materials. This method achieves practical accuracy for use in the early stages of vehicle development without the need for time-consuming and costly real vehicle tests. However, the need for improved quietness and compliance with dust regulations due to vehicle electrification requires more accuracy, leading to an increase in cases requiring judgment through real vehicle tests. To address

Ando, Takashi

Characterization and Aluminum Recovery from Chemical Milling Sludge in Aerospace Industry

2025-01-5016

03/21/2025

The chemical milling process used in the aerospace industry generates substantial metallic residue in the etching bath, referred to as chemical milling sludge (CMS). The direct disposal of CMS into the environment leads to ecological deterioration and economic losses. This study focused on the recovery of aluminum from the aerospace industry CMS, aiming to mitigate environmental harm and enhance resource efficiency. The energy-dispersive X-ray (EDX) analysis revealed that the aluminum content in extracted CMS increased significantly to 95.86%, compared to 28.98% in non-extracted sludge. The XRD analysis of the CMS extracted samples also revealed the presence of increased Al2O3. The surface morphology study suggested the irregularly shaped particles with large chunks, and fine granules were observed on CMS. The yield of Al2O3 was observed to be 35.9% (wt) prior to the calcination process followed by 12.1% (wt) after calcination. The phytotoxicity study indicated that the CMS inhibited

Prasad, Jag, Sonwani, Ravi Kumar

Experimental Investigation of Minimum Quantity Lubrication Strategy during Machining of Ti6Al4V Alloy

05-18-03-0022

03/03/2025

The experimental investigation analyzed the performance of three machining conditions: dry machining, cryogenic machining, and cryogenic machining with minimum quantity lubrication (MQL) on tool wear, cutting forces, material removal rate, and microhardness. The outcome of this study presents valuable knowledge regarding optimizing conditions of turning operations for Ti6Al4V and understanding the machinability under cryogenic-based cooling strategies. Based on the experimentation, cryogenic machining with MQL is the most beneficial approach, as it reduces cutting force and flank wear with a required material removal rate. This strategy significantly enhances the machining efficiency and quality of Ti6Al4V under variable feed rates (0.05 mm/rev, 0.1 mm/rev, 0.15 mm/rev, 0.2 mm/rev, 0.25 mm/rev) where cutting velocity (120 m/min) and depth of cut (1 mm) are constant. The effects of the main cutting force, feed force, thrust force, material removal mechanism, flank wear, and

Misra, Sutanu, Kumar, Yogesh, Paul, Goutam, Forouhandeh, Fariborz

Intelligent Pavement Maintenance Optimization Technique for Automatic Driving

2025-01-7153

02/21/2025

Compared to manual driving, autonomous driving is more prone to the rapid development and deterioration of pavement distress due to the concentration of driving paths. Therefore, a reasonable and efficient maintenance strategy is required. To address the challenges posed by the numerous constraints and objectives in the maintenance strategy generation process, this paper proposes a multi-objective optimization-based method for generating pavement maintenance strategies. The approach leverages advanced pavement distress detection technologies to establish an initial maintenance program, incorporating a range of constraints and maintenance objectives, such as cost-efficiency, performance longevity, and environmental impact. The method applies a genetic algorithm (GA) to iteratively refine and optimize the maintenance strategy, ensuring that the solutions align with both immediate and long-term performance goals for autonomous vehicle operations. A case study utilizing real-world road

Yang, Liwenyun, Li, Wei, Chen, Leilei

Preparation and Evaluation of Lubricating Properties of Neem Seed Oil under the Influence of an Anti-Wear Additive as Sustainable Alternative to Commercial Engine Oil

