• Corrosion Science and Technology
• /
• v.23 no.2
• /
• pp.83-92
• /
• 2024

A hot-dip simulator was utilized to replicate abnormal coating buildup observed during line stops at galvanize lines, assessing the influence of processing conditions on buildup (up to 14 mm/side). Steel samples from 19 coils (comprising IF, BH, LCAK, HSLA, DP600-DP1180, Si: 0.006 - 0.8 wt%, P: 0.009 - 0.045 wt%) were examined to explore the phenomenon of heavy coating growth. It was discovered that heavy coating buildup (~3 mm/h) and rapid strip dissolution (~0.17 mm/h) in a GA or GI pot can manifest with specific combinations of steel chemistry and processing conditions. The results reveal the formation of a unique coating microstructure, characterized by a blend of bulky Zeta crystals and free Zn pockets/networks due to the "Sandlin" growth mechanism. Key variables contributing to abnormal coating growth include steel Si content, anneal temperature, dew point in heating and soaking furnaces, Zn pot temperature, Zn bath Al%, and cold-rolling reduction%. At ArcelorMittal Dofasco galvanize lines, an automatic online warning system for operators and special scheduling for incoming Si-bearing steels have been implemented, effectively preventing further heavy buildup occurrences.

• Journal of the Korean Society for Precision Engineering
• /
• v.29 no.4
• /
• pp.409-416
• /
• 2012

Recently, surface modification technology is of importance to improve the wear resistance and the corrosive resistance for high accurate mechanical parts such as LM guide, Ball Screw and Roller Bearing etc., Those has generally featured on rolling contact mechanism to improve not only the wear and the friction, but also the accuracy and the corrosion performances. For surface modifications of high accurate mechanical parts, normally thermal spray, PVD, CVD and E.P. processes have been used with many materials such as DLC, raydent, W, Ni, Ti etc. Diamondlike carbon (DLC) films possess a combination of attractive properties and have been largely employed to modify the tribological behaviors such as friction, wear, corrosion, fretting fatigue, biocompatibility, etc. However, for rolling contact mechanism mechanical parts DLC films are needed to study for commercial benefit. Rolling contact mechanism has features on effects of cyclic motions and stresses, and also not simply sliding motions. The papers focused on the performance test of wear and corrosive resistance according to Me-DLC film thickness. And also, its thickness effect of wear analysis was carried out through the simulation of the maximum shear stress under the rolling contact surface. As the results, Me-DLC films have more potential to improve the wear resistance for high precision mechanical parts than raydent films.

• Journal of the Computational Structural Engineering Institute of Korea
• /
• v.15 no.1
• /
• pp.155-164
• /
• 2002

The journal bearings use in machine parts which move relative to each other and those reduce friction and wear of journals. The journal bearings are designed to operate in the hydyodynamic lubrication regime, but elastohydrodynamic lubrication nay occur if the pressures are too high or the running speeds are too low at machine elements. It is the phenomenon that the lubricant film is broken and some parts of surfaces are in rolling contact, so that wear will increase in mixed lubrication regime. The purpose of this study is to minimize the wear rate of journal bearings for extending machine life. The wear mate in mixed lubricated regime is selected as objective function because most of wear of the journal bearings develops in elastohydrodynamic lubrication. The journal bearings we represented by a bearing radius, shaft radius, and bearing width, but the bearing radius only is selected as design variables due to a bearing radius has an influence on friction loss, stability limit velocity, and film parameter, which are used as constraints. For numerical calculation, PLBA, that is a class of the RQP algorithm, is used.

• Journal of the Korea Academia-Industrial cooperation Society
• /
• v.18 no.1
• /
• pp.609-617
• /
• 2017

Railways are one of the safest and most important transportation systems in the world. On the other hand, due to the increasing complexity of the railway system and the running distance of rail vehicles, railway accidents occur continuously every year. In particular, in the case of high-speed trains and freight trains, if the function of the axle bearing is lost due to abnormal overheating of the axle box bearing, the load on the axle becomes uneven. Therefore, abnormal overheating in the train axle box bearings can cause serious accidents or derailments. For this purpose, a Hot Box Detector (HBD) was installed in the track side of a high speed line to detect abnormal overheating. This paper proposes an EWMA technique-based axle temperature monitoring method to detect abnormal overheating quickly and efficiently. A statistical design of the proposed method was also performed. The proposed method has better performance compared to the current method in the case of abnormal overheating and the performance is improved by approximately 170% at the maximum.

• Journal of the Korean Society for Nondestructive Testing
• /
• v.14 no.1
• /
• pp.16-22
• /
• 1994

In contrast to the machineries using rolling element bearings, systems with journal bearings generally operate in large scale and under severe loading condition such as steam generator turbines and internal combustion engines. Failure of the bearings in these machineries can result in the system breakdown. To avoid the time consuming repair and considerable economic loss, the detection of incipient failure in journal bearings becomes very important. In this experimental approach, acoustic emission monitoring is applied to the detection of incipient failure caused by several types of abnormal operating condition most probable in the journal bearing systems. It has been known that the intervention of foreign materials, insufficient lubrication and misassembly etc. are principal factors to cause bearing failure and distress. The experiment was conducted under such designed conditions as hard particles in the lubrication layer, insufficient lubrication, and metallic contact in the simulated journal bearing system. The results showed that acoustic emission could be an effective tool to detect the incipient failure in journal bearings.

