Search results for: ceramic cutting tools

Authors: Jung-Ho Moon, Tae Kwon Ha

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M2 steels, the typical Co-free high speed steel (HSS) possessing hardness level of 63~65 HRc, are most widely used for cutting tools. On the other hand, Co-containing HSS’s, such as M35 and M42, show a higher hardness level of 65~67 HRc and used for high quality cutting tools. In the fabrication of HSS’s, it is very important to control cleanliness and eutectic carbide structure of the ingot and it is required to increase productivity at the same time. Production of HSS ingots includes a variety of processes such as casting, electro-slag remelting (ESR), forging, blooming, and wire rod rolling processes. In the present study, electro-slag rapid remelting (ESRR) process, an advanced ESR process combined by continuous casting, was successfully employed to fabricate HSS billets of M2, M35, and M42 steels. Distribution and structure of eutectic carbides of the billets were analysed and cleanliness, hardness, and composition profile of the billets were also evaluated.

Keywords: high speed tool steel, eutectic carbide, microstructure, hardness, fracture toughness

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Authors: Abdelkader T. Ahmed

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Greywater is any wastewater draining from a household including kitchen sinks and bathroom tubs, except toilet wastes. Although this used water may contain grease, food particles, hair, and any number of other impurities, it may still be suitable for reuse after treatment. Greywater reusing serves two purposes including reduction the amount of freshwater needed to supply a household, and reduction the amount of wastewater entering sewer systems. This study aims to investigate and design a simple and cheap unit to treat the greywater in household via using ceramic membranes and reuse it in supplying water for toilet flushing. The study include an experimental program for manufacturing several tablet ceramic membranes from clay and sawdust with three different mixtures. The productivity and efficiency of these ceramic membranes were investigated by chemical and physical tests for greywater before and after filtration through these membranes. Then a treatment unit from this ceramic membrane was designed based on the experimental results of lab tests. Results showed that increase sawdust percent with the mixture increase the flow rate and productivity of treated water but decrease in the same time the water quality. The efficiency of the new ceramic membrane reached 95%. The treatment unit save 0.3 m3/day water for toilet flushing without need to consume them from the fresh water supply network.

Keywords: ceramic membranes, filtration, greywater, wastewater treatment

Procedia PDF Downloads 307

Authors: D. O. Ramadan, R. S. Dwyer-Joyce

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The measurement of the interface conditions in a cutting tool contact is essential information for performance monitoring and control. This interface provides the path for the heat flux to the cutting tool. This elevate in the cutting tool temperature leads to motivate the mechanism of tool wear, thus affect the life of the cutting tool and the productivity. This zone is representative by the tool-chip interface. Therefore, understanding and monitoring this interface is considered an important issue in machining. In this paper, an acoustic emission (AE) technique was used to find the correlation between AE parameters and the tool-chip interface. For this reason, a response surface design (RSD) has been used to analyse and optimize the machining parameters. The experiment design was based on the face centered, central composite design (CCD) in the Minitab environment. According to this design, a series of orthogonal cutting experiments for different cutting conditions were conducted on a Triumph 2500 lathe machine to study the sensitivity of the acoustic emission (AE) signal to change in tool-chip contact length. The cutting parameters investigated were the cutting speed, depth of cut, and feed and the experiments were performed for 6082-T6 aluminium tube. All the orthogonal cutting experiments were conducted unlubricated. The tool-chip contact area was investigated using a scanning electron microscope (SEM). The results obtained in this paper indicate that there is a strong dependence of the root mean square (RMS) on the cutting speed, where the RMS increases with increasing the cutting speed. A dependence on the tool-chip contact length has been also observed. However there was no effect observed of changing the cutting depth and feed on the RMS. These dependencies have been clarified in terms of the strain and temperature in the primary and secondary shear zones, also the tool-chip sticking and sliding phenomenon and the effect of these mechanical variables on dislocation activity at high strain rates. In conclusion, the acoustic emission technique has the potential to monitor in situ the tool-chip interface in turning and consequently could indicate the approaching end of life of a cutting tool.

