High Temperature Tribological Properties of Polybenzimidazole (PBI)

Polybenzimidazole (PBI) is a high performance polymer that can potentially replace metal components in some high temperature conditions where lubrication is challenging or impossible. Yet most characterisations so far have been conducted at relatively low temperatures. In this work, the tribological properties of PBI were examined with a steel ball-PBI disc contact at 280 °C under high load and high sliding speed conditions. The dry friction coefficient is relatively low and decreases modestly with increasing applied load. Surface analysis shows that PBI transfer layers are responsible for the low friction observed. In-situ contact temperature measurements were performed to provide for the first time direct links between the morphology and distribution of the transfer layer, and the temperature distribution in the contact. The results show that high pressure and high temperature in heavily loaded contacts promote the removal and the subsequent regeneration of a transfer layer, resulting in a very thin transfer layer on the steel counterface. FeOOH is formed in the contact at high loads, instead of Fe2O3. This may affect the adhesion between PBI and the counterface and thus influence the transfer layer formation process. To control PBI wear, contact temperature management will be crucial

Knowledge Based Cloud FE simulation – data-driven material characterization guidelines for the hot stamping of aluminium alloys

The Knowledge Based Cloud FEA (KBC-FEA) simulation technique allows multi-objective FE simulations to be conducted on a cloud-computing environment, which effectively reduces computation time and expands the capability of FE simulation software. In this paper, a novel functional module was developed for the data mining of experimentally verified FE simulation results for metal forming processes obtained from KBC-FE. Through this functional module, the thermo-mechanical characteristics of a metal forming process were deduced, enabling a systematic and data-driven guideline for mechanical property characterization to be developed, which will directly guide the material tests for a metal forming process towards the most efficient and effective scheme. Successful application of this data-driven guideline would reduce the efforts for material characterization, leading to the development of more accurate material models, which in turn enhance the accuracy of FE simulations

Tyre wear particles are toxic for us and the environment

This briefing paper discusses the current knowledge on the effects of tyre wear particles on our health and environment, highlights the need for an ambitious research agenda to build further understanding of the impacts on people and nature and develop solutions, and includes recommendations for policymakers

A micromechanical based finite element model approach to accurately predict the effective thermal properties of micro-aerated chocolate

Micro-aeration is a method to modify the sensorial attributes of chocolate but also affects the material properties of chocolate, which in turn, determine its material response during manufacturing and oral processes. This study aims to define the effect of micro-aeration on the thermal properties of chocolate by considering the changes of chocolate microstructure due to micro-aeration. Micro-aeration was found to alter the chocolate microstructure creating a layer of a third phase at the porous interfaces, which is argued to consist of cocoa butter of higher melting properties. A multiscale Finite Element Model is developed, which was confirmed by macroscale heat transfer measurements, to parametrically simulate the structural changes of micro-porous chocolates at the microscale level and estimate their effective properties, such as thermal conductivity and specific heat capacity. The developed multiscale computational model simulates the porous chocolate as a two-phase (chocolate- pores) or three-phase material (chocolate-cocoa butter layer- pores). The investigation identified a new, complex transient thermal mechanism that controls the behaviour of micro-aerated chocolate during melting and solidification. The results showed a maximum 13% reduction of keff and 15% increase of Cpeff with 15% micro-aeration resulting to a slower transient heat transfer through the micro-aerated chocolate. The reason is that the micro-aerated chocolate can store a larger amount of thermal energy than its solid counterpart. This effect slows down the transient heat transfer rate in the chocolate and modifies melting/solidification rate and impacts sensorial attributes during oral processing and cooling during manufacturing

Experimental and numerical evaluation of the effect of micro-aeration on the thermal properties of chocolate

Thermal properties, such as thermal conductivity, specific heat capacity and latent heat, influence the melting and solidification of chocolate. The accurate prediction of these properties for micro-aerated chocolate products with varying levels of porosity ranging from 0% to 15% is beneficial for understanding and control of heat transfer mechanisms during chocolate manufacturing and food oral processing. The former process is important for the final quality of chocolate and the latter is associated with sensorial attributes, such as grittiness, melting time and flavour. This study proposes a novel multiscale Finite Element Model to accurately predict the temporal and spatial evolution of temperature across chocolate samples. The model is evaluated via heat transfer experiments at temperatures varying from 16 °C to 45 °C. Both experimental and numerical results suggest that the rate of heat transfer within the micro-aerated chocolate is reduced by 7% when the 15% micro-aerated chocolate is compared to its solid counterpart. More specifically, on average, the thermal conductivity decreased by 20% and specific heat capacity increased by 10% for 15% micro-aeration, suggesting that micro-pores act as thermal barriers to heat flow. The latter trend is unexpected for porous materials and thus the presence of a third phase at the pore’s interface is proposed which might store thermal energy leading to a delayed release to the chocolate system. The developed multiscale numerical model provides a design tool to create pore structures in chocolate with optimum melting or solidifying response

Skin tribology: Science friction?

