The influence of burr formation and feed rate on the fatigue life of drilled titanium and aluminium alloys used in aircraft manufacture

Following drilling, fatigue life trials were performed on as-drilled and deburred specimens made from Ti–6Al–4V, AA7010 and AA2024, with feed rates varied at 2 levels. Deburring dramatically increased the fatigue performance of the Ti–6Al–4V and AA7010 samples by 69% and 283% respectively, but there was no significant effect on the AA2024 alloy. Fractography showed failure initiated near the exit burrs in Ti–6Al–4V and AA7010 specimens but not in the AA2024 workpieces. Correlation (R²) of fatigue notch factor against the sum of entrance and exit burr height was 0.68 and 0.79 for Ti–6Al–4V and AA7010 respectively, compared to 0.54 for AA2024.     

High-speed capillary zone electrophoresis with online photolytic optical injection

We report an online, optical injection interface for capillary zone electrophoresis (CZE) based upon photophysical activation of a caged, fluorogenic label covalently attached to the target analyte. This injection interface allows online analysis of biomolecular systems with high temporal resolution and high sensitivity. Samples are injected onto the separation capillary by photolysis of a caged-fluorescein label using the 351-364 nm irradiation of an Ar+ laser. Following injection, the sample is separated and detected via laser-induced fluorescence detection at 488 nm. Detection limits for online analysis of arginine, glutamic acid, and aspartic acid were less than 1 nM with separation times less than 5 s and separation efficiencies exceeding 1,000,000 plates/m. Rapid injection of proteins was demonstrated with migration times less than 500 ms and 0.5 nM detection limits. Online monitoring was performed with response times less than 20 s, suggesting the feasibility of this approach for online, in vivo analysis for a range of biologically relevant analytes.     

Development of a knowledge management initiative and system: A case study

As knowledge emerges as the primary strategic resource in the 21st century, many firms in the manufacturing and service sectors alike are beginning to introduce and implement Knowledge Management (KM). Organisations can certainly benefit from its application for enhanced decision support, efficiency and innovation, thus helping them to realise their strategic mission. However, KM is an emerging paradigm, and not many organisations have a clear idea of how to proceed with it. This paper presents the results of a case study conducted in one company in the United Kingdom (UK), the major aim being to identify how it has developed a KM initiative and system. Hopefully, the information extracted from this study will be beneficial to other organisations that are attempting to implement KM or to those that are in the throes of adopting it.     

The influence of cutter orientation and workpiece angle on machinability when high-speed milling Inconel 718 under finishing conditions

The paper details results from a comprehensive series of experiments on the effects of key operating variables; cutter orientation and workpiece tilt angle, on tool life/length cut, cutting force, workpiece surface roughness (R_a), subsurface microstructure/microhardness and residual stress, when high-speed milling under finishing conditions. In terms of length cut, the 8 mm diameter coated (TiAlCrN multi-layer) carbide ball nose end mills achieved tool life values approaching 200 m. Life results for the horizontal downwards orientation when cutting with a workpiece tilt angle of 45° were similar to those when operating with the workpiece mounted horizontally, however, cutting forces were significantly higher in the latter case. Evidence of tool chatter was also observed from cutting force signatures with the horizontal upwards mode. Mean compressive surface residual stresses up to −850 MPa measured parallel to the feed direction were obtained when machining using worn tools with a 0° workpiece inclination, while tensile stresses were obtained when machining with horizontal downwards orientation.     

Oxygen microsensor and its application to single cells and mouse pancreatic islets.

An oxygen microsensor with a < 3-micron tip diameter was developed for monitoring oxygen levels at single cells and mouse pancreatic islets. The sensor was fabricated by electrochemically recessing an etched Pt wire inside a pulled glass micropipet and then coating with cellulose acetate. This fabrication process was found to be simpler than previous oxygen electrode designs of comparable size. The microsensors had a average sensitivity of 0.59 +/- 0.29 pA/mmHg (mean +/- SD, n = 42), signals that were minimally perturbed by convection, and response times of < 1 s. The electrode was used to measure the oxygen gradient around and inside single mouse islets. The measurements demonstrate that oxygen levels within even the largest islets at maximal glucose stimulation are 67 +/- 1.6 mmHg (mean +/- SD, n = 5), indicating that islets have adequate oxygen supplies by diffusion under tissue culture conditions to support insulin secretion. The electrode was also used to record the dynamics of oxygen level at single islets as a function of glucose concentration. As glucose level was changed from 3 to 10 mM, oxygen level decreased by 15.8 +/- 2.3 mmHg (mean +/- SEM, n = 6) and oscillations with a period of 3.3 +/- 0.6 min (mean +/- SEM, n = 6) appeared in the oxygen level. In islets bathed in quiescent solutions containing 10 mM glucose, similar oscillations could be observed. In addition, in the quiet solutions it was possible to detect faster oscillations with a period of 12.1 +/- 1.7 s (mean +/- SEM, n = 6) superimposed on the slower oscillations. Oxygen consumption could also be observed at single insulinoma cells using the electrode. Individual cells also showed oscillations in oxygen consumption with a period of a few seconds. The results demonstrate that the electrode can be used for dynamic oxygen level recordings in biological microenvironments.     

