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Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs

Brag, Patrick; Piotter, Volker 1; Plewa, Klaus 1; Klein, Alexander 1; Herzfeldt, Mirko; Umbach, Sascha
1 Institut für Angewandte Materialien – Werkstoffkunde (IAM-WK), Karlsruher Institut für Technologie (KIT)

Abstract (englisch):

In subtractive manufacturing processes, swarf, burrs or other residues are produced, which can impair the function of a tribological system (e.g., journal bearings). To prevent premature engine damage, cleanliness requirements are defined for production processes. Damaging particle tests are an experimental approach for validating these defined cleanliness requirements. This methodical approach is not yet widely used. For one, the test setup must be developed and proven for the respective application. For another, in order to carry out the tests in a systematic manner, defined test particles with properties similar to those of the contaminants encountered in reality are required. In the second part of the paper, the process chain for manufacturing artificial test swarf by micro powder injection molding (MicroPIM) is described. The size and shape of the swarf were derived from real swarf via several abstraction processes. Although certain design guidelines for MicroPIM parts could not be taken into account, the targeted manufacturing tolerances were achieved in most cases. During demolding, it became apparent that the higher ejection forces of the free-formed geometries must be taken more into account in the design of the mold. ... mehr


Verlagsausgabe §
DOI: 10.5445/IR/1000162349
Veröffentlicht am 31.10.2023
Cover der Publikation
Zugehörige Institution(en) am KIT Institut für Angewandte Materialien – Werkstoffkunde (IAM-WK)
Publikationstyp Zeitschriftenaufsatz
Publikationsmonat/-jahr 09.2023
Sprache Englisch
Identifikator ISSN: 1996-1944
KITopen-ID: 1000162349
HGF-Programm 43.34.01 (POF IV, LK 01) Lightweight Materials for Structural and Medical Application
Erschienen in Materials
Verlag MDPI
Band 16
Heft 18
Seiten Art.-Nr.: 6276
Vorab online veröffentlicht am 19.09.2023
Schlagwörter MicroPIM; particle; shape characterization; damage; tribology; bearing
Nachgewiesen in Scopus
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