Application of nanoclay lubricants for lowering wear of tools for steel meshing - A case study

L. Pena-Paras, D. Maldonado-Cortes, F. Castillo, J. Leal, S. Garza

Research output: Contribution to journalConference article

1 Citation (Scopus)

Abstract

The tools that are employed for industrial woven steel wire mesh processing suffer significant wear, particularly those employed for bending the steel wire at the beginning of the process due to the high forces that are required. Lubricants are employed for the purpose of reducing friction between the tool and the steel wire in these types of processes, hence reducing tool wear. Nanoparticle additives have been investigated for improving the tribological performance of lubricants; due to their small size they may fill surface valleys reducing surface roughness, act as nanobearing limiting metal-metal contact, amongst others. Particularly, nanoclay nanoparticles, such as montmorillonite (MMT), have been proposed as nanoadditives for tribological applications due to being naturally occurring, environmentally friendly, and low-cost. In our work, MMT clay nanoparticles were dispersed by homogenization and ultrasonication in a water-based synthetic lubricant with varying concentrations (0.01, 0.05, and 0.10 wt.%). The wear preventive tribological properties of the prepared nanolubricants were characterized experimentally with a T-02 four-ball tribostester according to ASTM D4172. The wear scar diameters of the three lower steel balls of the four-ball tribopair were measured with an Alicona EdgeMaster optical measurement system. In our laboratory experiments wear scar diameter was reduced by 19% with a MMT clay nanoparticle concentration of only 0.01 wt.%. Higher concentrations (0.05 and 0.10 wt.%) resulted in lower improvements due to nanoparticle agglomeration in the lubricant. Finally, MMT clay nanolubricants were employed for the wire-bending process in a steel-meshing equipment with the nanoparticle concentration where the best tribological performance was found (0.01 wt.%). Tools were monitored for 120 h; tool wear was recorded by measuring the change in the wire-bending tool dimensions compared to the change obtained when the unfilled base lubricant was employed. For the first inch of the tool, where the highest force for bending the wire is required, tool wear in was lowered from 0.014 in to 0.006 in, representing an improvement of 57%. In average, the improvement on wear resistance for the tool was found to be 30%. The results found for this study demonstrate that MMT clay nanoparticle additives are able to improve wear resistance and extend tool life, resulting in considerable savings.

Original languageEnglish
Article number072004
JournalIOP Conference Series: Materials Science and Engineering
Volume400
Issue number7
DOIs
Publication statusPublished - 20 Sep 2018
Event6th International Conference on Modern Technologies in Industrial Engineering, ModTech 2018 - Constanta, Romania
Duration: 13 Jun 201816 Jun 2018

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Steel
Lubricants
Bentonite
Wear of materials
Clay minerals
Nanoparticles
Wire
Clay
Wear resistance
Bending tools
Metals
Synthetic lubricants
Agglomeration
Surface roughness
Friction
clay
Water
Processing

All Science Journal Classification (ASJC) codes

  • Materials Science(all)
  • Engineering(all)

Cite this

@article{098d7f75384f4a0a9df5cfd8482e83a8,
title = "Application of nanoclay lubricants for lowering wear of tools for steel meshing - A case study",
abstract = "The tools that are employed for industrial woven steel wire mesh processing suffer significant wear, particularly those employed for bending the steel wire at the beginning of the process due to the high forces that are required. Lubricants are employed for the purpose of reducing friction between the tool and the steel wire in these types of processes, hence reducing tool wear. Nanoparticle additives have been investigated for improving the tribological performance of lubricants; due to their small size they may fill surface valleys reducing surface roughness, act as nanobearing limiting metal-metal contact, amongst others. Particularly, nanoclay nanoparticles, such as montmorillonite (MMT), have been proposed as nanoadditives for tribological applications due to being naturally occurring, environmentally friendly, and low-cost. In our work, MMT clay nanoparticles were dispersed by homogenization and ultrasonication in a water-based synthetic lubricant with varying concentrations (0.01, 0.05, and 0.10 wt.{\%}). The wear preventive tribological properties of the prepared nanolubricants were characterized experimentally with a T-02 four-ball tribostester according to ASTM D4172. The wear scar diameters of the three lower steel balls of the four-ball tribopair were measured with an Alicona EdgeMaster optical measurement system. In our laboratory experiments wear scar diameter was reduced by 19{\%} with a MMT clay nanoparticle concentration of only 0.01 wt.{\%}. Higher concentrations (0.05 and 0.10 wt.{\%}) resulted in lower improvements due to nanoparticle agglomeration in the lubricant. Finally, MMT clay nanolubricants were employed for the wire-bending process in a steel-meshing equipment with the nanoparticle concentration where the best tribological performance was found (0.01 wt.{\%}). Tools were monitored for 120 h; tool wear was recorded by measuring the change in the wire-bending tool dimensions compared to the change obtained when the unfilled base lubricant was employed. For the first inch of the tool, where the highest force for bending the wire is required, tool wear in was lowered from 0.014 in to 0.006 in, representing an improvement of 57{\%}. In average, the improvement on wear resistance for the tool was found to be 30{\%}. The results found for this study demonstrate that MMT clay nanoparticle additives are able to improve wear resistance and extend tool life, resulting in considerable savings.",
author = "L. Pena-Paras and D. Maldonado-Cortes and F. Castillo and J. Leal and S. Garza",
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Application of nanoclay lubricants for lowering wear of tools for steel meshing - A case study. / Pena-Paras, L.; Maldonado-Cortes, D.; Castillo, F.; Leal, J.; Garza, S.

