Development of ultra-fine-grain binderless cBN tool for precision cutting of ferrous materials

A new cutting tool was developed from ultra-fine-grain (<100 nm), binderless cubic boron nitride (cBN) material fabricated by transforming hexagonal boron nitride to cBN by means of sintering under an ultra-high pressure of 10 GPa at 1800 °C. The cutting edges of the newly developed cBN tool can be made as sharp as those of single-crystal diamond tools. In this experiment, cBN and single-crystal diamond tools of the same shape were compared by precision cutting tests using stainless steel specimens and steel specimens coated with an electroless Ni-P layer. The surface roughness (R_z) of specimen surfaces cut with the cBN tool by means of planing was approximately 100 nm for both the Ni-P-coated steel and stainless steel specimens. Though similar R_z values were obtained for Ni-P layers cut by the cBN and diamond tools, an R_z value exceeding 2000 nm was obtained for stainless steel cut by the diamond tool. High-precision surfaces with R_z values of 50–100 nm were obtained for stainless steel specimens cut with the cBN tool under high-speed milling (942 m/min) conditions. These results indicate that the newly developed cBN tool is useful for the ultra-precision or precision cutting of ferrous materials.     

Ultra-precision finishing of micro-aspheric mold using a magnetostrictive vibrating polisher

Demands of micro-aspheric glass lenses are increasing in optical devices such as digital cameras and blu-ray players. In this paper, a novel vibration-assisted polishing machine using a magnetostrictive vibrating polisher is proposed and developed to improve the efficiency, surface roughness and stability of finishing. The magnetostrictive vibrating polisher can generate a radius of 30 μm circular vibrating motion at frequency 9.2 kHz. From the polishing experiments, a smooth removal function was obtained. The form accuracy was improved to less than 100 nm P–V and the surface roughness was reduced to 3.3 nm Rz (0.4 nm Ra).     

White light emission from blue InGaN LED precoated with conjugated copolymer/quantum dots as hybrid phosphor

In this work we fabricated white LEDs using a blue InGaN LED precoated conjugated copolymer/quantum dots (QDs) composite (green-emitting Poly {(9,9-dioctyl-2,7-divinylenefluorenylene)-alto-co-(2-methoxy-5-(2-ethylhexyloxy)-1,4-phenylene)}/red-emitting CdSe quantum dots) as a hybrid phosphor. The emission peak wavelengths of the blue and red emissions in the spectra were 462 and 618 nm, respectively. The green-emitting polymer had two emission peaks at 515 and 543 nm. The subpeak of the copolymer (515 nm) was decreased by the absorption of QDs as the ratio of QDs increased, while the emission of the QD (618 nm) increased. Therefore, changes in the CIE-1931 coordinate, color temperature (Tc) and color-rendering index (Ra) were dependent on the QDs to copolymer ratios. The white LED of the hybrid phosphor containing 20 wt.% QDs had a luminous efficiency of 44.2 l m/W at 20 mA with a CIE-1931 coordinate, Tc and Ra of (0.3297, 0.3332), 5620 K and 75.3, respectively.     

Amorphous Fe–B alloys in B–Fe–Ag multilayers studied by magnetization and Mössbauer measurements

Bulk and local magnetic properties were studied in [1 nm B + 1 nm ⁵⁷Fe + x nm Ag]₅, x = 1, 2, 4, 5 and 10, multilayer samples. Although Ag does not mix with either of the other two elements the magnetic properties of the multilayers are strongly influenced by the Ag thickness below x = 5, whereas no such effect is observed above this value. The Mössbauer measurements indicate a complete amorphization of the thin Fe layers in each sample, as a result of intermixing with the B layers. The variation of the magnetic properties is explained by the variation of the average B concentration of the amorphous Fe–B layers, which depends on the thickness of the Ag barrier layers. The magnetization measurements indicate ferromagnetic behaviour of the ultra-thin amorphous layers with the presence of less than 10% superparamagnetic moments for x = 5 and 10. The average B concentration of the amorphous Fe–B alloy, as estimated from the Fe hyperfine fields, is around 40 at%. It is significantly lower than the 60 at% nominal B concentration, suggesting the presence of an unalloyed B layer, as well. This picture is supported by transmission electron microscopy investigations which reveal two amorphous layers of different B concentration in between the crystalline Ag layers.     

