A Six-sigma approach for benchmarking of RP&M processes

This paper presents a methodology of using six-sigma quality tools for benchmarking of rapid prototyping & manufacturing (RP&M) processes. It involves the fabrication of a geometric benchmark part and a methodology to control and identify the best performance of the process to reduce the variablity in the fabricated parts. The approach is demonstrated with a case study based on the direct laser sintering (DLS) process for prototyping using plastic powder. In the case study an identified set of six-sigma/ statistical process control tools is employed to determine and best tune factors affecting the desired outcomes of the built parts.     

The intracellular distribution of vinculin and alpha2 integrin in epithelial cells and chondrocytes

The purpose of this study was to demonstrate the presence of vinculin and alpha₂ integrin in chondrocytes in situ and epithelial cells. We also determined that the appropriate fixation and extraction protocols for immunohistochemistry and laser scanning confocal microscopy for an integral membrane protein and an actin-associated protein in cultured cells and whole tissue was different. Cultured epithelial cells, whole mount human cornea and avian cartilage were fixed and prepared using a number of standard procedures used for indirect fluorescence immunohistochemistry. The distribution of vinculin was cell-type and fixation-specific. Chondrocytes and cultured epithelial cells demonstrated vinculin in areas that appear to be associated with filamentous actin. Vinculin was associated with cell membranes in human cornea. The expression of alpha₂ integrin observed in chondrocytes fixed with methanol, paraformaldehyde, or formaldehyde is consistent with its role in cell-substrate interaction, but may also suggest a role in dividing and differentiating cells. The localization of alpha₂ integrin in human corneal epithelia supports its role as a cell-cell adhesion molecule. The cytoplasmic distribution of vinculin and alpha₂ integrin in tissues fixed without detergent extraction suggests that the fixation step may be sufficient for antibody penetration and antigen extraction. These studies are the first report of vinculin and alpha₂ integrin in embryonic chondrocytes. In addition we have shown that confocal laser scanning microscopy combined with proper fixation and extraction protocols may optimize the localization of antigens in cultured and whole mount cells.     

The use of generalised deformation boundaries for the analysis of axisymmetric extrusion through curved dies

A generalised kinematically admissible velocity field is derived for axisymmetric extrusion through curved dies by employing rigid-plastic boundaries expressed in terms of arbitrarily chosen continuous functions. The corresponding upper-bound extrusion pressure is related directly to boundary functions for the plastically deforming region when the die shape, lubrication condition and material characteristics of the billet are given. The proposed method of analysis makes it possible to predict the deformation pattern as well as extrusion pressure. In computation a third-order polynomial is chosen for the die boundary and the bounding function for the plastic region is chosen to be a fourth-order polynomial. The workhardening effect is considered in the formulation. The plastic boundaries as well as stream lines are affected by various process parameters. The theory predicts the relatively faster axial flow at the center than near the die boundary for greater friction factor even with the same die shape. The effects of area reduction and die length are also discussed in relation to extrusion pressure and deformation. Experiments are carried out for steel billets at room temperature. Deformation patterns are measured for several area reductions by the photoetching technique and the extrusion pressure is measured using a load-cell. The predicted extrusion pressure is in excellent agreement with the value computed by the finite element method. The deformation patterns agree well with the experimental observation.     

Fabrication of porous bioactive structures using the selective laser sintering technique

Hydroxyapatite, a ceramic with which natural bone inherently bonds, has been incorporated into a polymer matrix to enhance the bioactivity of implant materials. In order to manufacture custom-made bioactive implants rapidly, selective laser sintering has been investigated to fabricate hydroxyapatite and polyamide composites and their properties investigated. One objective of this research was to identify the maximum hydroxyapatite content that could be incorporated into the matrix, which was sintered at various parameters. The study focused on investigating the control of porosity and pore size of the matrix by manipulating the selective laser sintering parameters of the laser power and laser scan speed. The interception method was used to analyse the internal porous morphology of the matrices which were cross-sectioned through the vertical plane. Most notably, all structures built demonstrated interconnection and penetration throughout the matrix. Liquid displacement was also used to analyse the porosity of the matrices. The laser power showed a negative relationship between porosity and variation in parameter values until a critical power value was reached. However, the same relationship for laser scan speed matrices was inconsistent. The effects of the laser power and laser scanning speed on the features of porous structures that could influence cell spreading, proliferation, and bone regeneration are presented.     

