The relationship between acoustic emission signals and cutting phenomena in turning process

The development of intelligent manufacturing by using machine tools is advancing in leaps and bounds. To maintain accuracy in machining and in the interests of fail-safe operation, monitoring of the cutting state or the final machining is very important. Acoustic emissions (AE) comprise elastic stress waves produced as a result of the deformation and fracture of materials. By measuring the AE generated during a turning process, it is possible to estimate the state of the machining operation. The correlation between cutting phenomena and AE in a turning process was examined experimentally by using a steel workpiece and a cermet tool in a numerically controlled turning process. The process of formation of chips, the types of chip, and the shear angle all markedly affected the AE signals. There was a strong negative correlation between the shear angle and the AE signal level. Similar results were obtained for various feed rates and for workpieces of various degrees of hardness. Correlations related to surface roughness and to tool wear are also described that permit the evaluation of the state of the turning process.     

Simulation of transverse crack formation on continuously cast peritectic medium carbon steel slabs

Reliable data are limited to the critical strain for the formation of transverse cracks on the slabs, owing to experimental difficulty to simulate temperature gradient in solidified shell in continuous casting mold. The present study is to determine the critical strain, ?_c, for the formation of transverse cracks on continuously cast slabs. A convenient and simple hot tensile test using rectangular test pieces with either V-notch or semi-circle notch or oscillation marks has been developed by placing the specimen under similar temperature gradient to that in solidified shell in the mold. The ?_c has been determined at a better accuracy and reproducibility, and the ?_c at a strain rate of 5?10^?4s^?1 is found to be a high 35% for test pieces without notch. It sharply decreases, however, to 10% for those with V- and semi-circle-notches, slightly decreases with increasing notch depth, and further decreases for those with oscillation marks that accompany solute segregation. Reduction of the oscillation mark depth is shown to be important measure to prevent the occurrence of transverse cracking of continuously cast slabs.     

Observation of metal on Si(0 0 1) by STM/STS and its consideration based on the first principles calculations

Local density of states (LDOS) is obtained by the first principles calculation based on the density functional theory on the Si(0 0 1)2 × 1 surface and on the surface with an Al dimer. At an Al dimer, LDOS has a high intensity in the conduction band region, which cannot be seen on the Si(0 0 1)2 × 1 surface. This tendency is observed in STS measurements as well. The possibility for a microelementary analysis is presented by applying this method to other metal atoms on the Si surface. Furthermore, it is pointed out that STS measurements should be always performed at the same tip-sample separation to obtain reproducible STS spectrums.     

Potentials of GHG reductions from wastewater treatment for the CDM

The study aims to evaluate the potential of GHG (greenhouse gas) reductions by installing an anaerobic digester in a wastewater treatment facility in Southeast Asia. Then the break-even point of additional investment to reduce GHG is obtained by exchanging carbon price as emissions credits. In the project scenario, the wastewater treatment system has the digester, where methane (biogas) is produced and recovered. Compared with the baseline scenario, the biogas has calorific value to produce heat and electri...     

220,000‐r/min, 2‐kW PM motor drive for turbocharger

This paper describes an ultrahigh‐speed permanent‐magnet synchronous motor drive, which is embedded in a turbocharger of an internal‐combustion engine. The electrical drive makes it possible to enhance output power of the turbocharger in a motoring mode and to retrieve combustion energy from exhaust gas in a regenerating mode. Computer simulations and experimental tests are conducted to examine various operation characteristics of a prototype. The experimental data demonstrate 220,000‐r/min operation at 2.2‐kW inverter output power, in good agreement with the simulation results and proving the feasibility of the proposed system. © 2007 Wiley Periodicals, Inc. Electr Eng Jpn, 161(3): 31–40, 2007; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/eej.20408     

Short‐current pulse‐based adaptive maximum‐power‐point tracking for a photovoltaic power generation system

This paper focuses on a maximum‐power‐point tracking method of photovoltaics via use of the short‐current pulse. It has been reported that the optimum operating current is proportional to the short current and that maximum‐power‐point tracking can be performed by detecting the short current. The proposed method utilizes the intermittent short‐current pulse to estimate the optimum operating current and its operating characteristics have experimentally been verified. Also, an adaptive mechanism to identify the parameter between the optimum current and the short current is discussed. A prototype of the controller has been set up and the experimental results have demonstrated excellent performance, proving the feasibility of the system. © 2002 Scripta Technica, Electr Eng Jpn, 139(1): 65–72, 2002; DOI 10.1002/eej.1147     

