Tool wear analysis and improvement of cutting conditions using the high-pressure water-jet assistance when machining the Ti17 titanium alloy

This paper presents experimental results concerning the machinability of the titanium alloy Ti17 with and without high-pressure water jet assistance (HPWJA) using uncoated WC/Co tools. For this purpose, the influence of the cutting speed and the water jet pressure on the evolution of tool wear and cutting forces have been investigated. The cutting speed has been varied between 50 m/min and 100 m/min and the water jet pressure has been varied from 50 bar to 250 bar. The optimum water jet pressure has been determined, leading to an increase in tool life of approximately 9 times. Compared to conventional lubrication, an increase of about 30% in productivity can be obtained.     

Measurement of dimensional stability of heat treated southern red oak (Quercus falcata Michx.)

The objective of this study was to investigate the effect of heat treatment on physical and mechanical properties including oven-dry density, weight loss, swelling, shrinkage, and hardness of southern red oak (Quercus falcata Michx.). The samples were treated at a temperature level of 190 °C for 3 h and 8 h. After heat treatment of the specimens, their dimensional stability in the form of swelling and shrinkage were determined by soaking them in water for 2 and 24 h. Hardness of samples as function of heat treatment was also measured using Janka hardness (ASTM D 1037–12). Tangential, radial and longitudinal swelling values of the samples exposed to 8 h heat treatment and soaked in water for 2 h were 0.245%, 0.236%, 0.098%, respectively. Corresponding values for the control samples were 0.504%, 0.455%, 0.135%. Overall hardness of the specimens was adversely influenced due to heat treatment. Based on the findings in this study shrinkage and swelling of the samples improved as a result of heat exposure. It appears that heat treatment would be a viable method to enhance dimensional stability of red oak for more effective utilization where enhanced hygroscopicity of such species is desired.     

The pore water pressure sensor based on Sagnac interferometer with polarization-maintaining photonic crystal fiber for the geotechnical engineering

The pore water pressure sensors with the six-hole suspended-core polarization-maintaining photonic crystal fiber (SC-PM-PCF) and commercial polarization-maintaining photonic crystal fiber (PM-PCF) are designed based Sagnac interferometer and calibrated in the laboratory. According to the theoretical analysis and calibration results, the transmission spectrum is very sensitive to the pore water pressure. It is found that the wavelength of the spectrum has a good linear relationship with variances of the surrounding pore water pressure, and the coefficient of wavelength–pressure of the commercial PM-PCF is 304.41 kPa/nm with the length of 35 cm as the sensing element while the coefficient of the SC-PM-PCF is 254.75 kPa/nm with the length of 100 cm. Finally, the two PM-PCF sensors are applied and compared with the conventional Pore water Pressure Transducers (PPTs) in a physical model test. It is found that measurements of the PM-PCF sensors are in good agreement with the results measured by the conventional PPTs.     

Performance evaluation of a cheap,open source,digital environmental monitor based on the Raspberry Pi

We report on the design, construction and evaluation of a low-cost digital environmental monitoring system based on a popular micro-computer board and mass market digital sensors. The system is based around the use of open source software and readily available digital sensors, providing key parameters required for environmentally-controlled calibration laboratories: air temperature, pressure and humidity. Each system logs data at set intervals with front-panel display, web page graphical display and email alerting when exceeding set tolerances. The sensors have been calibrated at the National Physical Laboratory using standards traceable to the SI. Long term stability of the system is estimated and in addition to monitoring of laboratory environments for regulatory purposes, the systems can also be used to provide on-demand values for local refractive index with an expanded (k = 2) uncertainty of 1.1 × 10⁻⁷ as required for many optical-based measuring systems.     

