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.     

Macroanatomic,light, and electron microscopic examination of pecten oculi in the seagull (Larus canus)

The present study was conducted to determine macroanatomic characteristic as well as light and electron microscopic examination (SEM) of pecten oculi and totally 20 bulbus oculi belonging to 10 seagulls (Larus canus) were used. Pecten oculi formations consisted of 18 to 21 pleats and their shape looked like a snail. Apical length of the pleats forming pecten oculi were averagely measured as 5.77 ± 0.56 mm, retina‐dependent base length was 9.01 ± 1.35 mm and height was measured as 6.4 ± 0.62 mm. In pecten oculi formations which extend up to 1/3 of the bulbus oculi, two different vascular formations were determined according to thickness of the vessel diameter. Among these, vessels with larger diameters which are less than the others in count were classified as afferent and efferent vessels, smaller vessels which are greater in size were classified as capillaries. Furthermore, the granules which were observed intensely in apical side of the pleats of pecten oculi were observed to distribute randomly along the plica.     

Magnetization of friction surfaces and wear particles by tribological processes

The relationship between magnetization of a friction surface and wear phenomena is discussed for the case of rubbing of nickel on nickel. Experiments were performed by sliding-friction tests of the pin-on-block type. Magnetization of the friction surface was estimated by measuring changes in the magnetic flux density with a Tesla meter, and the effects of lubrication and various normal loads on changes in the magnetic flux density were examined. Also, the magnetic flux density of wear particles was examined for single particles and particle aggregates. The magnetization of the friction surface was found to be related to surface damage by transfer (adhesion). Individual wear particles and aggregates of fine wear particles were all magnetized in one direction by tribological action, showing that wear particles and transfer particles on the friction surface are the principal source of magnetization.     

Controlled microtribology of a metal oxide surface

The rational control of the friction and wear (damage) of engineering, as opposed to model, surfaces under practical conditions such as high contact pressures has long been a technological challenge with much fundamental interest. Lubricant fluids and physisorbed surfactant monolayers (boundary lubricants) are effective friction modifiers but often fail at high loads. We show that the chemisorption of a suitably designed single-chained phosphonate surfactant onto crystalline α-alumina surfaces produces robust protective monolayers that significantly reduce the friction forces and wear even at high loads. The mechanisms are explained, which point to some general principles that offer a basis for scale-up in many different engineering systems. This revised version was published online in June 2006 with corrections to the Cover Date.     

The interaction of design and operation for optimized aluminum reduction

The aluminum reduction process may be thought of as having three facets: structure, which encompasses the physical design, layout and construction of the plant; operating systems, which deal with the methods for carrying out the various operations; and processes, which encompass the workings of the reduction process. Unless all three are properly balanced during the design and retrofit processes, suboptimal results will be obtained.     

Practical considerations for high spatial and temporal resolution dynamic transmission electron microscopy

Although recent years have seen significant advances in the spatial resolution possible in the transmission electron microscope (TEM), the temporal resolution of most microscopes is limited to video rate at best. This lack of temporal resolution means that our understanding of dynamic processes in materials is extremely limited. High temporal resolution in the TEM can be achieved, however, by replacing the normal thermionic or field emission source with a photoemission source. In this case the temporal resolution is limited only by the ability to create a short pulse of photoexcited electrons in the source, and this can be as short as a few femtoseconds. The operation of the photo-emission source and the control of the subsequent pulse of electrons (containing as many as 5 x 10(7) electrons) create significant challenges for a standard microscope column that is designed to operate with a single electron in the column at any one time. In this paper, the generation and control of electron pulses in the TEM to obtain a temporal resolution <10(-6)s will be described and the effect of the pulse duration and current density on the spatial resolution of the instrument will be examined. The potential of these levels of temporal and spatial resolution for the study of dynamic materials processes will also be discussed.     