Keywords: Acoustic emission, tool-chip interface, orthogonal cutting, monitoring

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Authors: Tarek M. Ahmed, Ahmed S. El Mesalamy, Amro M. Youssef, Tawfik T. El Midany

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Abrasive waterjet (AWJ) machining is considered as one of the most powerful cutting processes. It can be used for cutting heat sensitive, hard and reflective materials. Aluminum 2024 is a high-strength alloy which is widely used in aerospace and aviation industries. This paper aims to improve aluminum alloy and to investigate the effect of AWJ control parameters on surface geometry quality. Design of experiments (DoE) is used for establishing an experimental matrix. Statistical modeling is used to present a relation between the cutting parameters (pressure, speed, and distance between the nozzle and cut surface) and responses (taper angle and surface roughness). The results revealed a tangible improvement in productivity by using AWJ processing. The taper kerf angle can be improved by decreasing standoff distance and speed and increasing water pressure. While decreasing (cutting speed, pressure and distance between the nozzle and cut surface) improve the surface roughness in the operating window of cutting parameters.

Keywords: abrasive waterjet machining, machining of aluminum alloy, non-traditional cutting, statistical modeling

Procedia PDF Downloads 227

Authors: G. Blugan, B. Jiang, J. Thornberry, P. Sturzenegger, U. Gonzenbach, M. Misson, D. Cartlidge, R. Stenerud, J. Kuebler

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Low-cost ceramic spheres were developed and manufactured from the engineering ceramic aluminium oxide. Hollow spheres of 50 mm diameter with a wall thickness of 0.5-1.0 mm were produced via an adapted slip casting technique. It was possible to produce the spheres with good repeatability and with no defects or failures in the spheres due to the manufacturing process. The spheres were developed specifically for use in buoyancy devices for deep-sea exploration conditions at depths of 3000 m below sea level. The spheres with a 1.0 mm wall thickness exhibit a buoyancy of over 54% while the spheres with a 0.5 mm wall thickness exhibit a buoyancy of over 73%. The mechanical performance of the spheres was confirmed by performing a hydraulic burst pressure test on individual spheres. With a safety factor of 3, all spheres with 1.0 mm wall thickness survived a hydraulic pressure of greater than 150 MPa which is equivalent to a depth of more than 5000 m below sea level. The spheres were then incorporated into a buoyancy module. These hollow aluminium oxide ceramic spheres offer an excellent possibility of deep-sea exploration to depths greater than the currently used technology.

Keywords: buoyancy, ceramic spheres, deep-sea, oil exploration

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Authors: David Downey

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With the introduction of additive manufacturing (3D printing) to produce titanium (Ti6Al4V) components in the medical/aerospace and automotive industries, intricate geometries can be produced with virtually complete design freedom. However, the consideration of microstructural anisotropy resulting from the additive manufacturing process becomes necessary due to this design flexibility and the need to print a geometric shape that can consist of numerous angles, radii, and swept surfaces. A femoral knee implant serves as an example of a 3D-printed near-net-shaped product. The mechanical properties of the printed components, and consequently, their machinability, are affected by microstructural anisotropy. Currently, finish-machining operations performed on titanium printed parts using selective laser melting (SLM) utilize the same cutting tools employed for processing wrought titanium components. Cutting forces for components manufactured through SLM can be up to 70% higher than those for their wrought counterparts made of Ti6Al4V. Moreover, temperatures at the cutting interface of 3D printed material can surpass those of wrought titanium, leading to significant tool wear. Although the criteria for tool wear may be similar for both 3D printed and wrought materials, the rate of wear during the machining process may differ. The impact of these issues on the choice of cutting tool material and tool lifetimes will be discussed.

Keywords: additive manufacturing, build orientation, microstructural anisotropy, printed titanium Ti6Al4V, tool wear

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Authors: M. S. Kaiser, S. Reaz Ahmed

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Chip formation characteristics are investigated during surface finishing of high density polyethylene (HDPE) samples using a shaper machine. Both the cutting speed and depth of cut are varied continually to enable observations under various machining conditions. The generated chips are analyzed in terms of their shape, size, and deformation. Their physical appearances are also observed using digital camera and optical microscope. The investigation shows that continuous chips are obtained for all the cutting conditions. It is observed that cutting speed is more influential than depth of cut to cause dimensional changes of chips. Chips curl radius is also found to increase gradually with the increase of cutting speed. The length of continuous chips remains always smaller than the job length, and the corresponding discrepancies are found to be more prominent at lower cutting speed. Microstructures of the chips reveal that cracks are formed at higher cutting speeds and depth of cuts, which is not that significant at low depth of cut.