An ultra high-pressure test rig for measurements of small flow rates with different viscosities

Within the framework of a research project regarding investigations on a high-pressure Coriolis mass flow meter (CMF) a portable flow test rig for traceable calibration measurements of the flow rate (mass - and volume flow) in a range of 5 g min⁻¹ to 500 g min⁻¹ and in a pressure range of 0.1 MPa to 85 MPa was developed. The measurement principle of the flow test rig is based on the gravimetrical measuring procedure with flying-start-and-stop operating mode. Particular attention has been paid to the challenges of temperature stability during the measurements since the temperature has a direct influence on the viscosity and flow rate of the test medium. For that reason the pipes on the high-pressure side are double-walled and insulated and the device under test (DUT) has an enclosure with a separate temperature control. From the analysis of the first measurement with tap water at a temperature of 20 °C and a pressure of 82.7 MPa an extensive uncertainty analysis has been carried out. It was found that the diverter (mainly due to its asymmetric behaviour) is the largest influence factor on the total uncertainty budget. After a number of improvements, especially concerning the diverter, the flow test rig has currently an expanded measurement uncertainty of around 1.0% in the lower flow rate range (25 g min⁻¹) and 0.25% in the higher flow rate range (400 g min⁻¹) for the measurement of mass flow. Additional calibration measurements with the new, redesigned flow test rig and highly viscous base oils also indicated a good agreement with the theoretical behaviour of the flow meter according to the manufacturers׳ specifications with water as test medium. Further improvements are envisaged in the future in order to focus also on other areas of interest.     

On-site calibration system for trace humidity sensors

A portable device for calibration of trace humidity sensors and an adopted calibration procedure have been developed. The calibration device is based on humidity generation by permeating water through polymeric membrane tubes. Water vapour transmission rates for various polymers were experimentally determined in order to select the most suitable polymeric material. The developed trace humidity generator consists of a gas-flow polymeric hose immersed in a water reservoir thermostated by a sensor-controlled heater. Mole fractions of water vapour between 1 μmol mol⁻¹ and 350 μmol mol⁻¹ (equivalent to frost-point temperatures from −76 °C to −31 °C) were generated by varying either the operating temperature or gas flow. The operating temperature can be varied from 20 °C to 60 °C and kept stable within 0.1 K. Uncertainty analysis indicated that the trace humidity generator produces gas flows of constant humidity amounts with a relative expanded uncertainty less than 3.4% (k = 2) of the generated value.     

Application of blue laser direct-writing equipment for manufacturing of periodic and aperiodic nanostructure patterns

This study presents the novel development of low cost, highly efficient blue laser direct-writing equipment for using mask-less laser lithography to manufacture periodic and aperiodic nanostructure patterns. The system includes a long-stroke linear motor precision stage (X, Y), a piezoelectric nano-precision stage (Y, θz), a 3-DOF (degrees of freedom) laser interferometer measurement system, and a blue laser direct-writing optical system. The 3-DOF laser interferometer measurement system gives the control system feedback for displacement (X, Y, θz) of the equipment. The laser processing equipment consists of a blue laser direct-writing optical head, a field-programmable gate array (FPGA) alignment interface, and an optical head servo controller. The optical head operates at a wavelength of 405 nm. Processing the nanostructures on thermo-reaction inorganic resists with precise control of the laser intensity, taking advantage of the threshold effect to exceed the limitations of optical diffraction, and reduces the nanostructure hole size. The equipment can be used to fabricate various periodic nanostructure patterns, aperiodic nanostructure patterns, and two-dimensional patterns. The equipment positioning accuracy is within 50 nm at a speed of 50 mm/s, and the minimum critical dimension can be achieved about 100 nm or so.     

Sensory platform architecture for IN SITU monitoring the thermal comfort in rural environments – The case study at Federal Rural University of Amazonian,Brazil

This research presents an IN SITU sensory platform developed through the integration of air temperature and relative humidity sensors on an ecosystem in order to obtain some thermal characteristic of the rural environments. This sensory platform contains an expert system to detect the behaviors of environmental variables that result in risk or without risk alert to the thermal comfort for human and animal health. For this, the expert system analyses the environmental thermal conditions of the UFRA University, through temperature and humidity index (THI). The THI values estimated (processed) from data of temperature and relative humidity during the year 2012. Four intervals of THI were used to classify human health performance (THI < 74: comfort, 74 ⩽ THI < 79: hot; 79 ⩽ THI ⩽ 84: too hot, and THI > 84: extremely hot), and two intervals to classify animal production (79 ⩽ THI ⩽ 84: dangerous and THI > 84: emergency). The Amazon is located in the equatorial region and has a warm and humid climate that the prevailing mode reveals an alternation of two seasons throughout the year, hot and humid summer and rainy winter. The results that the most critical period occurs between May and October, although it was observed in every day of every year, the THI values during the hottest hours of the day (15:00 pm) range between 75.9 and 86.3, where humans and animals can suffer some degree of thermal stress, affecting negatively both. Therefore, we consider this platform as a good solution for thermal monitoring, which is based on IN SITU measurement technologies for rural environments.     

