The statistical modeling of surface roughness in high-speed flat end milling

Surface roughness is one of the most important requirements in machining process. The surface roughness value is a result of the tool wear. When tool wear increase, the surface roughness also increases. The determination of the sufficient cutting parameters is a very important process obtained by means of both minimum surface roughness values and long tool life. The statistical models were developed to predict the surface roughness.This paper presents the development of a statistical model for surface roughness estimation in a high-speed flat end milling process under wet cutting conditions, using machining variables such as spindle speed, feed rate, depth of cut, and step over. First- and second-order models were developed using experimental results of a rotatable central composite design, and assessed by means of various statistical tests. The highest coefficient of correlation (R_adj²) (88%) was obtained with a 10-parameter second-order model. Meanwhile, a time trend was observed in residual values between model predictions and experimental data, reflecting the probable effect of the tool wear on surface roughness. Thus, in order to enhance the estimation capability of the model, another independent variable was included into the model to account for the effect of the tool wear, and the total operating time of the tool was selected as the most suitable variable for this purpose. By inserting this new variable as a linear term into the model, R_adj² was increased to 94% and a good fit was observed between the model predictions and supplementary experimental data.In this study, it was observed that, the order of significance of the main variables is as X₅>X₃>X₄>X₁>X₂ (total machining time, depth of cut, step over, spindle speed and feed rate, respectively).     

Micro-milling performance of AISI 304 stainless steel using Taguchi method and fuzzy logic modelling

In this study, micro-milling of AISI 304 stainless steel with ball nose end mill was conducted using Taguchi method. The influences of spindle speed, feed rate and depth of cut on tool wear, cutting forces and surface roughness were examined. Taguchi’s signal to noise ratio was utilized to optimize the output responses. The influence of control parameters on output responses was determined by analysis of variance. In this study, the models describing the relationship between the independent variables and the dependent variables were also established by using regression and fuzzy logic. Efficiency of both models was determined by analyzing correlation coefficients and by comparing with experimental values. The results showed that both regression and fuzzy logic modelling could be efficiently utilized for the prediction of tool wear, cutting forces and surface roughness in micro-milling of AISI 304 stainless steel.     

Experimental and numerical studies on the determination of twist drill temperature in dry drilling: A new approach

In this paper, the influences of the spindle speed and feed rate on the drill temperature responses have been investigated. A new experimental approach was developed to measure drill temperature in drilling process. Drill temperatures were measured by inserting standard thermocouples through the coolant (oil) hole of TiAlN-coated carbide drills. Experimental parameters used in the study has based on Taguchi’s method. Experimental study was conducted by using two different workpiece materials, AISI 1040 steel and Al 7075-T651. The drill bit temperature was predicted using a numerical calculation with Third Wave AdvantEdge^TM Lagrangian based on explicit finite element analysis software. The results obtained from experimental study and finite element analyses (FEA) were compared. Good agreement between the measured and analyzed temperature results was found in dry drilling process.     

Mechanical,chemical, thermal,and rheological properties of recycled PA6/ABS binary and PA6/PA66/ABS ternary blends

The effects of multiple injection molding cycles on the chemical and mechanical properties of PA6/ABS and PA6/PA66/ABS blends are investigated. The chemical structures of both PA6/ABS binary and PA6/PA66/ABS ternary blends do not alter after recycling process. For PA6/ABS binary blend, it is found that the tensile strength, strain at break, elastic modulus, impact strength, flexural strength, and modulus of recycled blend decrease by 6.49%, 15.19%, 21.00%, 9.41%, 7.09%, and 8.25%, respectively, while MFI increases by 23.59% as compared with the virgin blend. After five recycling process for PA6/PA66/ABS ternary blend, the tensile strength, strain at break, and impact strength of recycled blend decrease by 18.00%, 50.80%, and 87.27%, respectively. However, flexural strength and modulus of PA6/PA66/ABS blend increase slightly. For virgin PA6/PA66/ABS blend, MFI value was 7.7 g/10 min and with recycling this value showed an important increase to 31.56 g/10 min after five cycles. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40810.     

Essential and trace elements content of commercial infant foods in the UK

There is a paucity of data in respect of the nutritional quality of complementary foods for infants and young children aged between 6 and 12 months. The primary objective of this study was to examine nutritive values of such complementary infant food on the UK market in order to ascertain their suitability relative to dietary guidelines for the 6–9 months age group. Quantitative analyses were conducted on eight different products representing four popular brands (meat and vegetable based) currently on sale in the UK. Eight major mineral and trace elements, namely: calcium, copper, magnesium, iron, zinc, potassium, sodium and selenium were measured by ICP–OES and ICP–MS. The results of these studies were referenced to the Recommended Nutrient Intake (RNI) values for 6–9 months old children, and a menu of entire daily intake of minerals and trace elements was composed taking into consideration the nutrient and energy intake from milk consumption. Based on these comparisons, all the food samples studied in this work contained less essential minerals than expected from the RNI values except for potassium in meat and vegetable based recipes. These results suggest that commercial complementary infant foods on the UK market may not contain the minimum levels of minerals required for the labelling declaration of micronutrient content (Commission Directive 2006/125/EC). This provides opportunities and scope for product optimisation to improve their nutritive value.     

