Thermal modeling of the metal cutting process — Part II: temperature rise distribution due to frictional heat source at the tool–chip interface

Heat partition and the temperature rise distribution in the moving chip as well as in the stationary tool due to frictional heat source at the chip–tool interface alone in metal cutting were determined analytically using functional analysis. An analytical model was developed that incorporates two modifications to the classical solutions of Jaeger's moving band (for the chip) and stationary rectangular (for the tool) heat sources for application to metal cutting. It takes into account appropriate boundaries (besides the tool–chip contact interface) and considers non-uniform distribution of the heat partition fraction along the tool–chip interface for the purpose of matching the temperature distribution both on the chip side and the tool side. Using the functional analysis approach, originally proposed by Chao and Trigger (Transactions of ASME, 1951; 73:57–68), a pair of functional expressions for the non-uniform heat partition fraction along the tool–chip interface — one for the moving band heat source (for the chip side) and the other for the stationary rectangular heat source (for the tool side) were developed. Using this analysis, the temperature rise distribution in the chip and the tool were determined for two cases of machining, namely, conventional machining of steel with a carbide tool at high Peclet number (N_Pe≈5–20) and ultraprecision machining of aluminum with a single-crystal diamond tool at low Peclet number (N_Pe–0.5). The calculated temperature rise distribution curves on the two sides of the tool–chip interface are found to be well matched for both cases. The analytical method developed was found to be much faster, easier to use, and more accurate than various numerical methods used earlier. Further, the model provides a better physical appreciation of the thermal aspects of the metal cutting process.     

H13激光熔凝组织及耐磨性研究

系统研究了Ｈ１３热作模具钢激光熔凝组织和性能。与常规组织相比,熔凝区的显微硬度,抗回火稳定性及耐磨性的均显著提高。     

Thermochemical hydrogen production using Rh/CeO2/γ-Al2O3 catalyst by steam reforming of ethanol and water splitting in a packed bed reactor

This study is focused on investigating the dual performance of Rh/CeO₂/γ-Al₂O₃ catalyst for steam reforming of ethanol (SRE) and thermochemical water splitting (TCWS) using a packed bed reactor. The catalyst is designed to be thermally stable containing an active phase of Rh and the redox component of CeO₂ for oxygen exchange, supported on γ-Al₂O₃. The catalyst has been characterised by SEM, XRD, BET, TPR, TPD, XPS and TGA before testing in the reactor. The optimal temperature for SRE reaction over this catalyst is between 700 °C and 800 °C to produce high concentrations of hydrogen (~60%), and low CO and CH₄. The selectivity towards CO and CH₄ is higher at low temperatures and drops with rise in reaction temperature. Further, Rh/CeO₂/γ-Al₂O₃ is found to be active for TCWS at relatively low temperatures (≤1200 °C). At temperatures as low as 800 °C, this catalyst is especially found suitable for multiple redox cycles, producing a total of 48.9 mmol/g_cat in four redox cycles. The catalyst can be employed for large number of redox cycles when the reactor is operated at lower temperatures. Finally, the reaction pathways have been proposed for both SRE and TCWS on Rh/CeO₂/γ-Al₂O₃ catalyst.     

A phenomenological model of polishing of silicon with diamond abrasive

A phenomenological model of polishing hemispherical silicon asperities with spherical diamond abrasives is presented. Removal of the asperity material is quantitatively determined by a removal rate constant K. It is based on our molecular dynamics (MD) simulation studies considering the probability of removal of asperity atoms by an abrasive. The dependence of the removal rate constant K on the diameter and velocity of abrasives, number of asperities and abrasives per unit area, and cutting depth has been investigated. The rate constant K is found to be insensitive to the density of asperities, but linearly dependent on the density of abrasives.     

On the performance of membraneless laminar flow-based fuel cells

This paper reports on the characterization and optimization of laminar flow-based fuel cells (LFFCs) for both performance and fuel utilization. The impact of different operating conditions (volumetric flow rate, fuel-to-electrolyte flow rate ratio, and oxygen concentration) and of different cell dimensions (electrode-to-electrode distances, and channel length) on the performance (both power density and fuel utilization) of individual LFFCs is investigated. A finite-element-method simulation, which accounts for all relevant transport processes and electrode reactions, was developed to explain the experimental results here. This model can be used to guide further LFFC optimizations with respect to cell design and operation conditions. Using formic acid as the fuel, we measured a peak power density of 55 mW cm⁻². By hydrodynamically focusing the fuel to a thin stream on the anode we were able to reduce the fraction of fuel that passes through the channel without reacting, thereby increasing the fuel utilization per pass to a maximum of 38%. This paper concludes with a discussion on the various trade-offs between maximizing power density and optimizing fuel utilization per pass for individual LFFCs, in light of scaling out to a multichannel LFFC-based power source system.     