Wear,cutting forces and chip characteristics when dry turning ASTM Grade 2 austempered ductile iron with PcBN cutting tools under finishing conditions

Experimental studies of wear, cutting forces and chip characteristics when dry turning ASTM Grade 2 austempered ductile iron (ADI) with polycrystalline cubic boron nitride (PcBN) cutting tools under finishing conditions were carried out. A depth of cut of 0.2 mm, a feed of 0.05 mm/rev and cutting speeds ranging from 50 to 800 m/min were used. Flank wear and crater wear were the main wear modes within this range of cutting speeds. Abrasion wear and thermally activated wear were the main wear mechanisms. At cutting speeds greater than 150 m/min, shear localization within the primary and secondary shear zones of chips appeared to be the key-phenomenon that controlled the wear rate, the static cutting forces as well as the dynamic cutting forces. Cutting speeds between 150 and 500 m/min were found to be optimum for the production of workpieces with acceptable cutting tool life, flank wear rate and lower dynamic cutting forces.     

Effect of femtosecond laser pretreatment on wear resistance of Al2O3/TiC ceramic tools in dry cutting

A femtosecond pulsed laser (pulse width: 120 fs, wavelength: 800 nm and repetition rate: 500 Hz) was used for the pretreatment on the rake face of Al₂O₃/TiC ceramic cutting tools. The evolution of surface morphology of pretreated cutting tools irradiated with different pulse energies was measured by scanning electron microscope (SEM) and atomic force microscope (AFM). Dry cutting tests were carried out with these pretreated tools and conventional tools on hardened steel. The effect of pulse energy on the wear resistance of these pretreated tools was investigated. Results show that the cutting forces have no significant difference between laser pretreated tools and the conventional tool; the cutting temperatures of laser pretreated tools were slightly reduced compared with the conventional tool. Meanwhile, we found that the laser pretreated tools increased the adhesions of chips on the rake face, but they can significantly improve the wear resistance of the rake face; and laser pulse energy was found to have a profound effect on the wear resistance of the laser pretreated tools.     

A novel magnetic actuator design for active damping of machining tools

Parts and cutting tools with large structural flexibility experience both forced and chatter vibrations during machining, resulting in poor surface finish or damage to the machine. This paper presents the design principles of a novel 3 degrees of freedom linear magnetic actuator which increases the damping and static stiffness of flexible structures during machining. The proposed actuator can deliver 248 N force in two radial (x, y) directions and 34 N×m (torque) in torsional (θ) direction up to 850 Hz. The force and torque reduces to 107 N and 14.5 N×m at 2000 Hz, hence it can actively damp a wide range of structural modes. The magnetic force is linearized with respect to the input current using magnetic configuration design strategy. Loop shaping controllers are designed for active damping of boring bar vibrations. The static and dynamic stiffnesses of the boring bar were considerably increased with the designed actuator, leading to a significant increase in chatter-free material removal rates during cutting tests.     

A study on ultrasonic elliptical vibration cutting of tungsten carbide

Sintered tungsten carbide (WC) is a versatile metal matrix composite (MMC) material widely used in the tool manufacturing industries. Machining of this material with conventional cutting (CC) method is a real challenge compared to other difficult-to-cut materials. Ultrasonic elliptical vibration cutting (UEVC) method is a novel and non-conventional cutting technique which has been successfully applied to machine such intractable materials for the last decade. However, few studies have been conducted on cutting of WC using single point diamond tool (SPDT) applying the UEVC technique. This paper presents an experimental study on UEVC of sintered WC (～15% Co) using polycrystalline diamond (PCD) tools. Firstly, experiments have been carried out to investigate the effect of cutting parameters in the UEVC method in terms of cutting force, flank wear, surface finish while cutting sintered WC. The tests have revealed that the PCD tools in cutting of WC by the UEVC method results in better cutting performance at 4 μm depth of cut (DOC) as compared to both a lower DOC (e.g. 2 μm) and a higher DOC (e.g. 6 or 8 μm). Moreover, the cutting performance improves with the decrease in both the feed rate and cutting speed in the UEVC method like conventional turning (CT) method. A minimum surface roughness, R_a of 0.036 μm has been achieved on an area of about 1257 mm² with the UEVC performance. The CT method has also been employed to compare its cutting performance against the UEVC method. It has been observed that the UEVC method results in better cutting performances in all aspects compared to the CT method. Theoretical analysis on the UEVC method and analysis of the experimental results have been carried out to explain the reasons of better surface finish at 4 μm DOC and better cutting performance of the UEVC method.     