Modeling of strengthening and softening in inelastic nanocrystalline materials with reference to the triple junction and grain boundaries using strain gradient plasticity

The work presented here provides a generalized structure for modeling polycrystals from micro- to nano-size range. The polycrystal structure is defined in terms of the grain core, the grain boundary and the triple junction regions with their corresponding volume fractions. Depending on the size of the crystal from micro to nano, different types of analyses are used for the respective different regions of the polycrystal. The analyses encompass local and nonlocal continuum or crystal plasticity. Depending on the physics of the region dislocation-based inelastic deformation and/or slip/separation is used to characterize the behavior of the material. The analyses incorporate interfacial energy with grain boundary sliding and grain boundary separation. Certain state variables are appropriately decomposed into energetic and dissipative components to accurately describe the size effects. This new formulation does not only provide the internal interface energies but also introduces two additional internal state variables for the internal surfaces (contact surfaces). One of these new state variables measures tangential sliding between the grain boundaries and the other measures the respective separation. Additional entropy production is introduced due to the internal subsurface and contacting surface. A multilevel Mori–Tanaka averaging scheme is introduced in order to obtain the effective properties of the heterogeneous crystalline structure and to predict the inelastic response of a nanocrystalline material. The inverse Hall–Petch effect is also demonstrated. The formulation presented here is more general, and it is not limited to either polycrystalline- or nanocrystalline-structured materials. However, for more elaborate solution of problems, a finite element approach needs to be developed.     

Multiscale Analysis of Multiple Damage Mechanisms Coupled with Inelastic Behavior of Composite Materials

Thermodynamically consistent constitutive equations are derived here in order to investigate size effects on the strength of composite, strain, and damage localization effects on the macroscopic response of the composite, and statistical inhomogeneity of the evolution-related damage variables associated with the representative volume element. This approach is based on a gradient-dependent theory of plasticity and damage over multiple scales that incorporates mesoscale interstate variables and their higher order gradients at both the macro- and mesoscales. This theory provides the bridging of length scales. The interaction of the length scales is a paramount factor in understanding and controlling material defects such as dislocation, voids, and cracks at the mesoscale and interpreting them at the macroscale. The behavior of these defects is captured not only individually, but also the interaction between them and their ability to create spatiotemporal patterns under different loading conditions. The proposed work introduces gradients at both the meso- and macroscales. The combined coupled concept of introducing gradients at the mesoscale and the macroscale enables one to address two issues simultaneously. The mesoscale gradients allow one to address issues such as lack of statistical homogeneous state variables at the macroscale level such as debonding of fibers in composite materials, cracks, voids, and so forth. On the other hand, the macroscale gradients allow one to address nonlocal behavior of materials and interpret the collective behavior of defects such as dislocations and cracks. The capability of the proposed model is to properly simulate the size-dependent behavior of the materials together with the localization problem. Consequently, the boundary-value problem of a standard continuum model remains well-posed even in the softening regime. The enhanced gradient continuum results in additional partial differential equations that are satisfied in a weak form. Additional nodal degrees of freedom are introduced that leads to a modified finite-element formulation. The governing equations can be linearized consistently and solved within the incremental iterative Newton-Raphson solution procedure.     

A Computer-Aided Panel Layout Procedure for Process Control Jobs—LAYGEN

The procedure presented in this paper is a computerized methodology to generate alternate, ergonomically sound layouts of large control panels. The displays and controls are laid out on a vertical and two inclined panels taking various ergonomic design principles into account. Required input data categories, general structure of the methodology, and output reports of LAYGEN are discussed.     

The effect of recycling number on the mechanical,chemical, thermal,and rheological properties of PBT/PC/ABS ternary blends: With and without glass‐fiber

The recycling possibilities of poly(butylene terephthalate)/polycarbonate/acrylonitrile–butadiene–styrene (PBT/PC/ABS) ternary blend with and without glass‐fiber content were investigated using repeated injection molding process. In this study, PBT/PC/ABS ternary blends were reprocessed at five times and the results were presented after each recycling process. The recycling possibility of PBT/PC/ABS ternary blend was evaluated by measuring the mechanical, chemical, thermal, and rheological properties. Mechanical properties were determined by the tensile strength, yield strength, strain at break, elastic modulus, impact strength, flexural strength, and flexural modulus. Chemical and thermal properties were evaluated by Fourier transform infrared spectroscopy, differential scanning calorimetry, thermal gravimetric analysis, and scanning electron microscopy. Rheological properties of the ternary blends were studied by melt flow index measurement. From the results, it was found that mechanical properties of recycled composites were better than virgin PBT/PC/ABS ternary blends. POLYM. COMPOS., 35:2074–2084, 2014. © 2014 Society of Plastics Engineers     

A review on the taste masking of bitter APIs: hot-melt extrusion (HME) evaluation

The majority of active pharmaceutical ingredients (APIs) found in oral dosage forms have a bitter taste. Masking the unpleasant taste of bitter, APIs is a major challenge in the development of such oral dosage forms. Taste assessment is an important quality-control parameter for evaluating taste-masked formulations of any new molecular entity. Hot-melt extrusion (HME) techniques, have very recently, been accepted from an industrial compliance viewpoint in relation to both manufacturing operations and development of pharmaceuticals. HME achieves taste masking of bitter APIs via various mechanisms such as the formation of solid dispersions and inter-molecular interactions and this has led to its wide-spread use in pharmaceutical formulation research. In this article, the uses of various taste evaluation methods and HME as continuous processing techniques for taste masking of bitter APIs used for the oral delivery of drugs are reviewed.