EFFECT OF TEMPERATURE, PARTICLE SIZE, LOAD AND SPEED … · and Taguchi method were used to...

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International Journal of Mechanical Engineering and Technology (IJMET)

Volume 9, Issue 3, March 2018, pp. 719–730, Article ID: IJMET_09_03_073

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=9&IType=3

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

EFFECT OF TEMPERATURE, PARTICLE SIZE,

LOAD AND SPEED ON THE DRY SLIDING

WEAR BEHAVIOR OF ALUMINIUM 8011-SIC

COMPOSITES

N. Ashok

Department of Mechanical Engineering,

Karpagam Academy of Higher Education, Coimbatore, India

P. Shanmughasundaram

Professor, Department of Mechanical Engineering,

Karpagam Academy of Higher Education, Coimbatore, India

Netsanet Ayele

Senior Lecturer, Department of Mechanical Engineering,

Arba Minch Institute of Technology, Arba Minch University, Arba Minch, Ethiopia-21

Atkilt Mulu

Senior Lecturer, Department of Mechanical Engineering,

Arba Minch Institute of Technology, Arba Minch University, Arba Minch, Ethiopia-21

ABSTRACT

Dry sliding wear test was conducted for Al8011-SiC composites fabricated with

reinforcement of 6 wt.% of (fine, intermediate, coarse) SiC particles for the

variation of temperatures (30 ° C, 60°C, 90°C) and for the variation in the load and

sliding speed. The result reveals that load was the most significant factor trailed by,

temperature, sliding speed and particle size on the wear loss. Wear loss of the

composites increases with the increase in temperature, load, sliding speed and

decrease in particle size within the prescribed level. Analysis of variance (ANOVA)

and Taguchi method were used to calculate the control of parameters on the wear loss

and significance of parameters. From the results it was clear that particle size,

temperature, load have major effect on the wear resistance.

Key words: Dry sliding wear test, Temperature, Particle size, ANOVA, Taguchi.

Cite this Article: N. Ashok, P.Shanmughasundaram, Netsanet Ayele and Atkilt Mulu,

Effect of Temperature, Particle Size, Load and Speed on the Dry Sliding Wear

Behavior of Aluminium 8011-Sic Composites, International Journal of Mechanical

Engineering and Technology 9(3), 2018, pp. 719–730.

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=9&IType=3

N. Ashok, P.Shanmughasundaram, Netsanet Ayele and Atkilt Mulu


1. INTRODUCTION

Composites are extensively used in the automobile industries [1].Particularly metal matrix

composites are used in automobile and aerospace applications. Wear is defined as the material

removal process when two surfaces contact each other. Ravikumar et al [2] analyzed the

effect of particle size of flyash on the wear loss and coefficient of friction on the Al380-fly

ash composites. It was found that larger particle size reinforcement exhibit superior wear

resistance than the other two particles. Tribological behaviour of Al6061-fly ash composites

were studied by Anil kumar et al [3]. Fine, intermediate, coarse fly ash particles were used as

the reinforcement to produce Al6061-fly ash composites by stir casting method. They

concluded that wear loss of the composites decreased with the reinforcement of coarse fly ash

particles. Kok et al [4] compared the effect of reinforcement of two different particle sizes of

alumina on the wear behaviour of Al-alumina composites .Their result indicated that the wear

resistance of the composites increased for the reinforcement of coarse alumina particles. The

decrease in particle size of reinforcement increases the wear loss of the composites was

studied by Rahimian et al [5].Effect of particle size of SiC ( ) on the wear loss of Al6061-SiC

and Al6061-SiC-Graphite composites were investigated by Mahadavi et al [6] .From the

results it was clear that fine SiC particles were weakly embedded and comes out easily at

greater loads, hence exhibit lesser wear resistance than the intermediate and coarse particles.

The effect of variation of temperatures (30°C, 60°C, 90°C) on the dry sliding wear behaviour

of AA7075-SiC composites were analyzed by P.Shanmughasundaram [7]. It was noted from

the results that the wear loss of the composites increased with the increase in temperature.