Keywords: HDPE, surface-finishing, chip formation, deformation, roughness

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Authors: V. Fuis, P. Janicek, T. Navrat

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The global solved problem is the calculation of the parameters of ceramic material from a set of destruction tests of ceramic heads of total hip joint endoprosthesis. The standard way of calculation of the material parameters consists in carrying out a set of 3 or 4 point bending tests of specimens cut out from parts of the ceramic material to be analysed. In case of ceramic heads, it is not possible to cut out specimens of required dimensions because the heads are too small (if the cut out specimens were smaller than the normalized ones, the material parameters derived from them would exhibit higher strength values than those which the given ceramic material really has). A special destruction device for heads destruction was designed and the solved local problem is the modification of this destructive device based on the analysis of tensile stress in the head for two different values of the depth of the conical hole in the head. The goal of device modification is a shift of the location with extreme value of 1 max from the region of head’s hole bottom to its opening. This modification will increase the credibility of the obtained material properties of bio ceramics, which will be determined from a set of head destructions using the Weibull weakest link theory.

Keywords: ceramic heads, depth of the conical hole, destruction test, material parameters, principal stress, total hip joint endoprosthesis

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Authors: Fangyuan Shao, Wei Liu, Deli Gao

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Polycrystalline diamond compact (PDC) bits have occupied a large market of unconventional oil and gas drilling. The application of PDC bits benefits from the efficient rock breaking of PDC cutters. In response to increasingly complex formations, many shaped cutters have been invited, but many of them have not been solved by the mechanism of rock breaking. In this paper, two kinds of PDC cutters: a new axe-shaped (NAS) cutter and cylindrical cutter (benchmark) were studied by laboratory experiments. NAS cutter is obtained by optimizing two sides of axe-shaped cutter with curved surfaces. All the cutters were put on a vertical turret lathe (VTL) in the laboratory for cutting tests. According to the cutting distance, the VTL tests can be divided into two modes: single-turn rotary cutting and continuous cutting. The cutting depth of cutting (DOC) was set at 1.0 mm and 2.0 mm in the former mode. The later mode includes a dry VTL test for thermal stability and a wet VTL test for wear resistance. Load cell and 3D optical profiler were used to obtain the value of cutting forces and wear area, respectively. Based on the findings of the single-turn rotary cutting VTL tests, the performance of A NAS cutter was better than the benchmark cutter on elastoplastic material cutting. The cutting forces (normal forces, tangential force, and radial force) and special mechanical energy (MSE) of a NAS cutter were lower than that of the benchmark cutter under the same condition. It meant that a NAS cutter was more efficient on elastoplastic material breaking. However, the wear resistance of a new axe-shaped cutter was higher than that of a benchmark cutter. The results of the dry VTL test showed that the thermal stability of a NAS cutter was higher than that of a benchmark cutter. The cutting efficiency can be improved by optimizing the geometric structure of the PDC cutter. The change of thermal stability may be caused by the decrease of the contact area between cutter and rock at given DOC. The conclusions of this paper can be used as an important reference for PDC cutters designers.

Keywords: axe-shaped cutter, PDC cutter, rotary cutting test, vertical turret lathe

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Authors: A. Shishkin, V. Mironovs, D. Goljandin, A. Korjakins

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The goal of this work is to develop sustainable and durable ceramic cellular structures using widely available natural resources- clay and milled waste glass. Present paper describes method of obtaining clay ceramic foam (CCF) with addition of milled waste glass in 5, 7 and 10 wt% by direct foaming with high speed mixer-disperser (HSMD). For more efficient clay and waste glass milling and mixing, the high velocity disintegrator was used. The CCF with 5, 7, and 10 wt% were obtained at 900, 950, 1000 and 1050 °C firing temperature and they have demonstrated mechanical compressive strength for all 12 samples ranging from 3.8 to 14.3 MPa and porosity 76-65%. Obtained CCF has compressive strength 14.3 MPa and porosity 65.3%.

Keywords: ceramic foam, waste glass, clay foam, glass foam, open cell, direct foaming

Procedia PDF Downloads 281

Authors: Jisoo Kim, Jin-Young Choi, MinSu Lee, Sunmook Lee

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Effects of ceramic nanoparticles on the improvement of durability of bone fixation devices have been investigated by assessing the durability of nanocomposite materials consisting of bioabsorbable polymer and ceramic nanoparticles, which could be applied for bone fixation devices such as plates and screws. Various composite ratios were used for the synthesis of nanocomposite materials by blending polylactic acid (PLA) and polyglycolic acid (PGA) as bioabsorbable polymer, and hydroxyapatite (HA) and tri-calcium phosphate (TCP) as ceramic nanoparticles. It was found that the addition of ceramic nanoparticles significantly enhanced the mechanical properties of the bone fixation devices compared to those fabricated with pure biopolymers. Particularly, the layer-by-layer approach for the fabrication of nanocomposites also had an effect on the improvement of bending strength. Durability tests were performed by measuring the changes in the bending strength of nanocomposite samples under varied temperature conditions for the accelerated degradation tests. It was found that Weibull distribution was the most proper one for describing the life distribution of devices in the present study. The mean lifetime was predicted by adopting Arrhenius Eq. Model for Stress-Life relationship.

