Search results for: ceramic cutting tools

Authors: Jon-Chao Hong, Tsai-Ru Fan, Shih-Min Hsu

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Virtual reality (VR) can generate mirror neurons that facilitate learners to transfer virtual skills to a real environment in skill training, and most studies approved the positive effect of applying in many domains. However, rare studies have focused on the experiential values of participants from a gender perspective. To address this issue, the present study used a VR program named kitchen assistant training, focusing on cutting vegetables and invited 400 students to practice for 20 minutes. Useful data from 367 were subjected to statistical analysis. The results indicated that male participants. From the comparison of average, it seems that females perceived higher than males in learning effectiveness. Expectedly, the VR-Cutting vegetables can be used for pre-training of real vegetable cutting.

Keywords: exponential value, facilitate learning, gender difference, virtual reality

Procedia PDF Downloads 63

Authors: Patricia N. Baguio, Angel Amy M. Bunag, Paul Bryan E. Ornopia, John Paul C. Suel

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This research investigates the viability and efficiency of employing ceramic tile additives derived from horn snail shell material, specifically calcium carbonate (CaCO₃). The study aims to evaluate the mechanical properties of ceramic tiles with Calcium Carbonate with varying amounts of CaCO₃, focusing on breaking and flexural strength. The research employs a comprehensive methodology, including material collection, slurry forming, shaping, drying, firing, and statistical analysis using paired sample T-tests. The result indicates a positive correlation between calcium carbonate (CaCO₃) application and ceramic tile strength, revealing increased breaking strength from 29.41 N (non-calcium Carbonate) to 46.02 N (70g CaCO3) and a substantial enhancement to 82.61 N with 150g CaCO₃. Comparative analyses show higher breaking and flexural strength in tiles with Calcium Carbonate with 150g CaCO₃ analysis (p = 0.011), indicating its feasibility for ceramic tile manufacturing, while 70g CaCO₃ shows no significant difference from non-calcium Carbonate tiles (p = 0.135). The addition of horn snail shells shows potential for improving ceramic tile quality and contributes positively to waste management in standard tile production processes.

Keywords: Horn snail shell, calcium carbonate, breaking strength, flexural strength

Procedia PDF Downloads 29

Authors: Patricia N. Baguio, Angel Amy M. Buñag, Paul Bryan E. Ornopia, John Paul C. Suel

Abstract:

This research investigates the viability and efficiency of employing ceramic tile additives derived from horn snail shell material, specifically calcium carbonate (CaCO₃). The study aims to evaluate the mechanical properties of ceramic tiles with calcium carbonate with varying amounts of CaCO₃, focusing on breaking and flexural strength. The research employs a comprehensive methodology, including material collection, slurry forming, shaping, drying, firing, and statistical analysis using paired sample T-tests. The result indicates a positive correlation between calcium carbonate (CaCO₃) application and ceramic tile strength, revealing increased breaking strength from 29.41 N (non-calcium carbonate) to 46.02 N (70g CaCO₃) and a substantial enhancement to 82.61 N with 150g CaCO₃. Comparative analyses show higher breaking and flexural strength in tiles calcium carbonate with 150g CaCO₃ analysis (p = 0.011), indicating its feasibility for ceramic tile manufacturing, while 70g CaCO₃ shows no significant difference from non-calcium carbonate tiles (p = 0.135). The addition of horn snail shells shows potential for improving ceramic tile quality and contributes positively to waste management in standard tile production processes.

Keywords: horn snail shell, calcium carbonate, breaking strength, flexural strength

Procedia PDF Downloads 29

Authors: Jhoanne Pedres Boñgol, Zhang Liu, Yuyin Qiu, King Lun Yeung

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Flexible ceramic sorbent material can be a viable technology to capture and recover emulsified fats, oils, and grease (FOG) that often cause sanitary sewer overflows. This study investigates the sorption capacity and recovery rate of ceramic material in surfactant-stabilized oil-water emulsion by synthesizing silica aerogel: SiO₂–X via acid-base sol-gel method followed by ambient pressure drying. The SiO₂–X is amorphous, microstructured, lightweight, flexible, and highly oleophilic. It displays spring-back behavior apparent at 80% compression with compressive strength of 0.20 MPa and can stand a weight of 1000 times its own. The contact angles measured at 0° and 177° in oil and water, respectively, confirm its oleophilicity and hydrophobicity while its thermal stability even at 450 °C is confirmed via TGA. In pure oil phase, the qe,AV. of 1x1 mm SiO₂–X is 7.5 g g⁻¹ at tqe= 10 min, and a qe,AV. of 6.05 to 6.76 g g⁻¹ at tqe= 24 hrs in O/W emulsion. The filter ceramic can be reused 50 x with 75-80 % FOG recovery by manual compression.