2025-28-0116

02/07/2025

The search for environmentally friendly and sustainable lubricants for automotive and industrial applications has led to extensive research on bio lubricants as a viable alternative to conventional engine oils and mineral oils. The biodegradable and ecofriendly nature of vegetable oil, makes it an excellent replacement for the depleting mineral oils. Still, a good number of modifications must be brought in, to overcome the drawbacks of vegetable oils. In this work, the preparation and evaluation of lubricating properties like tribological, rheological, thermal etc. of Neem seed oil (NSO) with and without additives were carried out and effectively compared with the lubricating properties of synthetic oil, Polyalphaolefin 6 (PAO 6) and with a commercial engine oil, SAE20W40. The copper oxide nanoparticles were dispersed in neem seed oil as additive in various proportions (0.1, 0.2, 0.3 and 0.4 wt.%) to enhance the tribological properties. The tribological analysis were carried out to

Menon, Krishnaprasad S, R, Ambigai

Study of Mechanical, Barrier and Tribological Behaviour of Jute & Glass Fiber Epoxy Hybrid Polymer

2025-28-0031

02/07/2025

The incorporation of natural available material into synthetic materials to form a fiber within a single polymer matrix has been ignited since environment concerns become crucial nowadays. Composite materials embedded with two or more types of fibers makes a composite as hybrid. The study of hybridization of natural and synthetic fibers brings out superior mechanical and tribological properties. In our present studies, fabrication of jute & glass fiber reinforced epoxy-based polymer hybrid composites were carried out using resin infusion technique. For comparing the various properties, the composite made of pure jute fiber i.e 100% jute, pure glass fiber i.e 100% glass, the hybrid composite containing 75% jute and 25% glass fiber, 50% jute and 50% glass fiber, and 25% jute and 75% glass fiber were made and its functional behaviors were studied. The results revealed the hybrid composite containing 25% jute and 75% glass fiber possessed maximum tensile strength of 292±5.8 MPa, flexural

J, Chandradass, T, Thirugnanasambandham, M, Amutha Surabi, P, Baskara Sethupathi, Rajendran, R, Murugadoss, Palanivendhan

Enhancing Disc Brake Performance: Investigating Squeal Noise, Wear, and the Application of Functionally Graded Materials in Brake Rotors

2025-28-0162

02/07/2025

Disc brakes play a vital role in automotive braking systems, offering a dependable and effective means of decelerating or halting a vehicle. The disc brake assembly functions by converting the vehicle's kinetic energy into thermal energy through friction. The performances of the brake assembly and user experience are significantly impacted by squeal noise and wear behaviour. This paper delves into the fundamental mechanisms behind squeal noise and assesses the wear performance of the disc brake assembly. Functionally graded materials (FGMs) are an innovative type of composite material, characterized by gradual variations in composition and structure throughout their volume, leading to changes in properties such as mechanical strength, thermal conductivity, and corrosion resistance. FGMs have emerged as a groundbreaking solution in the design and manufacturing of brake rotors, addressing significant challenges related to thermal stress, wear resistance, and overall performance. These

C V, Prasshanth, S, Gurumoorthy, Bhaskara Rao, Lokavarapu, S, Sridhar, S, Badri Narayanan, Kumar, Ajay, Biswas, Sayan

Evaluation on Mechanical and Metallurgical Properties of Wire Arc Additive Manufactured ER 2209 Duplex Stainless Steel for Automotive and Marine Applications

2025-28-0108

02/07/2025

The advancement of wire-arc additive manufacturing (WAAM) presents a significant opportunity to revolutionize the production of automotive components through the fabrication of complex, high-performance structures. This study specifically investigates the metallurgical, mechanical, and corrosion properties of WAAM-fabricated ER 2209 duplex stainless steel structures, known for their superior mechanical properties, excellent corrosion resistance, and favorable tribological behavior. The research aims to optimize WAAM process parameters to achieve high-quality deposition of ER 2209, ensuring structural integrity and performance suitable for both marine and various automotive applications. Microstructural analysis of the produced samples revealed the alloy’s dual-phase nature, with roughly equal amounts of ferrite and austenite phases uniformly mixed across the layers of deposition. This balanced microstructure contributes to the alloy’s excellent mechanical properties. Yield strength

A, Aravind, S, Jerome, Kumar, Ravi

New AR Glasses Use AI-Enhanced Holographic Imaging

TBMG-52468

02/01/2025

Researchers in the emerging field of spatial computing have developed a prototype augmented reality headset that uses holographic imaging to overlay full-color, 3D moving images on the lenses of what would appear to be an ordinary pair of glasses. Unlike the bulky headsets of present-day augmented reality systems, the new approach delivers a visually satisfying 3D viewing experience in a compact, comfortable, and attractive form factor suitable for all-day wear.