Keywords: bioabsorbable, bone fixation device, ceramic nanoparticles, durability assessment, nanocomposite

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Authors: Suha K. Shihab, Zahid A. Khan, Aas Mohammad, Arshad Noor Siddiquee

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This paper presents the influence of cutting parameters (cutting speed, feed and depth of cut) on flank wear (VB) in turning of 52100 hard alloy steel using multilayer coated carbide insert under dry condition. Nine experiments were performed based on Taguchi’s L9 orthogonal array. Analysis of variance (ANOVA) was used to determine the effects of the cutting parameters on flank wear. The results of the study revealed that the cutting speed (A) and feed rate (B) are the dominant factors affecting flank wear, while the depth of cut (C) has not a significant effect. The optimal combination of the cutting parameters for flank wear is found to be A1B1C1. The mathematical model for flank wear is found to be statistically significant. The predicted and measured values of flank wear are found to be very close to each other.

Keywords: flank wear, hard turning, Taguchi approach, optimization

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Authors: Amir Mahyar Khorasani, Ian Gibson, Moshe Goldberg, Mohammad Masoud Movahedi, Guy Littlefair

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One of the important factors in manufacturing processes especially machining operations is surface quality. Improving this parameter results in improving fatigue strength, corrosion resistance, creep life and surface friction. The reliability and clearance of removable joints such as thread and nuts are highly related to the surface roughness. In this work, the effect of different cutting parameters such as cutting fluid pressure, feed rate and cutting speed on the surface quality of the crest of thread in the high-speed milling of Brass C3600 have been determined. Two popular neural networks containing MLP and RBF coupling with Taguchi L32 have been used to model surface roughness which was shown to be highly adept for such tasks. The contribution of this work is modelling surface roughness on the crest of the thread by using precise profilometer with nanoscale resolution. Experimental tests have been carried out for validation and approved suitable accuracy of the proposed model. Also analysing the interaction of parameters two by two showed that the most effective cutting parameter on the surface value is feed rate followed by cutting speed and cutting fluid pressure.

Keywords: artificial neural networks, cutting conditions, high-speed machining, surface roughness, thread milling

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Authors: Ruedee Niyomrath

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The purposes of this research is aim to build the energy saving stove for stew coconut sugar. The research started from explores ceramic raw materials in local area, create the appropriate mixture of ceramic raw materials for construction material of stove, and make it by ceramic process. It includes design and build the energy saving stove, experiment the efficiency of energy saving stove as to thermal efficiency, energy saving, performance of time, and energy cost efficiency, transfer the knowledge for community, stove manufacturers, and technicians. The findings must be useful to the coconut sugar enterprises producing, to reduce the cost of production, preserve natural resources, and environments.

Keywords: ceramic raw material, energy saving stove, stove design, performance of stove, stove for stew coconut sugar

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Authors: Aung Kyaw Moe, Lukin Evgeny Stepanovich, Popova Nelya Alexandrovna

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In this paper, the effect of the additive content in the Al₂O₃-TiO₂-MnO system on the sintering of composite ceramics based on corundum was studied. The samples were pressed by uniaxial semi-dry pressing under 100 MPa and sintered at 1500 °С and 1550 °С. The properties of composite ceramics for porosity and flexural strength were studied. When the amount of additives increases, the properties of composite ceramic samples are better than samples without additives.

Keywords: ceramic, composite material, sintering, corundum

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Authors: Tsukasa Ogawa, Mitsuhiro Okayasu

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To examine the generation properties of electric power for piezoelectric (PbZrTiO3) ceramic plates, the electric-power generation characteristics were examined experimentally and numerically during cyclic bending under various loading fixtures with different contact condition, i.e., point and area contact. In the low applied loading condition between 10 and 50 N, increasing the load-contact area on the piezoelectric ceramic led to a nonlinear decrease in the generated voltage. Decreasing contact area, including the point contact, basically enhanced the generated voltage, although the voltage saturated during loading when the contact area is less than ϕ5 mm, which was attributed to the high strain status, resulting in the material failure, i.e., high stress concentration. In this case, severe plastic deformation and the domain switching were dominated failure modes in the ceramic. From this approach, it is clear that the applied load became more larger (50 ~100 N), larger contact area (ϕ10 ~ ϕ20 mm) became advantageous for power generation. Based upon this cyclic loading was carried out to investigate the fatigue characteristics of the piezoelectric ceramic late. For all contact conditions, electric voltage dropped in the beginning of the cyclic loading, although the higher electric generation was stable in the further cyclic loading for the contact area of ϕ10 ~ ϕ20 mm. In constant, further decrement of electric generation occurred for the point contact condition, and the low electric voltage was generated for the larger contact condition.