Keywords: adsorption, aerogel, emulsion, FOG

Procedia PDF Downloads 127

Authors: Venkatesan Sundaramoorthy

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The field of ceramics has undergone a remarkable transformation with the advent of additive manufacturing technologies. This comprehensive review explores the mechanical properties of additively manufactured ceramic components, focusing on key materials such as Alumina, Zirconia, and Silicon Carbide. The study delves into various authors' review technology into the various additive manufacturing techniques, including Stereolithography, Powder Bed Fusion, and Binder Jetting, highlighting their advantages and challenges. It provides a detailed analysis of the mechanical properties of these ceramics, offering insights into their hardness, strength, fracture toughness, and thermal conductivity. Factors affecting mechanical properties, such as microstructure and post-processing, are thoroughly examined. Recent advancements and future directions in 3D-printed ceramics are discussed, showcasing the potential for further optimization and innovation. This review underscores the profound implications of additive manufacturing for ceramics in industries such as aerospace, healthcare, and electronics, ushering in a new era of engineering and design possibilities for ceramic components.

Keywords: mechanical properties, additive manufacturing, ceramic materials, PBF

Procedia PDF Downloads 34

Authors: Justin Pargeter, Metin Eren

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Lithic miniaturization, the systematic production and use of small tools from small cores, was a consequential development in Pleistocene lithic technology. The bipolar reduction is an important, but often overlooked and misidentified, strategy for lithic miniaturization. This experiment addresses the role of axial bipolar reduction in processes of lithic miniaturization. The experiments answer two questions: what benefits does axial bipolar reduction provide, and can we distinguish axial bipolar reduction from freehand reduction? Our experiments demonstrate the numerous advantages of bipolar reduction in contexts of lithic miniaturization. Bipolar reduction produces more cutting edge per gram and is more economical than freehand reduction. Our cutting edge to mass values exceeds even those obtained with pressure blade production on high-quality obsidian. The experimental results show that bipolar reduction produces cutting edge quicker and is more efficient than freehand reduction. We show that bipolar reduction can be distinguished from freehand reduction with a high degree of confidence using the quantitative criteria in these experiments. These observations overturn long-held perceptions about bipolar reduction. We conclude by discussing the role of bipolar reduction in lithic miniaturization and Stone Age economics more broadly.

Keywords: lithic miniaturization, bipolar reduction, late Pleistocene, Southern Africa

Procedia PDF Downloads 690

Authors: D. Naresh Yadav, K. Anand Kishore, Bhaskar Bethi, Shirish H. Sonawane, D. Bhagawan

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The untreated industrial wastewater discharged into the environment causes the contamination of soil, water and air. Advanced treatment methods for enhanced wastewater treatment are attracting substantial interest among the currently employed unit processes in wastewater treatment. The textile industry is one of the predominant in wastewater production at current industrialized situation. The refused dyes at textile industry need to be treated in proper manner before its discharge into water bodies. In the present investigation, hybrid treatment process has been developed for the treatment of synthetic mixed dye wastewater. Photocatalysis and ceramic nanoporous membrane are mainly used for process integration to minimize the fouling and increase the flux. Commercial semiconducting powders (TiO2 and ZnO) has used as a nano photocatalyst for the degradation of mixed dye in the hybrid system. Commercial ceramic nanoporous tubular membranes have been used for the rejection of dye and suspended catalysts. Photocatalysis with catalyst has shown the average of 34% of decolorization (RB-32%, BG-34% and CR-36%), whereas ceramic nanofiltration has shown the 56% (RB-54%, BG-56% and CR-58%) of decolorization. Integration of photocatalysis and ceramic nanofiltration has shown 96% (RB-94%, BG-96% and CR-98%) of dye decolorization over 90 min of operation.

Keywords: photocatalysis, ceramic nanoporous membrane, wastewater treatment, advanced oxidation process, process integration

Procedia PDF Downloads 233

Authors: M. Derradji, W. B. Liu

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The current work discusses the effects of adding various types of ceramic fillers on the curing behavior, thermal, mechanical, anticorrosion, and UV shielding properties of the bisphenol-A based phthalonitrile resins. The effects of different ceramic filler contents and sizes as well as their surface treatments are also discussed in terms of their impact on the morphology and mechanisms of enhancement. The synergistic effect obtained by these combinations extends the use of the phthalonitrile resins to more exigent applications such as aerospace and military. The presented results reveal the significant advantages that can be obtained from the preparation of hybrid materials based on phthalonitrile resins and open the way for further research in the field.

