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wear mechanism and debris analysis of PEEK as an alternative to CoCrMo in the femoral component of total knee replacement

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Friction 2023年第10期11卷 1845-1861页

作者： Xinyue ZHANG Tao ZHANG Kai CHEN Handong XU Cunao FENG Dekun ZHANG School of Mechatronic Engineering China University of Mining and TechnologyXuzhou 221116China School of Materials and Physics China University of Mining and TechnologyXuzhou 221116China

The polyetheretherketone(PEEK)-highly cross-linked polyethylene(XLPE),all-polymer knee prosthesis has excellent prospects for replacing the traditional metal/ceramic-polyethylene joint prosthesis,improving the service life of the joint prosthesis and the quality of patients’*** long-term wear mechanism of PEEK-XLPE knee joint prosthesis is comprehensively evaluated from wear amount,wear morphology,and wear debris compared to that of CoCrMo-XLPE joint *** 5 million cycles of in vitro wear,the wear loss of XLPE in PEEK-XLPE(30.9±3.2 mg)is lower than that of XLPE in CoCrMo-XLPE(32.1±3.1 mg).Compared to the XLPE in CoCrMo-XLPE,the plastic deformation of XLPE in PEEK-XLPE is more severe in the early stage,and the adhesive peeling and adhesion are lighter in the later *** size distribution of XLPE wear debris in PEEK-XLPE is relatively dispersed,which in CoCrMo-XLPE is relatively *** debris is mainly flake and block debris,and the wear mechanism of XLPE was abrasive *** wear volume per unit area of PEEK femoral condyle(10.45×10^(5)μm^(3)/mm^(2))is higher than that of CoCrMo(8.32×10^(5)μm^(3)/mm^(2)).The PEEK surface is mainly furrows and adhesions,while the CoCrMo surface is mainly furrows and corrosion *** PEEK wear debris is mainly in flakes and blocks,and the CoCrMo wear debris is mainly in the shape of rods and *** wear mechanism of PEEK is abrasive wear and adhesion,and that of CoCrMo is abrasive wear and corrosion.

关键词： polyetheretherketone(PEEK)-highly cross-linked polyethylene(XLPE) cobalt-chromium-molybdenum(CoCrMo)-XLPE wear debris wear mechanism

wear mechanism of Cemented Carbide Tool in High Speed Milling of Stainless Steel

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Chinese Journal of Mechanical Engineering 2018年第6期31卷 177-186页

作者： Guang-Jun Liu Zhao-Cheng Zhou Xin Qian Wei-Hai Pang Guang-Hui Li Guang-Yu Tan School of Mechanical Engineering Tongji University College of Environmental Science and Engineering Tongji University School of Mechanical and Power Engineering Guangdong Ocean University

Adhesion of cutting tool and chip often occurs when machining stainless steels with cemented carbide tools. wear mechanism of cemented carbide tool in high speed milling of stainless steel 0Cr13Ni4 Mo was studied in this work. Machining tests on high speed milling of 0Cr13Ni4 Mo with a cemented carbide tool are conducted. The cutting force and cutting temperature are measured. The wear pattern is recorded and analyzed by high?speed camera, scanning electron microscope(SEM) and energy dispersive X?ray spectroscopy(EDS). It is found that adhesive wear was the dominant wear pattern causing tool failure. The process and microcosmic mechanism of the tool’s adhesive wear are analyzed and discussed based on the experimental results. It is shown that adhesive wear of the tool occurs due to the wear of coating, the a nity of elements Fe and Co, and the grinding of workpiece materials to the tool material. The process of adhesive wear includes both microcosmic elements di usion and macroscopic cyclic process of adhe?sion, tearing and fracture.

关键词： Cemented carbide tool High speed milling Stainless steel wear mechanism

wear mechanism of WC-Co Cemented Carbide Tool in Cutting Ti-6Al-4V Based on Thermodynamics

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Journal of Wuhan University of Technology(Materials Science) 2020年第5期35卷 973-979页

作者： HU Xiaolong SHAO Fang WANG Renwei Guizhou Institute o f Technology Guiyang 550003China School o f Mechanical Engineering Guizhou UniversityGuiyang 550025China School o f Mechanical Engineering Shandong UniversityJinan 250100China

In order to optimize the tool coating material and reduce the tool wear rate,the coating material and wear mechanism for carbide tools are proposed and analyzed based on thermodynamics *** deduced the Gibbs free energy function method and analyzed the enthalpy value of the coating material of cemented carbide *** rules of diffusion wear and oxidation wear for WC-Co-based carbide tools were analyzed based on the diffusion dissolution theory and the calculation method of the thermal effect of chemical *** diffusion wear and oxidation wear of WC-Co-based carbide tools when machining Ti-6Al-4V were studied with *** results indicate that a good prediction accuracy of both diffusion wear and oxidation wear can be achieved by the method of thermodynamic theory analysis *** conclusion will provide useful references for the optimization of cutting parameters and the improvement of the tool life.

