Effects Of Shape Coupling Unit And Characteristics On Dry Sliding Wear Performance Of Gray Cast Iron

With the development of manufacturing industry, obvious wear occur on the surfaceof the machine tool guideway can be due to cutting forces after a long-term operation.The wear will change the trajectory of the tool and degrade the accuracy. So the wearresistance of the machine tool guideway become the most important limiting factor in itsservice. As a common material of the machine tool guideway, gray cast iron has manyadvantages on shock absorption, cutability and so on, which cannot be replaced. So it isimportant to study the methods of prolonging the life of machine tool guideway withoutthe matrix material changing.Excellent properties can be obtained by material, shape, structure multiple coupling.The biological surfaces showed complex shapes, according to the research of the bionics,which can be applied in the study of wear resistant materials. In order to get better bionicefficacy, different shape coupling unit(two or more than two kinds of shape) is designedwhich is the innovation point of this paper. It is clearly different from the former researchon single shape coupling unit (punctate, striate or reticulate). Firstly, we studied theeffects of different shape coupling unit on wear performance based on the former researchof the single shape coupling unit on wear resistance. The remelting part, the surfacemorphology and matrix material were considered as coupling unit. The samples withpunctate and striate coupling unit, punctate and reticulate coupling unit were processed onthe material surface which consider not only the feasibility of processing in the actualapplication, but also the essence of bionic. Secondly, the effects of punctate couplingunit’s characteristics (order, distance between coupling unit or angle between couplingunit and slide direction) on wear performance were studied. Finally, the wear rule ofbionic specimens with different shape coupling unit were analyzed by dry sliding weartesting, stress-strain analysis by using ANSYS and morphology respectively. And then weput forward a new bionic coupling model for machine tool guideway, which couldprovide the basis in the actual production.Results show that the wear resistance of the bionic samples with different shapecoupling unit are better than the bionic samples with single shape coupling unit. When theangle between coupling unit and slide direction is45degrees, the bionic specimens withpunctate and striate coupling unit perform the best wear resistance. When the distancebetween bionic unit is2mm, the bionic specimens with punctate and striate coupling unit had the best wear resistance. The bionic specimens with punctate and reticulate couplingunit have the similar rule.In order to study the wear rule, a stress-strain analysis was done by using ANSYS.The different shape coupling unit reduces the stress on the matrix, resulting in the wearresistance improving. The coupling unit can bear greater load. Thus the support role canbe improved, resulting in the contact area reducing. Furrow length becomes shorter.Optimal matching between rigid unit and soft matrix contributes to reduce the adhesionand abrasive wear and prolonging the life of machine tool guideway by preparing theshape and distribution of hard coupling unit.