Load was the most important factor trailed by temperature and sliding velocity. Dry sliding

wear behaviour of Al6061-alumina (20 wt. %) and Al6061 unreinforced alloy were performed

at constant sliding speed and different loads and different temperatures. The results clearly

indicated that the temperature has no effect on the wear loss and friction coefficient of the

Al6061-alumina composites in the mild wear regime; however it has its control in the severe

wear regime of Al6061-alumina and unreinforced alloy [8]. With the variation of

microstructure, morphology, volume fraction of the reinforcing phase, nature of bonding

between the matrix material and mechanical properties of the reinforcing phase changes the

tribological properties of composites [9]. Mousavi Abarghouic and Syed Reihani [10]

compared the effect of temperature on the wear and friction behaviour of Al2024 and Al2024-

SiC composites fabricated by powder metallurgy method. Dry sliding wear test was

conducted using pin-on-disc machine for the variation in temperature from 20º to 250º C,

constant load of 20 N, sliding speed of 0.5 m/s and sliding distance of 250 mm. The results

clearly indicated that addition of SiC particles improve the wear resistance of composites.

When the critical temperature increased the wear loss and coefficient of friction decreases due

to the creation of self heating layer was analyzed by Mahdiar valefi et al [11]. The

temperature controls the wear loss and coefficient of friction of the CUO-Zirconia

composites. Higher wear loss was observed during the lower temperatures. Michael Rajan et

al [12] analyzed the dry sliding wear behaviour of Al7075-TiB2 composites fabricated by in-

situ reaction method. With the varying weight percentage of TiB2 (0, 3, 6 and 9 wt. % ).The

addition of TiB2 increases the wear resistance of the composites, however with the increase in

temperature wear loss increases. Faranak Farhadinia et al [13] analyzed the effect of

temperature on the dry sliding wear behaviour of hybrid composites. Al-alumina and (Al-

alumina-ZrB2 + TiB2 ) composites were fabricated by hot pressing method. Wear behaviour of

the hybrid composites for room temperature and at a temperature of 300 ºC were conducted.

They conclude that hybrid composites exhibit superior wear resistance at all temperatures

than the alloy. Dheerendra kumar Diwedi et al [14] conducted wear test on the Al-Si-Mg

alloys. The results clearly indicated that with the increase in Si content the critical temperature

of the alloy increases. For all the different weight percentages of Si, the wear loss and

Effect of Temperature, Particle Size, Load and Speed on the Dry Sliding Wear Behavior of

Aluminium 8011-Sic Composites


coefficient of friction initially decreases for the lower interface temperatures. However at the

critical temperature wear loss and coefficient of friction increased more rapidly. Hernandez et

al [15] compared the high temperature wear and friction map for boron steel tribo pair and

tool steel. The formation of protective layer in the tool steel and boron steel tribo pair reduces

the wear loss and friction coefficient at higher load and higher temperature. Wear behaviour

of the material (alloy) were conducted at different loads (25, 50, and 70 N) , different

temperatures (100,200, 300,400) and constant sliding speed of 0.2 m/s. Wear behaviour of Al-

Cu (4%) alloy and Al-Cu (4%) - TiB2 composites produced by in-situ method were analyzed

by kumar et al [16].With the increase in TiB2 weight percentage the wear loss of Al-Cu(4%)

alloy decreases at different loads and temperatures. The result clearly indicated that in the

case of Al-Cu -TiB2 composites the dominant wear mechanism were observed to be oxidation,

delamination and metal flow rate, however adhesion and metal flow for Al-Cu (4%) alloy.