关键词： cemented carbide thermodynamics titanium alloy wear mechanism

Gaussian process regression model incorporated with tool wear mechanism

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Chinese Journal of Aeronautics 2022年第10期35卷 393-400页

作者： Dehua LI Yingguang LI Changqing LIU National Key Laboratory of Science and Technology on Helicopter Transmission Nanjing University of Aeronautics and AstronauticsNanjing 210016China

Cutting tool condition directly affects machining quality and *** order to avoid severely worn tools used during machining process and fully release the remaining useful life in the meanwhile,a reliable evaluation method of remaining useful life of cutting tools is quite *** to the variation of cutting conditions,it is a challenge to predict remaining useful life of cutting tools by a unified *** order to address this issue,this paper proposes a method for predicting the remaining useful life of cutting tools in variable cutting conditions based on Gaussian process regression model incorporated with tool wear mechanism,where the predicted value at adjacent moments is constrained to a linear relationship by the covariance matrix of Gaussian model based on the assumption of progressive tool wear process,so the wear process under continuous changing conditions can be *** addition to that,the input feature space and the output of the model are also enhanced by considering the tool wear mechanism for improving prediction *** experiments are performed to verify the proposed method,and the results show that the proposed could improve the prediction of tool remaining useful life significantly.

关键词： Remaining useful life Cutting condition Tool wear wear mechanism Gaussian process regression

Intelligent Identification of wear mechanism via On-line Ferrograph Images

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Chinese Journal of Mechanical Engineering 2014年第2期27卷 411-417页

作者： WU Tonghai PENG Yeping SHENG Chenxing WU Jiaoyi Key Laboratory of Education Ministry for Modern Design and Rotor-Bearing Systems Xi'an Jiaotong University Reliability Engineering Institute School of Energy and Power Engineering Wuhan University of Technology

Condition based maintenance（CBM） issues a new challenge of real-time monitoring for machine health maintenance. wear state monitoring becomes the bottle-neck of CBM due to the lack of on-line information acquiring means. The wear mechanism judgment with characteristic wear debris has been widely adopted in off-line wear analysis; however, on-line wear mechanism characterization remains a big problem. In this paper, the wear mechanism identification via on-line ferrograph images is studied. To obtain isolated wear debris in an on-line ferrograph image, the deposition mechanism of wear debris in on-line ferrograph sensor is studied. The study result shows wear debris chain is the main morphology due to local magnetic field around the deposited wear debris. Accordingly, an improved sampling route for on-line wear debris deposition is designed with focus on the self-adjustment deposition time. As a result, isolated wear debris can be obtained in an on-line image, which facilitates the feature extraction of characteristic wear debris. By referring to the knowledge of analytical ferrograph, four dimensionless morphological features, including equivalent dimension, length-width ratio, shape factor, and contour fractal dimension of characteristic wear debris are extracted for distinguishing four typical wear mechanisms including normal, cutting, fatigue, and severe sliding wear. Furthermore, a feed-forward neural network is adopted to construct an automatic wear mechanism identification model. By training with the samples from analytical ferrograph, the model might identify some typical characteristic wear debris in an on-line ferrograph image. This paper performs a meaningful exploratory for on-line wear mechanism analysis, and the obtained results will provide a feasible way for on-line wear state monitoring.

关键词： wear mechanism characteristic wear debris ferrography image processing

Novel three-body nano-abrasive wear mechanism

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Friction 2022年第5期10卷 677-687页

作者： Ruling CHEN Shaoxian LI College of Mechanical Engineering Donghua UniversityShanghai 201620China

Current three-body abrasive wear theories are based on a macroscale abrasive indentation process,and these theories claim that material wear cannot be achieved without damaging the hard mating *** this study,the process of three-body nano-abrasive wear of a system including a single crystalline silicon substrate,an amorphous silica cluster,and a polyurethane pad,based on a chemical mechanical polishing(CMP)process,is investigated via molecular dynamics *** cluster slid in a suspended state in smooth regions and underwent rolling impact in the asperity regions of the silicon surface,realizing non-damaging monoatomic material *** proves that indentation-plowing is not necessary when performing CMP material ***,a non-indentation rolling-sliding adhesion theory for three-body nano-abrasive wear between ultrasoft/hard mating surfaces is *** wear theory not only unifies current mainstream CMP material removal theories,but also clarifies that monoatomic material wear without damage can be realized when the indentation depth is less than zero,thereby perfecting the relationship between material wear and surface *** results provide new understanding regarding the CMP microscopic material removal mechanism as well as new research avenues for three-body abrasive wear theory at the monoatomic scale.