Keywords: electric power generation, piezoelectric ceramic, lead zirconate titanate ceramic, loading conditions

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Authors: Salah Gariani, Islam Shyha, Fawad Inam, Dehong Huo

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A controlled cutting fluid impinging supply system (CUT-LIST) was developed to deliver an accurate amount of cutting fluid into the machining zone via well-positioned coherent nozzles based on a calculation of the heat generated. The performance of the CUT-LIST was evaluated against a conventional flood cutting fluid supply system during step shoulder milling of Ti-6Al-4V using vegetable oil-based cutting fluid. In this paper, the micro-hardness of the machined surface was used as the main criterion to compare the two systems. CUT-LIST provided significant reductions in cutting fluid consumption (up to 42%). Both systems caused increased micro-hardness value at 100 µm from the machined surface, whereas a slight reduction in micro-hardness of 4.5% was measured when using CUL-LIST. It was noted that the first 50 µm is the soft sub-surface promoted by thermal softening, whereas down to 100 µm is the hard sub-surface caused by the cyclic internal work hardening and then gradually decreased until it reached the base material nominal hardness. It can be concluded that the CUT-LIST has always given lower micro-hardness values near the machined surfaces in all conditions investigated.

Keywords: impinging supply system, micro-hardness, shoulder milling, Ti-6Al-4V, vegetable oil-based cutting fluid

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Authors: Tung-Hui Hsu, Wen-Yuh Jywe

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Five-axis computer numerical control (CNC) machine tools (three linear and two rotary axes) are ideally suited to the fabrication of complex work pieces, such as dies, turbo blades, and cams. The locations of the axis average line and centerline of the rotary axes strongly influence the performance of these machines; however, techniques to compensate for eccentric error in the rotary axes remain weak. This paper proposes optical (Non-Bar) techniques capable of calibrating five-axis CNC machine tools and compensating for eccentric error in the rotary axes. This approach employs the measurement path in ISO/CD 10791-6 to determine the eccentric error in two rotary axes, for which compensatory measures can be implemented. Experimental results demonstrate that the proposed techniques can improve the performance of various five-axis CNC machine tools by more than 90%. Finally, a result of the cutting test using a B-type five-axis CNC machine tool confirmed to the usefulness of this proposed compensation technique.

Keywords: calibration, compensation, rotary axis, five-axis computer numerical control (CNC) machine tools, eccentric error, optical calibration system, ISO/CD 10791-6

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Authors: Benchalak Muangmeesri

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This research is experiment glaze from use cullet that is broken decayed from the used such as, glass bottle, windshield , etc. For seek raw material compensation that is raw material of the glaze in ceramic. The objective of the research for study the ratio of the glaze that is appropriate for glaze ceramic products and evaluate the experiment glaze on the vitreous china. The experiment has limits in using ceramic process such as, using calculation formula with triaxial, the empirical formula’s of Seger, and formula calculation is the percentage of the compound. for choose formula has will the possibility for glaze on vitreous china. The experiments in 108 triaxial can choose best formula and calculate is be left just 6 a formula for the calculation. The calculation is the percentage of the raw materials. Find that, three formulas in six formula there is percentage amount of the raw material that is cullet has the amount the little more 10 percentages then repeated experiment just three formulas. Overall, this research have three formulas for used its and we get all processes achieved and well done.