Effect of high temperature from normal to 350º C on the wear and tensile behaviour of Al-Si

alloy fabricated by stir casting method were studied by Rajaram et al [17].From the results it

was clear that wear loss of Al-Si alloy decreased with the increase in temperature because of

the formation of oxide film, these oxide layers prevents the metal to metal contact, hence

superior wear resistance during sliding. Natarajan et al [18] analyzed the effect of temperature

using pin-on-disc machine on the dry sliding wear behaviour of Al6063- TiB2 composites

fabricated by in-situ method. Three different types of load (9.8, 19.6, 29.4 N) and three

different temperatures (100,200,300 ºC) were used. They concluded that with the increase in

weight percentage of TiB2, the wear loss decreases. However wear loss increased with the

increase in applied load. Composites exhibit superior wear resistance than the alloy. Dry

sliding wear behaviour of Al8090 alloy and Al 8090-SiC composites were analyzed by

Gomez del Rio [19]. From the results it was clear that transition of wear from mild to severe

were observed in both Al8090 alloy and Al8090-SiC composites. Wear behaviour of Al-12Si-

alumina, Al-12Si-Carbon fiber, Al-12Si-alumina- Carbon fiber were compared by Hui et al

[20]. Dry sliding wear test was conducted at a constant sliding speed (1.57 m/s) and sliding

distance (94 µm).Their result clearly indicated that Al-12Si-alumina-Carbon fiber hybrid

composites exhibit superior resistance than the other two composites for all the tested

temperatures. Transition of wear takes place to adhesion when the tested temperature reaches

to critical temperature.

2. MATERIALS AND METHODOLOGY

In this research work Al8011 was used as the matrix material and SiC particles of three

different particle sizes (63, 76, 89 µm) at 6wt. % were used as the reinforcement to produce

Al8011-SiC composites by stir casting method. Al8011 material was added into the graphite

crucible and made completely melt at the liquidus temperature of 780º C. Simultaneously SiC

particles were also preheated to 500ºC to remove the moisture content. Semi solid state was

reached, when the temperature was lowered to 720º C, then the preheated SiC particles, Mg

were added and stirred at the speed of 300 rpm for a time period of 10 mins. Then the melt

temperature was again increased to liquidus temperature and finally poured into the mould

and allowed to solidify.



Figure 1 Stir casting method

2.1. Dry Sliding wear test

Dry sliding wear test was conducted as per ASTM G99 standard using Pin-on-disc test rig.

The tested wear test specimens were machined to cylindrical shape according to the required

dimensions of 6mm diameter and 25 mm length and polished well before testing. The wear

test were conducted for the variation of three different temperatures (30ºC, 60ºC, 90ºC) and

for three different loads (10N, 20N, 30N), three different sliding speeds (200,300,400 rpm)

for a constant time period of 10 mins at room temperature (34ºC and relative humidity

60%).The composite specimen was pressed against the rotating steel disc of track diameter

100mm.Initially before testing the surface temperature of the composite pins was adjusted to

the required temperature and speed of the rotating disc also maintained at a constant required

speed. The wear loss in terms of microns is directly proportional to the height loss of the pin

while sliding; coefficient of friction and frictional force were also measured simultaneously.

With the help of “Magnum Data Acquisition Software” the tested readings were collected,

displayed and stored in the computer.

Figure 2 Pin-on-disc apparatus.

3. RESULTS AND DISCUSSION

Fig (3 to 11) shows the influence of temperature, load, and sliding velocity on the wear loss of

Al8011-SiC composites. When the applied load was increased from 10 N to 30 N at the

sliding speed of 200 rpm and temperature of 60ºC for 150 mesh size ,wear loss was increased

by 33% i.e. 48 µm to 64 µm. It was also observed form the figures that with the increase in

sliding speed the wear loss increases. When the sliding speed was increased from 200rpm to

400 rpm at the constant load of 20N, and temperature of 90ºC, the wear loss was increased by

20% for 180 mesh size. The wear loss was directly proportional to the applied load, sliding

velocity and temperature. The wear loss of Al8011-SiC composites increased with the




increase in applied load, temperature and sliding speed. Al8011-SiC (89µm) coarse

composites exhibit lesser wear loss than the intermediate and fine composites. It can be noted

that wear resistance of coarse SiC particles was higher than the other two particles at all

temperatures, sliding speed and applied load.