Keywords: mechanical properties, particle reinforced composites, polymer matrix composites (PMCs), thermal properties

Procedia PDF Downloads 122

Authors: Ahmed A. D. Sarhan, M. Sayuti, M. Hamdi

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Due to rapid consumption of world's fossil fuel resources and impracticality of large-scale application and production of renewable energy, the significance of energy efficiency improvement of current available energy modes has been widely realized by both industry and academia. In the CNC machining field, the key solution for this issue is by increasing the effectiveness of the existing lubrication systems as it could reduce the power required to overcome the friction component in machining process. For more improvement, introducing the nanolubrication could produce much less power consumption as the rolling action of billions units of nanoparticle in the tool chip interface could reduce the cutting forces significantly. In this research, the possibility of using carbon onion nanolubrication with DLC cutting tool is investigated to reduce the machining power consumption. Carbon onion nanolubrication has been successfully developed with high tribology performance and mixed with ordinary mineral oil. The proper sonification method is used to provide a way to mix and suspend the particles thoroughly and efficiently. Furthermore, Diamond-Like Carbon (DLC) cutting tool is used and expected to play significant role in reducing friction and cutting forces and increasing abrasion resistance. The results showed significant reduction of the cutting force and the working power compared with the other conditions of using carbon black and normal lubrication systems.

Keywords: carbon onion, nanolubrication, machining power consumption, DLC cutting tool

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Authors: Fanyuan Shao, Wei Liu, Deli Gao

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Polycrystalline diamond composite (PDC) cutter is made of diamond powder as raw material, cobalt metal or non-metallic elements as a binder, mixed with WC cemented carbide matrix assembly, through high temperature and high-pressure sintering. PDC bits with PDC cutters are widely used in oil and gas drilling because of their high hardness, good wear resistance and excellent impact toughness. And PDC cutter is the main cutting tool of bit, which seriously affects the service of the PDC bit. The wear resistance of the PDC cutter is measured by cutting granite with a vertical turret lathe (VTL). This experiment can achieve long-distance cutting to obtain the relationship between the wear resistance of the PDC cutter and cutting distance, which is more closely to the real drilling situation. Load cell and 3D optical profiler were used to obtain the value of cutting forces and wear area, respectively, which can also characterize the damage and wear of the PDC cutter. PDC cutters were cut via electrical discharge machining (EDM) and then flattened and polished. A scanning electron microscope (SEM) was used to observe the distribution of binder cobalt and the size of diamond particles in a diamond PDC cutter. The cutting experimental results show that the wear area of the PDC cutter has a good linear relationship with the cutting distance. Simultaneously, the larger the wear area is and the greater the cutting forces are required to maintain the same cutting state. The size and distribution of diamond particles in the polycrystalline diamond layer have a great influence on the wear resistance of the diamond layer. And PDC cutter with fine diamond grains shows more wear resistance than that with coarse grains. The deep leaching process is helpful to reduce the effect of binder cobalt on the wear resistance of the polycrystalline diamond layer. The experimental study can provide an important basis for the application of PDC cutters in oil and gas drilling.

Keywords: polycrystalline diamond compact, scanning electron microscope, wear resistance, cutting distance

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Authors: In-Hyuck Song, Jang-Hoon Ha

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Recently, porous ceramic membranes have attracted great interest due to their outstanding thermal and chemical stability. In this paper, we report the results of our efforts to determine whether we could prepare a diatomite-kaolin composite coating to be deposited over a sintered diatomite support layer that could reduce the largest pore size of the sintered diatomite membrane while retaining an acceptable level of permeability. We determined under what conditions such a composite coating over a support layer could be prepared without the generation of micro-cracks during drying and sintering. The pore characteristics of the sintered diatomite membranes were studied by scanning electron microscopy and capillary flow porosimetry.

Keywords: ceramic membrane, diatomite, water treatment, sintering

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Authors: Abdulrazzaq Hammal

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In this study, Syrian sand was used to create ceramic membranes. The process of preparing the membranes involved several steps, starting with the purification of the studied sand using hydrochloric acid, sorting according to granular size, and mixing the sand with liquid sodium silicates as a binder. Next, the effects of binder ratio, pressure formation, treatment temperature, and sand grain size were studied. Further, nanoparticles of silver were added to the formed membranes to improve their ability to purify bacterially polluted water. Prepared membranes were quite successful in removing bacteria and chemicals from water, and the water's requirements were brought up to level with Syrian drinking water standards.

