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Binder jet 3D printing of ceramic materials is an additive manufacturing technology that enables the production of complex and multi-functional parts through the selective jet binding of precursor powder beds. The present study makes use of the 3D Sand Printing (3DSP) process to create moulds and cores in the casting industry. The use of the 3DSP components as functional parts in industrial production is limited due to the uncertainty associated with their mechanical properties, such as their permeability and thermal stability. Moreover, because of the porous nature of their printed structures, their mechanical properties are dispersed and rather difficult to reproduce. This study aims to characterise the impact of different printing parameters on the mechanical performance of printed parts. For this purpose, a specific device was made in order to assess the mechanical characteristics of samples printed via this technique. The effects of processing parameters such as the printing orientation and building direction on the compressive properties of the printed specimens have also been carefully studied. Microstructural analyses were performed to better understand the relationship between the 3DSP process and the mechanical properties of the components produced from it. The results show that the mechanical tests carried out significantly improve the property reproducibility of the samples made using this technique.

International audience; In this work, Al-Fe-Cr quasicrystal reinforced Al matrix composite was in-situ prepared by using selective laser melting from powder mixture of Al-Cu-Fe-Cr quasicrystal and pure Al. The effect of selective post-aging treatment on microstructure and mechanical properties were determined with focus on the metastable phases. The microstructural analysis, which was determined by X-ray diffraction and scanning electron microscopy, indicates that the Al-based intermetallic is precipitated from supersaturated α-Al after the aging process. Moreover, the compression tests were performed on the samples in form of dense and lattice structures (50% porosity). The elastic modules of dense and lattice structural samples reduce from 21.3 GPa and 4.4–14.6 GPa and 3.6 GPa by using a low cooling-rated aging process. After aging process, the compressive deformation behavior of dense part changes from elastic-plastic-fracture mode to elastic-plastic-densification mode. On the other hand, the failure mechanism of lattice structural sample changes from rapid-single-stage to slow-double-stage with an improvement of the strain at failure.

International audience; The friction of concrete on the interior skin of formworks takes place during the pouring of concrete into the molds. The present work investigates the friction of a granular material (i.e. fresh concrete) against metallic and polymeric surfaces. Interfacial behavior between different formulated concretes and formwork skins is characterized using a plane-plane tribometer dedicated to concrete tribometer. The formwork surface is measured before and after testing to quantify the wear issue. A Coulomb friction law is observed within the range of tested normal pressures. Tribological tests reveal that friction mechanisms depend on the interface properties. Two underlying mechanisms are hypothesized to explain the wearing of the formwork skin: a granulate-formwork solid-solid friction and a capillary-dominated friction.

International audience; The cosmetic aspect is one of the main functions of industrial surfaces in numerous applications. Even the smallest surface defects may have a critical effect on the cosmetic tolerability of such industrial surfaces. Thus, surfaces are generally coated at the last manufacturing process stage to cover existing defects and to certify their cosmetic quality. The surface quality is however constantly controlled after coating that induces an increase of lead-time increase and production costs. This is due to a various flaw patterns and a lack of uncoated surfaces specifications. Hence, the identification of relevant surface morphological parameters underlies an objective and automatic cosmetic control performance. In fact, this relevant parameter selection allows tracking surface flaws during the coating finishing operation. This paper presents a comprehensive overview of various feature selection tools for data analysis (Neighbourhood Component Analysis (NCA), ReliefF, Sequential wrapper method, Decision tree) to extract relevant information out of physical data. A design of experiment based on scratches test on amorphous polymers to generate typical controlled defects has been performed. Then, several cosmetic defects characteristics were extracted from experimental measurements. Feature selection approaches were applied and compared to determine the most relevant parameters. The advantages and limitations of each method for data analysis have been highlighted in the case of real engineering surface quality control.

International audience; In this research, Al-Fe-Cr quasicrystal (QC) reinforced Al-based metal matrix composites were in-situ manufactured by using selective laser melting (SLM) from the powder mixture. The parametrical optimization based on our previous work was performed with focus on laser scanning speed. From the optimized parameters, an almost dense (99.7%) free-crack sample was fabricated with an ultra-fine microstructure. A phase transition from decagonal QC Al65Cu25Fe10Cr5 to icosahedral QC Al91Fe4Cr5 could be observed as laser scanning speed decreases. Differential scanning calorimetry curves show that the QC phase is quiet stable until 500 °C. And then, the effects of annealing temperature on the microstructural and mechanical properties were determined. The results indicate that the recrystallization and growth behavior of α-Al grains could be prevented by QC particle during annealing. Furthermore, the growth of QC particle, which tends to form a porous structure, leads an improvement of Young modulus and decline of ductility.

The sticking of the concrete on metallic formworks during building construction generates many concrete wall defects. Several solutions have been proposed, among which surface lubrication and polymeric coatings are commonly applied. In this paper, the main functional signatures of a steel formwork skin and a polymeric coating were determined to understand their effect on the concrete sticking. The topographical, chemical and mechanical signatures of the surfaces were characterized at near-surface regions. The top of the steel formwork a 10 µm-thick layer is constituted of two oxides each one having specific tribological properties. Adding the polymeric coating on the formwork skin surface lowers its surface tension, which lowers the sticking by reducing the wettability. Moreover, the smaller roughness of the coating limits the susceptibility of mechanical anchoring. Nevertheless, scratch testing suggests a short durability of the polymeric coating due to its weak resistance to abrasion.

