Search results for: TiB2 coated cemented carbide tool.

Authors: T. Sakamoto, S. Kainuma

Abstract:

Firstly, in order to examine the influence of the remaining amount of the rust on the coating film durability, the accelerated deterioration tests were carried out. In order to prepare test specimens, uncoated steel plates were corroded by the Salt Spray Test (SST) prior to the accelerated deterioration tests, and then the prepared test specimens were coated by epoxy resin and phthalic acid resin each of which has different gas-barrier performance. As the result, it was confirmed that the under-film corrosion occurred in the area and the adjacency to great quantities of salt exists in the rust, and did not occurred in the specimen which was applied the epoxy resin paint after the surface preparation by the power tool. Secondly, in order to clarify the influence of the corrosive factors on the coating film durability, outdoor exposure tests were conducted for one year on actual steel bridge located at a coastal area. The tests specimens consist of coated corroded plates and the uncoated steel plates, and they were installed on the different structural members of the bridge for one year. From the test results, the uncoated steel plates which were installed on the underside of the member are easily corrosive and had highly correlation with the amount of salt in the rust. On the other hand, the most corrosive under-film steel was the vertical surface of the web plate. Thus, it was confirmed that under-film corrosion rate was not match with corrosion rate of the uncoated steel. Consequently, it is estimated that the main factors of under-film corrosion are gas-barrier property of coating film and corrosive factors such as water vapor and temperature. The salt which significantly corrodes the uncoated steel plate is not directly related to the under-film corrosion.

Keywords: Accelerated deterioration test, Coating durability, Environmental factor, Under-film corrosion.

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Authors: S. Y. Lin, C. H. Kuan, C. H. She, W. T. Wang

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In this study, ultrasonic assisted machining (UAM) technique is applied in side-surface milling experiment for glass-ceramic workpiece material. The tungsten carbide cutting-tool with diamond coating is used in conjunction with two kinds of cooling/lubrication mediums such as water-soluble (WS) cutting fluid and minimum quantity lubricant (MQL). Full factorial process parameter combinations on the milling experiments are planned to investigate the effect of process parameters on cutting performance. From the experimental results, it tries to search for the better process parameter combination which the edge-indentation and the surface roughness are acceptable. In the machining experiments, ultrasonic oscillator was used to excite a cutting-tool along the radial direction producing a very small amplitude of vibration frequency of 20KHz to assist the machining process. After processing, toolmaker microscope was used to detect the side-surface morphology, edge-indentation and cutting tool wear under different combination of cutting parameters, and analysis and discussion were also conducted for experimental results. The results show that the main leading parameters to edge-indentation of glass ceramic are cutting depth and feed rate. In order to reduce edge-indentation, it needs to use lower cutting depth and feed rate. Water-soluble cutting fluid provides a better cooling effect in the primary cutting area; it may effectively reduce the edge-indentation and improve the surface morphology of the glass ceramic. The use of ultrasonic assisted technique can effectively enhance the surface finish cleanness and reduce cutting tool wear and edge-indentation. 

Keywords: Glass-ceramic, ultrasonic assisted machining, cutting performance, edge-indentation

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Authors: M. N. Nwodo, Y. P. Cheng, N. H. Minh

Abstract:

