Wear Evaluation Through Finite Element Analysis and Tribological Testing

2022-PLET

The objective of this project is to compare the wear properties of additively manufactured metals and traditional machined metals.

 

Team Members

Cole Ruffo | Cole Wolfe | | |

Project Poster

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Project Summary

 

Overview

Wear studies were conductd using a tribological Pin-on-Disk testing machine that was designed and assembled by the group. Furthermore, FEA ANSYS analysis was conducted to validate physical results. Finally, SEM imaging was conducted to determine if abrasive wear was occurring.

Objectives

It is expected that BeCu and Aluminum will show greater wear resistance than the material being used to create the additively manufactured mold inserts (AlSi10Mg). For the tribological PoD tests, it is expected that the results will be within +/- 0.5mm3 of the FEA results for Aluminum, showing abrasive wear.

Approach

  • Research Project
  • Design accelerated PoD wear test machine
  • Conduct PoD test using various materials
  • Conduct FEA ANSYS analysis using various materials
  • Compare results from both tests
  • Conduct SEM imaging

Outcomes

  • FEA can suggest what materials are going to wear more/less, but should not be used if the desire is to accurately predict how much wear will occur on a part for a specific sliding distance
  • Hypothesis was supported that BeCu showed greater wear resistance than ALSi10Mg but disproved that AlSi10Mg showed greater resistance than aluminum
  • Hypothesis disproved PoD results and FEA results would be +/- 0.5 cubic mm (53.6mm3 , 6.9mm3 for S7).
  • SEM supported hypothesis abrasive wear would occur