Roles of interface roughness and internal stress in magnetic anisotropy of CoPt/AlN multilayer films

Magnetic anisotropy of CoPt/AlN multilayer films has been studied by systematically varying the nominal thickness of CoPt layers, t_CoPt (1–10 nm), and the annealing temperature, T_a (300–500 °C). The as-deposited films show in-plane magnetic anisotropy in the full range of t_CoPt, whereas the annealed films show perpendicular magnetic anisotropy (PMA) within small t_CoPt but change to in-plane magnetic anisotropy when t_CoPt is over a certain thickness. The critical thickness for such anisotropic transformations increases as the T_a increases. The maximum PMA obtained in this work is 1.13 × 10⁷ erg cm^?3. The interface roughness was analyzed by cross-sectional high-resolution electron microscopy and X-ray reflectivity using an abrupt interface model with a Debye exponent shape. The internal stress was analyzed by X-ray diffraction using an equal biaxial stress model. The results show that the CoPt/AlN interface roughness decreases from 0.385 nm to 0.158 nm and the internal stress increases from ?2.36 GPa (compressive) to 1.73 GPa (tensile), as the T_a increases to 500 °C. The roles of the interface roughness and the internal stress in the magnetic anisotropy of CoPt/AlN multilayer films are studied.     

Low core loss of Fe85Si2B8P4Cu1 nanocrystalline alloys with high Bs and B800

The Fe–Si–B–P–Cu nanocrystalline alloys exhibit high saturation magnetic flux density (B_s) as well as good soft magnetic properties such as low coercivity, high effective permeability and low magnetostriction after nanocrystallization. In this paper, the Fe₈₅Si₂B₈P₄Cu₁ alloy has been newly developed. On the viewpoint of magnetic softness, the Fe₈₅Si₂B₈P₄Cu₁ nanocrystalline alloy reveals low core loss (W) at a commercially frequency of 50 Hz in the maximum induction (B_m) range of up to 1.75 T, and the W in the B_m range of less than 1.8 T is smaller than that of the highest-graded oriented Si-steel due to high magnetic flux density at 800 A/m (B₈₀₀) of above 1.8 T and excellent magnetic softness originated from much higher Fe content and uniform nanocrystalline structure with small magnetostriction. The electrical resistivity (ρ) is relative higher than Si-steels. Thus the Fe–Si–B–P–Cu alloys are attractive for applying to magnetic parts such as motors, transducers, choke-coils and so-forth.     

Transition from homogeneous-like to shear-band deformation in nanolayered crystalline Cu/amorphous Cu–Zr micropillars: Intrinsic vs. extrinsic size effect

The microcompression method was used to investigate the compressive plastic flow behavior of nanolayered crystalline/amorphous (C/A) Cu/Cu–Zr micropillars within wide ranges of intrinsic layer thicknesses (h ～ 5–150 nm) and extrinsic sample sizes (350–1425 nm) with the goal of revealing the intrinsic size effect, extrinsic size effect and their interplay on the plastic deformation behavior. The nanolayered C/A micropillars exhibited deformation behaviors of strain-hardening followed by strain-softening that were dependent on the thickness of the layers. At h ? 10 nm, the strain-softening is related to shear deformation that is caused by fractures in the amorphous layers. At h > 10 nm, however, the strain-softening is related to the reduction in dislocation density caused by dislocation absorption. Correspondingly, the deformation mode of the C/A micropillars transitioned from homogeneous-like to shear band type as h decreased to the critical value of ～10 nm, which is indicative of a significant intrinsic size effect. The extrinsic size effect on the plastic deformation also became remarkable when h was less than ～10 nm, and the interplay between the intrinsic and extrinsic size effects leads to an ultrahigh strength of ～4.8 GPa in the C/A micropillars, which is close to the ideal strength of Cu and considerably greater than the ideal strength of the amorphous phase. The underlying strengthening mechanism was discussed, and the transition in deformation mode was quantitatively described by considering the strength discrepancy between the two constituent crystalline and amorphous layers at different length scales.     

