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Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs

In subtractive manufacturing processes, swarf, burrs or other residues are produced, which can impair the function of a tribological system (e.g., journal bearings). To prevent premature engine damage, cleanliness requirements are defined for production processes. Damaging particle tests are an expe...

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Autores principales: Brag, Patrick, Piotter, Volker, Plewa, Klaus, Klein, Alexander, Herzfeldt, Mirko, Umbach, Sascha
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10532478/
https://www.ncbi.nlm.nih.gov/pubmed/37763554
http://dx.doi.org/10.3390/ma16186276
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author Brag, Patrick
Piotter, Volker
Plewa, Klaus
Klein, Alexander
Herzfeldt, Mirko
Umbach, Sascha
author_facet Brag, Patrick
Piotter, Volker
Plewa, Klaus
Klein, Alexander
Herzfeldt, Mirko
Umbach, Sascha
author_sort Brag, Patrick
collection PubMed
description In subtractive manufacturing processes, swarf, burrs or other residues are produced, which can impair the function of a tribological system (e.g., journal bearings). To prevent premature engine damage, cleanliness requirements are defined for production processes. Damaging particle tests are an experimental approach for validating these defined cleanliness requirements. This methodical approach is not yet widely used. For one, the test setup must be developed and proven for the respective application. For another, in order to carry out the tests in a systematic manner, defined test particles with properties similar to those of the contaminants encountered in reality are required. In the second part of the paper, the process chain for manufacturing artificial test swarf by micro powder injection molding (MicroPIM) is described. The size and shape of the swarf were derived from real swarf via several abstraction processes. Although certain design guidelines for MicroPIM parts could not be taken into account, the targeted manufacturing tolerances were achieved in most cases. During demolding, it became apparent that the higher ejection forces of the free-formed geometries must be taken more into account in the design of the mold. The experiments on the test setup also revealed that the artificial test swarf was unexpectedly brittle and was therefore ground up in the bearing gap without causing any substantial damage to the bearing. Thus, the artificial test swarf in its current sintered state is not a suitable substitute for micromilled swarf. However, MicroPIM could still be used to manufacture test particles in applications involving lower mechanical forces.
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spelling pubmed-105324782023-09-28 Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs Brag, Patrick Piotter, Volker Plewa, Klaus Klein, Alexander Herzfeldt, Mirko Umbach, Sascha Materials (Basel) Article In subtractive manufacturing processes, swarf, burrs or other residues are produced, which can impair the function of a tribological system (e.g., journal bearings). To prevent premature engine damage, cleanliness requirements are defined for production processes. Damaging particle tests are an experimental approach for validating these defined cleanliness requirements. This methodical approach is not yet widely used. For one, the test setup must be developed and proven for the respective application. For another, in order to carry out the tests in a systematic manner, defined test particles with properties similar to those of the contaminants encountered in reality are required. In the second part of the paper, the process chain for manufacturing artificial test swarf by micro powder injection molding (MicroPIM) is described. The size and shape of the swarf were derived from real swarf via several abstraction processes. Although certain design guidelines for MicroPIM parts could not be taken into account, the targeted manufacturing tolerances were achieved in most cases. During demolding, it became apparent that the higher ejection forces of the free-formed geometries must be taken more into account in the design of the mold. The experiments on the test setup also revealed that the artificial test swarf was unexpectedly brittle and was therefore ground up in the bearing gap without causing any substantial damage to the bearing. Thus, the artificial test swarf in its current sintered state is not a suitable substitute for micromilled swarf. However, MicroPIM could still be used to manufacture test particles in applications involving lower mechanical forces. MDPI 2023-09-19 /pmc/articles/PMC10532478/ /pubmed/37763554 http://dx.doi.org/10.3390/ma16186276 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Brag, Patrick
Piotter, Volker
Plewa, Klaus
Klein, Alexander
Herzfeldt, Mirko
Umbach, Sascha
Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs
title Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs
title_full Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs
title_fullStr Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs
title_full_unstemmed Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs
title_short Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs
title_sort development and production of artificial test swarf to examine wear behavior of running engine components—part 2: experimentally derived designs
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10532478/
https://www.ncbi.nlm.nih.gov/pubmed/37763554
http://dx.doi.org/10.3390/ma16186276
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