To functionalize a glassy polymer surface like the Polycarbonate (PC) several process are needed: milling, turning, polishing and a chemical attack process. These processes sign the surface on a large band frequency from mm-wavelength for the milling, to the nm-wavelength for the polishing and the chemical attack process, passing through the µm-wavelength for turning. However, the band frequency available with a measurement is limited by the size of the measure and the step scale of the sampling. In this paper, a method to characterize the evolution of the surface has been developed with Wavelet Transform approach. Surfaces of each step were measured with an interferometer under different magnifications (x5, x50, x115). Their signatures calculated with Mexican hat wavelet transform were lengthened by continuity between the different magnification. Some conditions of the continuity are needed as having the same size and the same step scale on the measurement by adding interpolation points for the lower magnification. The results show clear correlation between the multistage process signatures and the function printability evolution like optical, design and mechanical.

International audience; Concrete, a commonly used material in the construction industry, interacts with metallic surfaces such as formwork during pouring and reinforced bar during lifespan. Formworks are designed to minimize hardened concrete adherence in order to avoid wall defects after formwork removal. In opposite, reinforced bar designs aim at maximizing their adherence to concrete for optimizing the transmission of mechanical solicitations. The present review investigates the surface properties that govern bonding of freshly poured concrete onto metallic surfaces. Identifying the underlying mechanisms of adhesion highlighted the importance of substrate characteristics (roughness, composition), concrete curing and compaction), and interfacial additives (release agents, wetting). This paper addresses the basic requirements in designing a functional surface interacting with concrete and emphasizes today challenges.

Multiple parallel scratches are often analyzed to understand the material removal mechanisms due to abrasion. However, successive scratches with different orientations may represent better the conditions found in machining processes, such as honing and belt finishing. The objective of this work was to analyze the cutting forces and the phenomena of material removal due to abrasion, arising from angular scratches in low carbon steel. Experimental and numerical techniques were considered. In both, analyses considered the presence of an initial set of parallel scratches, followed by a second set of scratches with different orientations (10, 20 or 30°) with respect to the previous one. The cutting action was performed by a tool representing an abrasive particle, which had a cono-spherical geometry with 235 µm tip radius and 30° apex angle. The cutting settings were: 50 m/min scratch velocity and 100 µm depth of cut. In the experimental part, scratches were conducted using a shaper machine tool equipped with a tungsten carbide (WC-Co) stylus. Tests were conducted on a Kistler platform, which allowed force measurement. Surfaces were later analyzed with an optical profilometer. The numerical simulations considered a ductile damage model with element deletion to provide the material removal during the scratches. Experimental and numerical results showed that the angle affects the cutting forces, especially when one scratch crosses a previously scratched region. The 20° case was the most critical, especially in terms of the cutting forces, due to the accentuated material strain-hardening for this condition. Likewise, this fact was corroborated by numerical results, which indicated a higher energy necessary to plastic deformation, and a reduced material removal at 20°.

International audience; Honing is a manufacturing process which uses friction and abrasion mechanisms at a reduced velocity to print a multiscale and anisotropic texture on the liner surface of automotive engines. It enables to enhance the functional performances of a ring-pack system. However, industrial honing basically generates cross-hatched rectilinear textures. This paper proposes new surface textures, generatedby an innovative honing prototype machine, with original patterns (circles and ellipses) at different size and aspect ratio. Then, the friction performances of each generated surface are evaluated using a reciprocating ring–liner tribometer and compared with industrial helical slide honed (HSH) texture. The results show that ellipse patterns oriented at ring sliding direction contribute the most to reduce the friction coefficient.

International audience; Fe-Ni-Si soft magnetic parts, using Ni coated high silicon steel powder, were manufactured by selective laser melting process. The type of defect changes from porosity to cracks and the relative density increases, from 50% to 99%, with the decreasing laser scanning speed. The microstructural analyses indicate that the low laser scanning speed fully melted the nickel coating and high-silicon steel core. The EBSD study showed that the separated island and lamellar mesostructures appeared on the top and side view respectively. Moreover, no apparent texture were observed. The magnetization saturation of SLM processed sample decreased, as the laser scanning speed was increased. Consequently, the magnetic properties of SLM processed Fe-Ni-Si alloy also showed anisotropic feature in building and scanning directions, which can be attributed to their different mesostructure.

International audience; The molten metal flow under low-pressure filling was investigated both experimentally and numerically insidesand molds with different cross sections and different pressure ramps. The proposed fluid dynamics simulationpredicts quantitatively the observed filling oscillations. An analytical model is developed to link the over-heightwith the geometrical restriction and the pressure ramp. The calculated over-height is proportional to the rampand non-linearly impacted by the section change as confirmed by the experimental results.

Surface texturation at micro- and meso-scales plays an important role in applications where cosmetic, aesthetic and self-cleaning functionalities are specified. This research paper deals with a multiscale surface, in which texturing and texture have a larger influence because they are scaled differently. The experimental approach highlights the important effect of texture and texturing on the anti-fingerprinting performance rated in term of surface wettability. We examine first, in detail, the wetting response of surfaces textured on aluminum alloy 6063 plates using nano-peening with various processing parameters. Roughness was measured by atomic force microscopy (AFM) and interferometry. Surface wettability was quantified using the sessile drop method. The calculation takes into account the wetting behavior of the textured surfaces at different scales. Correlations were made between the surface roughness and its functionality.