An orifice meter for bidirectional air flow measurements: Influence of gas thermo-hygrometric content on static response and bidirectionality

This paper presents the design and calibration of an ISO non-compliant orifice plate flowmeter whose intended use is for respiratory function measurements in the bidirectional air flow range ±9 L/min.The novelty of the proposed sensor consists of a plate beveled in both upstream and downstream sides: a symmetrical geometry is adopted in order to perform bidirectional measurements of flow rate. A mathematical model is introduced to quantify the influence of temperature on the sensor output. Four different positions of the pressure static taps are evaluated in order to maximize bidirectionality. An index is also introduced in order to quantitatively estimate the anti-symmetry of the sensor's response curve.Trials are carried out to evaluate the influence on sensor output of air temperatures (22 °C, 30 °C and 37 °C) at different values of relative humidity (5%, 55% and 85%). Experimental data show a quite good agreement with the theoretical model (R²>0.98 in each condition).The influence of air temperature on the sensor output is minimized by introducing a correction factor based on the theoretical model leading to measurement repeatability better than 2% in overall range of calibration. The mean sensitivity in the calibration range is about 2 kPa L⁻¹·min allowing to obtain a sensor discrimination threshold lower than 0.2 L/min in both directions. The time constant of the whole measurement system, equal to 2.40±0.03 ms, leads to a bandwidth up to 80 Hz making the sensor suitable for respiratory function measurements.     

Design of multi-degree-of-freedom micromachined vibratory gyroscope with double sense-modes

This paper presents a novel multi-degree-of-freedom (multi-DOF) micromachined vibratory gyroscope design operated at atmospheric pressure. In this design, the complete 2-DOF vibratory structure is utilized in drive-mode and sense-mode and also, the 2-DOF sense-mode is implemented in both driving frame and proof frame, which form the double 2-DOF sense-modes. The 2-DOF vibratory structure could provide drive-mode and sense-mode with large bandwidth and the double 2-DOF sense-modes could provide high gain of gyroscope system, which improves the inherent robustness and sensitivity simultaneously. The simulation results demonstrate that the summed signal of drive-mode dynamic response is consistent with that of sense-mode and that the gain of proposed multi-DOF micromachined vibratory gyroscope can reach up to −10 dB, increased by above 8 dB compared to the design with single 2-DOF sense-mode. Meanwhile, the 3 dB bandwidth of gyroscope system is larger than 200 Hz.     

Improved critical flow factors and representative equations for four calibration gases

The critical flow nozzle is widely used to calibrate flowmeters in gas flow measurement. Its use requires the critical flow factor, C*, a parameter dependent upon the thermophysical properties of the gas at the nozzle throat, and the upstream temperature and pressure. This paper presents C* values for four calibration gases (air, argon, nitrogen and methane), calculated from the most recent reference quality equations of state, over a wider range of temperature and pressure than previously available, 200–600 K and up to 20 MPa. In addition, a new empirical equation has been developed to represent the calculated values accurately, thus eliminating the need for complex calculations or interpolations from tables.     

SCADA system for oil refinery control

A Supervisory Control and Data Acquisition (SCADA)/Programmable Logic Control (PLC) system is always used to control small industries like water treatment stations; electric power stations and irrigation systems. Oil and gas refineries generally rely on a Distributed Control System (DCS) to provide all process and equipment control functionality. In this paper, a SCADA/PLC system is used to control a whole oil refinery instead of the conventional control through DCS. The design and specific implementation method of a SCADA/PLC real system in an oil refinery process is introduced. It consists of four main units: a crude oil storage unit, a crude oil pretreatment unit, a distillation unit and products storage/dispatch unit. The output products from crude oil refinery process are Liquefied Petroleum Gas (LPG), Naphtha, Gasoline, Kerosene and Diesel that have a great usage in our daily life. The reason for using the Multipoint Interface/Decentralized Peripherals (MPI/DP) connection in main control loop instead of Ethernet connection is that MPI/DP speed is 185 kbps and Ethernet connection speed is 10/100 kbps, which increases the speed of transfer data through the system. Displacer level transmitters and automatic servo level gauging transmitters are used for measuring levels in the crude oil refinery process. Also differential pressure flow transmitters are used for measuring flow rate. Temperature transmitters with thermocouple temperature elements are used for temperature control. Constructing a highly stable and reliable SCADA/PLC system instead of DCS must realize automatic management and control of oil refinery process in order to avoid the waste of manpower, physical resources, and also to increase the safety of workers.     