Keywords: cullet, glaze, pottery, ceramic

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Authors: Mehmet Ali Avcı, Medine Çopur Doğrusöz

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This study has been carried out in the Selcuk University, Department of Fields Crops Research and Application Greenhouse. 4 different grass genotypes (1 Lolium perenne L., 1 Poa trivialis L., 1 Festuca ovina L., and 1 Festuca arundinacea Scheb.) have been used in the application. It has been done with four repetition according to design of random parcel test. The research have been started with the implementation of 3 clones to each pot of each kind on 07.12.2009. It has been processed normally. When the plants have filled % 80 of the pot and have grown to the height of 7-10 cm, 5 cm has cut. After the first cutting, there have been applied 4 cutting frequency within the periods of 5, 10, 15, 20 days. Number of tillers, the degree of filling the bottom, the height of plant, the length of leaf and the width of the leaf have been measured. This procedure have been repeated in once a-five-day-periods, once a-ten-day-periods, once a-fifteen-day-periods, once a-twenty-day-periods, the data have been taken, and it has completed in 60 days. All the plants in the pots have been reaped from the 5cm height on 16.08.2010. The first measures have been taken for each quality. It is aimed to set the effects of different cutting frequency on the some grass kinds’ some plant characteristics.

Keywords: cutting frequency, Festuca, Lolium, Poa

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Authors: Balwinder Singh

Abstract:

In the current competitive environment, casting industry has several challenges such as production of intricate castings, near net shape castings, decrease lead-time from product design to production, improved casting quality and to control costs. The raw materials used to make ceramic shell play an important role in determining the overall final ceramic shell characteristics. In this work, primary slurries were formulated using various combinations of zircon flour, fused silica and aluminosilicate powders as filler, colloidal silica as binder along with wetting and antifoaming agents (Catalyst). Taguchi’s parameter design strategy has been applied to investigate the effect of primary slurry parameters on the viscosity of the slurry and primary coating of shell. The result reveals that primary coating with low viscosity slurry has produced a rough surface of the shell due to stucco penetration.

Keywords: ceramic shell, primary slurry, filler, slurry viscosity, surface roughness

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Authors: Rafał Kamiński, Joel Rech, Philippe Bertrand, Christophe Desrayaud

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Titanium alloys are among the most important material in the aircraft industry, due to its low density, high strength, and corrosion resistance. However, these alloys are considered as difficult to machine because they have poor thermal properties and high reactivity with cutting tools. The Selective Laser Melting (SLM) process becomes even more popular through industry since it enables the design of new complex components, that cannot be manufactured by standard processes. However, the high temperature reached during the melting phase as well as the several rapid heating and cooling phases, due to the movement of the laser, induce complex microstructures. These microstructures differ from conventional equiaxed ones obtained by casting+forging. Parts obtained by SLM have to be machined in order calibrate the dimensions and the surface roughness of functional surfaces. The ball milling technique is widely applied to finish complex shapes. However, the machinability of titanium is strongly influenced by the microstructure. So the objective of this work is to investigate the influence of the SLM process, i.e. microstructure, on the machinability of titanium, compared to conventional forming processes. The machinability is analyzed by measuring surface roughness, cutting forces, cutting tool wear for a range of cutting conditions (depth of cut ap, feed per tooth fz, spindle speed N) in accordance with industrial practices.

Keywords: ball milling, microstructure, surface roughness, titanium

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Authors: M. Benghersallah, L. Boulanouar, G. List, G. Sutter

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The present work is an experimental study on the dry high speed turning of Ti-6Al-4V titanium alloy. The objective of this study is to see for high cutting speeds, how wear occurs on the face of insert and how to evolve cutting forces and chip formation. Cutting speeds tested is 600, 800, 1000 and 1200 m / min in orthogonal turning with a carbide insert tool H13A uncoated on a cylindrical titanium alloy part. Investigation on the wear inserts with 3D scanning microscope revered the crater formation is instantaneous and a chip adhesion (welded chip) causes detachment of carbide particles. In these experiments, the chip shape was systematically investigated at each cutting conditions using optical microscopy. The chips produced were collected and polished to measure the thicknesses t2max and t2min, dch the distance between each segments and ɸseg the inclination angle As described in the introduction part, the shear angle f and the inclination angle of a segment ɸseg are differentiated. The angle ɸseg is actually measured on the collected chips while the shear angle f cannot be. The angle ɸ represents the initial shear similar to the one that describes the formation of a continuous chip in the primary shear zone. Cutting forces increase and stabilize before removing the tool. The chip reaches a very high temperature.