Five-axis automated measurement by coordinate measuring machine

This research paper presents an analysis of the undercut interference and inclination interference caused by complicated 3D workpiece during measurement. The objective of this research is to propose a solution to the collision between measuring probe and workpiece for the purpose of automation and interference-free measurement. The fundamental procedure is based on the 3D CAD model of workpiece and five-axis coordinate measuring machine (CMM) measuring facility to generate an interference-free stylus orientation through three phases—adjustment of inclination angle under linear contour, adjustment of inclination angle under non-linear contour, and definition of rotation-free angle. Such manner not only solves the interference problems but also incorporates the minimization of counts of measuring probe rotation. In terms of methodology, the research adopts projection of cutting plane to determine the interference status of the measuring point, and based on the measuring inclination angle on the proposition of self-intersected contour and cross-intersected contour concepts, the range of safe rotation range can be determined by sweeping operation. Following the presented methods and procedures, the five-axis CMM simulation system for automated measurement is finally developed to validate the feasibility of proposed solution.     

In-situ TEM on (de)hydrogenation of Pd at 0.5-4.5 bar hydrogen pressure and 20-400°C

We have developed a nanoreactor, sample holder and gas system for in-situ transmission electron microscopy (TEM) of hydrogen storage materials up to at least 4.5 bar. The MEMS-based nanoreactor has a microheater, two electron-transparent windows and a gas inlet and outlet. The holder contains various O-rings to have leak-tight connections with the nanoreactor. The system was tested with the (de)hydrogenation of Pd at pressures up to 4.5 bar. The Pd film consisted of islands being 15 nm thick and 50-500 nm wide. In electron diffraction mode we observed reproducibly a crystal lattice expansion and shrinkage owing to hydrogenation and dehydrogenation, respectively. In selected-area electron diffraction and bright/dark-field modes the (de)hydrogenation of individual Pd particles was followed. Some Pd islands are consistently hydrogenated faster than others. When thermally cycled, thermal hysteresis of about 10-16 °C between hydrogen absorption and desorption was observed for hydrogen pressures of 0.5-4.5 bar. Experiments at 0.8 bar and 3.2 bar showed that the (de)hydrogenation temperature is not affected by the electron beam. This result shows that this is a fast method to investigate hydrogen storage materials with information at the nanometer scale.     

Energetic ion loss detector on the Alcator C-Mod tokamak

A scintillator-based energetic ion loss detector has been successfully commissioned on the Alcator C-Mod tokamak. This probe is located just below the outer midplane, where it captures ions of energies up to 2 MeV resulting from ion cyclotron resonance heating. After passing through a collimating aperture, ions impact different regions of the scintillator according to their gyroradius (energy) and pitch angle. The probe geometry and installation location are determined based on modeling of expected lost ions. The resulting probe is compact and resembles a standard plasma facing tile. Four separate fiber optic cables view different regions of the scintillator to provide phase space resolution. Evolving loss levels are measured during ion cyclotron resonance heating, including variation dependent upon individual antennae.     

Calibration and quantification of fast intracellular motion (FIM) in living cells using correlation analysis

Video rate confocal laser scanning microscopy at the highest spatial and temporal resolution of backscattered light (BSL) imaging allowed for regular observation of fast intracellular motion (FIM) first revealed in living neoplastic cells. However, the absence of an objective evaluation has hampered further study of the mechanisms and biological significance of FIM. Particularly, a quantification of apparent differences in velocities that would complement and improve the current demonstration of FIM by color coding using the combination of red-green-blue (RGB) images had been missing. Standard methods of tracking or pattern recognition could not be applied because of the fuzzy nature of images of FIM. A search for a suitable method led to correlation analysis. It was calibrated on Brownian motion and a known type of motion, such as cell marginal ruffling, compared with FIM. Results approved its explanatory potential. Therefore, several crucial incidences of FIM could be analyzed. Apart from an argument against viewing FIM as a manifestation of simple Brownian motion, the correlation analysis of FIM in the adjacent peripheries of a rat fibroblast and a K4 rat sarcoma cell confirmed the notion of higher and uneven distribution of velocity of FIM in a tumor cell so far shown in color-coded images only. This result and other yet unpublished observations indicate that the velocity and topology of FIM can also contribute to a biological distinction between neoplastic and normal cells. Regular application of the correlation analysis should further expand the study of FIM for its mechanisms and predictive value. Such an approach should be thoroughly examined for a contribution to the knowledge of cancer cells.