关键词： wear mechanism material removal mechanism three-body abrasive wear chemical mechanical polishing(CMP) molecular dynamics simulation

Erosive wear and wear mechanism of in situ TiC_P/Fe Composites

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Journal of Materials Science & Technology 2005年第5期21卷 719-723页

作者： Zhaojing LIU, Zhiliang NING , Fengzhen LI, Xiurong YAO and Shanzhi RENSchool of Materials Science and Engineering, Harbin University of Science and Technology, Harbin 150080, China School of Materials Science and Engineering Harbin University of Science and Technology Harbin 150080 China

The base structure of in situ TiCp/Fe composites fabricated under industrial condition was changed by different heat treatments. Erosive wear tests were carried out and the results were compared with that of wear-resistant white cast iron. The results suggest that the wear resistance of the in situ TiCp/Fe composite is higher than that of wear-resistant white cast iron under the sand erosive wear condition. The wear mechanism of the wear-resistant white cast iron was a cycle process that base surface was worn and carbides were exposed, then carbides was broken and wear pits appeared. While the wear mechanism of in situ TiCp/Fe composite was a cycle process that base surface was worn and TiC grains were exposed and dropped. The wear resistance of in situ TiCp/Fe composite was lower than that of wear-resistant white cast iron under the slurry erosive wear condition. Under such circumstance, the material was not only undergone erosive wear but also electrochemistry erosion due to the contact with water in the medium. The wear behaviours can be a combination of two kinds of wear and the sand erosive wear is worse than slurry erosive wear.

关键词： In situ TiCp/Fe composite Erosive wear wear mechanism

Effects of fiber orientation on tool wear evolution and wear mechanism when cutting carbon fiber reinforced plastics

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Chinese Journal of Aeronautics 2023年第5期36卷 549-565页

作者： Weizhou WU Shipeng LI Xuda QIN Wentao LIU Xin CUI Hao LI Mengrui SHI Haibao LIU Key Laboratory of mechanism Theory and Equipment Design of Ministry of Education Tianjin UniversityTianjin 300350China Tianjin Aerospace Long March Launch Vehicle Manufacturing Co.Ltd Tianjin 30000China Centre for Aeronautics School of AerospaceTransport and ManufacturingCranfield UniversityCranfield MK430ALUK

The aim of the present paper is to reveal the influence of different fiber orientations on the tool wear evolution and wear mechanism. Side-milling experiments with large-diameter milling tools are conducted. A finite element(FE) cutting model of carbon fiber reinforced plastics(CFRP)is established to get insight into the cutting stress status at different wear stages. The results show that different fiber orientations bring about distinct differences in the extent, profile and mechanism of tool wear. Severer wear occurs when cutting 45° and 90° plies, followed by 0°, correspondingly,the least wear is obtained when θ = 135°(θ represents the orientation of fibers). Moreover, the worn profiles of cutting tools when θ = 0° and 45° are waterfall edge, while round edge occurs whenθ = 135° and a combined shape of waterfall and round edge is obtained when θ = 90°. The wear mechanisms under different fiber orientations are strongly dependent on the cutting stress distributions. The evolution of tool wear profile is basically consistent with the stress distribution on the tool surface at different wear stages, and the extent of tool wear is determined by the magnitude of stress on the tool surface. Besides, the worn edges produce an actual negative clearance angle,which decreases the actual cutting thickness and leads to compressing and bending failure of fibers beneath the cutting region as well as low surface qualities.

关键词： Carbon fiber reinforced plastics(CFRP) Fiber orientation Finite element method(FEM) Tool wear wear mechanism

Analysis of wear mechanism and Influence Factors of Drum Segment of Hot Rolling Coiler

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Chinese Journal of Mechanical Engineering 2013年第2期26卷 351-355页

作者： ZHANG Jian PENG Yan LIU Hongmin LIU Yunfei National Engieering Research Center for Equipment and Technology of Cold Rolling Strip Yanshan University State Key Laboratory of Metastable Materials Science and Technology Yanshan University

Because the work environment of segment is complex, and the wear failures usually happen, the wear mechanism corresponding to the load is a key factor for the solution of this problem. At present, many researchers have investigated the failure of segment, but have not taken into account the compositive influences of matching and coiling process. To investigate the wear failure of the drum segment of the hot rolling coiler, the MMU-5G abrasion tester is applied to simulate the wear behavior under different temperatures, different loads and different stages, and the friction coefficients and wear rates are acquired. Scanning electron microscopy（SEM） is used to observe the micro-morphology of worn surface, X-ray energy dispersive spectroscopy（EDS） is used to analyze the chemical composition of worn surface, finally the wear mechanism of segment in working process is judged and the influence regulars of the environmental factors on the material wear behaviors are found. The test and analysis results show that under certain load, the wear of the segment changes into oxidation wear from abrasive wear step by step with the temperature increases, and the wear degree reduces; under certain temperature, the main wear mechanism of segment changes into spalling wear from abrasive wear with the load increases, and the wear degree slightly increases. The proposed research provides a theoretical foundation and a practical reference for optimizing the wear behavior and extending the working life of segment.

关键词： friction coefficient wear rate micro-morphology wear mechanism wear resistance