Keywords: dry high speed, orthogonal turning, chip formation, cutting speed, cutting forces

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Authors: Jawad Ul Haq, Evan Mazur, Ahmed Qureshi, Mohamed Al-Hussein

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The uses of wood in furniture, building, bridges and aluminum in transportation and construction, make aluminum and forest economy a prominent matter in North America. Machines available to date to cut the aforementioned materials are mostly industry oriented with complex structure and operations which require special training and skill. Furthermore, requirements such as pneumatics, 3-phase supply are associated with cost, maintenance, and safety hazards. Power saws are very useful tools used to cut and shape materials; however, they can cause serious hand injuries. Operator’s hands in table saw are vulnerable as they are used to guide pieces into the saw. Apart from hands, saw operator is also prone to material being kicked back out of the saw or sustain eye or respiratory injuries due to rapidly flying sawdust and other debris. In this paper, design of an automatic saw cutting machine has been proposed to ensure safety, portability, usage at domestic level and capability to cut both aluminum and wood. This paper demonstrates detailed Mechanical design in SOLIDWORKS and Control Systems using Programmable Logic Controller (PLC), based on the aforementioned design objectives.

Keywords: programmable logic controller, saw cutting, control, automation

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Authors: T. Zlámal, J. Petrů, M. Pagáč, P. Krajkovič

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For the required function of components with the thermal spray coating, it is necessary to perform additional machining of the coated surface. The paper deals with assessing the surface integrity of Metco 2042, a plasma sprayed coating, after its machining. The selected plasma sprayed coating serves as an abradable sealing coating in a jet engine. Therefore, the spray and its surface must meet high quality and functional requirements. Plasma sprayed coatings are characterized by lamellar structure, which requires a special approach to their machining. Therefore, the experimental part involves the set-up of special cutting tools and cutting parameters under which the applied coating was machined. For the assessment of suitably set machining parameters, selected parameters of surface integrity were measured and evaluated during the experiment. To determine the size of surface irregularities and the effect of the selected machining technology on the sprayed coating surface, the surface roughness parameters Ra and Rz were measured. Furthermore, the measurement of sprayed coating surface hardness by the HR 15 Y method before and after machining process was used to determine the surface strengthening. The changes of strengthening were detected after the machining. The impact of chosen cutting parameters on the surface roughness after the machining was not proven.

Keywords: machining, plasma sprayed coating, surface integrity, strengthening

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Authors: Mohieddine Benghersallah, Lakhdar Boulanouar, Salim Belhadi

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Currently, higher production rate with required quality and low cost is the basic principle in the competitive manufacturing industry. This is mainly achieved by using high cutting speed and feed rates. Elevated temperatures in the cutting zone under these conditions shorten tool life and adversely affect the dimensional accuracy and surface integrity of component. Thus it is necessary to find optimum cutting conditions (cutting speed, feed rate, machining environment, tool material and geometry) that can produce components in accordance with the project and having a relatively high production rate. Response surface methodology is a collection of mathematical and statistical techniques that are useful for modelling and analysis of problems in which a response of interest is influenced by several variables and the objective is to optimize this response. The work presented in this paper examines the effects of cutting parameters (cutting speed, feed rate and depth of cut) on to the surface roughness through the mathematical model developed by using the data gathered from a series of milling experiments performed.

Keywords: Statistical analysis (RSM), Bearing steel, Coating inserts, Tool life, Surface Roughness, End milling.

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Authors: Mitsuhiro Okayasu

Abstract:

To better understand the lattice characteristics of lead zirconate titanate (PZT) ceramics, the lattice orientations and domain-switching characteristics have been directly examined during loading and unloading using various experimental techniques. Upon loading, the PZT ceramics are fractured linear and nonlinearly during the compressive loading process. The strain characteristics of the PZT ceramic were directly affected by both the lattice and domain switching strain. Due to the piezoelectric ceramic, electrical activity of lightning-like behavior occurs in the PZT ceramics, which attributed to the severe domain-switching leading to weak piezoelectric property. The characteristics of domain-switching and reverse switching are detected during the loading and unloading processes. The amount of domain-switching depends on the grain, due to different stress levels. In addition, two patterns of 90˚ domain-switching systems are characterized, namely (i) 90˚ turn about the tetragonal c-axis and (ii) 90˚ rotation of the tetragonal a-axis. In this case, PZT ceramic was loaded by the thermal stress at 80°C. Extent of domain switching is related to the direction of c-axis of the tetragonal structure, e.g., that axis, orientated close to the loading direction, makes severe domain switching. It is considered that there is 90˚ domain switching, but in actual, the angle of domain switching is less than 90˚, e.g., 85.4° ~ 90.0°. In situ TEM observation of the domain switching characteristics of PZT ceramic has been conducted with increasing the sample temperature from 25°C to 300°C, and the domain switching like behavior is directly observed from the lattice image, where the severe domain switching occurs less than 100°C.