International audience; Nowadays buildings construction is performed by pouring concrete into molds called formworks that are usually prefabricated metallic modules. Defects such as stripping may possibly form during the removal of the formwork if the interfacial bonding between the concrete and the formwork is high. Making use of a new pull-off tensile test designed in our laboratory, a correlation has been established between the formwork surface functional signatures and its adherence propensity to concrete. The originality of this near-to-surface test was to characterizethe concrete-to-formwork adherence by measuring the required force to pull the concrete from the formwork surface. The design of the test coupon was validated by finite element analysis that proves the small deformation of the tested formwork specimen under the tensile loading and the homogeneity of the applied tensile stress at the interface. The interfacial bonding to concrete has been compared between bare and coated formwork. Both metallic and polymer coatings have been studied. The analyses of the pull-off test results enabled us to understand the bonding mechanisms at the concrete-coating interfaces. The pull-off tensile test was proven capable of ranking formwork coatings according to their adherence to concrete.

Current demands of higher damage-tolerance in the Aerospace industry resulted in resurging interest in β , or near β , titanium alloys. The combination of attractive properties of this class of alloys also led to the consideration of beta alloys for castings. Such alloys, however, are more difficult to cut than α - β titanium alloys due to their limited ability to work harden and the effect of β -stabilizers on ductility. These factors affect failure modes and active wear mechanisms of cutting inserts. This paper investigates some of the wear modes exhibited by WC-Co inserts when end milling the α near- β alloy Ti- x . In addition to being of near- β composition, this alloy is characterized by a fine sized microstructure (range of 1−5 μ m). The study focuses on SEM and EDS observations of the wear patterns exhibited by two groups of inserts. The first is uncoated WC-Co, whereas the second is coated with multi layers of TiAlN. The results of this post-mortem study are compared to wear patterns, observed under identical conditions, while milling the α - β alloy Ti6Al4V. Results show that inserts used in machining the Ti- x alloy exhibit wear modes that contrast those exhibited when machining Ti64. The paper discusses factors leading to such occurrences and studies the influence of the alloy microstructure on tool effectiveness and failure modes.

Dry machining is being recognized as ecological machining due to its less environmental impact and manufacturing cost. However, the choice of dry machining is mainly influenced by the workpiece material properties, machining operation and cutting conditions. The recent emergence of austempered ductile iron (ADI) can be considered a significant economic advantage to the increasing industrial demand for cost- and weight-efficient materials. However, due to its microstructure-induced inherent properties, ADI is considered hard-to-machine material. Thus, the dry drilling of ADI is investigated in this paper. The ADI material used in the present study is produced using an innovative process route for near net shape casting production. Drilling experiments are conducted on a DMU80P Deckel Maho five-axis machining centre using PVD-coated carbide tools under dry cutting environment. The dry drilling of ADI under different cutting conditions is evaluated in terms of specific cutting force and tool wear analysis. The influence of cutting conditions on chip morphology and surface roughness is also investigated. The experimental results revealed that the combination of the low feed rate and higher cutting speed leads to the higher mechanical and thermal loads on the tool's cutting edge, resulting in higher specific cutting force values. This behaviour is further supported by the chip morphology analysis, which revealed the formation of segmented chips at higher cutting speed with segment spacing increase with an increase in feed rate. Depending upon the cutting parameters, different modes of tool failures including crater wear, flank wear, chipping, breakage and built-up edge were observed. Surface roughness analysis revealed the influence of tool wear and chip morphology on the machined surface finish.

International audience; The texture change during running-in alters the performance and efficiency of a tribo-mechanical system. During mass production of cylinder liners, a final finishing stage known as ''plateau honing'' is commonly added to reduce the running-in wear process of the liner surface. The majority of researchers think that this operation improves the engine efficiency and decreases oil consumption. It was believed that there are close links between the surface topography of honed cylinders change and their wear resistance during running-in. However, these interactions have not yet been established. Some running-in wear models were developed in the open literature to predict topographical surface changes without considering the running-in conditions. The present paper thus investigates the various aspects of the wear modeling that caused running- in problems in honed surfaces and its implications on ring-pack friction performance. To illustrate this, plateau honing experiments under different conditions were first carried out on an instrumented vertical honing machine. The plateau honing experiments characterize the surface modifications during running-in wear of cast-iron engine bores using advanced characterization method. Based on the experimental evidence, a running-in wear model was developed. Finally, a numerical extension of the developed model was applied to solve the Reynolds equation by taking into account the real surface topographies of the engine bore. This enables us to predict realistic friction performance within the cylinder ring-pack tribosystem.