In the process of recovering oil in weak sandstone formations, the strength of sandstones around the wellbore is weakened due to the increase of effective stress/load from the completion activities around the cavity. The weakened and de-bonded sandstone may be eroded away by the produced fluid, which is termed sand production. It is one of the major trending subjects in the petroleum industry because of its significant negative impacts, as well as some observed positive impacts. For efficient sand management therefore, there has been need for a reliable study tool to understand the mechanism of sanding. One method of studying sand production is the use of the widely recognized Discrete Element Method (DEM), Particle Flow Code (PFC^3D) which represents sands as granular individual elements bonded together at contact points. However, there is limited knowledge of the particle-scale behavior of the weak sandstone, and the parameters that affect sanding. This paper aims to investigate the reliability of using PFC^3D and a simple Darcy flow in understanding the sand production behavior of a weak sandstone. An isotropic tri-axial test on a weak oil sandstone sample was first simulated at a confining stress of 1MPa to calibrate and validate the parallel bond models of PFC^3D using a 10m height and 10m diameter solid cylindrical model. The effect of the confining stress on the number of bonds failure was studied using this cylindrical model. With the calibrated data and sample material properties obtained from the tri-axial test, simulations without and with fluid flow were carried out to check on the effect of Darcy flow on bonds failure using the same model geometry. The fluid flow network comprised of every four particles connected with tetrahedral flow pipes with a central pore or flow domain. Parametric studies included the effects of confining stress, and fluid pressure; as well as validating flow rate – permeability relationship to verify Darcy’s fluid flow law. The effect of model size scaling on sanding was also investigated using 4m height, 2m diameter model. The parallel bond model successfully calibrated the sample’s strength of 4.4MPa, showing a sharp peak strength before strain-softening, similar to the behavior of real cemented sandstones. There seems to be an exponential increasing relationship for the bigger model, but a curvilinear shape for the smaller model. The presence of the Darcy flow induced tensile forces and increased the number of broken bonds. For the parametric studies, flow rate has a linear relationship with permeability at constant pressure head. The higher the fluid flow pressure, the higher the number of broken bonds/sanding. The DEM PFC^3D is a promising tool to studying the micromechanical behavior of cemented sandstones.

Keywords: Discrete Element Method, fluid flow, parametric study, sand production/bonds failure.

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Authors: D. V. Sreekanth, M. Sreenivasa Rao

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Abrasive jet machining is one of the promising non-traditional machining processes which uses mechanical energy (pressure and velocity) for machining various materials. The process parameters that influence the metal removal rate are kerfs, surface finish, depth of cut, air pressure, and distance between nozzle and work piece, nozzle diameter, abrasive type, abrasive shape, and mass flow rate of abrasive particles. The abrasive particles coming out with high pressure not only hits work surface but also passes through the nozzle resulting in erosion. This paper focuses mainly on the effect of different parameters on the erosion of nozzle in Abrasive jet machining. Three different types of nozzles made of sapphire, tungsten carbide, and high carbon high chromium steel (HCHCS) are used for machining glass and the erosion of these nozzles are calculated. The results are shown in tabular form and graphical representation.

Keywords: AJM, nozzle, sapphire, tungsten carbide, chrome steel.

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Authors: M. B. Limooei, Hadi Ebrahimifar, Sh. Hosseini

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Protective coatings that resist oxide scale growth and decrease chromium evaporation are necessary to make stainless steel interconnect materials for long-term durable operation of solid oxide fuel cells (SOFCs). In this study a layer of cobalt was electroplated on the surface of AISI 441 ferritic stainless steel which is used in solid oxide fuel cells for interconnect applications. The oxidation behavior of coated substrates was studied as a function of time at operating conditions of SOFCs. Cyclic oxidation has been also tested at 800ºC for 100 cycles. Cobalt coating during isothermal oxidation caused to the oxide growth resistance by limiting the outward diffusion of Cr cation and the inward diffusion of oxygen anion. Results of cyclic oxidation exhibited that coated substrates demonstrate an excellent resistance against the spallation and cracking.

Keywords: Oxidation resistance, full cell, Cobalt coating, ferritic stainless steel.

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Authors: M.A. Kamely, M.Y. Noordin

Abstract:

A judicious choice of insert material, tool geometry and cutting conditions can make hard turning produce better surfaces than grinding. In the present study, an attempt has been made to investigate the effect of cutting tool materials on cutting forces (feed force, thrust force and cutting force) in finish hard turning of AISI D2 cold work tool steel. In conclusion of the results obtained with a constant depth of cut and feed rate, it is important to note that cutting force is directly affected by cutting tool material.

