Significant improvement of semi-solid microstructure and mechanical properties of A356 alloy by ARB process

Accumulative roll bonding (ARB) process was used in this study as an effective method for manufacturing high-strength, finely-dispersed and highly-uniform A356 alloy. It was found that when the number of ARB cycles was increased, the uniformity of silicon particles in the aluminum matrix improved, the particles became finer and spheroider and therefore, the tensile strength (TS) and ductility of the samples improved. The microstructure of the manufactured A356 alloy after five ARB cycles indicated a totally modified structure such that it's TS and elongation values reached 269 MPa and 5.3% which were 2.6 and 2.5 times greater than those of the as-cast material, respectively. Also, the hardness value increased from 55.4 (for as-cast sample) to 100.2 HV (after the fifth cycle of ARB), and registered 81% increase.     

Hydrometallurgical Extraction of Vanadium from Mechanically Milled Oil-Fired Fly Ash: Analytical Process Optimization by Using Taguchi Design Method

In this study, the Taguchi design method was employed to determine the optimum experimental parameters in extraction of vanadium by NaOH leaching of oil-fired fly. Prior to designed experiments, the raw precipitates were mechanicallly milled using a high-energy planetary ball mill. Experimental parameters were investigated as follows: mechanical milling (MM) times (2 and 5?hours), NaOH (1 and 2 molar concentration) as reaction solution (RS), powder to solution (P/S) ratios (100/400 and 100/600?mg/mL), temperature (T) of reaction system (303 K and 333?K [30?°C and 60?°C]), stirring times (ST) of reaction media (4 and 12?hours), stirring speed (SS) being adjusted to 400 and 600?rpm, and rinsing times (RT) of remained filtrates (1 and 3?hours). Statistical analysis of signal-to-noise ratio followed by analysis of variance was performed in order to estimate the optimum levels and their relative contributions. Data analysis is carried out using L₈ orthogonal array consisting of seven parameters each with two levels. The optimum conditions were MM1 (3?hours), RS2 (2 molar NaOH), P/S2 (100/600?mg/mL), T2 (333?K [60?°C]), ST2 (12?hours), SS1 (400?rpm), and RT1 (1?hour). Finally, from environmental and economical points of view, the process is faster and better organized by employing this analytical design method.     

Tooling device design for vibration-assisted high speed shaping of PMMA

PMMA optical components that are used as one of the most important parts of high precision equipments and machines are increasingly replacing the glass due to the various advantages of PMMA. Especially in Light Guide Panels, the PMMA sheet that is used in Liquid Crystal Displays plays an important role in scattering the incident light and requires very fine machining as the sheet is directly related to the optical characteristics of the panels. The High Speed End milling and High Speed Shaping processes that are widely adopted and applied to the precise machining of Light Incident Plane still have quality problems, such as cracks, breakages, poor waviness, and straightness. This paper presents the tooling device design for machining a Light Incident Plane through vibration-assisted High Speed Shaping for increasing the optical quality by minimizing the above-mentioned problems. The cutting tool and the tool post presented in this paper are designed by the authors to increase the magnitude of the cutting stroke by adopting the resonant frequency without weakening the stiffness and to reduce vibrations during even high speed feeding. The dynamic characteristics of the cutting tool and the tool post are evaluated through simulation and experiment as well. The results reveal very appropriate dynamic characteristics for vibration-assisted High Speed Shaping.     

Three dimensional modeling and finite element simulation of a generic end mill

The geometry of cutting flutes and the surfaces of end mills is one of the crucial parameters affecting the quality of the machining in the case of end milling. These are usually represented by two-dimensional models. This paper describes in detail the methodology to model the geometry of a flat end mill in terms of three-dimensional parameters. The geometric definition of the end mill is developed in terms of surface patches; flutes as helicoidal surfaces, the shank as a surface of revolution and the blending surfaces as bicubic Bezier and biparametric sweep surfaces. The proposed model defines the end mill in terms of three-dimensional rotational angles rather than the conventional two dimensional angles. To validate the methodology, the flat end milling cutter is directly rendered in OpenGL environment in terms of three-dimensional parameters. Further, an interface is developed that directly pulls the proposed three-dimensional model defined with the help of parametric equations into a commercial CAD modeling environment. This facilitates a wide range of downstream technological applications. The modeled tool is used for finite element simulations to study the cutting flutes under static and transient dynamic load conditions. The results of stress distribution (von mises stress), translational displacement and deformation are presented for static and transient dynamic analysis for the end mill cutter flute and its body. The method described in this paper offers a simple and intuitive way of generating high-quality end mill models for use in machining process simulations. It can be easily extended to generate other tools without relying on analytical or numerical formulations.     

Laser and GTAW torch processing of Fe–Cr–B coatings on steel

A comparison has been made of the relationship between microstructure and microhardness developed by surface melting Nanosteel SHS 7170 Fe–Cr–B alloy powder onto a plain carbon steel surface. This powder was initially developed as a high velocity oxyfuel sprayed coating, giving a strength 10 times that of mild steel, and is particularly suitable for surface protection against wear and corrosion. In the present study, the alloy powder was injected into the laser melted surface, while a preplaced powder was melted using the gas tungsten arc welding (GTAW) technique. The laser track consisted of fine dendrites and needle-like microstructures, which produced a maximum hardness value of over 800 HV, while the GTAW track produced a mixture of equiaxed and columnar grain microstructures with a maximum hardness value of 670 HV. The lower hardness values are considered to be associated with dilution and grain size.     

Dynamically vulcanized polypropylene/ethylene‐propylene diene monomer/organoclay nanocomposites: Effect of mixing sequence on structural,rheological, and mechanical properties

Dynamically vulcanized thermoplastic elastomer (TPE) nanocomposites based on polypropylene (PP), ethylene‐propylene diene monomer (EPDM) and cloisite 15A were prepared via direct melt mixing in a co‐rotating twin‐screw extruder. The mixing process was carried out with optimized processing parameters (barrel temperature = 180°C; screw speed = 150 rpm; and feeding rate = 0.2 kg/hr). The formulation used to prepare the nanocomposites was fixed to 75/20/5 (PP/EPDM/Cloisite^©15A), expressed in mass fraction. Effect of mixing sequence on the properties of vulcanized and unvulcanized (TPE) nanocomposites prepared under similar conditions was investigated using X‐ray diffraction (XRD) and a tensile testing machine. Results showed that the sequence of mixing does affect the properties of final TPE nanocomposites. Accordingly, nanocomposite samples prepared through mixing the preblended PP/clay masterbatch with EPDM phase, show better clay dispersion within the polymer matrix. J. VINYL ADDIT. TECHNOL., 22:320–325, 2016. © 2014 Society of Plastics Engineers