The sand mold 3D printing technologies enable the manufacturing of molds with great dimensional accuracy. However, the roughness of as-cast components is higher when cast in a 3D printed mold rather than in a traditional sand mold. Coating the inner cavity is an efficient solution but can be costly and, in the narrowest cavities, not achievable. Finding a procedure to reduce the as-cast roughness without coating would ease the casting procedures. In the present work, surface analysis of ZE41 magnesium alloy is presented after being cast in 3D printed furan sand molds without coating using the low-pressure casting process. The molten metal temperature was measured during casting at different positions along the cast cavity. The as-cast surface roughness was correlated to the molten metal temperature and solid fraction at the time of contact against the sand mold surface.

International audience; Honing is an industrial alternative of internal grinding for finishing large-diameter bores of internal combustion engine cylinders. This paper introduces a hybrid approach for a multi-scale analysis of surface finish in abrasive honing. The methodology is based on morphological identification of scratch pattern of manufactured surfaces, produced at various honing conditions, and their 2D continuous wavelet decomposition. The activated abrasion mechanisms were then discussed based on quantitative analysis of geometrical scratch pattern and multi-scale surface modifications of honing signature. Results show clearly that honed surface finish is primarily controlled by the size and the geometry of abrasive grains (i.e. wear of abrasive sticks). Since the abrasive is in continuous balanced contact with the work in honing operating at constant-force grinding, there is less deflection of the work. Moreover, it appears that honing signature shows a multi-scale fractal structure along the observation scales. This makes it possible to identify an optimal honing route preserving honing sticks abrasiveness and increasing their texturing capacity to confer high volume of oil retention at honed surfacefinish.

International audience; Skin in biological systems, including humans, perform several synchronized tasks (mechanical, protec-tive, tactile, sensory, etc.). Tribological function is among skin tasks and may determine the survivabilityof many species. Cross comparison of tribological functional traits of skin of different species, albeit interesting, is rarely encountered, if at all exists, in tribology literature. One interesting example is that of snake and human skins. This skin pair was the subject of many studies for transdermal drug delivery. Results in that context concluded that snakeskin is highly compatible with human skin despite apparent differences in surface structure and topology. The reported compatibility raises curious question ofwhether there exists frictional or tribological compatibility between the two skins and if so, under what conditions, and which context. In this work, we report, for the first time in open literature, results of a comprehensive comparative investigation of shed snakeskin and human skin with respect to tribological behaviour. To this end, we compared the frictional response of shed skin obtained from P. regius and human skin from different anatomical sites, gender, and age. The results imply that, in essence, the mechanisms governing the friction response of human skin are common to snake skin despite difference in chemical composition and apparent surface structure. In particular, both skin types display sensitivity to hysteresis and adhesive dissipation. Human skin, however, being more sensitive to hysteresis than snakeskin. One interesting finding of the study is that the ratio of the coefficients of friction for snake and human skin, when sliding on the same interface, depends on the reciprocal of their respective moduli of elasticity.

The present paper investigates the simulation analysis of simultaneous mold filling and solidification of ductile iron casting in a permanent mold by virtue of its thermal characteristics. Thermal analysis was performed to determine the solidification behavior and nature of alloy of the melt during its solidification. It revealed the variation in the nature of alloy due to the variations in eutectic freezing and carbon equivalent of the melt. The obtained thermal parameters from the thermal analysis were further used for the casting simulation of the melt. The simulation results show a progressive solidification behavior of the casting. There is a significant decrease in the overall heat transfer coefficient with time during the solidification process. The simulation results were further verified experimentally. The experimental results show porosity defects at the top section of the casting. Two distinct zones (center and outer) were observed on the produced samples based on the average graphite nodule counts and average graphite nodule size.

International audience; Multistage abrasive finishing processes (grinding, polishing, honing, etc.) are commonly used to produce the geometrical properties of a surface to meet its technical functionalities in the operating characteristics of contacting parts in friction, relating to their durability and reliability (running-in performance, wear resistance, load-carrying capacity, etc.). Coarse abrasive grits followed progressively finer ones are used, which leads to a multiscale stratified surface texture. In this article, a numerical model of elastohydrodynamic (EHD) contact coupled to a multiscale surface texture model was developed that allows tracking the scale effect of surface features and their interactions on friction performance and lubricant flow under hydrodynamic lubrication conditions. Because the simulation model has as an input the surface topography and to overcome the variability in surface finish formation, textured surfaces at different stages of the finishing process were simulated (virtual texturing method). Surface topography can be decomposed into two principal components: superficial roughness and valleys. Superficial roughness was modeled using a fractal model and a scaling factor was introduced to model valley patterns. The results show the relationship between friction and surface scales.

A cylinder liner possesses fairly intricate surface requirements due to its complicated functions. It needs to provide adequate surface roughness to resist wear as well as to store and retain lubricants during high temperatures. The liner surface texture is anisotropic, produced by the honing process, with resultant deep visible scratches left on it [1] . The prominence of the honing grooves observed suggests that surface texture significantly affects ring-pack performance, although this effect is not clearly understood. In this paper, a numerical model was developed to investigate the effects of groove characteristics on the lubrication condition and friction at the interface between the piston ring and cylinder liner. This model aims to solve the average Reynolds equation, which depends on the real surface topographies of the cylinder liner, and describes the influence of surface irregularities on the lubricant flow under hydrodynamic lubrication conditions, considering lubricant film rupture and cavitations. Numerical results help to determine the optimum lateral groove characteristics to reduce friction and then noxious emissions.