Keywords: ceramic, membrane, water, wastewater

Procedia PDF Downloads 37

Authors: Reem M. Altuwirqi, Mohja S. Summan, Entesar A. Ganash, Safia H. Hamidalddin, Tamer E. Youssef, Mohammed A. Gondal

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Laser-Induced Breakdown Spectroscopy (LIBS) technique using 1064 nm Nd: YAG laser was optimized and applied for investigating the existence of radioactive elements (uranium) in twenty-six different ceramic tiles. These tiles were collected from the local Saudi market. Qualitative and quantitative analysis for trace radioactive elements like uranium in these samples was achieved using LIBS. The plasma parameters such as temperature and electron density were calculated to confirm that the plasma generated by the tile samples under laser irradiation can be related to analyte concentrations. In order to perform a quantitative analysis, calibration curves were constructed for two uranium lines (U II (424.166 nm) and U II (424.437 nm)). The Uranium activity concentration in Bq/kg for each sample was measured. Cross-validation of LIBS results with a conventional technique such as Gamma-Ray spectroscopy was also carried out for five ceramic samples. The results show that the LIBS method is an effective way of determining radioactive elements such as uranium in ceramic tiles. Moreover, the uranium concentrations of the investigated samples were below the permissible safe limit for building materials in the majority of samples. Such LIBS system could be applied to determine the presence of natural radioactive elements in ceramic tiles and their radioactivity level rapidly to ensure that they are under the safe allowed limit.

Keywords: laser-induced breakdown spectroscopy, gamma-ray spectroscopy, natural radioactivity, uranium, ceramic tiles

Procedia PDF Downloads 139

Authors: M. Benghersallah, 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. Cutting forces increase and stabilize before removing the tool. The chip reaches a very high temperature.

Keywords: titanium alloy, dry hjgh speed turning, wear insert, MQL technique

Procedia PDF Downloads 527

Authors: D. Nareshyadav, K. Anand Kishore, D. Bhagawan

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Water scarcity is the much-identified issue all over the world. The available sources of water need to be reused to sustainable future. The present work explores the treatment of dye wastewater using combinative photocatalysis and ceramic nanofiltration membrane. Commercial ceramic membrane and TiO₂ catalyst were used in this study to investigate the removal of crystal violet dye from the aqueous solution. The effect of operating parameters such as inlet pressure, initial concentration of crystal violet dye, catalyst (TiO₂) loading, initial pH was investigated in the individual system as well as the combined system. In this study, 95 % of dye water was decolorized and 89 % of total organic carbon (TOC) was removed by the hybrid system for 500 ppm of dye and 0.75 g/l of TiO₂ concentrations at pH 9. The operation of the integrated photocatalytic reactor and ceramic membrane filtration has shown the maximum removal of crystal violet dye compared to individual systems. Hence this proposed method may be effective for the removal of Crystal violet dye from effluents.

Keywords: advanced oxidation process, ceramic nanoporous membrane, dye degradation/removal, hybrid system, photocatalysis

Procedia PDF Downloads 144

Authors: Md. R. Shattique, Md. T. Zaki, Md. G. Kibria

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Fly-ash bricks give a comprehensive solution towards recycling of fly-ash and since there is no requirement of firing to produce them, they are also eco-friendly bricks; little or no carbon-dioxide is emitted during their entire production cycle. As bricks are the most essential and widely utilized building materials in the construction industry, the significance of developing an alternate eco-friendly brick is substantial in modern times. In this paper, manufacturing and potential utilization of Fly-ash made building bricks have been studied and was found to be a prospective substitute for fired clay bricks that contribute greatly to polluting the environment. Also, a comparison between sand made and ceramic dust made Fly-ash bricks have been carried out experimentally. The ceramic dust made bricks seem to show higher compressive strength at lower unit volume weight compared to sand made Fly-ash bricks. Moreover, the water absorption capacity of ceramic dust Fly-ash bricks was lower than sand made bricks. Then finally a statistical comparison between fired clay bricks and fly-ash bricks were carried out. All the requirements for good quality building bricks are matched by the fly-ash bricks. All the facts from this study pointed out that these bricks give a new opportunity for being an alternate building material.

