Modeling of Particle Emission During Dry Orthogonal Cutting

Because of the risks associated with exposure to metallic particles, efforts are being put into controlling and reducing them during the metal working process. Recent studies by the authors involved in this project have presented the effects of cutting speeds, workpiece material, and tool geometry on particle emission during dry machining; the authors have also proposed a new parameter, named the dust unit (D _u), for use in evaluating the quantity of particle emissions relative to the quantity of chips produced during a machining operation. In this study, a model for predicting the particle emission (dust unit) during orthogonal turning is proposed. This model, which is based on the energy approach combined with the microfriction and the plastic deformation of the material, takes into account the tool geometry, the properties of the worked material, the cutting conditions, and the chip segmentation. The model is validated using experimental results obtained during the orthogonal turning of 6061-T6 aluminum alloy, AISI 1018, AISI 4140 steels, and grey cast iron. A good agreement was found with experimental results. This model can help in designing strategies for reducing particle emission during machining processes, at the source.     

Icosahedral medium-range orders and backbone formation in an amorphous alloy

Analyses of metallic amorphous solids constructed using molecular dynamics (MD) simulations have demonstrated that individual short-range orders (SROs) are linked with neighboring SROs and form various medium-range orders (MROs). These MROs have been observed to have different structural stability depending on their linking patterns. On the basis of the assessment of the structural stability of various MROs, we propose new types of structural organization, namely, icosahedral medium-range orders (I-MROs) and their extended-range order that forms the backbone of amorphous solids. We also discuss why the atomic-scale structure of an amorphous alloy can be more appropriately described in terms of I-MROs, rather than by the degree of short-range ordering as characterized by the fractions of SROs.     

Fabrication of Al matrix composite reinforced with submicrometer-sized Al<Subscript>2</Subscript>O<Subscript>3</Subscript> particles formed by combustion reaction between HEMM Al and V<Subscript>2</Subscript>O<Subscript>5</Subscript> composite particles during sintering

To fabricate an Al-V matrix composite reinforced with submicron-sized Al₂O₃ and Al_xV_y (Al₃V, Al₁₀V) phases, high energy mechanical milling (HEMM) and sintering were employed. By increasing the milling time, the size of mechanically milled powder was significantly reduced. In this study, the average powder size of 59 μm for Al, and 178 μm for V₂O₅ decreased with the formation of a new product, Al-Al₂O₃-Al_xV_y, with a size range from 1.3 μm to 2.6 μm formed by the in-situ combustion reaction during sintering of HEM milled Al and V₂O₅ composite powders. The in-situ reaction between Al and V₂O₅ during the HEMM and sintering transformed the Al₂O₃ and Al_xV_y (Al₃V, Al₁₀V) phases. Most of the reduced V reacted with excess the Al to form Al_xV_y (Al₃V, Al₁₀V) with very little V dissolved into Al matrix. By increasing the milling time and weight percentage of V₂O₅, the hardness of the Al-Al₂O₃-Al_xV_y composite sintered at 1173 K increased. The composite fabricated with the HEMM Al-20wt.%V₂O₅ composite powder and sintering at 1173 K for 2 h had the highest hardness.     

Improvement of slurry erosion resistance of martensite/ferrite duplex stainless steel by hot rolling

Test samples of martensite/ferrite duplex stainless steels (M/Fss) were prepared using thermal-mechanical processes and their slurry erosion behaviors were systematically studied. Test results show that hot rolling is an attractive process for improving erosion resistance. This improvement is more evident at higher impinging angles and larger reduction ratios. The thermal-mechanical-treated samples exhibit higher slurry erosion resistance for all impinging angles compared to that obtained by conventional quenching treatment without rolling. The variation tendency of the erosion rate versus the impinging angle for samples rolled with different degrees of reduction is similar in that the erosion rate initially increases and then decreases as the impinging angles increase from 15° to 90°, reaching a maximum at approximately 30°. After impingement erosion, the surface morphologies of the samples exhibit many long furrows and ridges at a low impinging angle of 30°. At a high impinging angle of 90°, the samples exhibit a worn surface with abundant overlapping and irregular concavities. The surface hardness of the samples after impingement erosion increases as the impinging angles and reduction ratios increase due to the enhanced effects of both work hardening and the formation of straininduced martensite.     

Electrochemical drilling inclined holes using wedged electrodes

This paper presents electrochemical machining of inclined holes using wedge-shaped electrodes. Numerical simulation has been carried out to study the initial flow fields of the machining area with and without the wedged tip at different machining inclination angles. Experiments were conducted consequently to study the machining characteristics affected by each flow field distribution mentioned above. Theoretical and experimental analyses indicate that inclined hole machining using wedged electrodes distributes the electrolyte flow more uniformly and hence leads to a more stable machining process. Wedged electrodes could be used in electrochemical drilling to efficiently drill high-quality holes with large inclination angles.     

Performance characterization of a small-capacity thermoacoustic cooler for air-conditioning applications

The performance of a working prototype, operated with and without water flow through the heat exchangers, was measured and found to be in reasonably close agreement to predictions from a simulation code, DELTAE, based on linear thermoacoustic theory. Further analysis and DELTAE simulations showed that the coefficient of performance may be significantly reduced when the stack temperature profile becomes non-linear, i.e. when the system is operated for a temperature span smaller than the optimal value for a given stack length. Guidelines to avoid this condition are provided.     

Enhancement of the punch pin durability induced by the PVD coating in production process of the automotive inner pipe

This experimental studies were carried out in order to understand the effects of the PVD coating and the UNSM treatment of HSS55 (high speed steel 55) during the production of the automotive inner pipe by the plastic deformation of S45C. The field test and the SEM images revealed that the PVD coating is necessary in spite of the high compressive residual stresses which were formed at the head of a punch pin. Upon the application of the AlCrN coating with the UNSM treatment the productivity and reliability of a punch pin had improved more than about 2.6 times compared to that of the TiN coating without the UNSM treatment. It is likely that the improvement is caused by the decreased stress concentration factor by the ‘wrapped in oxides’ inside of an abrasion pit. The abrasion pits were mostly generated within range of 5% ∼ 50% of the diameter ratio from the end of a pin and reached the maximum value about 17% from the end of a pin.     

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.