Machinability study on drilling of green austempered ductile iron (ADI) grade was conducted using a TiAlN-coated tungsten carbide drill. The green ADI grade was produced by a novel manufacturing technology known as continuous casting-heat treatment technology to save energy and time in foundry. However, in spite of good combination of strength, toughness and enhanced wear resistance, the microstructural properties of ADI sometimes lead to machinability issues. The effect of cutting parameters on cutting force coefficients, chip morphology, and surface integrity of the drilled surface were discussed. Results showed that the strength properties of novel ADI are comparable to that of ASTM grade 1 ADI, whereas percent elongation is comparable to that of ASTM grade 2 ADI. Results obtained also showed that the combined effect of cutting speed at its higher values and feed rate at its lower values can result in increasing cutting force coefficients and specific cutting energy. At higher cutting speed, hardness values increases at the subsurface layer of the drilled surface due to plastic deformation.

International audience; This paper addresses the effects of bonds and grains of abrasive tools on the edge aspect of ground glass surface. Diamond grains and silicon carbide (SiC) grains combined with two bond types, i.e., resin and metal, were considered for this study. The surface edge characteristics were characterized using scanning electron microscope (SEM) and interferometer observations. In particular, the spectrum of arithmetic mean was investigated for distinguishing the different scales of analysis. Experimental results showed that the grinding forces vary sensitively with bond type and wheel velocity. Using diamond grains' wheel, it was found that roughness level obtained with metallic bond is lower than that obtained with resin bond. However, using a resin-bonded wheel, two mechanisms of material removal were revealed according to grains' type. (i) A partial ductile regime, i.e., ductile streaks and brittle fracture, obtained with diamond grains, and (ii) a fully ductile regime obtained with SiC grains. Thus, it was found that ground surface obtained using SiC grains' wheel has a better roughness than that obtained using diamond grains wheel. Besides, SiC grains seem to lead to more marked streaks and form defects.

Progressive failure of unidirectional glass fiber-reinforced polymer composites (FRP) was studied using finite element analysis in orthogonal machining. Chip formation process and damage modes such as matrix cracking, fiber–matrix debonding and fiber breaking were modelled by degrading the material properties. Damage analysis was carried out using Hashin, Maximum stress and Hoffman failure criteria. After damage was detected, selective stiffness degradation was applied to the workpiece material. The objective of this study is to better understand the chip formation process and to analyse the cutting-induced damage from initiation stage until complete chip formation. The effect of the fiber orientation on cutting forces and sub-surface damage was investigated with different failure criteria. The results were addressed in terms of cutting forces evolution and damage progression in the composite structure during machining. It was demonstrated that the use of the stiffness degradation concept with the appropriate failure criterion responds potentially in a predictable fashion to changes in chip formation process for machining of FRPs.

Cobalt-base materials are widely used as weld hardfacing deposits in hot forging industry. When the cobalt-base hardfacing alloys are deposited using the MIG welding process, the weld energy with the sequences of the welding are at least the two important variables which influence the behaviour of most hardfacing deposits in service conditions. The purpose of this work is to consider their role in connection with the work-hardening ability of Stellite 21 weld hardfacing deposits. An experimental parametric study of several welded-layers related to their friction behaviour is performed. The friction-induced work hardening (FIWH) ability of Stellite 21 deposits is considered to assess the influence of the two welding parameters. Results show that depending on the used welding sequences, the amount of the applied energy determines the dilution rates across the thickness of the deposits. Microscopic observations at the friction surface confirm that the highest FIWH rates, owing to stacking faults brought out, increase the wear resistance.

The contribution of gear tooth flank surface micro-finish on gear noise has not yet been taken into consideration. This paper is devoted to study the simultaneous effect of tooth roughness and lubricant viscosity on automotive gear vibrations. The vibrations performances were evaluated on an instrumented test rig under both dry and wet conditions. A non-destructive replication technique coupled to 3D optical measures was used to acquire the flanks topographies, which were characterized using multiscale decomposition. A three-dimensional finite element simulation of a helical gear was performed to assess the micro-scales impact on gear noise. Numerical representative surfaces morphologies were introduced into the simulation and compared through the transmission error calculation. Results have shown gear noise dependence on tooth finishing processes.

This paper deals with a study on the dry machinability of the nickel-based hardfacing layers used in the manufacturing of hot tooling. Several machining tests were carried out on 56NiCrMoV7 steel block with thickness of 60 mm (substrate). Five layers of Hastelloy C type with thickness varying between 2 and 3 mm were deposited on the substrate using flux cored-wire welding (pulsed semi-automatic MIG). In the accelerated machining tests (AMT), only the nature of the hardfacing layers were changed. The cutting speed Vc of 80 m/min, the axial depth of cut ap of 0.12 mm, the radial depth of cut ac of 12 mm and the feed rate fz of 0.05 mm/tooth were considered in the AMT tests. It was found that the main limitation of this hardfacing in machining is associated with its highly heterogeneous metallurgical structure. This heterogeneity consists of a dendritic network (ductile nickel phase) separated by a fragile interdendritic dispersion (carbide phase and fine or coarse precipitate phases). This is expressed during cutting tests by the high hardness of the workpiece surface that involves premature wear of cutting tools. This deterioration is caused by the adhesion of the produced chips (dry sticking friction) leading to notches and very severe chipping of the cutting edge, following a crumbling of the tool material.