Keywords: coal fly-ash, ceramic dust, burnt clay bricks, sand, gypsum, absorption capacity, unit volume weight, compressive strength

Procedia PDF Downloads 390

Authors: Jonathan Okewu

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Socio-economic occurrences and developments in any society is usually a thing of concern especially when this is been jeopardised as a result of insecurity of all sorts. There are numerous channels that such issues are brought to the fore for attention. Among this channels are the art media and more precisely the ceramic art media. Renown ceramic artists in Nigeria have taken to the medium of expression (clay) to contribute to succinct issues as it affects the society. This study takes advantage of a unique form of ceramic press moulding termed clay palm press. This uncommon production technique has been developed in this study to interrogate socio-economic insecurity in the form of ceramic art titled; “dancing in bullets and in brokenness”. This work was made possible through a ceramic medium that has been termed “terracotta on canvas”. Extensive studio practice was carried out to generate the terracotta forms for this study. Findings from this study indicates that the medium and mode of execution of the art work shows a unique side of working with clay that negates tactile or three dimensionality of inured ceramic practice. Additionally, the process of clay palm press in this study indicates that it could be therapeutical against medical conditions of muscles of the palm. This is because the process tightens and develops the muscles of the palm further. Dancing in bullets and in brokenness as portrayed through the medium of terracotta on canvas that social and security challenges are not a limiting factor to a resolute Nigerian, despite all, the strong will of Nigerians keeps persisting and overcoming challenges.

Keywords: canvas, dancing in bullets and in brokenness, metaphor, terracotta, palm press

Procedia PDF Downloads 98

Authors: A. Alshebani, Y. Swesi, S. Mrayed, F. Altaher, I. Musbah

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Cs-type nanocomposite zeolite membrane was successfully synthesized on an alumina ceramic hollow fibre with a mean outer diameter of 1.7 mm; cesium cationic exchange test was carried out inside test module with mean wall thickness of 230 μm and an average crossing pore size smaller than 0.2 μm. Separation factor of n-butane/H2 obtained indicate that a relatively high quality closed to 20. Maxwell-Stefan modeling provides an equivalent thickness lower than 1 µm. To compare the difference an application to CO2/N2 separation has been achieved, reaching separation factors close to (4,18) before and after cation exchange on H-zeolite membrane formed within the pores of a ceramic alumina substrate.

Keywords: MFI membrane, nanocomposite, ceramic hollow fibre, CO2, ion-exchange

Procedia PDF Downloads 263

Authors: Deba Kumar Sarma, Sanjib Kr. Rajbongshi

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Surface finish is an important product quality in machining. At first, experiments were carried out to investigate the effect of the cutting tool nose radius (considering 1mm and 0.65mm) in prediction of surface finish with process parameters of cutting speed, feed and depth of cut. For all possible cutting conditions, full factorial design was considered as two levels four parameters. Commercial Mild Steel bar and High Speed Steel (HSS) material were considered as work-piece and cutting tool material respectively. In order to obtain functional relationship between process parameters and surface roughness, neural network was used which was found to be capable for the prediction of surface roughness within a reasonable degree of accuracy. It was observed that tool nose radius of 1mm provides better surface finish in comparison to 0.65 mm. Also, it was observed that feed rate has a significant influence on surface finish.

Keywords: full factorial design, neural network, nose radius, surface finish

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Authors: Elżbieta Cygan, Bączek, Piotr Wyżga

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This paper presents the results of research on the physical, mechanical, and tribological properties of materials constituting the matrix in sintered metallic-diamond tools. The ground powders based on the Fe-Mn-Cu-Sn-C system were modified with micro-sized particles of the ceramic phase: SiC, Al₂O₃ and consolidated using the SPS (spark plasma sintering) method to a relative density of over 98% at 850-950°C, at a pressure of 35 MPa and time 10 min. After sintering, an analysis of the microstructure was conducted using scanning electron microscopy. The resulting materials were tested for the apparent density determined by Archimedes’ method, Rockwell hardness (scale B), Young’s modulus, as well as for technological properties. The performance results of obtained diamond composites were compared with the base material (Fe–Mn–Cu–Sn–C) and the commercial alloy Co-20% WC. The hardness of composites has achieved the maximum at a temperature of 900°C; therefore, it should be considered that at this temperature it was obtained optimal physical and mechanical properties of the subjects' composites were. Research on tribological properties showed that the composites modified with micro-sized particles of the ceramic phase are characterized by more than twice higher wear resistance in comparison with base materials and the commercial alloy Co-20% WC. Composites containing Al₂O₃ phase particles in the matrix material were composites containing Al₂O₃ phase particles in the matrix material were characterized by the lowest abrasion wear resistance. The manufacturing technology presented in the paper is economically justified and can be successfully used in the production process of the matrix in sintered diamond-impregnated tools used for the machining of an industrial floor system. Acknowledgment: The study was performed under LIDER IX Research Project No. LIDER/22/0085/L-9/17/NCBR/2018 entitled “Innovative metal-diamond tools without the addition of critical raw materials for applications in the process of grinding industrial floor systems” funded by the National Centre for Research and Development of Poland, Warsaw.

