Search results for: Powder metallurgy Cu-Cr alloy powder

Authors: Shady Sayed, Samer Wagdy, Ahmed Badawy, Moutaz M. Hegaze

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A symmetrical single mass resonant gyroscope is discussed in this paper. The symmetrical design allows matched resonant frequencies for driving and sensing vibration modes, which leads to amplifying the sensitivity of the gyroscope by the mechanical quality factor of the sense mode. It also achieves decoupled vibration modes for getting a low zero-rate output shift and more stable operation environment. A new suspension beams design is developed to get a symmetrical gyroscope with matched and decoupled modes at the same time. Finite element simulations are performed using ANSYS software package to verify the theoretical calculations. The gyroscope is fabricated from aluminum alloy 2024 substrate, the measured drive and sense resonant frequencies of the fabricated model are matched and equal 81.4 Hz with 5.7% error from the simulation results.

Keywords: Decoupled mode shapes, resonant sensor, symmetrical gyroscope, finite element simulation.

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Authors: V. Arbabi , I. Ebrahimzadeh, H. Ghanbari, M.M. Kaykha

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Horizontal continuous casting is widely used to produce semi-finished non-Ferrous products. Homogeneity in the metallurgical characteristics and mechanical properties for this product is vital for industrial application. In the present work, the microstructure and mechanical properties of a horizontal continuous cast two-phase brass billet have been studied. Impact strength and hardness variations were examined and the phase composition and porosity studied with image analysis software. Distinct differences in mechanical properties were observed between the upper, middle and lower parts of the billet, which are explained in terms of the morphology and size of the phase in the microstructure. Hardness variation in the length of billet is higher in upper area but impact strength is higher in lower areas.

Keywords: Horizontal Continuous Casting, Two-phase brasses, CuZn40Al1 alloy, Microstructure, Impact Strength.

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Authors: S. Ghorbani, N. I. Polushin

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The machinability of workpieces (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron) in turning operation has been carried out using different types of cutting tool (conventional, cutting tool with holes in toolholder and cutting tool filled up with composite material) under dry conditions on a turning machine at different stages of spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). Experimentation was performed as per Taguchi’s orthogonal array. To evaluate the relative importance of factors affecting surface roughness the single decision tree (SDT), Decision tree forest (DTF) and Group method of data handling (GMDH) were applied.

Keywords: Decision Tree Forest, GMDH, surface roughness, taguchi method, turning process.

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Authors: S. Ghorbani, N. I. Polushin

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In this study, an approach to identify factors affecting on surface roughness in a machining process is presented. This study is based on 81 data about surface roughness over a wide range of cutting tools (conventional, cutting tool with holes, cutting tool with composite material), workpiece materials (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). A single decision tree (SDT) analysis was done to identify factors for predicting a model of surface roughness, and the CART algorithm was employed for building and evaluating regression tree. Results show that a single decision tree is better than traditional regression models with higher rate and forecast accuracy and strong value.

Keywords: Cutting condition, surface roughness, decision tree, CART algorithm.

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Authors: Jung-Ho Moon, Tae Kwon Ha

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In the present study, M2 high speed steels were fabricated by using electro-slag rapid remelting process. Carbide structure was analysed and the fracture toughness and hardness were also measured after austenitization treatment at 1190 and 1210oC followed by tempering treatment at 535oC for billets with various diameters from 16 to 60 mm. Electro-slag rapid remelting (ESRR) process is an advanced ESR process combined by continuous casting and successfully employed in this study to fabricate a sound M2 high speed ingot. Three other kinds of commercial M2 high speed steels, produced by traditional method, were also analysed for comparison. Distribution and structure of eutectic carbides of the ESRR billet were found to be comparable to those of commercial alloy and so was the fracture toughness.

