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Research Papers: Friction & Wear

A Study on Modified Mechanical and Wear Characteristics of Epoxy-Particulate Filled Homogenous Composites and Their Functionally Graded Materials

[+] Author and Article Information
Siddhartha1

Department of Mechanical Engineering, National Institute of Technology, Hamirpur 177005, Indiasid.fgm@gmail.com

Amar Patnaik

Department of Mechanical Engineering, National Institute of Technology, Hamirpur 177005, Indiaamar_mech@sify.com

Alok Satapathy

Department of Mechanical Engineering, National Institute of Technology, Rourkela 759008, India

Amba D. Bhatt

Department of Mechanical Engineering, Motilal Nehru National Institute of Technology, Allahabad 211004, Indiaamba_bhatt@yahoo.com

1

Corresponding author.

J. Tribol 133(1), 011601 (Nov 08, 2010) (11 pages) doi:10.1115/1.4002543 History: Received January 16, 2010; Revised September 03, 2010; Published November 08, 2010; Online November 08, 2010

This article presents the investigations on modified mechanical and wear characteristics of cement kiln dust (CKD) reinforced homogeneous epoxy composites and its functionally graded materials developed for tribological applications. CKD reinforced homogeneous and functionally graded epoxy composites are developed by simple mechanical stirring and vertical centrifugal casting technique, respectively. Mechanical properties of these graded composites are evaluated and compared with those of homogenously filled epoxy composites. Sliding wear tests are conducted over a range of sliding velocities (105–314 cm/s), normal loads (20–40 N), filler contents (020wt%), and sliding distances (0.5–2 km). For this, a pin-on-disk machine and the design of experiments approach using Taguchi’s orthogonal arrays are used. A theoretical model is proposed for estimating the sliding wear rates for homogeneous, as well as graded composites. The results found from the theoretical model so proposed are found to be in good agreement with the experimental values under similar test conditions. This study reveals that the presence of cement kiln dust particles enhances the sliding wear resistance of epoxy resin and the homogeneous composites suffer greater wear loss than the graded composites. scanning electron microscopy micrograph confirms the graded dispersion of CKD particles in the matrix.

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Figures

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Figure 1

Schematic diagram showing the processes of formation of wear particle

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Figure 2

Linear graphs for L27 array

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Figure 3

(a) Schematic representation of the different zones characterized as a function of the distance from the geometrical center of the samples: Hv1:49(R1=0 mm), Hv2:60(R2=1.0 mm), Hv3:62(R3=2.0 mm), Hv4:64(R4=3.0 mm), Hv5:65(R5=4.0 mm), and Hv6:66(R6=5.0 mm) for 20 wt % CKD graded specimen. (b) Trend of microhardness variation of the composites with CKD concentration. (c) Variation of microhardness of the composites with CKD content. (d) Variation of tensile strength with CKD content. (e) Variation of flexural strength with CKD content. (f) Variation of tensile modulus of the composites with CKD content. (g) Variation of impact strength of the composites with CKD content.

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Figure 4

(a) Effect of control factors on wear rate (homogeneous composites) and (b) effect of control factors on wear rate (graded composites)

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Figure 5

(a) Interaction graph between A×B for wear rate (homogeneous composites) and (b) interaction graph between A×B for wear rate (graded composites)

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Figure 6

Variation of friction coefficient with load for the CKD/epoxy composites (sliding speed: 105 cm/s and time: 15 min)

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Figure 7

Changes of wear with load for the CKD/epoxy composites (sliding speed: 200 rpm and time: 15 min)

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Figure 8

SEM micrograph of CKD filled epoxy composites under different operating conditions

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