Molecular dynamics studies of atomic-scale tribological characteristics for different sliding systems

A slider-slab sliding model for hard-to-soft and soft-to-soft sliding systems with abrasive and non-abrasive wear conditions is used to investigate atomic-scale friction. The molecular dynamics simulation uses the Morse potential to calculate interatomic forces between atoms. Separation distance between the slider and the slab is changed to simulate repulsive and attractive interactive force fields exerted on interface between two sliding components. Effects of the interaction potential parameters on the sliding friction are investigated. The relationship of frictional force, normal force and temperature rise of the slider and the slab during sliding are established. Comparison of the hard-to-soft and the soft-to-soft sliding system are carried out and shows different tribological phenomena.     

Ultra-precision lapping of machinable ceramic Si3N4-BN by in-process electrolytic dressing

The machinable ceramic Si₃N₄-BN is a material which is increasingly being employed for automobile bearings and machinable ceramics. This material is very hard and has high resistance against volatile temperature and wear. It's efficient quality and accurate surfaces have always been of high demand for many applications in the industrial field. Besides, this material is varied by the percentage of BN contained in it, and the characteristics of lapping also varies according to this percentage of BN. Hence, in-process electrolytic dressing for ultra-precision lapping was introduced and used to experiment with the differing BN percentages in machinable ceramic Si₃ N₄. Metal-bonded super-abrasive diamond lapping wheels have superior qualities such as high bond strength, high stability and high machinability. The major problems encountered are wheel loading and glazing, which impedes the effectiveness of the cast-iron bonded diamond lapping wheel and, therefore, dressing should be considered. In this respect, in-process electrolytic dressing (IED) is proposed as an effective method regarding continuous protruding abrasives on the surface of wheels, whereby loading and glazing phenomena can apparently disappear. In this paper, the machining characteristics of machinable ceramic Si₃N₄-BN have been studied by adapting the IED lapping process in terms of the percentage of h-BN material.     

Deformation behaviour of elastic-plastic tubes under external pressure and axial load

A constitutive equation taking into account corner formation on the yield surface and the Bauschinger effect is developed. The behaviour of circular long tubes subjected to external pressure and axial load under plane strain and generalized plane-strain conditions are analyzed in conjunction with the proposed constitutive equation. The influence of axial load, the Bauschinger effect and corner formation, including the corner angle, and the mobility of the corner axis to the direction of stress history upon such global deformation behaviour as maximum pressure, pressure vs displacement relation and axial strain, are clarified. With regard to local deformation, these effects on the strain rate and strain localization, surface unevenness and shear band formation from the highly strained internal surface are investigated.     

Kinematic calibration for a hybrid 5DOF manipulator based on 3-RPS in-actuated parallel manipulator

The measurement method is a decisive step for any calibration method. This paper studies the practical performance of a 5DOF manipulator based on a 3-RPS parallel mechanism. By comparing the controlling data that resides in parallel part and serial part at different orientations, a calibration method has been put forward and proved to be applicable. The precision of the calibrated model mainly depends on the number of measurements carried out. The distribution of measurement points also affects the precision and the measurement number could be significantly reduced if uniform distribution were ensured.     

An accurate analytical approach to electron crystallography

A much more accurate analytical expression of dynamical electron diffraction than the phase object approximation (POA) formula has been derived in this paper which decreases the restriction of sample thickness up to almost one order of magnitude compared to POA theory. The importance of the new expression is twofold. First, a sample with such a thickness that new expression remains valid can be prepared experimentally. Second, the new expression reveals a clear and straightforward relationship between the wave function and crystal potential. In the expression, the effect of dynamical diffraction on wave function can be simply attributed to two factors TP(D) = (sin(lambda pi zg2))/(4pi2g2) and TA(D) = [1 - cos(lambda pi zg2)]/4pi2g2. Compared to the effect of transfer functions of an electron microscope on wave function, we found that TP(d) and TA(d) play the same role as transfer function but are independent of the instrument.For this reason, we here call the former as "extrinsic transfer functions" and the latter as "intrinsic" ones. In principle, one should correct not only extrinsic transfer functions but also intrinsic ones if one desires to achieve higher resolution.