Keywords: abrasive wear resistance, metal matrix composites, sintered diamond tools, Spark Plasma Sintering

Procedia PDF Downloads 41

Authors: A. Alshebani, Y. Swesi, S. Mrayed, F. Altaher, I. Musbah

Abstract:

Cs-type nanocomposite zeolite membrane was successfully synthesized on a alumina ceramic hollow fibre with a mean outer diameter of 1.7 mm, cesium cationic exchange test was carried out inside test module with mean wall thickness of 230 μm and an average crossing pore size smaller than 0.2 μm. Separation factor of n-butane/H2 obtained indicate that a relatively high quality closed to 20. Maxwell-Stefan modeling provides an equivalent thickness lower than 1 µm. To compare the difference an application to CO2/N2 separation has been achieved, reaching separation factors close to (4,18) before and after cation exchange on H-zeolite membrane formed within the pores of a ceramic alumina substrate.

Keywords: MFI membrane, CO2, nanocomposite, ceramic hollow fibre, ion-exchange

Procedia PDF Downloads 454

Authors: Bing-Jing Li, Sih-Yin Wang, Tse-Chun Yeh, Yuan-Bin Chen

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Microwave dielectric ceramic materials of (Mg1-xNix)2(Ti0.95Sn0.05)O4 for x = 0.01, 0.03, 0.05, 0.07 and 0.09 were prepared and sintered at 1250–1400ºC. The microstructure and microwave dielectric properties of the ceramic materials were examined and measured. The observations shows that the content of Ni2+ ions has little effect on the crystal structure, dielectric constant, temperature coefficient of resonant frequency (τf) and sintering temperatures of the ceramics. However, the quality values (Q×f) are greatly improved due to the addition of Ni2+ ions. The present study showed that the ceramic material prepared for x = 0.05 and sintered at 1325ºC had the best Q×f value of 392,000 GHz, about 23% improvement compared with that of Mg2(Ti0.95Sn0.05)O4.

Keywords: (Mg1-xNix)2(Ti0.95Sn0.05)O4, microwave dielectric ceramics, high quality factor, high frequency wireless communication

Procedia PDF Downloads 456

Authors: Seyed Hamed Hashemi Sohi, Gerald Jo Denoga

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Machining or metal cutting is one of the most widely used production processes in industry. The quality of the process and the resulting machined product depends on parameters like tool geometry, material, and cutting conditions. However, the relationships of these parameters to the cutting process are often based mostly on empirical knowledge. In this study, computer modeling and simulation using LS-DYNA software and a Smoothed Particle Hydrodynamic (SPH) methodology, was performed on the orthogonal metal cutting process to analyze three-dimensional deformation of AISI 1045 medium carbon steel during machining. The simulation was performed using the following constitutive models: the Power Law model, the Johnson-Cook model, and the Zerilli-Armstrong models (Z-A). The outcomes were compared against the simulated results obtained by Cenk Kiliçaslan using the Finite Element Method (FEM) and the empirical results of Jaspers and Filice. The analysis shows that the SPH method combined with the Zerilli-Armstrong constitutive model is a viable alternative to simulating the metal cutting process. The tangential force was overestimated by 7%, and the normal force was underestimated by 16% when compared with empirical values. The simulation values for flow stress versus strain at various temperatures were also validated against empirical values. The SPH method using the Z-A model has also proven to be robust against issues of time-scaling. Experimental work was also done to investigate the effects of friction, rake angle and tool tip radius on the simulation.

Keywords: metal cutting, smoothed particle hydrodynamics, constitutive models, experimental, cutting forces analyses

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Authors: Ahmet Yönetken

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Al metal matrix composites reinforced with AlN have been fabricated by Tube furnace sintering at various temperatures. A uniform nickel layer on Al(%1AlN)%19Ni, Al(%2AlN)%18Ni, Al(%3AlN)%17Ni, Al(%4AlN)%16Ni, Al(%5AlN)%15Ni powders were deposited prior to sintering using electroless plating technique, allowing closer surface contact than can be achieved using conventional methods such as mechanical alloying. A composite consisting of quaternary additions, a ceramic phase, AlN, within a matrix of Al, AlN, Ni has been prepared at the temperature range between 550°C and 650°C under Ar shroud. X-Ray diffraction, SEM (Scanning Electron Microscope) density, and hardness measurements were employed to characterize the properties of the specimens. Experimental results carried out for 650°C suggest that the best properties as comprehension strength σmax and hardness 681.51(HV) were obtained at 650°C, and the tube furnace sintering of electroless Al plated (%5AlN)%15Ni powders is a promising technique to produce ceramic reinforced Al (%5AlN)%15Ni composites.