Tribological Behavior and Mechanical Characteristics of AL6061 Alloy with AL2O3 and Multi-Walled Carbon Nanotubes Reinforcement Nanoparticles (Hybrid Nano Carbon Tube)

2024-01-5244

01/28/2025

The objective of this study is to optimize and characterize an Al6061/Al2O3/MWCNT nanocomposite produced through stir casting. The investigation focused on various concentrations of 2%, 3%, and 5% by weight of Al2O3/MWCNT nanoparticles, with an average Al2O3 particle size of 40 nm. The Al6061 matrix exhibited a uniform distribution of these nanoparticles. Microstructural analysis of the nanocomposite was conducted using scanning electron microscopy. The study examined the tribological properties, including wear and coefficient of friction, as well as the tensile strength and hardness of the Al6061/Al2O3/MWCNT nanocomposites. The results indicated a significant enhancement in mechanical properties, with the ultimate tensile strength (UTS) increasing from 122 MPa to 157 MPa, and the yield tensile strength (YTS) rising from 52 MPa to 76 MPa. At a 5% concentration of Al2O3/MWCNT, the hardness test showed an increase from 28 BHN to 55 BHN. The improvement ratios for 2%, 3%, and 5

Haridass, R., Subramani, N., Viknesh, S., Mathan Kumar, M., Mownitharan, M. S.

Fabrication and Characterization of Silicon Carbide and Aluminum Oxide Reinforced 6061-T6 Aluminum Matrix Composites

2024-01-5262

01/28/2025

Aluminum Matrix Composites (AMCs) are gaining traction in aerospace, automotive, and marine industries due to their superior mechanical properties. By integrating hard ceramic particles such as silicon carbide (SiC) and aluminum oxide (Al₂O₃) into aluminum matrices, these composites exhibit enhanced wear resistance and strength-to-weight ratios. This study explores the fabrication and characterization of 6061-T6 aluminum alloy matrix composites, reinforced individually with SiC and Al₂O₃ particles through the squeeze casting technique. The research includes a comprehensive analysis of microstructures and mechanical properties, focusing on compressive strength, Brinell hardness, and tribological behavior. Findings reveal that SiC and Al₂O₃ reinforcements boost compressive strength by up to 27% and 47%, respectively, and increase hardness by up to 29% and 20%, respectively, compared to unreinforced aluminum.

Thirumavalavan, R., Santhosh, V., Sugunarani, S., Regupathi, S., Sundaravignesh, S.

Wear Characteristics of Hybrid Aluminium 8011 Matrix Composites Reinforced with Silicon Carbide Particles and Titanium Diboride

2024-01-5259

01/28/2025

This study investigates the wear and hardness properties of AA8011 hybrid metal matrix composites (MMCs) reinforced with silicon carbide (SiCp) and titanium diboride (TiB₂), addressing a significant gap in the existing literature regarding the optimization of reinforcement levels in AA8011. The goal is to enhance the material’s wear resistance and hardness for high-performance applications. While AA8011 is known for its excellent mechanical properties and corrosion resistance, limited research has focused on optimizing both wear behavior and surface hardness through the combination of TiB₂ and SiCp reinforcements. Using the pin-on-disk method, this study explores various compositions, showing that the composite containing 2% TiB₂ and 1% SiCp exhibited the best wear resistance, with a 25% improvement over the base alloy, and an increase in hardness by more than 115%. Developing AA8011-based composites with enhanced durability and hardness for use in demanding environments such as

Thirumavalavan, R., Mugendiran, V., Santhosh, V., Manoj, M., Sundaravignesh, S.