3D FE modelling of high-speed ball nose end milling

The paper details research and development of a Lagrangian-based, 3D finite element (FE) model to simulate the high-speed ball nose end milling of Inconel 718 nickel-based superalloy using the commercial FE package ABAQUS Explicit. The workpiece material was modelled as elastic plastic with isotropic hardening and the flow stress defined as a function of strain, strain rate and temperature. Workpiece material data were obtained from uniaxial compression tests at elevated strain rates and temperatures (up to 100/s and 850°C, respectively) on a Gleeble 3500 thermo-mechanical simulator. The data were fitted to an overstress power law constitutive relationship in order to characterise flow behaviour of the material at the level of strain rates found in machining processes (typically up to 10⁵/s). Evolution of the chip was initially seen to progress smoothly, with the predicted machined workpiece contour showing good correlation with an actual chip profile/shape. Cutting force predictions from the FE model were validated against corresponding experimental values measured using a piezoelectric dynamometer, while modelled shear zone/chip temperatures were compared with previously determined experimental data. The model was successful in predicting the forces in the feed and step-over direction to within 10% of corresponding experimental values but showed a very large discrepancy with the thrust force component (～90%). Modelled shear-plane temperatures calculated at the point of maximum cutting force were found to demonstrate very good agreement with measured values, giving a discrepancy of ～5%. The simulation required a computational time of approximately 167 h to complete one full revolution of the ball end mill at 90 m/min cutting speed.     

Effect of laminate configuration and feed rate on cutting performance when drilling holes in carbon fibre reinforced plastic composites

Composites use in the aerospace industry is expanding, in particular carbon fibre reinforced plastics (CFRP) for structural components. Machinability can however be problematic especially when drilling, due to CFRP's inherent anisotropy/in-homogeneity, limited plastic deformation and abrasive characteristics. Following a brief review on composites development and associated machining, the paper outlines experimental results when twist drilling 1.5 mm diameter holes in 3 mm thick CFRP laminate using tungsten carbide (WC) stepped drills. The control variables considered were prepreg type (3 types) and form (unidirectional (UD) and woven), together with drill feed rate (0.2 and 0.4 mm/rev). A full factorial experimental design was used involving 12 tests. Response variables included the number of drilled holes (wear criterion VB_Bmax ≤ 100 μm), thrust force and torque, together with entry and exit delamination (conventional and adjusted delamination factor values calculated) and hole diameter. Best results were obtained with woven MTM44-1/HTS oven cured material (3750 holes) while the effect of prepreg form on tool life was evident only when operating at the higher level of feed rate. Thrust forces were typically under 125 N with torque values generally below 65 Nmm over the range of operating parameters employed. Finally, the delamination factor (F_d) measured at hole entry and exit ranged between ～1.2–1.8 and 1.0–2.1 respectively.     

Review on ultrasonic machining

Ultrasonic machining is of particular interest for the cutting of non-conductive, brittle workpiece materials such as engineering ceramics. Unlike other non-traditional processes such as laser beam, and electrical discharge machining, etc., ultrasonic machining does not thermally damage the workpiece or appear to introduce significant levels of residual stress, which is important for the survival of brittle materials in service. The fundamental principles of ultrasonic machining, the material removal mechanisms involved and the effect of operating parameters on material removal rate, tool wear rate and workpiece accuracy are reviewed, with particular emphasis on the machining of engineering ceramics. The problems of producing complex 3-D shapes in ceramics are outlined.     

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.     

The Machining of γ-TiAI Intermetallic Alloys

Titanium intermetallic materials are likely to play a significant role in the production of future aeroengines. The paper details the machinabilty of a range of gamma titanium aluminide (γ-TiAl) intermetallic alloys when turning, grinding, HSM, drilling, EDM and ECM. Comprehensive literature review data is augmented with experimental results for turning, turn-milling and temperature measurement when high speed milling. Despite the ability to produce crack free surfaces when grinding and HSM, turning and drilling remain problematic. Turned surfaces are in general characterised by workpiece smearing, numerous arc shaped cracks, subsurface lamellae deformation and significant strain hardening, although the use of PCD tooling and ultrasonic assisted cutting has been shown to minimise these effects.