A Pitot tube system for obtaining water velocity profiles with millimeter resolution in devices with limited optical access

An automated, miniature, S-type Pitot tube system was created to obtain fluid velocity profiles at low flows in equipment having limited optical access, which prevents the use of standard imaging techniques. Calibration of this non-standard Pitot tube at small differential pressures with a custom, low-pressure system is also described. Application of this system to a vertical, high-pressure, water tunnel facility (HWTF) is presented. The HWTF uses static flow conditioning elements to stabilize individual gaseous, liquid, or solid particles with water for optical viewing. Stabilization of these particles in the viewing section of the HWTF requires a specific flow field, created by a combination of a radially expanding test section and a special flow conditioner located upstream of the test section. Analysis of the conditioned flow field in the viewing section of the HWTF required measurements across its diameter at three locations at 1 mm spatial resolution. The custom S-type Pitot tube system resolved pressure differences of <100 Pa created by water flowing at 5–30 cm/s while providing a relatively low response time of ~300 s despite the small diameter (<1 mm) and long length (340 mm) of the Pitot tube needed to fit the HWTF geometry. Particle imaging velocimetry measurements in the central, viewable part of the HWTF confirmed the Pitot tube measurements in this region.     

Influence of tube wall longitudinal heat conduction on temperature measurement of cryogenic gas with low mass flow rates

Longitudinal heat conduction is an important parameter in the cryogenic field, especially in cryogenic heat exchangers. In the present study, the parasitic effect of tube wall longitudinal heat conduction on temperature measurement within the tube has been studied for cryogenic gas with low mass flow rates by finite element method and experimental tests. The effects of various parameters such as tube outlet temperature, tube wall thermal conductivity, mass flow rate, and tube wall thickness have been investigated. Axial positioning errors of temperature sensor due to tube wall longitudinal heat conduction were higher for lower gas flow rates. The results showed that the tube wall thermal conductivity leads to axial heat conduction within the tube wall, but the higher tube wall thermal conductivity does not lead to bigger axial positioning error of temperature sensor at tube outlet. According to data obtained from simulations and experiments, sensor with distance of 5 mm from tube outlet had 14.92% and 8.51% temperature measurement error (with respect to gas flow temperature at tube outlet) for tube wall thermal conductivities of 16 and 400 W m⁻¹ K⁻¹, respectively.     

Effects of materials and solution temperatures on cavitation erosion of pure titanium and titanium alloy in seawater

Cavitation erosion was studied for various pure titanium and titanium alloy samples using a rotating disk method in seawater at 303, 318, and 333 K. Their respective erosion resistances were evaluated in terms of Vickers hardness (HV). The resistance increased in order with increasing hardness: pure titanium samples of first, second, and third types, and titanium alloy (Ti–6Al–4V). The relative temperature was defined as 273 K for freezing temperature and 373 K for boiling temperature under pressurized water. The volume loss rate of test specimens increased with rising seawater temperature of 289–316 K of the relative temperature, as well as in cases using cavitating liquid jet and vibratory apparatuses.     

Thermal experimental verification on effects of nanoparticles for enhancing electric and dielectric performance of polyvinyl chloride

This paper presents investigation on the enhancement of dielectric constant characterization of polyvinyl chloride (PVC) by organic and inorganic nanoparticles under variant frequencies and thermal conditions. Dielectric spectroscopy has been experiment dielectric properties of polyvinyl chloride at various frequencies (0.01 Hz–1 MHz) and temperatures (20–80 °C); then, it has been specified the effective nanoparticles on dielectric constant performance compared with unfilled base matrix polymer. Therefore, it has been got optimum types and concentrations of nanoparticles that have been used for controlling and enhancing dielectric constant characterization of polyvinyl chloride.     

