Fabrication of Various Dimple Shapes and Arrays on a Hypereutectic Al-Si Alloy Using a Turning Process
محورهای موضوعی : Manufacturing process monitoring and controlJaharah A. Ghani 1 , Faarih Farhan Mohd Nasir Mohd Nasir 2 , Mohd Nor Azam bin Mohd Dali 3 , Wan Fathul Hakim W. Zamri 4 , Mohd Shahir Kasim 5 , Che Hassan Che Haron 6
1 - Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
2 - Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
3 - Politeknik Ungku Omar, Jalan Raja Musa Mahadi, 31400 Ipoh, Perak, Malaysia
4 - Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
5 - Faculty of Manufacturing Engineering, Technical University of Malaysia, Durian Tunggal, Malaysia
6 - Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
کلید واژه: Turning Process, Dimple Shapes, Al-Si Alloy, DATT,
چکیده مقاله :
A hypereutectic Al-Si alloy piston has great potential for use in the automotive industry, especially for engine components, due to its lightweight, excellent castability, good thermal conductivity, high strength and excellent corrosion resistance. The silicon content in the A390 is between 17-18%. This article presents various shapes of dimples that can be fabricated on a cylindrical shape part of A390 using the turning process with aid of dynamic assisted tooling (DATT). To minimize the number of the experiment, the Taguchi method, with an L8 orthogonal array, was used to accommodate two different sets of seven parameters used in the fabrication of dimpled structures, i.e. cutting speed of 2-9 m/min, feed rate of 0.4-0.6 mm/rev, DOC of 0.05-0.01 mm, frequency of 15-28 Hertz, the amplitude of 1-3 mm, using two different cutting tool i) rake angle of +4o and -8.5o, relief angle of 4o and 7o, and nose radius of 0.4 and 0.8 mm, ii) Rake angle of +9° and -20°, and relief angle of +7° and +17°, and nose radius 8 mm. By using these turning parameters, 3 dimple shapes were produced; spherical, short drop and long drop shapes, with almost square and hexagonal arrays.
[1] Dhingra, R. and Das, S. 2014. Life cycle energy and environmental evaluation of downsized vs. lightweight material automotive engines. Journal of Cleaner Production 85:347-358.
[2] Hirsch, J. 2014. Recent development in aluminium for automotive application. Transactions of Nonferrous Metal Society of China, 24:1995-2002.
[3] Zeren, M. 2007. The effect of heat treatment on aluminium-based piston alloys. Material and Design. 28:2511-2517.
[4] Lee, J. A. 2003. Cast Aluminium Alloy for High Temperature Applications. The 132nd TMS Annual Meeting & Exhibition San Diego Convention Centre, San Diego, CA.
[5] Holmberg, K., Andersson, P. and Erdemir, A. 2012. Global energy consumption due to friction in passenger cars. Tribology International. 47:221-234.
[6] Holmberg, K., Andersson, P. and Nylund, N.O. Makela, K. and Erdemir, A. 2014. Global energy consumption due to friction in trucks and buses. Tribology International. 78:94-114.
[7] Bruzzone, A. A.G., Costa, H.L., Lonardo, P.M. and Lucca, D. A. 2008. Advances in engineering surfaces for functional performance. CIRP Annals: Manufacturing Technology. 57:750 -769.
[8] Xiaolei, W., Wei, L., Fei, Z. and Di, Z. 2009. Preliminary investigation of the effect of dimple size on friction in line contact. Tribology International. 42:1118 – 1123.
[9] Basnyat, P., Luster, B., Muratore. C., Voevodin, A.A., Haasch, R. and Zakeri, R. 2008. Sur-face Texturing for adaptive solid lubrication. Surface & Coatings Technology. 203:73-9.
[10] Voevodin, A.A., and Zabinski, J.S. 2006. Laser surface texturing for adaptive solid lubrication. Wear. 261:1285-92.
[11] Gachot, C., Rosenkranz, A., Hsu, S.M. and Costa, H.L. 2017. A critical assessment of surface texturing for friction and wear improvement. Wear. 372 (3):21-41.
[12] Rosenkranz, A., Grützmacher, P.G., Gachot, C. and Costa, H.L. 2019. Surface texturing in machine elements− a critical discussion for rolling and sliding contacts, Advanced Engineering Materials. 21(8):190-194.
[13] Fratila, D. and Caizar, C. 2011. Application of Taguchi method to selection of optimal lubrication and cutting condition in face milling of AlMg3. Journal of Cleaner Production, 19: 640-645.
[14] Nasir, F.F.M., Ghani, J.A., Zamri, W.F.H.W. and Kasim, M.S. 2019. State-of-the-art surface texturing and methods for tribological performance, World Review of Science, Technology and Sustainable Development. 15(4):330-357.
[15] Yu, H., Deng, H., Huang, W. and Wang, X. 2011. The effect of dimple shapes on friction of parallel surfaces, Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology. 225 (8):693-703.