Keywords: PZT, lead zirconate titanate, piezoelectric ceramic, domain switching, material property

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Authors: H. Higashiyama, M. Sano, F. Nakanishi, M. Sugiyama, O. Takahashi, S. Tsukuma

Abstract:

The heat island phenomenon becomes one of the environmental problems. As countermeasures in the field of road engineering, cool pavements such as water retaining pavements and solar radiation reflective pavements have been developed to reduce the surface temperature of asphalt pavements in the hot summer climate in Japan. The authors have studied on the water retaining pavements with cement–based grouting materials. The cement–based grouting materials consist of cement, ceramic waste powder, and natural zeolite. The ceramic waste powder is collected through the recycling process of electric porcelain insulators. In this study, mixing ratio between the ceramic waste powder and the natural zeolite and a type of cement for the cement–based grouting materials is investigated to measure the surface temperature of asphalt pavements in the outdoor. All of the developed cement–based grouting materials were confirmed to effectively reduce the surface temperature of the asphalt pavements. Especially, the cement–based grouting material using the ultra–rapid hardening cement with the mixing ratio of 0.7:0.3 between the ceramic waste powder and the natural zeolite reduced mostly the surface temperature by 20 °C and more.

Keywords: ceramic waste powder, natural zeolite, road surface temperature, water retaining pavements

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Authors: M A. Habit, S. A. Syed-Sahil, A. Bahari

Abstract:

Abstract—Laser cutting is a method of manufacturing process that uses laser in order to cut materials. It provides and ensures extreme accuracy which has a clean cut effect, CO2 laser dominate this application due to their good- quality beam combined with high output power. It comes with a small scale and it has a limitation in cutting sizes of materials, therefore it is more appropriate for custom- made products. The same laser cutting machine is also capable in cutting fine material such as fine silk, cotton, leather, polyester, etc. Lack of explorations and knowledge besides being unaware about this technology had caused many of the designers not to use this laser cutting method in their collections. The objectives of this study are: 1) To identify the potential of laser cutting technique in Custom-Made Garments for men’s casual wear: 2) To experiment the laser cutting technique in custom made garments: 3) To offer guidelines and formula for men’s custom- made casualwear designs with aesthetic value. In order to achieve the objectives, this research has been conducted by using mixed methods which are interviews with two (2) local experts in the apparel manufacturing industries and interviews via telephone with five (5) local respondents who are local emerging fashion designers, the questionnaires were distributed to one hundred (100) respondents around Klang Valley, in order to gain the information about their understanding and awareness regarding laser cutting technology. The experiment was conducted by using natural and man- made fibers. As a conclusion, all of the objectives had been achieved in producing custom-made men’s casualwear and with the production of these attires it will help to educate and enhance the innovation in fine technology. Therefore, there will be a good linkage and collaboration between the design experts and the manufacturing companies.

Keywords: custom-made, fashion, laser cut, men’s wear

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Authors: Mefleh Hamideen

Abstract:

In this investigation, the activity concentrations of ²²⁶Ra, ²³²Th, and ⁴⁰K, of some ceramic tile materials used in the local market of Jordan for interior decoration were determined by making use of High Purity Germanium (HPGe) detector. Twenty samples of the different countries of origin and sizes used in Jordan were analyzed. The concentration values of the last-mentioned radionuclides ranged from 30 Bq.kg⁻¹ (Sample from Jordan) to 98 Bq.kg⁻¹ (Sample from China) for ²²⁶Ra, 31 Bq.kg⁻¹ (Sample from Italy) to 98 Bq.kg⁻¹ (Sample from China) for ²³²Th, and 129 Bq.kg⁻¹ (Sample from Spain) to 679 Bq.kg⁻¹ (Sample from Italy) for ⁴⁰K. Based on the calculated activity concentrations, some radiological parameters have been calculated to test the radiation hazards in the ceramic tiles. In this work, the following parameters: Total absorbed dose rate (DR), Annual effective dose rate (HR), Radium equivalent activity (Raeq), Radon emanation coefficient F (%) and Radon mass exhalation rate (Em) were calculated for all ceramic tiles and listed in the body of the work. Fortunately, the average calculated values of all parameters are less than the recommended values for each parameter. Consequently, almost all the examined ceramic materials appear to have low radon emanation coefficients. As a result of that investigation, no problems on people can appear by using those ceramic tiles in Jordan.

Keywords: radon emanation coefficient, radon mass exhalation rate, total annual effective dose, radon level

Procedia PDF Downloads 157