Figure 3 Effect of temperature, load, sliding speed and 150 mesh particle size on the wear loss of

Al8011-SiC composites



Figure 5 Effect of temperature, load and sliding speed and 150 mesh particle size on the wear loss of


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Figure 9 Effect of temperature, load , sliding speed and 220 mesh particle size on the wear loss of






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Figure 12 Effect of temperature on the wear loss of Al8011-SiC (220 mesh) composites

Figure 13 Effect of particle size for the similar temperature, load, sliding speed on the wear loss of


Fig 12.shows the influence of temperature on the wear behaviour of Al8011-SiC

composites. With the raise in temperature from 30ºC to 90ºC at any given load and sliding

speed the wear loss of the composites increases. It was also observed form the Fig 12. that

with the increase in temperature form 60ºC to 90ºC at sliding speed of 200 rpm and load of

30 N, wear loss increased form 107µm to 122µm.When the temperature of the pin increased,

the wear loss of Al8011-SiC composites increases due to the softening of the material. This

softening of the material was observed more in the Al8011-SiC (fine) composites, hence

Al8011-SiC (fine) composites exhibit higher wear loss. From the Fig.13 it was clear that

coarse composites (72µm) exhibit superior wear resistance than the intermediate (88µm) and

fine (100 µm) at constant testing conditions of load (20 N),Sliding speed (300 rpm)and

temperature (60°C).

4. TAGUCHI TECHNIQUE

Design of Experiments technique is a well organized and structured technique to indicate the

relationship between the parameters which controls the process and its responses. Taguchi

method is a systematic method and it is selected to analyze the performance of the process

parameters which will give the required output. In this research work L27 orthogonal array

was used and wear test was performed based on the array. In this study “smaller is better” S/N

ratio was selected to find the optimum parameter to minimize the wear loss. 27 wear tests




were conducted and each experiment was repeated thrice to eliminate errors. In addition,

ANOVA technique was also used to study the control of parameters on the performance. The

parameters and levels are presented in the Table 1.The measured wear loss and S/N ratios are

presented in the Table 2.

Table 1 Parameters and levels

Code

Parameters

Levels

I II III

A Temperature (°C) 30 60 90

B Mesh size 220(63µm) 180(76 µm) 150(89µm)

C Load (N) 10 20 30

D Sliding speed

(rpm)

200 300 400

To minimize the wear loss of Al8011-SiC composites, from the results of response table

for S/N ratio (Table 3) it was clear that maximum value of delta was observed for the applied

load, hence it has the highest influence on the wear loss. The delta value infers that load has

the major impact on the wear loss trailed by temperature, sliding speed and mesh size. From

the response diagram for S/N ratios (Figure 14) it was found that optimum parameters for

reducing the wear loss would be mesh size (150(89µm)),applied load (10N),temperature

(30ºC) and sliding speed (200 rpm).From the results it was clear that wear resistance

decreases with the increase in temperature. Wear loss of the composites increased with the

increase in applied load and sliding speed. ANOVA was conducted by using MINITAB 17

software. ANOVA technique was used to calculate the parameters percentage contribution on

the performance characteristic. The p value is used to indicate the significance of each

parameter. When the p value is less than 0.05 it shows that they are highly significant at 95%

confidence level. The last column of the Table 4 indicates the parameters percentage

contribution on the wear loss. It is clear from the Table 4 that the load (42.11%) was the most

dominant factor trailed by temperature (20.20%) ,sliding speed (19.97%) and mesh size

(16.26%) controlling the wear loss.

