Surface integrity study of WEDM with various wire electrodes: experiments and analysis

Abstract

Wire electrical discharge machining (WEDM) is always significant for its high-precision machining. However, due to the generation of high discharge energy during machining, machined surfaces are often got distorted. These might be upgraded by choosing the correct tool with proper machining condition. The effects of the electrode materials and process parameters on different responses of WEDM like average surface roughness, recast layer thickness, and surface morphology are systematically examined here to enhance the knowledge of WEDM and its correlation with electrode property. The experiments have been carried out on one of the expensive steel namely Maraging steel 300 due to its applicability in tooling and aerospace industries. Plain brass wire, zinc-coated brass wire (ZCB), and silver-coated brass (SCB) wires are used as a tool electrode for analysis. Comparative experimental studies prove that among BW, ZCB, and SCB, the overall performance of SCB is commendable owing to the high-quality surface considering control parameters in low discharge energy level. However, the second-best performance is shown by ZCB.     

Labelled-replica techniques: post-shadow labelling of intramembrane particles in freeze-fracture replicas

Three methods are described for direct post-fracture, post-shadow labelling of individual classes of intramembrane particles (IMPs) in freeze-fracture replicas of biological membranes. The P-face IMPs corresponding to the acetylcholine receptor complexes (AChRs) of vertebrate neuroeffector junctions are identified by post-replication labelling with ferritin-antibody complexes and with neurotoxin-biotin-avidin-colloidal gold affinity ligands. (The freeze-etch nomenclature of Branton et al., 1975, is used in this report.) These post-shadow labelling techniques resemble conventional en bloc labelling techniques except that the labelling reagents must penetrate a thin but discontinuous layer of platinum superimposed on the molecules of interest. In the ‘sectioned labelled-replica technique’, the replicated and labelled tissues are stained, embedded in plastic and sectioned parallel to the replica-tissue interfaces. In the direct ‘labelled-replica techniques’, the replicated and labelled samples are freeze-dried or critical point dried, the labelled surfaces are stabilized by carbon coating, and the underlying tissues are dissolved, allowing the labelled-replicas to be examined as conventional freeze-fracture replicas. The unshadowed side of each AChR IMP is shown to retain sufficient biochemical information to permit both immunospecific and neurotoxin specific labelling despite formaldehyde fixation, freezing, fracturing, platinum shadowing, and thawing in aqueous media. A new mixed ferricyanide-osmium staining method reveals electron opaque structures spanning the membrane bilayer in the same size, number and distribution as the labelled IMPs. These experiments demonstrate the feasibility of identifying individual IMPs in freeze-fracture replicas and may allow the identification of specific membrane lesions in human disease.     

In vivo remineralization of acid-etched enamel in non-brushing areas as influenced by fluoridated orthodontic adhesive and toothpaste

This study aimed to evaluate the in vivo remineralization of acid-etched enamel in non-brushing areas as influenced by fluoridated orthodontic adhesive and toothpaste. One hundred and twenty teeth from 30 volunteers were selected. The teeth were assigned to four treatments: no treatment (negative control); 37% phosphoric acid-etching (PAE) (positive control); PAE + resin-modified glass ionomer cement (RMGIC); and, PAE + composite resin. Patients brushed teeth with fluoridated (n = 15) or non-fluoridated (n = 15) toothpastes, so that etched enamel was protected with screens and it was not in contact with the brush bristles. Remineralization was evaluated by means of laser fluorescence (LF), environmental scanning electronic microscopy, and energy dispersive spectrometry after extraction. The LF means were compared by means of Wilcoxon and Mann Whitney tests. Environmental scanning electron microscopy scores were compared among the groups using a Kruskal Wallis test, whereas the Ca/P ratio was evaluated by means of an Analysis of Variance with subparcels (treatments) and Tukey's post-hoc test. There were no statistically significant differences between the tooth pastes and between the orthodontic adhesives evaluated. Most teeth presented only partial enamel remineralization. Therefore, the fluoride released by the RMGIC was not enough to cause increased crystal regrowth in the acid-etched enamel. The use of fluoridated toothpaste did not provide positive additional effect.     