The authors acknowledge the urban community of Châlonsen Champagne(Cités en Champagne) for their financial support. The authors also wish to thank “AD majoris SAS France” for providing the NFRP samples used in this research.; Recently, natural fiber reinforced plastic (NFRP) materials are becoming a viable alternative to synthetic fiber in many industrial applications which not require high structural performances. However, machining of NFRP such as milling process is almost unavoidable operation to facilitate the parts assembly in addition to the finishing of final products. The present study thus focused on the influence of natural fiber types on tribological behavior during profile milling process. Three types of short natural fibers (bamboo, sisal and miscanthus) reinforced polypropylene (PP) composites are investigated. The quality of NFRP machined surface is quantified using a multiscale analysis based on wavelets decomposition. The natural fiber effect related to the machined surface quality is hence identified at all scales from roughness to waviness. The bamboo fibers reinforced plastics which exhibit high contact stiffness shows the smoother surface finish after machining. Therefore, the multiscale surface roughness is used as descriptor of natural fiber influence on the machining mechanisms and to establish the cutting signature of NFRP materials.; International audience; Recently, natural fiber reinforced plastic (NFRP) materials are becoming a viable alternative to synthetic fiber in many industrial applications which not require high structural performances. However, machining of NFRP such as milling process is almost unavoidable operation to facilitate the parts assembly in addition to the finishing of final products. The present study thus focused on the influence of natural fiber types on tribological behavior during profile milling process. Three types of short natural fibers (bamboo, sisal and miscanthus) reinforced polypropylene (PP) composites are investigated. The quality of NFRP machined surface is quantified using a multiscale analysis based on wavelets decomposition. The natural fiber effect related to the machined surface quality is hence identified at all scales from roughness to waviness. The bamboo fibers reinforced plastics which exhibit high contact stiffness shows the smoother surface finish after machining. Therefore, the multiscale surface roughness is used as descriptor of natural fiber influence on the machining mechanisms and to establish the cutting signature of NFRP materials.

Machining in dry mode is characterized by intense thermo-mechanical loading. The coupling between the thermal and the mechanical loads may lead to tool failure, especially when machining the so-called hard-to-cut alloys. Within such environments the efficiency of heat removal plays an important role in preserving the structural integrity of the tool. Efficient heat removal in dry machining depends solely on the intrinsic thermal proper- ties of the tool for uncoated tools and on the effective properties of the tool-coating combinations for coated tools. Thermal loads may also accelerate wear of the tool. As such, a relationship between the wear and the intrinsic thermal properties of the tool is worthy of investigation. This paper investigates such a relationship. Here we team numerical simulations to SEM-imagery to map the thermal conductivity within the tool zone of action of a coated carbide tool. The results indicate that, depending on the temperature rise, the tool-tip might undergo a severe drop in thermal conduction. This drop may locally restrict the ability of the tool material to dissipate the applied thermal load. This may nucleate thermally congested clusters within the tool-tip where the material completely loses the ability to transport heat. Thermal congestion renders an energeti- cally active zone where the thermal energy available may be used to activate wear through different mechanisms. It is also found that the immediate layer under the surface of the tool tip is important to enhance the ability of the tool material to dissipate the thermal loads. The results also highlight the importance of matching the temperature dependant properties of the different coating layers in order to enhance delamination resistance.

International audience; The improvement of environment efficiency of automotive internal combustion engine becomes a fundamental objective. The cylinder engine surface texture considerably influences the functional performances of the ring-pack tribo-system. These surfaces are obtained by honing process that was pioneered in the last decade. Several innovative honing techniques were developed resulting in new surface textures with different cross-hatch angle obtained after several stages: the rough and finish honing and final stage. The aim of this study is to investigate the effect of variable cross-hatch angle generated at a final stage. These measured obtained surfaces are measured by a 3D white light interferometer and used as input data of the numerical model to estimate the friction. The results show the importance of this ‘residual’ angle.

International audience; The honing process produces surface liners with specific functional properties. Engine performances and life expectancy are directly impacted by the quality of honed surface. The form quality, the roughness and the surface appearance manufactured by honing determine the friction of the piston in the liner. The process is however mechanically complex and the selection of the process parameters is currently based on empirical methods. The aim of this paper is thus to develop a macroscopic simulation environment which will help end-users during this setting-up stage. The development of this virtual tool is based on a space-time discretization and a macroscopic cutting model taking into account local contacts between the workpiece and the abrasive stones. The space-time discretization allows representing the machine environment including the tool, the workpiece and the machine kinematics. The cutting model allows converting kinematics and abrasive contacts in dynamic data and material removal rate by calculation. The cutting model is initially adjusted based on simple experiments. The stock removal equation is then extrapolated to the whole range of stone cutting conditions. This approximation allows simulating the real process and a whole honing cycle. Results are validated by comparison with industrial context experiments. The simulation of the whole honing cycle allows predicting the form quality, one of the roughness criteria and the surface appearance. Moreover, simulation results are represented by means of maps that allow looking at quality criteria for each point of the surface.