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

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Authors: Ch. Thee, Junhua Dong, Wei Ke

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The atmospheres in many cities along the coastal lines in the world have been rapidly changed to coastal-industrial atmosphere. Hence, it is vital to investigate the corrosion behavior of steel exposed to this kind of environment. In this present study, Electrochemical Impedance Spectrography (EIS) and film thickness measurement were applied to monitor the corrosion behavior of weathering steel covered with a thin layer of the electrolyte in a wet-dry cyclic condition, simulating a coastal-industrial environment at 25oC and 60% RH. The results indicate that in all cycles, the corrosion rate increases during the drying process due to an increase in anion concentration and an acceleration of oxygen diffusion enhanced by the effect of the thinning out of the electrolyte. During the wet-dry cyclic corrosion test, the long-term corrosion behavior of this steel depends on the periods of exposure. Corrosion process is first accelerated and then decelerated. The decelerating corrosion process is contributed to the formation of the protective rust, favored by the wet-dry cycle and the acid regeneration process during the rusting process.

Keywords: Atmospheric corrosion, EIS, low alloy, rust.

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Authors: Sh. Hosseini, M. B. Limooei, M. Hossein Zade, E. Askarnia, Z. Asadi

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Manganese steel (Hadfield) is one of the important alloys in industry due to its special properties. High work hardening ability with appropriate toughness and ductility are the properties that caused this alloy to be used in wear resistance parts and in high strength condition. Heat treatment is the main process through which the desired mechanical properties and microstructures are obtained in Hadfield steel. In this study various heat treatment cycles, differing in austenising temperature, time and quenching solution are applied. For this purpose, the same samples of manganese steel was heat treated in 9 different cycles, and then the mechanical properties and microstructures were investigated. Based on the results of the study, the optimum heat treatment cycle was obtained.

Keywords: Manganese steel (Hadfield), heat treatment, austenising temperature, austenising time, quenching solution, mechanical properties.

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Authors: Sharon S. Wu, Yong S. Park

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This project aims to study and evaluate the motorcycle crash bar, which is used to reduce injuries caused by side impacts to the motorcycle, and then develop an improved design using the engineering design process theory based on the current benchmark crash bar in order to lower the severity of motorcycle crash injuries. For this purpose, simulations for the crash bar are set up so that it travels at an angle towards a fixed concrete wall and collides at certain velocities. 3D CAD models are first designed in SolidWorks and dynamic crash simulations are then carried out using ANSYS to determine the lowest maximum Von-Mises stress over time and deformations by adjusting the parameters used in manufacturing the crash bar, including the velocity of the crash, material used, geometries with various radius fillets, and different thicknesses for the bar. The results of the simulation are used to determine the optimum parameters for a safer crash bar to withstand higher stress and deformation. Specifically, the von-Mises stress was reduced by at least 75% compared with the benchmark design by choosing aluminum alloy and a true unibar design.

Keywords: Crash bar, crash simulation, engineering design, motorcycle safety.

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Authors: Iwona Nowak, Jacek Smolka, Andrzej J. Nowak

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The paper discusses a 3D numerical solution of the inverse boundary problem for a continuous casting process of alloy. The main goal of the analysis presented within the paper was to estimate heat fluxes along the external surface of the ingot. The verified information on these fluxes was crucial for a good design of a mould, effective cooling system and generally the whole caster. In the study an enthalpy-porosity technique implemented in Fluent package was used for modeling the solidification process. In this method, the phase change interface was determined on the basis of the liquid fraction approach. In inverse procedure the sensitivity analysis was applied for retrieving boundary conditions. A comparison of the measured and retrieved values showed a high accuracy of the computations. Additionally, the influence of the accuracy of measurements on the estimated heat fluxes was also investigated.

Keywords: Boundary inverse problem, sensitivity analysis, continuous casting, numerical simulation.