Precision design and control of a flexure-based roll-to-roll printing system

This paper presents the design, characterization, and control of a flexure-based roll-to-roll (R2R) printing system that achieves nanometer level precision and repeatability. The R2R system includes an unwinding/rewinding module, a web guide mechanism, and a core positioning stage consisting of two monolithic compliant X–Y stages that control the position/force of the print roller. During the printing process, capacitance probes, eddy current sensors and load cells are used to monitor the displacements of the flexure stage and contact force in real time. Control strategies, including decoupling, PID, and cascade control, have been implemented to decouple the cross-axis and cross-stage motion coupling effect and improve the overall precision and dynamic performance. In actual printing processes, the contact force and roller position can be uniformly controlled within ±0.05 N and ±200 nm respectively across a 4 in. wide PET web. To demonstrate the performance, a positive microcontact printing (MCP) process is adapted to the R2R system, printing various fine metal patterns, e.g., optical gratings and electrodes, in a continuous fashion.     

Tribological characterisation of siliconcarbonitride ceramics derived from preceramic polymers

Amorphous SiCN ceramics were prepared in a laboratory scale as disk shaped specimens with 10 mm diameter and 0.3 mm thickness. The friction and wear behaviour was characterised in gross slip fretting tests under unlubricated conditions at room temperature against steel (100Cr6) and ceramic (Al₂O₃). Tests with a ball-on-disk contact were performed in laboratory air with different content of water vapour. The results show clearly that the relative humidity has a significant effect on friction and wear behaviour. All tests in dry air lead to higher friction and higher wear rate than in normal air. Improved friction and wear behaviour was observed with increasing pyrolysis temperature up to 1100 °C of the SiCN specimens. This is attributed to increasingly better mechanical properties and higher stiffness of the amorphous network due to the evaporation of gaseous organic species and the formation of free graphite like carbon.     

Diagonal in space of coordinate measuring machine verification using an optical-comb pulsed interferometer with a ball-lens target

This paper presents a new optical method of coordinate measuring machine (CMM) verification. The proposed system based on a single-mode fiber optical-comb pulsed interferometer with a ball lens of refractive index 2 employed as the target. The target can be used for absolute-length measurements in all directions. The laser source is an optical frequency comb, whose repetition rate is stabilized by a rubidium frequency standard. The measurement range is confirmed to be up to 10 m. The diagonals of a CMM are easier to verify by the proposed method than by the conventional artifact test method. The measurement uncertainty of the proposed method is also smaller than that of the conventional method because the proposed measurement system is less affected by air temperature; it achieves an uncertainty of approximately 7 μm for measuring lengths of 10 m. The experimental results show that the measurement accuracy depends on noise in the interference fringe, which arises from airflow fluctuations and mechanical vibrations.     

Measurement of seed spacing uniformity performance of a precision metering unit as function of the number of holes on vacuum plate

The objective of the study was to determine the seed spacing uniformity performance of a precision metering unit when vacuum plates with different number of holes were used. In order to meet this objective, the performances of vacuum plates with different number of holes were evaluated in the laboratory conditions by employing sticky belt tests and seed spacing values were measured computerized measurement system (CMS) for the cotton and corn seeds. Quality of feed index, multiple index, miss index as well as coefficient of precision (CP3) were considered as the performance indicators for precision seeding. The forward speed values were as selected as 1.0, 1.5 and 2.0 m s⁻¹ while vacuum plates with hole diameter of 3.5 mm for cotton and 4.5 mm for corn seeds were used. For both, cotton and corn seeds, five different vacuum plates (20, 26, 36, 52, and 72 holes) were considered in the experiments. In the experiments, vacuum pressure was applied at 6.3 kPa. Based on the findings in this work it appears that 1.0 and 1.5 m s⁻¹ of forward speed values were found to provide the highest performance levels for all vacuum plates. However such performance substantially decreased when forward speed increased to 2.0 m s⁻¹. In overall, the highest performance was determined when 26 and 36 holes were used for cotton and corn, respectively.