Review of Mechanical Properties of Basalt Fibre-Reinforced Polymer Composites for Automotive Applications

2024-01-5246

01/28/2025

The industrial world focuses on developing eco-friendly, natural fibres such as reinforcing lightweight, inexpensive compounds in modern days. Basalt, a rare phenomenon, derives its origins from molten volcanic rocks, which is essential for their cost-effectiveness and offers different glass fibre properties. High mechanical strength, outstanding wear resistance, and exceptional durability in a variety of environmental conditions are all displayed by basalt fibres. These fibres are ideal for reinforcing polymer composites because of their mechanical properties at high temperatures. Furthermore, basalt fibres are appropriate for long-term applications because they resist corrosion and degradation while maintaining structural integrity over time. This article provides a brief overview of basalt fibres as a substitute for glass fibres and as composite materials. Additionally, attempts are being made to draw attention to the expanding field of basalt fibre research. In the review, studies

Chidambaranathan, Bibin, Raghavan, Sheeja, Soundararajan, Gopinath, Arunkumar, S., Ashok Kumar, R., Rajesh, K.

Influence of High-Temperature Annealing Parameters on Wear and Friction Mechanisms in Polypropylene Carbon Fiber Composites

2025-01-5000

01/15/2025

Fused deposition modeling (FDM) is a rapidly growing additive manufacturing method employed for printing fiber-reinforced polymer composites. Nonetheless, the performance of printed parts is often constrained by inherent defects. This study investigates how the varying annealing parameter affects the tribological properties of FDM-produced polypropylene carbon fiber composites. The composite pin specimens were created in a standard size of 35 mm height and 12 mm diameter, based on the specifications of the tribometer pin holder. The impact of high-temperature annealing process parameters are explored, specifically annealing temperature and duration, while maintaining a fixed cooling rate. Two set of printed samples were taken for post-annealing at temperature of 85°C for 60 and 90 min, respectively. The tribological properties were evaluated using a dry pin-on-disc setup and examined both pre- (as-built) and post-annealing at temperature of 85°C for 60 and 90 min printed samples

Nallasivam, J.D., Sundararaj, S., Kandavalli, Sumanth Ratna, Pradab, R.

Self-Learning Method for Shift Hub Position in a Double-Input Shaft Hybrid Gearbox Using Linear Active Disturbance Rejection Control and Nutcracker Optimization Algorithm

02-18-01-0004

01/07/2025

Due to manufacturing, assembly, and actuator wear, slight deviations between the actual and logical positions of various gears in a transmission system may accumulate, affecting shift quality, reducing shift accuracy, and causing operational anomalies. To address this issue, a self-learning method based on the top dead center (TDC) and lower dead center (LDC) was proposed, specifically for the hybrid gearbox of an electric torque converter (eTC) module and a double-input shaft gearbox (DIG). The linear active disturbance rejection control (LADRC) method was employed to estimate and manage the nonlinear resistance during the motion of the shifting motor. To simplify the controller parameter problem, the nutcracker optimization algorithm (NOA) was utilized to tune the LADRC parameters, thereby optimizing the position self-learning process. The control strategy was modeled using MATLAB/SIMULINK, and its reasonableness was verified through hardware-in-the-loop (HIL) tests. Based on these

Hong, Hanchi, Quan, Kangning, d’Apolito, Luigi, Xu, Li

Composite Brake Pads Reinforcement with Natural Fiber: A Comparative Analysis of Mechanical and Thermal Properties