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Authors: Jung-Ho Moon, Myung-Gon Yoon, Tae Kwon Ha

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High temperature deformation behavior of cast 310S stainless steel has been investigated in this study by performing tensile and compression tests at temperatures from 900 to 1200^oC. Rectangular ingots of which the dimensions were 350×350×100 in millimeter were cast using vacuum induction melting. Phase equilibrium was calculated using the FactSage®, thermodynamic software and database. Thermal expansion coefficient was also measured on the ingot in the temperature range from room temperature to 1200^oC. Tensile strength of cast 310S stainless steel was 9 MPa at 1200^oC, which is a little higher than that of a wrought 310S. With temperature decreased, tensile strength increased rapidly and reached up to 72 MPa at 900^oC. Elongation also increased with temperature decreased. Microstructure observation revealed that s phase was precipitated along the grain boundary and within the matrix over 1200^oC, which is detrimental to high temperature elongation.

Keywords: Stainless steel, STS 310S, high temperature deformation, microstructure, mechanical properties.

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Authors: K. Kalaiselvan, A. Elango

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In general, it is desirable to finish the weld quickly, before a large volume of surrounding metal heats up and expands. The welding process used, type, welding current and speed of travel, thus, affect the degree of shrinkage and distortion of a weldment. The use of mechanized welding equipment reduces welding time, metal affected zone and consequently distortion. This article helps to define what weld distortion is and then provide a practical understanding of the causes of distortion, effects of shrinkage in butt joint welded assemblies using TI6AL4VA and Aluminium AA2024 alloy sheet. The beam offset position to the joint interface towards titanium and aluminium side. The factors affecting distortion during welding is also given. Test results reveal that welding speed is the significant parameter to decide the extent of distortion. Also welding from Al side reduces the distortion while Ti side increases the distortion.

Keywords: Nd:YAG Pulsed laser welding, Titanium/Aluminium thin sheet butt joint, distortion.

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Authors: Jungho Moon, Tae Kwon Ha

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Effect of alloying on the microstructure and mechanical properties of heat-resisting duplex stainless steel (DSS) for Mg production was investigated in this study. 25Cr-8Ni based DSS’s were cast into rectangular ingots of which the dimension was 350×350×100 mm3 . Nitrogen and Yttrium were added in the range within 0.3 in weight percent. Phase equilibrium was calculated using the FactSage®, thermodynamic software. Hot exposure, high temperature tensile and compression tests were conducted on the ingots at 1230oC, which is operation temperature employed for Mg production by Silico-thermic reduction. The steel with N and Y showed much higher strength than 310S alloy in both tensile and compression tests. By thermal exposition at 1230oC for 200 hrs, hardness of DSS containing N and Y was found to increase. Hot workability of the heat-resisting DSS was evaluated by employing hot rolling at 1230 oC. Hot shortness was observed in the ingot with N and found to disappear after addition of Y.

Keywords: Duplex Stainless Steel, alloying elements, eutectic carbides, microstructure, aging treatment.

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Authors: M. Azadbakht, M. E. Shayan, H. Jafari, E. Ghajarjazi, A. Kiapei

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Transmission shafts are affected by various forces, for example, during acceleration or sudden breaks, bending during transportation, vertical forces that lead to cuts. One of the main failures in combines is breaking shaft which repairmen refer it. Structural resistance of canal against torque is very important in the beginning of the movement. For analyzing stress, a typical sample from a type of combine was selected, called JD955 combine. Long shaft in this combine was analyzed with finite element method by Ansys13 generic package under static load. Conducted analysis showed that there is a maximum stress in contact surfaces of indentations and also in place of changing diameter. Safety factor value is low in parts of the shaft and this increases the probability of failure at these points. To improve the conditions with the least cost and an approach of product improvement, using alternative alloy is important.

Keywords: John Deere, Ansys, Shaft, Stress, Grain Combine harvester, Finite element, Failure.

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Authors: Nasim Daemi, Gholam Hossein Majzoobi

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In this work, bending fatigue life of notched specimens with various notch geometries and dimensions is investigated by experiment and Manson-Caffin theoretical method. In this theoretical method, fatigue life of notched specimens is calculated using the fatigue life obtained from the experiments for plain specimens (without notch). Three notch geometries including ∪-shape, ∨-shape and C -shape notches are considered in this investigation. The experiments are conducted on a rotary bending Moore machine. The specimens are made of a low carbon steel alloy, which has wide application in industry. The stress- life curves are captured for all notched specimen by experiment. The results indicate that Manson-Caffin analytical method cannot adequately predict the fatigue life of notched specimen. However, it seems that the difference between the experiments and Manson-Caffin predictions can be compensated by a proportional factor.