In: IOP Conference Series: Materials Science and Engineering, Vol. 400, No. 7, 072004, 20.09.2018.

Research output: Contribution to journalConference article

TY - JOUR

T1 - Application of nanoclay lubricants for lowering wear of tools for steel meshing - A case study

AU - Pena-Paras, L.

AU - Maldonado-Cortes, D.

AU - Castillo, F.

AU - Leal, J.

AU - Garza, S.

PY - 2018/9/20

Y1 - 2018/9/20

N2 - The tools that are employed for industrial woven steel wire mesh processing suffer significant wear, particularly those employed for bending the steel wire at the beginning of the process due to the high forces that are required. Lubricants are employed for the purpose of reducing friction between the tool and the steel wire in these types of processes, hence reducing tool wear. Nanoparticle additives have been investigated for improving the tribological performance of lubricants; due to their small size they may fill surface valleys reducing surface roughness, act as nanobearing limiting metal-metal contact, amongst others. Particularly, nanoclay nanoparticles, such as montmorillonite (MMT), have been proposed as nanoadditives for tribological applications due to being naturally occurring, environmentally friendly, and low-cost. In our work, MMT clay nanoparticles were dispersed by homogenization and ultrasonication in a water-based synthetic lubricant with varying concentrations (0.01, 0.05, and 0.10 wt.%). The wear preventive tribological properties of the prepared nanolubricants were characterized experimentally with a T-02 four-ball tribostester according to ASTM D4172. The wear scar diameters of the three lower steel balls of the four-ball tribopair were measured with an Alicona EdgeMaster optical measurement system. In our laboratory experiments wear scar diameter was reduced by 19% with a MMT clay nanoparticle concentration of only 0.01 wt.%. Higher concentrations (0.05 and 0.10 wt.%) resulted in lower improvements due to nanoparticle agglomeration in the lubricant. Finally, MMT clay nanolubricants were employed for the wire-bending process in a steel-meshing equipment with the nanoparticle concentration where the best tribological performance was found (0.01 wt.%). Tools were monitored for 120 h; tool wear was recorded by measuring the change in the wire-bending tool dimensions compared to the change obtained when the unfilled base lubricant was employed. For the first inch of the tool, where the highest force for bending the wire is required, tool wear in was lowered from 0.014 in to 0.006 in, representing an improvement of 57%. In average, the improvement on wear resistance for the tool was found to be 30%. The results found for this study demonstrate that MMT clay nanoparticle additives are able to improve wear resistance and extend tool life, resulting in considerable savings.

AB - The tools that are employed for industrial woven steel wire mesh processing suffer significant wear, particularly those employed for bending the steel wire at the beginning of the process due to the high forces that are required. Lubricants are employed for the purpose of reducing friction between the tool and the steel wire in these types of processes, hence reducing tool wear. Nanoparticle additives have been investigated for improving the tribological performance of lubricants; due to their small size they may fill surface valleys reducing surface roughness, act as nanobearing limiting metal-metal contact, amongst others. Particularly, nanoclay nanoparticles, such as montmorillonite (MMT), have been proposed as nanoadditives for tribological applications due to being naturally occurring, environmentally friendly, and low-cost. In our work, MMT clay nanoparticles were dispersed by homogenization and ultrasonication in a water-based synthetic lubricant with varying concentrations (0.01, 0.05, and 0.10 wt.%). The wear preventive tribological properties of the prepared nanolubricants were characterized experimentally with a T-02 four-ball tribostester according to ASTM D4172. The wear scar diameters of the three lower steel balls of the four-ball tribopair were measured with an Alicona EdgeMaster optical measurement system. In our laboratory experiments wear scar diameter was reduced by 19% with a MMT clay nanoparticle concentration of only 0.01 wt.%. Higher concentrations (0.05 and 0.10 wt.%) resulted in lower improvements due to nanoparticle agglomeration in the lubricant. Finally, MMT clay nanolubricants were employed for the wire-bending process in a steel-meshing equipment with the nanoparticle concentration where the best tribological performance was found (0.01 wt.%). Tools were monitored for 120 h; tool wear was recorded by measuring the change in the wire-bending tool dimensions compared to the change obtained when the unfilled base lubricant was employed. For the first inch of the tool, where the highest force for bending the wire is required, tool wear in was lowered from 0.014 in to 0.006 in, representing an improvement of 57%. In average, the improvement on wear resistance for the tool was found to be 30%. The results found for this study demonstrate that MMT clay nanoparticle additives are able to improve wear resistance and extend tool life, resulting in considerable savings.

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