2024-01-5112

12/30/2024

This work pioneers the development of eco-friendly brake pads using coconut fiber and sawdust as reinforcement materials, combined with abrasives and friction modifiers. The innovation lies in the utilization of these natural fibers, which are not only cost-effective and abundantly available but also contribute to the sustainability of brake pad manufacturing. The study aims to explore the feasibility and performance of these organic fibers in brake pad applications. Coconut fiber and sawdust were chosen for their unique properties, such as high strength-to-weight ratio and thermal stability, making them ideal candidates for enhancing brake pad performance. The inclusion of abrasives and friction modifiers further optimizes the braking efficiency and durability of the pads. Comprehensive testing was conducted, including hardness, compression, wear (using a pin-on-disc apparatus), and thermogravimetric analysis (TGA), to thoroughly evaluate the mechanical properties and thermal

Ajay Devan, V., Gunasekar, N., Ravikumar, K., Balaguru, B. A., Deepak, S.

Tribological Investigation of Wear Behavior and Mechanisms in B390 and Sr-Modified B390 Aluminum Alloys under Dry and Wet Conditions

2024-01-5109

12/12/2024

Wear-resistant, die-cast B390 aluminum represents a relevant material frequently used in the automotive industry. The wear and its relation to the microstructure along with different alloying additives is studied with efforts toward improved performance. Alloying by Sr allows for a lower Fe content helps in mitigating iron needling. This paper addresses wear performance of B390 and Sr-modified B390 alloys, tested against pearlitic cast iron, used for manufacture of piston rings. The wear tests were designed by using an ASTM G99 standardized pin-on-disc protocol at “wet” (motor oil) and “dry” conditions and were performed using a UMT (Bruker) benchtop tester. The polished cross-sections and friction surfaces were studied to identify the microstructural differences and dominating wear mechanisms. Interestingly, the stronger and harder Sr-modified B390 alloys wear more at dry conditions compared to the standard die-cast B390 alloy. This was ascribed to a change in wear mechanisms of the

Kancharla, Sai Krishna, Jogineedi, Rohit, Singireddy, Vishal Reddy, Mirzababaei, Saereh, Dierks, Mike, Filip, Peter

Machining Studies on AISI 4140 Steel as Automotive Axle and Drive Shafts in Automobile via Numerical Simulation

2024-01-5232

12/10/2024

This study focuses on machining automobile parts such as drive shafts and axles made of low alloy steel AISI 4140. The influence of cutting inserts geometrical parameters, viz., relief angle (RIA), rake angle (RAA), and nose radius (NA) are studied by designing experiments using Taguchi’s methodology. Numerical simulation is conducted using DEFORM-2D; a suitable L9 orthogonal array (OA) is considered for this work for varying combinations of inputs, and the resultant cutting force, maximum principal stress, and tool life are determined. Adopting a signal-to-noise (S/N) ratio minimizes the outputs for better machining conditions and achieves high-quality components with precision, tolerance, and accuracy. The ideal conditions obtained from the S/N ratio are RAA of 6°, RIA of 3°, and NR of 0.6 mm. Analysis of variance presents that the NR influences the resultant cutting force, wear depth, and work piece damage 73.51%, RAA following by 23.99%, and RIA by 2.03% achieved with a R2 value of

Senthilkumar, N.

Wear Behaviour of Banana Fiber Mat/Rice Husk/ Multi-Walled Carbon Nanotube Hybrid Polymer Matrix Composites Using Taguchi Technique

2024-01-5233

12/10/2024

The main aim of this experimental study is to investigate the wear properties of a hybrid composite material composed of a banana fibre mat, rice husk powder, and an epoxy matrix polymer filled with multi-walled carbon nanotubes (MWCNT). This research emphasizes the assessment of the composite's characteristics and behaviour. The adjustment of various ratios of fibres and fillers within polymer matrix hybrid composites finds application in numerous engineering fields, particularly in the automotive and aerospace industries. The experimental evaluation is conducted using a pin-on-disk wear tester to analyze the specimens in terms of pin wear, friction coefficient, and friction force. Experimental trials were conducted using L9 orthogonal arrays following the Taguchi design of experiments, and the output response was optimized by implementing a hybrid approach of Gray relational analysis. It depends upon the suitability of the wear performance needs of the application to obtain the

Senthilkumar, N., Ramu, S., Yuvaperiyasamy, M., Sabari, K.