Keywords: fatigue life, Mason-Caffin method, notchedspecimen, stress-life curve.

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Authors: Travis J. Meyer, Jasodra Ramlall, Phyo Thu, Nidhi Gadura

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For centuries humans have used the antimicrobial properties of copper to their advantage. Yet, after all these years the underlying mechanisms of copper mediated cell death in various microbes remain unclear. We had explored the hypothesis that copper mediated increased levels of lipid peroxidation in the membrane fatty acids is responsible for increased killing in Escherichia coli. In this study we show that in both gram positive (Staphylococcus aureus) and gram negative (Pseudomonas aeruginosa) bacteria there is a strong correlation between copper mediated cell death and increased levels of lipid peroxidation. Interestingly, the non-spore forming gram positive bacteria as well as gram negative bacteria show similar patterns of cell death, increased levels of lipid peroxidation, as well as genomic DNA degradation, however there is some difference in loss in membrane integrity upon exposure to copper alloy surface.

Keywords: Antimicrobial, copper, gram positive, gram negative.

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Authors: K. Rattanachan

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In sheet metal forming process, raw material mechanical properties are important parameters. This paper is to compare the wall’s incline angle or formability of SS 400 steel and SUS 304 stainless steel in single point incremental forming. The two materials are ferrous base alloyed, which have the different unit cell, mechanical property and chemical composition. They were forming into cone shape specimens having 100 mm diameter with different wall’s incline angle: 90o, 75o and 60o. The investigation was continued until the specimens formed surface facture. The experimental result showed that the smaller the wall incline angle higher the formability with the both materials. The formability limit of the ferrous base alloy was approx. 60o wall’s incline angle. By nature, SS 400 has higher formability than SUS 304. This result can be used as the initial data in designing the single point incremental forming parts.

Keywords: NC incremental forming, Single point incremental forming, Wall incline angle, Formability.

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Authors: Chansopheak Seang, Afia David Kouadri, Eric Ragneau

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Three dimensional analysis of thermal model in laser full penetration welding, Nd:YAG, by transparent mode DP600 alloy steel 1.25mm of thickness and gap of 0.1mm. Three models studied the influence of thermal dependent temperature properties, thermal independent temperature and the effect of peak value of specific heat at phase transformation temperature, AC1, on the transient temperature. Another seven models studied the influence of discretization, meshes on the temperature distribution in weld plate. It is shown that for the effects of thermal properties, the errors less 4% of maximum temperature in FZ and HAZ have identified. The minimum value of discretization are at least one third increment per radius for temporal discretization and the spatial discretization requires two elements per radius and four elements through thickness of the assembled plate, which therefore represent the minimum requirements of modeling for the laser welding in order to get minimum errors less than 5% compared to the fine mesh.

Keywords: FEA, welding, discretization, ABAQUS user subroutine DFLUX

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Authors: Ramesh S., Sasiraaju A. S., Sidhaarth K., Sudhan Rajkumar N., Manivel Muralidaran V.

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This work presents the result of investigations aimed at determining the hardness of the welded Chromoly (A 4130) steel plate of 2” thickness. Multi pass welding for the thick sections was carried out and analyzed for the Chromoly alloy steel plates. The study of hardness at the weld metal reveals that there is the presence of different micro structure products which yields diverse properties. The welding carried out using GMAW with ER70s-2 electrode. Single V groove design was selected for the butt joint configuration. The presence of hydrogen has been suppressed by selecting low hydrogen electrode. Preheating of the plate prior to welding reduces the cooling rate which also affects the weld metal microstructure. The shielding gas composition used in this analysis is 80% Ar-20% CO2. The experimental analysis gives the detailed study of the hardness of the material.

Keywords: Chromoly, Gas Metal Arc Weld (GMAW), Hardness, Multi pass weld, Shielding gas composition.