Keywords: electroless nickel plating, ceramic-metal composites, powder metallurgy, sintering

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Authors: I. Kerti, G. Sezen, S. Daglilar

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This present work is focused on studying to improve low wetting behaviour between liquid metal and ceramic particles. Ceramic particles like SiC and B4C have attracted great attention because of their usability as reinforcement for composite materials. However, poor wettability of particles is one of the major drawbacks of metal matrix composite production. Various methods have been studied to enhance the wetting properties between ceramic materials and metal substrates during ceramic reinforced metal matrix composites. Among these methods, autocatalytic nickel deposition is a unique process for the enhancement of the surface properties of ceramic particles. In fact, it is difficult to obtain continuous and uniform metallic coating on ceramic powders. In this study deposition of nickel boron layer on ceramic particles via autocatalytic plating in borohydride baths were investigated. Firstly, powders with different particle sizes were sensitized and activated respectively in order to ensure catalytic properties. Following the pre-treatment operations, particles were transferred into the coating bath containing nickel sulphate or nickel chloride as the Ni2+ source. The results show that a better bonding and uniform coating layer were obtained for Ni-B coatings with the Ni2+ source of NiCl2.6H2O as compared to NiSO4.6H2O. With the progress of the time, both particle surfaces are completely covered by a continuous and thin nickel boron layer. The surface morphology of the coatings that were analysed using scanning electron microscopy (SEM) show that SiC and B4C particles both distributed and different thickness of Ni-B nanolayers have been successfully coated onto the particles. The particles were mounted into a polimeric resin and polished in order to observe the thickness and the continuity of the coating layer. The composition of the coating layers were also evaluated by EDS analyses. The SEM morphologies and the EDS results of the coatings at different reaction times were adopted for detailed discussion of the Ni-B electroless plating mechanism.

Keywords: boron carbide, electroless coating, nickel boron deposition, silicon carbide

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Authors: Hany Mohamed Abdu, Mohamed Hassan Gadallah, El-Giushi Mokhtar, Yehia Mahmoud Ismail

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Laser beam cutting is one nontraditional machining process. This paper optimizes the parameters of Laser beam cutting machining parameters of Stainless steel (316L) by considering the effect of input parameters viz. power, oxygen pressure, frequency and cutting speed. Statistical design of experiments are carried in three different levels and process responses such as 'Average kerf taper (Ta)' and 'Surface Roughness (Ra)' are measured accordingly. A quadratic mathematical model (RSM) for each of the responses is developed as a function of the process parameters. Responses predicted by the models (as per Taguchi’s L27 OA) are employed to search for an optimal parametric combination to achieve desired yield of the process. RSM models are developed for mean responses, S/N ratio, and standard deviation of responses. Optimization models are formulated as single objective problem subject to process constraints. Models are formulated based on Analysis of Variance (ANOVA) using MATLAB environment. Optimum solutions are compared with Taguchi Methodology results.

Keywords: optimization, laser cutting, robust design, kerf width, Taguchi method, RSM and DOE

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Authors: Junior Nomani

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This paper presents a novel approach to modelling the metal cutting of duplex stainless steels, a two-phase alloy regarded as a difficult-to-machine material. Calculation and control of shear strain and stresses during cutting are essential to achievement of ideal cutting conditions. Too low or too high leads to higher required cutting force or excessive heat generation causing premature tool wear failure. A 2D finite element cutting model was created based on electron backscatter diffraction (EBSD) data imagery of duplex microstructure. A mesh was generated using ‘object-oriented’ software OOF2 version V2.1.11, converting microstructural images to quadrilateral elements. A virtual workpiece was created on ABAQUS modelling software where a rigid body toolpiece advanced towards workpiece simulating chip formation, generating serrated edge chip formation cutting. Model results found calculated stress strain contour plots correlated well with similar finite element models tied with austenite stainless steel alloys. Virtual chip form profile is also similar compared experimental frozen machining chip samples. The output model data provides new insight description of strain behavior of two phase material on how it transitions from workpiece into the chip.