• Journal of the Korean institute of surface engineering
• /
• v.45 no.6
• /
• pp.226-231
• /
• 2012

Characteristics of carburized surface layers in 0.18C-3.5Ni-1.5Cr-0.2Mo steels for main shaft bearings of wind turbines have been analyzed and evaluated before and after rolling contact fatigue tests. Mixed microstructure consisting of retained austenite and tempered martensite has been formed with compressive residual stresses in the surface hardened layers of the specimens showing uniform hardness distribution with value about Hv700 after vacuum carburizing and tempering. It has been found on the raceway of the layers of the specimens after rolling contact fatigue tests that the amount of retained austenite decreased and compressive residual stresses increased, resulting from cyclic contact stresses applied during the tests. It has been also revealed that higher durability of the bearings can be obtained through controlling the amount of the retained austenite in the surface of the bearing steels to be lower in this study.

• Journal of Korean Institute of Industrial Engineers
• /
• v.27 no.1
• /
• pp.61-68
• /
• 2001

A rotor system is composed of a rotating shaft with supporting bearings. The rotor system is widely used in every rotating machinery such as the turbine generator and the high precision machine tools. A negligible error or malfunction in the rotor, however, can cause a catastrophic failure in the system then result in the environmental and economic disasters. A diagnosis of the rotor system is important in preventing these kinds of failures and disasters. Up to now, many researchers have devoted in the development of diagnosing tools for the system. The basic principles behind the tools are to retrieve the data through the sensors for a specific state of the system and then to identify the specific state through the heuristic methods such as neural network, fuzzy logic, and decision matrix. The proper usage of the heuristic methods will enhance the performance of the diagnostic procedure when together used with the statistical signal processing. In this paper, the methodologies in using the above 3 heuristic methods for the diagnostics of the rotor system are established and also tested and validated for the data retrieved from the rolling element bearing and journal bearing supported system.

• Korean Journal of Materials Research
• /
• v.24 no.10
• /
• pp.550-555
• /
• 2014

The present study deals with the effects of tempering treatment on the microstructure and mechanical properties of Cu-bearing high-strength steels. Three kinds of steel specimens with different levels of Cu content were fabricated by controlled rolling and accelerated cooling, ; some of these steel specimen were tempered at temperatures ranging from $350^{\circ}C$ to $650^{\circ}C$ for 30 min. Hardness, tensile, and Charpy impact tests were conducted in order to investigate the relationship of microstructure and mechanical properties. The hardness of the Cu-added specimens is much higher than that of Cu-free specimen, presumably due to the enhanced solid solution hardening and precipitation hardening, result from the formation of very-fine Cu precipitates. Tensile test results indicated that the yield strength increased and then slightly decreased, while the tensile strength gradually decreased with increasing tempering temperature. On the other hand, the energy absorbed at room and lower temperatures remarkably increased after tempering at $350^{\circ}C$; and after this, the energy absorbed then did not change much. Suitable tempering treatment remarkably improved both the strength and the impact toughness. In the 1.5 Cu steel specimen tempered at $550^{\circ}C$, the yield strength reached 1.2 GPa and the absorbed energy at $-20^{\circ}C$ showed a level above 200 J, which was the best combination of high strength and good toughness.

• Tribology and Lubricants
• /
• v.33 no.3
• /
• pp.119-125
• /
• 2017

In this study, we perform a numerical analysis to predict the film thickness and lubrication regions for a thrust ball bearing under different operating conditions. Film thinning and replenishment affect the film thickness in starved lubrication. As the inlet meniscus position is brought to the edge of the Hertz contact, the thin film thickness is calculated as starved equation. We use a film replenishment model to determine the recovery film thickness between rolling elements. We use a hydrodynamic model to describe film recovery, that results from the effects of surface tension. In this model, we consider the surface tension gradient in fluid depression as the driving force for fluid recovery. We use Fourier transform method to determine the time-dependent depth of depressed oil. We calculate the change in the central film thickness graphically by using the recovery equation in starved elastohydrodynamic lubrication(EHL) under operating conditions that include numbers of balls, sliding velocity, applied force, and ambient film thickness. We evaluate the degree of starvation by using the distance from the center of the contact area to the meniscus position. Parched lubrication, a phenomenon where the film thickness decreases consistently, occurs at the severe condition. We determine optimal values with respect to the numbers of balls, and sliding velocity. The investigation can contribute to the design operating conditions for proper lubrication.

• Journal of the Korean Society for Precision Engineering
• /
• v.28 no.3
• /
• pp.285-291
• /
• 2011

The error motion of a machine tool spindle directly affects the surface errors of machined parts. The error motions of the spindle are not desired errors in the three linear direction motions and two rotating motions. Those are usually due to the imperfect of bearings, stiffness of spindle, assembly errors, external force or unbalance of rotors. The error motions of the spindle have been needed to be decreased to desired goal of spindle's performance. The level of error motion is needed to be estimated during the design and assembly process of the spindle. In this paper, the estimation method for the five degree of freedom (5 D.O.F) error motions of the spindle is suggested. To estimate the error motions of the spindle, waviness of shaft and bearings, external force model was used as input data. And, the estimation models are considering geometric relationship and force equilibrium of the five degree of the freedom. To calculate error motions of the spindle, not only imperfection of the shaft, bearings, such as rolling element bearing, hydrostatic bearing, and aerostatic bearing, but also driving elements such as worm, pulley, and direct driving motor systems, were considered.