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Authors: Soroor Ghaziof, Wei Gao

Abstract:

Zn alloy and composite coatings are widely used in buildings and structures, automobile and fasteners industries to protect steel component from corrosion. In this paper, Zn-Ni-Al2O3 nanocomposite coatings were electrodeposited on mild steel using a novel sol enhanced electroplating method. In this method, transparent Al2O3 sol was added into the acidic Zn-Ni bath to produced Zn-Ni- Al2O3 nanocomposite coatings. The effect of alumina sol on the electrodeposition process, and coating properties was investigated using cyclic voltammetry, XRD, ESEM and Tafel test. Results from XRD tests showed that the structure of all coatings was single γ- Ni5Zn21 phase. Cyclic voltammetry results showed that the electrodeposition overpotential was lower in the presence of alumina sol in the bath, and caused the reduction potential of Zn-Ni to shift to more positive values. Zn-Ni-Al2O3 nanocomposite coatings produced more uniform and compact deposits, with fine grained microstructure when compared to Zn-Ni coatings. The corrosion resistance of Zn-Ni coatings was improved significantly by incorporation of alumina nanoparticles into the coatings.

Keywords: Zn-Ni-Al2O3 composite coatings, steel, sol-enhanced electroplating, corrosion resistance.

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Authors: Reimund Neugebauer, Welf-Guntram Drossel, Andre Bucht, Christoph Ohsenbrügge

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In this paper the authors propose and verify an approach to control heat flow in machine tool components. Thermal deformations are a main aspect that affects the accuracy of machining. Due to goals of energy efficiency, thermal basic loads should be reduced. This leads to inhomogeneous and time variant temperature profiles. To counteract these negative consequences, material with high melting enthalpy is used as a method for thermal stabilization. The increased thermal capacity slows down the transient thermal behavior. To account for the delayed thermal equilibrium, a control mechanism for thermal flow is introduced. By varying a gap in a heat flow path the thermal resistance of an assembly can be controlled. This mechanism is evaluated in two experimental setups. First to validate the ability to control the thermal resistance and second to prove the possibility of a self-sufficient option based on the selfsensing abilities of thermal shape memory alloys.

Keywords: energy-efficiency, heat transfer path, MT thermal stability, thermal shape memory alloy

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Authors: S. O. Adeosun, E. I. Akpan, S. A. Balogun, A. S. Abdulmunim

Abstract:

SiC reinforced Aluminum samples were produced by stir casting of liquid AA1200 aluminum alloy at 600-650ºC casting temperature. 83µm SiC particles were rinsed in 10g/l, 20g/l and 30g/l molar concentration of Sncl₂ through cleaning times of 0, 60, 120, and 180 minutes. Some cast samples were tested for mechanical properties and some were subjected to heat treatment before testing. The SnCl₂ rinsed SiC reinforced aluminum exhibited higher yield strength, hardness, stiffness and elongation which increases with cleaning concentration and time up to 120 minutes, compared to composite with untreated SiC. However, the impact energy resistance decreases with cleaning concentration and time. The improved properties were attributed to good wettability and mechanical adhesion at the fiber-matrix interface. Quenching and annealing the composite samples further improve the tensile/yield strengths, elongation, stiffness, hardness similar to those of the as-cast samples.

Keywords: Al-SIC, Aluminum, Composites, Intermetallic, Reinforcement, Tensile Strength, Wetting.

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Authors: S. S. Ng, Z. Hassan, H. Abu Hassan

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III-nitride quaternary InxAlyGa1-x-yN alloys have experienced considerable interest as potential materials for optoelectronic applications. Despite these interesting applications and the extensive efforts to understand their fundamental properties, research on its fundamental surface property, i.e., surface phonon polariton (SPP) has not yet been reported. In fact, the SPP properties have been shown to provide application for some photonic devices. Hence, there is an absolute need for thorough studies on the SPP properties of this material. In this work, theoretical study on the SPP modes in InAlGaN quaternary alloys are reported. Attention is focus on the wurtzite (α-) structure InxAlyGa1-x-yN semi-crystal with different In composition, x ranging from 0 to 0.10 and constant Al composition, y = 0.06. The SPP modes are obtained through the theoretical simulation by means of anisotropy model. The characteristics of SP dispersion curves are discussed. Accessible results in terms of the experimental point of view are also given. Finally, the results revealed that the SPP mode of α-InxAlyGa1-x-yN semiconductors exhibits two-mode behavior.