International audience; The paper discusses a flexible honing technology by describing the new prototype machine with its specificity. Three original methods produced by the flexible honing prototype have been studied. A path combines the two contemporary methods of industrial honing: the helical slide honing at 135° at the bottom of the cylinder and the conventional honing at 45° on the upper part. This method of honing shows the effectiveness of specific motion tracking to remove traces of inversions. Circular trajectories with large radii can be traveled quickly without consuming too much energy. The high cutting speed promotes the removal of material thus saving time. Finally, the multi-circle paths can get original textures thus proving the feasibility of all patterns.

International audience; The cylinder bore surface texture, widely produced by the honing technique, is an essential factor for a good engine performance (friction, oil consumption, running-in, wear etc.). This explains the improvement and development of various new honing techniques. These different honing processes generate surfaces with various texture features characteristics (roughness, valleys depth, cross hatch angle, etc.). This paper addresses a comparison of ring-pack friction for cylinder surfaces produced by plateau honing and helical slide honing. It takes in consideration the mutual effect of superficial plateau roughness amplitude and honing angle. A numerical model is developed to predict friction within the cylinder ring-pack system in mixed lubrication regime. The results show the effectiveness of helical slide honed surface texture in comparison to plateau honed bore surfaces

Developing deterministic surfaces relies on controlling the structure of the rubbing interface so that not only the surface is of optimized topography, but also is able to self-adjust its tribological behavior according to the evolution of sliding conditions. In seeking inspirations for such designs, many engineers are turning toward the biological world to correlate surface structure to functional behavior of bio-analogs. From a tribological point of view, squamate reptiles offer diverse examples where surface texturing, submicron and nano-scale features, achieve frictional regulation. In this paper, we study the frictional response of shed skin obtained from a snake (Python regius). The study employed a specially designed tribo-acoustic probe capable of measuring the coefficient of friction and detecting the acoustical behavior of the skin in vivo. The results confirm the anisotropy of the frictional response of snakes. The coefficient of friction depends on the direction of sliding: the value in forward motion is lower than that in the backward direction. In addition it is shown that the anisotropy of the frictional response may stem from profile asymmetry of the individual fibril structures present within the ventral scales of the reptile.

Cutting tools are subject to extreme thermal and mechanical loads during operation. The state of loading is intensified in dry cutting environment especially when cutting the so called hard-to-cut-materials. Although, the effect of mechanical loads on tool failure have been extensively studied, detailed studies on the effect of thermal dissipation on the deterioration of the cutting tool are rather scarce. In this paper we study failure of coated carbide tools due to thermal loading. The study emphasizes the role assumed by the thermo-physical properties of the tool material in enhancing or preventing mass attrition of the cutting elements within the tool. It is shown that within a comprehensive view of the nature of conduction in the tool zone, thermal conduction is not solely affected by temperature. Rather it is a function of the so called thermodynamic forces. These are the stress, the strain, strain rate, rate of temperature rise, and the temperature gradient. Although that within such consideration ...

International audience; This paper outlines a new method to evaluate roughness parameters considering the scale used for their evaluation. Application is performed for grinding hardened steel with abrasive belts. Seven working variables are considered through a two-level experimental design. For all configurations, 30 surface profiles were recorded by tactile profilometry and rectified by a first degree B-spline fitting before calculating a set of current roughness parameters. The relevancy of each roughness parameter, to highlight process parameters influence, is then estimated for each scale by variance analysis. The results show that each influent input parameter is characterised by a related relevant evaluation length.

International audience; In this paper, a hybrid analytical-numerical approach is performed for the orthogonal cutting process. The modelling of the thermomechanical material flow in the primary shear zone, the tool-chip contact length and the sliding-sticking zones are obtained from an analytical approach. In addition, the Finite Element method is used to solve the non linear thermal problem in the chip. Our aim is to propose an approach which can easily be used to identify the main parameters governing tool wear and to explain the experimental trends. The effects of cutting conditions and material behaviour on the sliding-sticking zones and on the temperature distribution along the tool-chip interface can be evaluated from this approach. It has been found that the sliding-sticking zones at the tool-chip interface strongly control the local conditions of stress, velocity and temperature

International audience; Glass shaping, which corresponds to the removal of the edges of a specimen, is the last finishing operation in glass manufacturing. This process has several functions on the final shaped glass including removing sharp edges, improving mechanical resistance, decreasing surface damage and giving it an aesthetical aspect. This article addresses the effects of working parameters, including grinding forces and consumed power, on surface edge finishing and damage mechanism induced during glass grinding. Microscopic observations and multi-scale analysis have also been conducted to investigate the surface edge characteristics. Experimental results show three damage regimes. The first (regime I) is a partial ductile regime with cutting action accompanied by chip formation. The second (regime II) is a crushing (or fragmentation) regime. The last (regime III) is also a partial ductile regime but by ploughing action with displaced material. The shaped surface obtained in the regime II has a better roughness than that obtained in regime I and III. However, regimes I and III include streaks and form defects which are not present in regime II. Similar to metallic materials, the evolution of force components show a linear relationship between normal and tangential forces. This implicates a constant average contact pressure and friction coefficient (l) between the flat grains and the workpiece.