Polyethylene Sheet Dispersion and Optical Constant Changes Due to Electron Beam Irradiation

2024-01-5234

12/10/2024

Radiation has garnered the most attention in the research that has been conducted on polyethylene sheets. According to the calculations, there were 145892.35 kGy in total radiation doses administered. An ultraviolet visible spectrophotometer was used to examine the impact that electron beam irradiation had on the optical constants. Two of the most crucial variables taken into account when calculating the optical constants and the absorption coefficient are the reflectance and transmittance of polyurethane sheets. Reduced light transmission through the sheet achieves these characteristics, which are related to the transmittance and reflectance of the Fresnel interface. Cross linking makes it more challenging for the polyurethane molecular chains to become fixed. Both the refractive index and the dispersion properties have been altered as a direct result of this. Despite the fact that the doses of electron irradiation were getting lower, it eventually rose to 105 kGy. Contrary to the

Kaushik, Nitish, Sandeep, Ch, Srinivasan, V. P., Prakash, B. Vijaya, Kalaiarasan, S., Arunkumar, S.

Fabrication and Functional Behavior Studies of Polypropylene Composite Containing Hybrid Reinforcements

05-18-02-0015

12/06/2024

Hybrid reinforcement-made polypropylene (PP) composites are beneficial over monolithic PP and utilized for various engineering and non-engineering applications. The present investigation of PP hybrid composites is developed with 10 percentages of weight (wt%) of E-glass fiber embedded with 0–6 wt% of silicon carbide via compression technique associated with hot press. E-glass fiber and SiC influencing wear rate, tensile strength, and microhardness behavior of PP and its composites are experimentally investigated. The peak loading of SiC as 6 wt% into PP/10 wt% E-glass fiber is recorded as better wear resistance (0.021 mm3/m), maximum tensile strength value (54.9 MPa), and highest hardness (68 HV). Moreover, the investigation results of hybrid PP composite are better resistance to wear and hiked tensile and hardness behavior compared to monolithic PP. This PP/10 wt% E-glass fiber/6 wt% of SiC hybrid composite is adopted for high-strength to lightweight sports goods applications.

Venkatesh, R.

Development of an Assessment Methodology for Synchronizer Ring (CuZn Alloy) Wear Durability

2024-28-0185

12/05/2024

Gear shifting effort or force especially in manual transmission has been one of the key factors for subjective assessment in passenger vehicle segment. An optimum effort to shift into the gears creates a big difference in overall assessment of the vehicle. The gear shifting effort travels through the transmission shifting system that helps driver to shift between the different available gears as per the torque and speed demand. The shifting system is further divided into two sub-systems. 1. Peripheral system [Gear Shift Lever with knob and shift Cable Assembly] and Shift system inside the transmission [Shift Tower Assembly, Shift Forks, Hub and sleeve Assembly with keys, Gear Cones and Synchronizer Rings etc.] [1]. Both the systems have their own role in overall gear shifting effort. There has been work already done on evaluation of the transmission shifting system as whole for gear shifting effort with typical test bench layouts. Also, work has been on assessment of life of the

Singh, Paramjeet, Yadav, Sanjay Kumar

An Experimental Study of Clutch Wear Profile on a Vehicle with Automated Manual Transmission and Simulating the Same on Test Bench for Future Applications

2024-28-0193

12/05/2024

Clutch wear is a significant factor affecting vehicle performance and maintenance costs, and understanding its dynamics is crucial for original equipment manufacturers (OEMs) to enhance product reliability and customer satisfaction. It is important to predict clutch wear to enable customers to understand the condition of their clutch and the remaining clutch life, to avoid sudden vehicle breakdowns. This paper explains the approach of measuring the clutch wear profile on an actual vehicle and simulating the same conditions on a powertrain test bench, with the establishment of a correlation in clutch wear profiles.