Keywords: III-nitride semiconductor, attenuated total reflection, quaternary alloy, surface phonon polariton.

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Authors: Seon Soon Choi

Abstract:

The fatigue crack growth is stochastic because of the fatigue behavior having an uncertainty and a randomness. Therefore, it is necessary to determine the probability distribution of a grown crack size at a specific fatigue crack propagation life for maintenance of structure as well as reliability estimation. The essential purpose of this study is to present the good probability distribution fit for the grown crack size at a specified fatigue life in a rolled magnesium alloy under different specimen thickness conditions. Fatigue crack propagation experiments are carried out in laboratory air under three conditions of specimen thickness using AZ31 to investigate a stochastic crack growth behavior. The goodness-of-fit test for probability distribution of a grown crack size under different specimen thickness conditions is performed by Anderson-Darling test. The effect of a specimen thickness on variability of a grown crack size is also investigated.

Keywords: Crack size, Fatigue crack propagation, Magnesium alloys, Probability distribution, Specimen thickness.

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Authors: Md. Ashikur Rahman Khan, M. M. Rahman

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In electrical discharge machining (EDM), a complete and clear theory has not yet been established. The developed theory (physical models) yields results far from reality due to the complexity of the physics. It is difficult to select proper parameter settings in order to achieve better EDM performance. However, modelling can solve this critical problem concerning the parameter settings. Therefore, the purpose of the present work is to develop mathematical model to predict performance characteristics of EDM on Ti-5Al-2.5Sn titanium alloy. Response surface method (RSM) and artificial neural network (ANN) are employed to develop the mathematical models. The developed models are verified through analysis of variance (ANOVA). The ANN models are trained, tested, and validated utilizing a set of data. It is found that the developed ANN and mathematical model can predict performance of EDM effectively. Thus, the model has found a precise tool that turns EDM process cost-effective and more efficient.

Keywords: Analysis of variance, artificial neural network, material removal rate, modelling, response surface method, surface finish.

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Authors: Maziar Ramezani, Thomas Neitzert, Timotius Pasang

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This paper aims at experimental and numerical investigation of springback behavior of sheet metals during L-bending process with emphasis on Stribeck-type friction modeling. The coefficient of friction in Stribeck curve depends on sliding velocity and contact pressure. The springback behavior of mild steel and aluminum alloy 6022-T4 sheets was studied experimentally and using numerical simulations with ABAQUS software with two types of friction model: Coulomb friction and Stribeck friction. The influence of forming speed on springback behavior was studied experimentally and numerically. The results showed that Stribeck-type friction model has better results in predicting springback in sheet metal forming. The FE prediction error for mild steel and 6022-T4 AA is 23.8%, 25.5% respectively, using Coulomb friction model and 11%, 13% respectively, using Stribeck friction model. These results show that Stribeck model is suitable for simulation of sheet metal forming especially at higher forming speed.

Keywords: Friction, L-bending, Springback, Stribeck curves.

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Authors: B. Käfer, V. K. Bheemineni, H. Lammer, M. Kotnik, F. O. Riemelmoser

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Axial compression tests are performed on circular tubes made of Aluminum EN AW 6060 (AlMgSi0.5 alloy) in T66 state. All the received tubes have the uniform outer diameter of 40mm and thickness of 1.5mm. Two different lengths 100mm and 200mm are used in the analysis. After performing compression tests on the uniform tube, important crashworthy parameters like peak force, average force, crush efficiency and energy absorption are measured. The present paper has given importance to increase the percentage of crush efficiency without decreasing the value energy absorption of a tube, so a circumferential notch was introduced on the top section of the tube. The effects of position and cut-out lengths of a circumferential notch on the crush efficiency are well explained with relative deformation modes and force-displacement curves. The numerical simulations were carried on the software tool ANSYS/LS-DYNA. It is seen that the numerical results are reasonably good in agreement with the experimental results. 