Grinding performance and workpiece integrity when superabrasive edge routing carbon fibre reinforced plastic (CFRP) composites

Data is presented for wheel wear, cutting forces and workpiece integrity when high speed routing 10 mm thick CFRP laminates using single layer electroplated diamond and CBN grinding points as opposed to standard end milling tools. A 60,000 rpm retrofit spindle was utilised to accommodate the 10 mm diameter wheels having grit sizes of 76, 151 and 252 μm employed under either roughing or finishing parameters. Wear of CBN points exhibited a near two-fold increase over diamond with a similar ratio for cutting forces. Despite use of flood cooling, point geometry when roughing compromised life and integrity due to excessive clogging.     

Microstructural analysis of wear micromechanisms of WC–6Co cutting tools during high speed dry machining

This original study investigates the damages of WC–6Co uncoated carbide tools during dry turning of AISI 1045 steel at mean and high speeds. The different wear micromechanisms are explained on the basis of different microstructural observations and analyses made by different techniques: (i) optical microscopy (OM) at macro-scale, (ii) scanning electron microscopy (SEM), with back-scattered electron imaging (BSE) at micro-scale, (iii) energy dispersive spectroscopy (EDS), X ray mapping with wavelength dispersive spectroscopy (WDS) for the chemical analyses and (iv) temperature evolution during machining. We noted that at conventional cutting speed Vc ≤ 250 m/min, normal cutting tool wear types (adhesion, abrasion and built up edge) are clearly observed. However, for cutting speed Vc > 250 m/min a severe wear is observed because the behavior of the WC–6Co grade completely changes due to a severe thermomechanical loading. Through all SEM micrographs, it is observed that this severe wear consists of several steps as: excessive deformation of WC–6Co bulk material and binder phase (Co), deformation and intragranular microcracking of WC, WC grain fragmentation and production of WC fragments in the tool/chip contact. Thus, the WC fragments accumulated at the tool/chip interface cause abrasion phenomena and pullout WC from tool surface. WC fragments contribute also to the microcutting and microploughing of chips, which lead to form a transferred layer at the tool rake face. Finally, based on the observations of the different wear micromechanisms, a scenario of WC–6Co damages is proposed through to a phenomenological model.     

Performance of coated tungsten carbide tools on milling printed circuit board

This study investigates the performance of the ZrN tools coated by the pulsed-DC reactive magnetron sputtering on milling memory modules of PCB (printed circuit board). A speed-adjustable rotation system was designed to find out the optimal process parameters through grey relational analysis and Taguchi method, such as the sputtering distance, flow rate of nitrogen and rotational speed of tool. From the sputtering experiment, the two parameters having greatest effects are the ratio of argon to nitrogen as well as the rotational speed of tool. Within the range of the experimental equipments, the optimal ratio of argon to nitrogen flow rate is 10:4 (sccm), and the optimal rotational speed of tool is around 8 rpm. The average micro-hardness of the surface of the ZrN-coated tools are increased from 15 GPa to 21 GPa compared with uncoated tools by nano-indentator measurement. From the cutting experiments, the cutting tool life of an uncoated tungsten carbide tool is around 38 m, and that of a ZrN-coated tool is around 115 m. And the statistical process capability index (Cpk) of the coated tool also rises from 0.788 to 1.858. It is observed that a ZrN-coated tool not only can extend its used life, but also can improve the cutting quality.     