Similar features in Z bands of both skeletal and cardiac muscle revealed by image enhancement

We have shown previously that the small square (ss) and basket weave (bw) states of the Z band lattice in cardiac and skeletal muscle are related to the contractile state of the muscle. We have used two-dimensional image processing techniques on digitized electron micrographs to enhance the structural features of each projected lattice form in cardiac and skeletal muscle. Four different processing techniques were employed to assess the effect of enhancement artifacts on the resulting Z band images. We observed only slight differences between enhanced images of a particular Z band form produced by the four different techniques. Every enhanced image showed an approximate four-fold symmetry independent of muscle type or Z band lattice form. Each enhanced image showed four cross-connecting Z-filaments which appeared to connect each axial filament to the four nearest axial filaments. In bw images from both cardiac and skeletal muscle, axial filaments had a greater apparent diameter and a greater interaxial filament spacing than in the ss images. In both muscle types, the cross-connecting Z-filaments appeared to overlap half-way between axial filaments in the ss images while the bw images showed no such overlap. These structural features are consistent with a dynamic Z band lattice that participates in muscle contraction.     

Comparison of the wear resistance of various grades of cemented carbides that may find application in wood machining

A laboratory test is described in which specimens of rectangular cemented carbide tool inserts of a standard size are allowed to slide against a rapidly rotating fiberboard disc in either the presence or the absence of a mist spray of a dilute organic acid (tannic acid or acetic acid) to simulate the cutting of green wood and cured wood respectively. It is shown that the worn surfaces of cemented carbide tools used in (field) service are remarkably similar to the worn surfaces of specimens used in the laboratory (simulation) tests.Extensive results are presented that show quantitatively the progressive wear of a wide range of cemented carbides as a function of time for sliding under wet and dry conditions. It is shown that wear depends on the type and amount of binder present in the cemented carbide and on the nature of the environment. Materials with Co-Cr and Ni-Cr binders containing significant amounts of chromium showed the greatest resistance to wear.     

Surface damage during machining of annealed 18% nickel maraging steel Part 1 — Unlubricated conditions

The effect of cutting speed and tool wear land length on the surface damage produced during the machining of annealed 18% nickel maraging steel under dry orthogonal conditions was determined. Machined test pieces were examined with a scanning electron microscope and an optical microscope. Surface roughness was determined with a profilometer.The results of the investigation show that during machining a wide variety of different forms of surface damage is generated. The machined surfaces show extended regions where both coarse and fine scale surface damage have occurred at cutting speeds up to 0.1 m s^?1, whereas at cutting speeds greater than 0.1 m s^?1 the surfaces show evidence only of fine scale surface damage. It is suggested that the regions of coarse scale surface damage are associated with the phenomenon of partially discontinuous chip formation and the nucleation of cracks in the vicinity of the tool nose region. Several mechanisms of crack nucleation and propagation, which are thought to account for the occurrence of many aspects of the surface topography observed, are presented and discussed. It is suggested also that the regions of fine scale surface damage are associated with the phenomenon of continuous chip formation and interaction between the tool nose region and the freshly machined workpiece surface.It is shown that scanning electron microscopy is more indicative of the true condition of the surface than surface roughness measurements.     

The role of tool composition and tool geometry in controlling the surface finish in machining wood

An examination of several brazed cemented carbide tool inserts that were used in service for cutting cured (dry) pine is described. A laboratory test is also described where the relative resistance to chipping of the brazed tool inserts was measured.It is shown that tool wear occurs through a continuous increase in the tool cutting edge radius that produces a deterioration in the appearance of the machined surface. It is also shown that an increase in either the binder volume fraction or the tool wedge angle produces an increase in the energy absorbed on impact. It is suggested that if progressive wear determines the useful life of a cemented carbide cutting tool then a low volume fraction of binder is required whereas if tool edge chipping determines the useful life of a cutting tool then a large volume fraction of binder and a large tool wedge angle are required.     

VEDA: a web-based virtual environment for dynamic atomic force microscopy

We describe here the theory and applications of virtual environment dynamic atomic force microscopy (VEDA), a suite of state-of-the-art simulation tools deployed on nanoHUB (www.nanohub.org) for the accurate simulation of tip motion in dynamic atomic force microscopy (dAFM) over organic and inorganic samples. VEDA takes advantage of nanoHUB's cyberinfrastructure to run high-fidelity dAFM tip dynamics computations on local clusters and the teragrid. Consequently, these tools are freely accessible and the dAFM simulations are run using standard web-based browsers without requiring additional software. A wide range of issues in dAFM ranging from optimal probe choice, probe stability, and tip-sample interaction forces, power dissipation, to material property extraction and scanning dynamics over hetereogeneous samples can be addressed.