The application of tribological knowledge is not just restricted to optimizing mechanical and chemical engineering problems. In fact, effective solutions to friction and wear related questions can be found in our everyday life. An important part is related to skin tribology, as the human skin is frequently one of the interacting surfaces in relative motion. People seem to solve these problems related to skin friction based upon a trial-and-error strategy and based upon on our sense for touch. The question of course rises whether or not a trained tribologist would make different choices based upon a science based strategy? In other words: Is skin friction part of the larger knowledge base that has been generated during the last decades by tribology research groups and which could be referred to as Science Friction? This paper discusses the specific nature of tribological systems that include the human skin and argues that the living nature of skin limits the use of conventional methods. Skin tribology requires in vivo, subject and anatomical location specific test methods. Current predictive friction models can only partially be applied to predict in vivo skin friction. The reason for this is found in limited understanding of the contact mechanics at the asperity level of product-skin interactions. A recently developed model gives the building blocks for enhanced understanding of friction at the micro scale. Only largely simplified power law based equations are currently available as general engineering tools. Finally, the need for friction control is illustrated by elaborating on the role of skin friction on discomfort and comfort. Surface texturing and polymer brush coatings are promising directions as they provide way and means to tailor friction in sliding contacts without the need of major changes to the produc

Demanding it all from the novice mechanical engineer through design and manufacture

A core design and manufacture group project has been run in the second year of the Mechanical Engineering undergraduate programme at Imperial College for over two decades where students are required to develop highly loaded rotating machinery, such as a pump or a winch, early in the second year of their undergraduate study. The aim has been to provide a practical opportunity to apply and develop skills learnt in the first year and to provide the experience of manufacturing, operating and testing what has been designed. While these projects have been a mainstay of the educational experience for many years, there has been a persistent concern that the projects are deterministic and highly constrained. The course team and student body have debated and now implemented a new project that is both less constrained and more appealing to the student cohort. In this project the students are tasked with developing a transmission for an electric scooter. The project has resulted in a significant diversity in designs and, importantly, the students embracing the curriculum content with fervour. The challenge still requires attention to the application of fundamental mechanical engineering principles such as transmissions, solid mechanics and materials, but also focuses on electronic control systems, battery and motor characteristics, high current and power, health and safety and a range of transferable skills. The multi-disciplinary nature of the project combined with an appealing application has resulted in a highly engaged year group. This paper reports on the project and includes an analysis of the diversity of designs and student effort

Effect of temperature on tribological performance of polyetheretherketone-polybenzimidazole blend

Polyetheretherketone (PEEK) is one of the most commonly used High Performance Polymers (HPP) although its high temperature performance is poor. In this study, polybenzimidazole (PBI), a HPP with one of the highest glass transition temperatures currently available, is blended to PEEK to form a 50:50 blend (TU60). Tribological performance of the blend (TU60) was investigated by rubbing it against steel at temperatures up to 280 °C. Results obtained are compared to those from neat PEEK and neat PBI. All three polymers were thermally stable during the duration of tests. However chemical analyses on polymeric transfer layers on steel surfaces and polymer debris suggest polymer degradation. The degradation observed is shear-assisted, possibly promoted by shear heating. Indeed the estimated interfacial temperature based on Jaeger model was above the melting point of PEEK in some cases. TU60 outperforms PEEK in all test conditions and PBI at 280 °C. TU60 formed transfer layers on steel similar to that of PEEK. When contact temperature is closed to the melting point of PEEK, PEEK in the TU60 creates a low strength transfer layer which acts as an interfacial lubricant. This reduces friction which in turn reduces PBI degradation in TU60 at high temperature. This work provides a strategy for creating interfacial layers to improve polymer tribological performance while maintaining the integrity of the polymer

Hot stamping of AA6082 tailor welded blanks: experiments and knowledge based cloud FE (KBC-FE) simulation

A novel hot stamping technique known as ‘Solution Heat treatment, Forming and in-die Quenching (HFQ®)’ was employed to manufacture lightweight structural components from AA6082 tailor-welded blanks (TWBs) of different thickness combinations: 1.5–1.5 and 2.0–1.0 mm. A finite element (FE) model was built to study the deformation characteristics during the hot stamping process. The FE model was successfully validated by comparing simulation results with experimental ones. Subsequently, the verified simulation results were analysed through a novel multi-objective FE platform known as ‘Knowledge-Based Cloud – Finite Element (KBC-FE)’. KBC-FE operates in a cloud environment and offers various advanced unique functions via functional modules. The ‘formability’ module was implemented in the current study to predict the limiting dome height and failure mode during the hot stamping process. Good agreements were achieved between the predicted and experimental results, from which studies were extended to predict the forming features of 2.0–1.5 mm TWBs. The ‘formability’ module has successfully captured the complex nature of a hot stamping process, featuring a non-isothermal and non-linear loading path. The formability of TWBs was found to be dependent on forming speed and blank thickness, out of which the latter has a dominant effect