Machinability study of tungsten carbide using PCD tools under ultrasonic elliptical vibration cutting

Sintered tungsten carbide (WC) is an extremely hard and brittle material extensively used in tool manufacturing industries. However, the current cutting technologies for shaping this typical hard-to-machine material are still cost ineffective. In this study, polycrystalline diamond (PCD) tools are used to study the machinability of sintered WC (~15% Co) by applying the ultrasonic elliptical vibration cutting (UEVC) technique. Firstly, it presents the UEVC principle and the effects of speed ratio (i.e. the ratio of the nominal cutting speed to the maximum tool vibration speed in the cutting direction) on the tool–workpiece relative motion as the cutting speed greatly influences the UEVC performance. Then UEVC experiments are carried out to analyze the cutting force, tool-wear progression, chip formation and surface quality against the cutting time at different speed ratios. The results show that when the speed ratio decreases, the resultant cutting force and the tool flank wear decrease while the surface finish improves. Average surface roughness, R_a, in a range between 0.030 and 0.050 μm is achieved at speed ratios less than 0.107. The experimental findings suggest that the commercial PCD tools can be used to machine sintered WC to achieve ultraprecision surface by applying the UEVC technique, which will be cost effective for miniature cutting technologies in future.     

Interactions of polarons in poly(3-dodecythiophene) at low temperature

Zero-field cooled-field-cooled (ZFC-FC) technique was used to investigate the effect of low temperature (4.6 K) on the interactions of polarons in weakly FeCl₃-doped poly(3-dodecylthiophene (PDDT). It was found that the magnetic properties of the system changed with the length of time system spent at low temperature: the Currie–Weiss paramagnetism gradually changed over to “antiferromagnetism” and ultimately to diamagnetism. This effect is connected with the thermochromic properties of self-organized PDDT in primary (10–15 nm) or secondary (30–50 nm) induced aggregates, in which cooling under the glass transition temperature T_g (～240 K) causes extension of the effective conjugation length of coplanar polymer chains. Changes in magnetic properties are related to the inter- and intra-chain interactions of polaron states within both the primary and secondary induced aggregates.     

Enhancing magnetocrystalline anisotropy of the Fe70Pd30 magnetic shape memory alloy by adding Cu

Fe–Pd–Cu thin films are of great interest for applications in magnetic shape memory microsystems due to their increased martensitic transformation temperature. Here we analyse the consequences of Cu addition to Fe–Pd on the binding energy and magnetic properties by a combination of thin film experiments and first-principles calculations. Strained epitaxial growth of Fe₇₀Pd_30-xCu_x with x = 0, 3, 7 is used to freeze intermediate stages during the martensitic transformation. This makes a large range of tetragonal distortion susceptible for analysis, ranging from body-centred cubic to beyond face-centred cubic (1.07 < c/a_bct < 1.57). We find that Cu enhances the quality of epitaxial growth, while spontaneous polarization and Curie temperature are reduced only moderately, in agreement with our calculations. Beyond c/a_bct > 1.41 the samples undergo structural relaxations through adaptive nanotwinning. Cu enhances the magnetocrystalline anisotropy constant K₁ at room temperature, which reaches a maximum of ?2.4 × 10⁵ J m^?3 around c/a_bct = 1.33. This value exceeds those of binary Fe₇₀Pd₃₀ and the prototype Ni–Mn–Ga magnetic shape memory system. Since K₁ represents the maximum driving energy for variant reorientation in magnetic shape memory systems, we conclude that Fe–Pd–Cu alloys offer a promising route towards microactuator applications with significantly improved work output.     

The characterization of structure,thermal stability and magnetic properties of Fe–Co–B–Si–Nb bulk amorphous and nanocrystalline alloys