Chopra, Chandan, Kumar, Varun, Mamidigumpula, Mohan Kumar Reddy

Influence of Discrete Load Cases on Optimization of Chain Guide Design of Crawler Dozers under Various Ground Conditions

2024-28-0270

12/05/2024

The undercarriage is a critical component in machines such as crawlers, excavators, and compact track loaders. It includes vital elements such as the track frame, chain guides, rollers, track chains, idlers, carrier rollers, final drive, and sprockets. Among all these machines, crawler dozers encounter harsh environments with various ground conditions. During operations, the chains are subjected to traverse and side loads, which cause the chains to tend to slip out of the bottom rollers. The chain guide plays a crucial role in assisting and maintaining the chain in the correct position. The forces acting on chain guides are influenced by factors such as track chain tension, roller wear, chain link wear, and counter-rotation (where one track moves forward while the other moves in reverse). Among all the load cases, there are two critical load cases which are vital to be studied in order to determine the required number of chain guides along with other attributes like profile or section

Masane, Nishant, Bhosale, Dhanaji, Sarma, Neelam K

Low-Duty Inertia Dynamometer Hydraulic Brake Wear Test Procedures for Vehicles Above 4536 kg (10000 pounds) of GVWR

J3006_202412 (Current)

12/03/2024

This Recommended Practice is derived from OEM and tier-1 laboratory tests and applies to two-axle multipurpose passenger vehicles, or trucks with a GVWR above 4536 kg (10 000 pounds) equipped with hydraulic disc or drum service brakes. Before conducting testing for a specific brake sizes or under specific test conditions, review, agree upon, and document with the test requestor any deviations from the test procedure. Also, the applicable criteria for the final test results and wear rates deemed as significantly different require definition, assessment, and proper documentation; especially as this will determine whether or not Method B testing is needed. This Recommended Practice does not evaluate or quantify other brake system characteristics such as performance, noise, judder, ABS performance, or braking under extreme temperatures or speeds. Minimum performance requirements are not part of this recommended practice. Consistency and margin of pass/fail of the minimum requirements

Truck and Bus Hydraulic Brake Committee

Aviation Safety Expert Unites Industry to Safeguard Aviation Supply Chain

TBMG-52128

12/01/2024

In the summer of 2023, a receiving clerk in the procurement department of TAP Air Portugal, a Lisbon-based airline, made a curious discovery: A $65 engine part that should have appeared brandnew showed signs of significant wear. The clerk checked the documentation from the London-based parts supplier and noticed that the submitted documentation was also suspicious.

Continuous Curvature Parking Path Planning for Unmanned Mining Trucks Using Transition Curves and Model Predictive Control

02-18-01-0003

11/15/2024

Geometric methods based on Reeds–Shepp (RS) curves offer a practical approach for the parking path planning of unmanned mining truck, but discontinuous curvature can cause tire wear and road damage. To address this issue in mine scenario, a continuous curvature parking path planning method based on transition curve and model predictive control (MPC) is proposed for mine scenarios. Initially, according to the shovel position information issued by the cloud dispatching platform, a reference line is planned using RS curves. In order to mitigate the wear and tear of the tires and the damage to unstructured roads due to the in situ steering caused by the sudden change of the curvature, a transition curve consisting of clothoid–arc–clothoid that satisfies the kinematics of continuous vehicle steering is designed on the basis of RS curves to achieve the continuity of road curvature, which will contribute to the economy of tire and handling performance. The calculation of Fresnel integral