Keywords: Duplex stainless steel, ABAQUS, OOF2, Chip formation

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Authors: Lakshminarayanan, Vijayaraghavan, Krishnamurthy

Abstract:

The ever-increasing demand for high efficiency in automotive and aerospace applications requires new materials to suit to high temperature applications. The Ceramic Matrix Composites nowadays find its applications for high strength and high temperature environments. In this paper, Al2O3 and Sic ceramic materials are taken in particulate form as matrix and reinforcement respectively. They are blended together in Ball Milling and compacted in Cold Compaction Machine by powder metallurgy technique. Scanning Electron Microscope images are taken for the samples in order to find out proper blending of powders. Micro harness testing is also carried out for the samples in Vickers Micro Hardness Testing Equipment. Surface grinding of the samples is also carried out in Surface Grinding Machine in order to find out grinding force estimates. The surface roughness of the grounded samples is also taken in Surface Profilometer. These are yielding promising results.

Keywords: ceramic matrix composite, cold compaction, material characterization, particulate and surface grinding

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Authors: Vimanyu Chadha, Ranganath M. Singari

Abstract:

Drilling composite materials is a frequently practiced machining process during assembling in various industries such as automotive and aerospace. However, drilling of glass fiber reinforced plastic (GFRP) composites is significantly affected by damage tendency of these materials under cutting forces such as thrust force and torque. The aim of this paper is to investigate the influence of the various cutting parameters such as cutting speed and feed rate; subsequently also to study the influence of number of layers on delamination produced while drilling a GFRP composite. A plan of experiments, based on Taguchi techniques, was instituted considering drilling with prefixed cutting parameters in a hand lay-up GFRP material. The damage induced associated with drilling GFRP composites were measured. Moreover, Analysis of Variance (ANOVA) was performed to obtain minimization of delamination influenced by drilling parameters and number layers. The optimum drilling factor combination was obtained by using the analysis of signal-to-noise ratio. The conclusion revealed that feed rate was the most influential factor on the delamination. The best results of the delamination were obtained with composites with a greater number of layers at lower cutting speeds and feed rates.

Keywords: analysis of variance, delamination, design optimization, drilling, glass fiber reinforced plastic composites, Taguchi method

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Authors: Abid Hussain, Binay Kumar

Abstract:

Environment-friendly lead-free Na₀.₅₂K₀.₄₄Li₀.₀₄Nb₀.₈₄Ta₀.₁₀Sb₀.₀₆O₃ (NKLNTS) ceramic was synthesized by solid-state reaction method in search of a potential candidate to replace lead-based ceramics such as PbZrO₃-PbTiO₃ (PZT), Pb(Mg₁/₃Nb₂/₃)O₃-PbTiO₃ (PMN-PT) etc., for various applications. The ceramic was calcined at temperature 850 ᵒC and sintered at 1090 ᵒC. The powder X-Ray Diffraction (XRD) pattern revealed the formation of pure perovskite phase having tetragonal symmetry with space group P4mm of the synthesized ceramic. The surface morphology of the ceramic was studied using Field Emission Scanning Electron Microscopy (FESEM) technique. The well-defined grains with homogeneous microstructure were observed. The average grain size was found to be ~ 0.6 µm. A very large value of piezoelectric charge coefficient (d₃₃ ~ 754 pm/V) was obtained for the synthesized ceramic which indicated its potential for use in transducers and actuators. In dielectric measurements, a high value of ferroelectric to paraelectric phase transition temperature (Tm~305 ᵒC), a high value of maximum dielectric permittivity ~ 2110 (at 1 kHz) and a very small value of dielectric loss ( < 0.6) were obtained which suggested the utility of NKLNTS ceramic in high-temperature ferroelectric devices. Also, the degree of diffuseness (γ) was found to be 1.61 which confirmed a relaxor ferroelectric behavior in NKLNTS ceramic. P-E hysteresis loop was traced and the value of spontaneous polarization was found to be ~11μC/cm² at room temperature. The pyroelectric coefficient was obtained to be very high (p ∼ 1870 μCm⁻² ᵒC⁻¹) for the present case indicating its applicability in pyroelectric detector applications including fire and burglar alarms, infrared imaging, etc. NKLNTS ceramic showed fatigue free behavior over 107 switching cycles. Remanent hysteresis task was performed to determine the true-remanent (or intrinsic) polarization of NKLNTS ceramic by eliminating non-switchable components which showed that a major portion (83.10 %) of the remanent polarization (Pr) is switchable in the sample which makes NKLNTS ceramic a suitable material for memory switching devices applications. Time-Dependent Compensated (TDC) hysteresis task was carried out which revealed resistive leakage free nature of the ceramic. The performance of NKLNTS ceramic was found to be superior to many lead based piezoceramics and hence can effectively replace them for use in piezoelectric, pyroelectric and long duration ferroelectric applications.

Keywords: dielectric properties, ferroelectric properties , lead free ceramic, piezoelectric property, solid state reaction, true-remanent polarization

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