master moulds are used to cast copper anode moulds. these iron moulds are made of grey or nodular cast irons. according to desirable properties of ductile irons, it was expected that ductile cast iron moulds could have performed their nominal life. but in service, these moulds have not performed their nominal life and they have experienced premature failures due to warping and cracking. also gr...

An investigation of the friction and sliding wear of gray cast iron against chromium plated cast irons was carried out on a newly constructed reciprocating friction and wear tester. The tests were the first to be done on the test rig under dry conditions and at the speed of 170 cm/min, and variable loads of 20-260 N for a duration of 15 min. to 3 hours. The gray cast iron surfaces worn by a pro...

Honing is a process for finishing surfaces to obtain smooth surface. This process is used for final polish of inner parts such as engines cylinders. Optimizing this process has always been a big challenge for mass production of cylinder blocks of internal combustion engines. Honing process has some variable parameters, thus to get their optimum rates the automobile cylinders were tested. In thi...

Honing is a process for finishing surfaces to obtain smooth surface. This process is used for final polish of inner parts such as engines cylinders. Optimizing this process has always been a big challenge for mass production of cylinder blocks of internal combustion engines. Honing process has some variable parameters, thus to get their optimum rates the automobile cylinders were tested. In thi...

A novel scuffing methodology was developed utilising variable specimen geometry to replicate numerically modelled top compression ring contact pressures (4–62 MPa) from a 12.8-litre heavy duty diesel engine as function of stroke position. Scuffing grade 250 cast iron induced by reciprocating sliding (TE77) against drip lubricated (PAO4) 52100 rectangular operating at 15 Hz and 311 N normal load...

the premature breakage in some four cylinder diesel engine crankshafts was reported. all crankshafts were failed from the same region. failures had occurred in the first crankpin, the nearest crankpin to the flywheel. dynamic analysis and finite element modelling were carried out to determine the state of stress in the crankshaft. fem results revealed that the first crankpin fillet is the most ...