Zhang, Haosen, Chen, Qiushi, Wu, Guangqiang

Research on Multi-Mode Switching Strategy for Electromagnetic Suspension

2024-01-7005

11/15/2024

This study proposes a multi-mode switching control strategy based on electromagnetic damper suspension (EMDS) to address the different performance requirements of suspension systems on variable road surfaces. The working modes of EMDS are divided into semi-active damping mode and energy harvest mode, and the proposed mode switching threshold is the weighted root mean square value of acceleration. For the semi-active damping mode, a controller based on LQR(Linear Quadratic Regulator) was designed, and a variable resistance circuit was also designed to meet the requirements of the semi-active mode, which optimized the damping effect relative to passive suspension. For the energy harvest mode, an energy harvest circuit was designed to recover vibration energy. In order to reduce the deterioration of suspension performance caused by frequent mode switching in the mode switching strategy, as frequent system switching can lead to system disorder, deterioration of damping effect, and

Zeng, Sheng, Zhang, Bangji, Tan, Bohuan, Qin, An, Lai, Jiewen, Wang, Shichen

Recent Developments on Aluminum 7075-Based Composite with Industrial Waste Fly Ash by Stir Casting and Their Applications

05-18-02-0009

11/07/2024

Recent developments in manufacturing techniques and the development of Al7075 metal matrix composites (MMCs) with reinforcements derived from industrial waste have been steadily gaining popularity for aerospace and automobile applications due to their outstanding properties. However, there are still a lot of limitations with these composite materials. A great deal of research has been done to create new Al7075 MMC materials with the use of economic fly ash (FA) that possesses superior mechanical properties, corrosion resistance, density, and cycle cost. This review outlines different synthesis techniques used in the development of Al7075 MMCs using stir casting. Effects of FA along with other reinforcements on the mechanical, wear, machining, and microstructural properties of the composite are also discussed. Finally, a summary of the application of FA-based MMCs and a recap of the previous discoveries and challenges are reported. Future scope and potential areas of application are

Kumar, Randhir, Mondal, Sharifuddin

Comparative Investigations of Tool Wear and Cutting Force for Wet and Dry Turning of Super Duplex Stainless Steels 2507

05-18-02-0012

11/07/2024

Super Duplex Stainless Steels (SDSS) are attracting attentions of the manufacturing industries due to the excellent corrosion resistance to critical corrosion. But SDSS2507 is the hardest to machine with lowest machinability index among DSS family. Moreover, formation of built-up layer (BUL) and work hardening tendency makes it further difficult to machine. Researchers have the conflict in opinions on using wet machining or dry machining using tool coatings. In this investigation SDSS2507 machining is carried out using uncoated and PVD–TiAlSiN-coated tools. The wet and dry machining environment are compared for increase in cutting speed from 170 m/min to 230 m/min. Excellent properties of PVD–TiAlSiN coatings exhibited microhardness of 39 GPa and adhesion strength of 88 N, which outperformed the uncoated tools. Tool life exhibited by coated tools was four times higher than uncoated tools. Wet machining was found to be ineffective when PVD-coated tools are used, exhibiting the same

Sonawane, Gaurav Dinkar, Bachhav, Radhey

Failure of Power Steering Gears of the Heavy-Duty Trucking: A Tribological Investigation

2024-01-4300

11/05/2024

A power steering system helps the heavy-duty operator move the vehicle easily with the hydraulic pump that provides the fluid pressure and facilitating adequate operation. Some failures in the power steering system are due to external and internal factors that can reduce its service life. The external factors could be identified by ocular inspection but normally, due to internal failures, it is necessary to use a hydraulic pressure flow meter. However, this device makes it impossible to detect failures caused by the selected lubricant. This work aims to investigate the causes of power steering system seizure by using the tribological wear examination process and the lubricant characterization under some actual operation conditions. The lubricant characterization was carried out in a four balls tester using fresh and used samples of a re-refined oil based ATF, SAE 15 W40 and synthetic SAE 5 W30 oils at two temperatures. In general, the results showed an unsteady friction profile with

García-Maldonado, Miguel, Gallardo, Ezequiel, Mozqueda-Flores, Luis, Vite-torres, Manuel

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