Recently bulk amorphous alloys have attracted great attention due to their excellent magnetic properties. The glass-forming ability of bulk amorphous alloys depends on the temperature difference (ΔT_x) between glass transition temperature (T_g) and crystallization temperature (T_x). The increase of ΔT_x causes a decrease of the critical cooling rate (V_c) and growth of the maximum casting thickness of bulk amorphous alloys. The aim of the present paper is to characterize the structure, the thermal stability and magnetic properties of Fe₃₆Co₃₆B₁₉Si₅Nb₄ bulk amorphous alloys using XRD, Mössbauer spectroscopy, DSC and VSM methods. Additionally the magnetic permeability μ_i (at force H ≈ 0.5 A/m and frequency f ≈ 1 kHz) and the intensity of disaccommodation of magnetic permeability Δμ/μ(t₁) (Δμ = μ(t₁ = 30 s) ? μ(t₂ = 1800 s)), have been measured, where μ is the initial magnetic permeability measured at time t after demagnetisation, the Curie temperature T_C and coercive force H_c of rods are also determined with the use of a magnetic balance and coercivemeter, respectively.Fe–Co–B–Si–Nb bulk amorphous alloys were produced by pressure die casting with the maximum diameters of 1 mm, 2 mm and 3 mm.The glass transition temperature (T_g) of studied amorphous alloys increases from 807 K for a rod with a diameter of 1 mm to 811 K concerning a sample with a diameter of 3 mm. The crystallization temperature (T_x) has the value of 838 K and 839 K for rods with the diameters of 1 mm and 3 mm, respectively. The supercooled liquid region (ΔT_x = T_x ? T_g) has the value of about 30 K. These values are presumed to be the origin for the achievement of a good glass-forming ability of the Fe–Co–B–Si–Nb bulk amorphous alloy. The investigated amorphous alloys in the form of rods have good soft magnetic properties (e.g. M_s = 1.18–1.24 T). The changes of crystallization temperatures and magnetic properties as a function of the diameter of the rods (time of solidification) have been stated.     

Crystal structure and physical properties of EPCo4.7Ge9 (EP = Sr,Ba, Eu)

BaCo_4.7Ge₉ (BaCo_5?xGe₉, x = 0.29) is a novel ternary compound which forms incongruently from the melt and crystallizes in a unique structure type (space group Pnma; a = 1.39910(2), b = 0.40218(2), c = 1.69882(2) nm, Z = 4). Isotypic compounds were found with SrCo_4.7Ge₉ (a = 1.39389(8), b = 0.39665(1), c = 1.67860(9) nm) and EuCo_4.7Ge₉ (a = 1.3910(1), b = 0.39425(2), c = 1.6741(2) nm). Physical properties (electrical resistivity, specific heat, magnetic susceptibility) were studied for BaCo_4.7Ge₉ and EuCo_4.7Ge₉. BaCo_4.7Ge₉ shows metallic behaviour but neither a superconducting nor a magnetic phase transition was observed for temperatures as low as T = 2 K. Magnetic susceptibility and specific heat data of EuCo_4.7Ge₉, evidence the onset of antiferromagnetic order at 18.5 K. Both magnetic ordering and the effective magnetic moment derived verify the Eu²⁺ state with a total angular momentum j = 7/2.     

Synthesis,photoluminescent and electroluminescent properties of a novel europium(III) complex involving both hole- and electron-transporting functional groups

A novel europium(III) complex involving a carbazole fragment as hole-transporting group and an oxadiazole fragment as electron-transporting group was synthesized and used as red light-emitting material in organic light-emitting diodes (OLEDs). The complex is amorphous, and exhibits high glass transition temperature (T_g = 157 °C) and high thermal stability with a 5% weight loss temperature of 367 °C. Two devices, device 1: ITO/NPB (40 nm)/Eu(III) complex (30 nm)/Alq₃ (30 nm)/LiF (1 nm)/Al (100 nm) and device 2: ITO/NPB (40 nm)/3% Eu(III) complex: CBP (30 nm)/BCP (10 nm)/Alq₃ (30 nm)/LiF (1 nm)/Al (100 nm), were fabricated, where NPB is N,N′-di(naphthalene-1-yl)-N,N′-diphenyl-benzidine, Alq₃ is tris(8-hydroxyquinoline) Al(III), CBP is 4,4′-bis(carbazole-9-yl)-biphenyl, and BCP is 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline, respectively. In contrast with device 1, owing to less self-quenching and better charge confinement, device 2 shows improved performances: the maximum luminance of device 2 was dramatically increased from 199 to 1845 cd/m², the maximum current efficiency was increased from 0.69 to 2.62 cd/A, the turn-on voltage was decreased from 9.5 to 5.5 V, and higher color purity was attained.