Keywords: Crash box, Notch triggering, Energy absorption, FEM simulation.

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Authors: Taher El-Bitar, Maha El-Meligy, Eman El-Shenawy, Almosilhy Almosilhy, Nader Dawood

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The steel contains 0.3% C and 0.004% B, beside Mn, Cr, Mo, and Ni. The alloy was processed by using 20-ton capacity electric arc furnace (EAF), and then refined by ladle furnace (LF). Liquid steel was cast as rectangular ingots. Dilatation test showed the critical transformation temperatures Ac₁, Ac₃, M_s and M_f as 716, 835, 356, and 218 °C. The ingots were austenitized and soaked and then rough rolled to thin slabs with 80 mm thickness. The thin slabs were then reheated and soaked for finish rolling to 6.0 mm thickness plates. During the rough rolling, the roll force increases as a result of rolling at temperatures less than recrystallization temperature. However, during finish rolling, the steel reflects initially continuous static recrystallization after which it shows strain hardening due to fall of temperature. It was concluded that, the steel plates were successfully heat treated by quenching-tempering at 250 ºC for 20 min.

Keywords: Armor steel, austenitizing, critical transformation temperatures, dilatation curve, martensite, quenching, rough and finish rolling processes, soaking, tempering, thermo-mechanical processing.

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Authors: Zoltán Weltsch, József Hlinka, Eszter Kókai

Abstract:

The temperature dependence of wettability (wetting angle, Θ (T)) for Ag-based melts on graphite and Al2O3 substrates is compared. Typical alloying effects are found, as the Ag host metal is gradually replaced by various metallic elements. The essence of alloying lies in the change of the electron/atom (e/a) ratio. This ratio is also manifested in the shift of wetting angles on the same substrate. Nevertheless, the effects are partially smeared by other (metallurgical) factors, like the interaction between the oxygenalloying elements and by the graphite substrate-oxygen interaction. In contrast, such effects are not pronounced in the case of Al2O3 substrates. As a consequence, Θ(T) exhibits an opposite trend in the case of two substrates. Crossovers of the Θ(T) curves were often found. The positions of crossovers depend on the chemical character and concentration of solute atoms. Segregation and epitaxial texture formation after solidification were also observed in certain alloy drops, especially in high concentration range. This phenomenon is not yet explained in every detail.

Keywords: Contact angle, graphite, silver, soldering, solid solubility, substrate, temperature dependence, wetting.

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Authors: J. Chen, N. Hundal

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Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.

Keywords: Surface roughness, taguchi parameter design, turning center, turn-milling operations, vertical machining center.

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Authors: S. Ghorbani, N. I. Polushin

Abstract:

Chatter vibrations, occurring during cutting process, cause vibration between the cutting tool and workpiece, which deteriorates surface roughness and reduces tool life. The purpose of this study is to investigate the influence of cutting parameters and tool construction on surface roughness and vibration in turning of aluminum alloy AA2024. A new design of cutting tool is proposed, which is filled up with epoxy granite in order to improve damping capacity of the tool. Experiments were performed at the lathe using carbide cutting insert coated with TiC and two different cutting tools made of AISI 5140 steel. Taguchi L9 orthogonal array was applied to design of experiment and to optimize cutting conditions. By the help of signal-to-noise ratio and analysis of variance the optimal cutting condition and the effect of the cutting parameters on surface roughness and vibration were determined. Effectiveness of Taguchi method was verified by confirmation test. It was revealed that new cutting tool with epoxy granite has reduced vibration and surface roughness due to high damping properties of epoxy granite in toolholder.

Keywords: ANOVA, damping capacity, surface roughness, Taguchi method, vibration.

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