Design of precise functional surfaces is essential for many future applications. In the technological realm, the accumulated experience with construction of such surfaces is not sufficient. Nature provides many examples of dynamic surfaces worthy of study and adoption, at least in concept, within human engineering. This work probes the load-bearing metrological features of the ventral skin in snakes. We examine the structure of two snake species that mainly move by rectilinear locomotion. These are Python regius (Pythonidae) and Bitis gabonica (Vipridae). To this end, we focus on the load-bearing characteristics of the ventral skin surface (i.e., the Sk family of parameters). Therefore, detailed comparison is drawn between the metrological structure of the reptilian surfaces and two sets of technological data. The first set pertains to an actual commercial cylinder liner, whereas the second set is a summary of recommended surface finish metrological values for several commercial cylinder liner manufacturers. The results highlight several similarities between the two types of surfaces. In particular, it is shown that there is a striking correspondence between the sense of texture morphology within both surfaces (although their construction evolved along entirely different paths). It is also shown that reptilian surfaces manifest a high degree of specialization with respect to habitat constraints on wear resistance and adhesive effects. In particular, their surface displays a high degree of pre-conditioning to functional requirements, which eliminates the need for a running-in period.

Laser texturing is one of the leading technologies applied to modify surface topography. To date, however, a standardized procedure to generate deterministic textures is virtually non-existent. In nature, especially in squamata, there are many examples of deterministic structured textures that allow species to control friction and condition their tribological response for efficient function. In this work, we draw a comparison between industrial surfaces and reptilian surfaces. We chose the Python regius species as a bio-analogue with a deterministic surface. We first study the structural make up of the ventral scales of the snake (both construction and metrology). We further compare the metrological features of the ventral scales to experimentally recommended performance indicators of industrial surfaces extracted from open literature. The results indicate the feasibility of engineering a laser textured surface based on the reptilian ornamentation constructs. It is shown that the metrological features, key to efficient function of a rubbing deterministic surface, are already optimized in the reptile. We further show that optimization in reptilian surfaces is based on synchronizing surface form, textures and aspects to condition the frictional response. Mimicking reptilian surfaces, we argue, may form a design methodology potentially capable of generating advanced deterministic surface constructs capable of efficient tribological function.

Functional surfaces of optical lens are commonly achieved by a multi-stage diamond turning. This high precision process acts in a wide range of wavelength and allows producing 3-dimensional free form optical surfaces with excellent surface finish that meets application requirements. However, the relationships between process variables and surface characteristics are not yet predictable. In this paper, the concept of the multiscale process signature (MPS) is applied to track the effect of diamond turning process variables (cutting velocity, feed rate, cutting depth, tool roughness,...) on the surface topography from micro-roughness to waviness. The MPS is developed based on continuous wavelet transform and it depicts the essential changes of the surface state produced on the original surface after diamond turning. Using this concept, the effects of different working variables are isolated and theirs active wavelength bands were identified.

Multiscale surface topography characterization is mostly suited than standard approaches because it is more adapted to the multi-stage process generation. Wavelet transform represents a power tool to perform the multiscale decomposition of the surface topography in a wide range of wavelength. However, characterization results depend closely on the topography data acquisition instrument (resolution, height accuracy, sensitivity...) and also on the wavelet analysis method (discrete or continuous transform). In particular, the choice of wavelet function can have significant effect on the analysis results. In this paper, we present experimental work on a number of popular wavelets functions with the aim of finding wavelets that exhibit optimal description of honed surface features when continuous wavelet transform is used. We demonstrate that the regularity property of wavelet function has a significant influence on the characterization performances. This comparative study shows also that the Morlet wavelet is the more adapted wavelet basis function for multiscale characterization of honed surfaces using continuous wavelet transform.

International audience; This article presents a multi-scale theory based on wavelet decomposition to characterize the evolution of roughness in relation with a finishing process or an observed surface property. To verify this approach in production conditions, analyses were developed for the finishing process of the hardened steel by abrasive belts. These conditions are described by seven parameters considered in the Tagushi experimental design. The main objective of this work is to identify the most relevant roughness parameter and characteristic length allowing to assess the influence of finishing process, and to test the relevance of the measurement scale. Results show that wavelet approach allows finding this scale.

Deterministic surfaces are constructs of which profile, topography and textures are integral to the function of the system they enclose. They are designed to yield a predetermined tribological response. Developing such entities relies on controlling the structure of the rubbing interface so that, not only the surface is of optimized topography, but also is able to self-adjust its tribological behaviour according to the evolution of sliding conditions. In seeking inspirations for such designs, many engineers are turning toward the biological world to study the construction and behaviour of bio-analogues, and to probe the role surface topography assumes in conditioning of frictional response. That is how a bio-analogue can self-adjust its tribological response to adapt to habitat constraints. From a tribological point of view, Squamate Reptiles, offer diverse examples where surface texturing, submicron and nano-scale features, achieves frictional regulation. In this paper, we study the frictional response of shed skin obtained from a snake (Python regius). The study employed a specially designed tribo-acoustic probe capable of measuring the coefficient of friction and detecting the acoustical behavior of the skin in vivo. The results confirm the anisotropy of the frictional response of snakes. The coefficient of friction depends on the direction of sliding: the value in forward motion is lower than that in the backward direction. Diagonal and side winding motion induces a different value of the friction coefficient. We discuss the origin of such a phenomenon in relation to surface texturing and study the energy constraints, implied by anisotropic friction, on the motion of the reptile.