Seismic proof test of a reinforced concrete containment vessel (RCCV): Part 1: Test model and pressure test

In Japan, the Nuclear Power Engineering Corporation (NUPEC), sponsored by the Ministry of Economy, Trade and Industry (METI), has been conducting a series of seismic reliability proving tests using full-scale or close to full-scale models to simulate actual important equipment that is critical for seismic safety of nuclear power plants. The tests are intended to validate the seismic design and reliability with a sufficient margin even under destructive earthquakes. A series of tests was carried out on a reinforced concrete containment vessel (RCCV) for advanced boiling water reactor (ABWR) from 1992 to 1999. A large-scale high-performance shaking table at Tadotsu Engineering Laboratory, the largest in the world, was used for this test. Part 1 reports the test model and the results of pressure and leak tests. Part 2 describes test procedures, input waves and the results of verification tests such as changes of stiffness, characteristic frequency and damping ratio, the failure of the model and the load deflection. Part 3 shows the seismic safety margin that was evaluated from the energy input during the failure test to a design basis earthquake. Part 4 reports simulation analysis results by a stick model with lumped masses.     

Structural,Thermal and Magnetic Properties of Thin Metal Films and Adsorbate–Substrate Systems Studied by XAFS and XMCD

Thin metal films often exhibit interesting properties that are essentially different from the bulk ones. XAFS (X-ray absorption fine structure) and XMCD (X-ray magnetic circular dichroism) techniques are quite suitable to investigate structural, thermal and magnetic properties of thin metal films. In this proceeding, we will present following two topics concerning structural and magnetic properties of adsorbates on thin metal films. The first one is the adsorption geometry of SO₂ on a 1-monolayer (ML) Pd thin film grown on a Ni(111) single crystal. It was found by S K-edge XAFS that SO₂ is lying flat on 1-ML Pd/Ni(111). This result is not similar to the bulk Pd surface but to the bulk Ni one. This finding indicates significant modification of the electronic structure of the 1-ML Pd film compared to the bulk one. The second topic is the magnetic moment induced on CO adsorbed on Ni epitaxial films grown on Cu(001). The O K-edge XMCD results revealed that in the perpendicularly magnetized 10-ML Ni film the orbital moment of CO is parallel to the substrate Ni magnetization, while it is antiparallel in the in-planar magnetized 6-ML and thick (>100 ML) films. The origin of the induced orbital moment at CO is discussed.     

Marangoni flow at the gas/melt interface of steel

Direct observation with a scanning laser microscope was made to determine the direction and velocity of surface flow of steel melt in the vicinity of the solid/melt (S/M) interface. During solidification, a fast solutal Marangoni flow moving away from the S/M interface was confirmed to exist on steel melts containing oxygen and sulfur of 10 to 105 ppm. Even in such a low range of oxygen and sulfur content, the solutal Marangoni flow can be very fast, carrying inclusion particles up to the free surface along the S/M interface. During heating and holding, however, a thermal Marangoni flow combined with convective flow generated a reverse flow directed toward the S/M interface. These features have important relevance to inclusion entrainment and solute segregation during the solidification of steel. This article is based on a presentation given in the Mills Symposium entitled “Metals, Slags, Glasses: High Temperature Properties & Phenomena,” which took place at The Institute of Materials in London, England, on August 22–23, 2002.     

Hydrogen production by combining two types of photosynthetic bacteria with different characteristics

The double-layer photobioreactor using two types of photosynthetic bacteria, Rhodobacter sphaeroides RV and its reduced-pigment mutant, MTP4, was developed for efficient hydrogen production. The two types of bacteria had different characteristics on light energy, hydrogen production rate and conversion efficiency. MTP4 produced hydrogen more efficiently under high light conditions and RV did so under low light conditions. Illuminated light toward the surface of a photobioreactor quasi-exponentially declines as it penetrates into the reactor. When two types of bacteria were placed using the developed reactor according to this light distribution, the hydrogen production rate reached 3.64 l/m²/h at a light intensity of 500 W/m² in 24 h and the conversion efficiency of light energy to hydrogen was 2.18%. These values were 33% higher than those of only using RV. The low light in the deep part of the reactor was utilized efficiently, resulting in a higher hydrogen production rate.