Table 2 Measured values and S/N ratios for wear loss of Al8011-SiC (6 wt. %) composites

Parameters

Exp.No

Parameters

Values

Exp.No

Temperature

°C

(A)

Mesh Size (B) Load, N (C) Sliding

Speed,

rpm

(D)

Wear(µm) Signal/ Noise

Ratio 1 30 220 (63 µm) 10 200 44 -32.8691

2 30 220 (63 µm) 20 300 72 -37.1466

3 30 220 (63 µm) 30 400 142 -43.0458

4 30 180 (76 µm) 10 300 52 -34.3201

5 30 180 (76 µm) 20 400 76 -37.6163

6 30 180 (76 µm) 30 200 62 -35.8478

7 30 150 (89 µm) 10 400 45 -33.0643

8 30 150 (89 µm) 20 200 40 -32.0412

9 30 150 (89 µm) 30 300 80 -38.0618

10 60 220 (63 µm) 10 200 58 -35.2686

11 60 220 (63 µm) 20 300 100 -40

12 60 220 (63 µm) 30 400 152 -43.6369

13 60 180 (76 µm) 10 300 61 -35.7066

14 60 180 (76 µm) 20 400 101 -40.0864



Table 3 Response table for Signal to noise ratios

Figure 14 Main Effects plot for S/N ratio

Table 4 ANOVA analysis for wear loss

Dof: degrees of freedom; Seq.SS: sequential sums of squares; Adj.Ms: adjusted sums of squares; Pc:

Percentage of contribution.

906030

-36

-37

-38

-39

-40

220(63µm)180(76µm)150(89µm)

302010

-36

-37

-38

-39

-40

400300200

A Temperature(°C)

Me

an

of

SN

ra

tio

s

B Mesh size

C Load (N) D Sliding speed(rpm)

Main Effects Plot for SN ratios

Data Means

Signal-to-noise: Smaller is better

Wear loss

15 60 180 (76 µm) 30 200 93 -39.3697

16 60 150 (89 µm) 10 400 62 -35.8478

17 60 150 (89 µm) 20 200 56 -34.9638

18 60 150 (89 µm) 30 300 94 -39.4626

19 90 220 (63 µm) 10 200 69 -36.777

20 90 220 (63 µm) 20 300 113 -41.0616

21 90 220 (63 µm) 30 400 159 -44.0279

22 90 180 (76 µm) 10 300 76 -37.6163

23 90 180 (76 µm) 20 400 107 -40.5877

24 90 180 (76 µm) 30 200 114 -41.1381

25 90 150 (89 µm) 10 400 75 -37.5012

26 90 150 (89 µm) 20 200 72.5 -37.2068

27 90 150 (89 µm) 30 300 106 -40.5061

Level A Temperature (°C) B Mesh size C Load (N) D Sliding speed (rpm)

I -36.00 -39.31 -35.44 -36.16

II -38.26 -38.03 -37.86 -38.21

III -39.60 -36.52 -40.57 -39.49

Delta 3.60 2.80 5.13 3.33

Rank 2 4 1 3

Wear parameter Dof Seq.SS F value P value Pc (%)

A Temperature (°C) 2 5425.4 53.45 0.000 20.20

B Mesh size 2 4365.1 42.56 0.000 16.26

C Load (N) 2 11307.7 115.47 0.000 42.11

D Sliding speed (rpm) 2 5361.2 52.29 0.000 19.97

Error 18 390.6 1.45

Total 26 26850.5 100




5. CONCLUSIONS

Tribological behaviour of Al8011-SiC composites has been performed with the help of

Taguchi and ANOVA method. The following conclusions have been drawn, the wear loss of

the composites increased with the increase in the applied load, sliding speed and temperature.

Wear resistance decreased for the increase in temperature at all applied load and sliding

speed. It was clear that the optimum parameters for reducing the wear loss would be applied

load (10 N), temperature (30ºC), sliding speed (200 rpm) and mesh size (150 (89µm)). It can

be concluded that the applied load (42.11%) was the most significant factor controlling the

wear loss of the composites followed by the temperature (20.20%), sliding speed (19.97) and

mesh size (16.26%).

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