Microwave-mediated synthesis for improved morphology and pseudocapacitance performance of nickel oxide

Synthetic methods greatly control the structural and functional characteristics of the materials. In this article, porous NiO samples were prepared in conventional-reflux and microwave assisted heating method under homogeneous precipitation conditions. The NiO samples synthesized in conventional reflux method showed flakelike morphology, whereas the sample synthesized in microwave methods showed hierarchical porous ball like surface morphology with uniform ripple-shaped pores. The NiO samples characterized using BET method were found to bear characteristic meso- and macroporosity due to differently crystallized Ni(OH)(2) precursors under various heating conditions. Thermogravimety analysis showed morphology dependent decomposition of Ni(OH)(2) precursors. The microwave synthesized porous NiO sample with unique morphology and pore size distribution showed significantly improved charge storage and electrochemical stability than the flaky NiO sample synthesized by employing conventional reflux method. The cyclic voltammetry measurements on microwave synthesized NiO sample showed considerably high capacitance and better electrochemical reversibility. The charge-discharge measurements made at a discharge current of 2 A/g showed higher rate specific capacitance (370 F/g) for the NiO sample synthesized by microwave method than the sample synthesized by reflux method (101 F/g). The impedance study illustrates lower electronic and ionic resistance of rippled-shaped porous NiO due to its superior surface properties for enhanced electrode-electrolyte contact during the Faradaic redox reactions. It has been further established from the Ragone plot that the microwave synthesized NiO sample shows higher energy and power densities than the reflux synthesized NiO sample. Broadly, this study reveals that microwave-mediated synthesis approach is significantly a better strategy for the synthesis of porous NiO suitable to electrochemical supercapacitor applications.     

Imaging Dislocations in Single-Crystal SrTiO<Subscript>3</Subscript> Substrates by Electron Channeling

Electron channeling contrast imaging (ECCI) using a conventional pole-mounted backscatter detector in a commercial scanning electron microscope (SEM) has been implemented to analyze extended defects. In-grown extended defects in bulk SrTiO₃ (001) substrates such as dislocation loops, subsurface dislocations parallel to the surface, and surface-penetrating dislocations have been distinguished by ECCI. The techniques of dislocation-selective etching and ECCI have been compared side-by-side, where surface-penetrating dislocations have been shown to have one-to-one correspondence with ECCI spot features. g·b and g·b × u have been implemented for subsurface portions of intrinsic dislocations, being identified as screw dislocations with Burgers vector in the 〈100〉 direction.     

Multiresolution analysis as an approach for tool path planning in NC machining

Wavelets permit multiresolution analysis of curves and surfaces. A complex curve can be decomposed using wavelet theory into lower resolution curves. The low-resolution (coarse) curves are similar to rough-cuts and high-resolution (fine) curves to finish cuts in NC machining. In this paper, we investigate the applicability of multiresolution analysis using B-spline wavelets to NC machining of contoured 2D objects. High-resolution curves are used close to the object boundary similar to conventional offsetting while lower resolution curves are used farther away from the object boundary. Experimental results indicate that wavelet-based tool path planning improves machining efficiency. Tool path length is reduced, sharp corners are smoothed out thereby reducing uncut areas and larger tools can be selected for rough-cuts.     

Does Electronic Type Matter when Single‐Walled Carbon Nanotubes are Used for Electrode Applications?

Single‐walled carbon nanotube (SWNT) electrodes that are chemically and mechanically robust are fabricated using a simple drop cast method with thermal annealing and acid treatment. An electronic‐type selective decrease in sheet resistance of SWNT electrodes with HNO₃ treatment is shown. Semiconducting SWNTs show a significantly higher affinity toward hole doping in comparison to metallic SWNTs; a ≈12‐fold and a ≈fivefold drop in sheet resistance, respectively. The results suggest the insignificance of the electronic type of the SWNTs for the film conductivity after hole doping. The SWNT films have been employed as transparent hole extracting electrodes in bulk heterojunction (BHJ) organic photovoltaics. Performances of the devices enlighten the fact that the electrode film morphology dominates over the electronic type of the doped SWNTs with similar sheet resistance and optical transmission. The power conversion efficiency (PCE) of 4.4% for the best performing device is the best carbon nanotube transparent electrode incorporated large area BHJ solar cell reported to date. This PCE is 90% in terms of PCEs achieved using indium tin oxide (ITO) based reference devices with identical film fabrication parameters indicating the potential of the SWNT electrodes as an ITO replacement toward realization of all carbon solar cells.