Keywords: hard turning, cutting force, cutting tool materials, mixed ceramic, cbn

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Authors: Mohamed Zakaulla, A. R. Anwar Khan

Abstract:

Al6061 alloy base matrix, reinforced with particles of silicon carbide (10 wt %) and Graphite powder (1wt%), known as hybrid composites have been fabricated by liquid metallurgy route (stir casting technique) and optimized at different parameters like applied load, sliding speed and sliding distance by taguchi method. A plan of experiment generated through taguchi technique was used to perform experiments based on L27 orthogonal array. The developed ANOVA and regression equations are used to find the optimum coefficient of friction and wear under the influence of applied load, sliding speed and sliding distance. On the basis of “smaller the best” the dry sliding wear resistance was analysed and finally confirmation tests were carried out to verify the experimental results.

Keywords: Analysis of variance, dry sliding wear, Hybrid composite, orthogonal array, Taguchi technique.

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Authors: A. Korchunov, M. Chukin, N. Koptseva, M. Polyakova, A. Gulin

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A way of achieving nanodimentional structural elements in high carbon steel by special kind of heat treatment and cold plastic deformation is being explored. This leads to increasing interlamellar spacing of ferrite-carbide mixture. Decreasing the interlamellar spacing with cooling temperature increasing is determined. Experiments confirm such interlamellar spacing with which high carbon steel demonstrates the highest treatment and hardening capability. Total deformation degree effect on interlamellar spacing value in a ferrite-carbide mixture is obtained. Mechanical experiments results show that high carbon steel after heat treatment and repetitive cold plastic deformation possesses high tensile strength and yield strength keeping good percentage elongation.

Keywords: High-carbon steel, nanodimensional structural element, interlamellar spacing.

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Authors: M. Bagheri, P. Mottaghizadeh

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Reliable information about tool temperature distribution is of central importance in metal cutting. In this study, tool-chip interface temperature was determined in cutting of ST37 steel workpiece by applying HSS as the cutting tool in dry turning. Two different approaches were implemented for temperature measuring: an embedded thermocouple (RTD) in to the cutting tool and infrared (IR) camera. Comparisons are made between experimental data and results of MSC.SuperForm and FLUENT software. An investigation of heat generation in cutting tool was performed by varying cutting parameters at the stable cutting tool geometry and results were saved in a computer; then the diagrams of tool temperature vs. various cutting parameters were obtained. The experimental results reveal that the main factors of the increasing cutting temperature are cutting speed (V ), feed rate ( S ) and depth of cut ( h ), respectively. It was also determined that simultaneously change in cutting speed and feed rate has the maximum effect on increasing cutting temperature.

Keywords: Cutting parameters, Finite element modeling, Temperature measurement, Tool-chip interface temperature.

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Authors: A. J. Babajanyan, T. A. Abrahamyan, H. A. Minasyan, Kh. V. Nerkararyan

Abstract:

Optical radiation emitted from a metal-coated fiber tip apex at liquid-air interface was measured. The intensity of the output radiation was strongly depend on the relative position of the tip to a liquid-air interface and varied with surface fluctuations. This phenomenon permits in-situ real-time investigation of nano-metric vibrations of the liquid surface and provides a basis for development of various origin ultrasensitive vibration detecting sensors. The described method can be used for detection of week seismic vibrations.

Keywords: Fiber-tip, Liquid-air interface, Nano vibration, Opto-mechanical sensor.

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Authors: Erdinç Vural, Bülent Özdalyan, Serkan Özel

Abstract:

The four-stroke single cylinder diesel engine has been used in this study, the pistons and valves of the engine have been stabilized, the aluminum oxide (Al₂O₃) in different ratios has been added in the power of zirconium (ZrO₂) magnesium oxide (MgO), and has been coated with the plasma spray method. The pistons and valves of the combustion chamber of the engine are coated with 5 different (ZrO₂ + MgO), (ZrO₂ + MgO + 25% Al₂O₃), (ZrO₂ + MgO + 50% Al₂O₃), (ZrO₂ + MgO + 75% Al₂O₃), (Al₂O₃) sample. The material tests have been made for each of the coated engine parts with the scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX) and X-ray diffraction (XRD) using Cu Kα radiation surface analysis methods. The engine tests have been repeated for each sample in any electric dynamometer in full power 1600 rpm, 2000 rpm, 2400 rpm and 2800 rpm engine speeds. The material analysis and engine tests have shown that the best performance has been performed with (ZrO₂ + MgO + 50% Al₂O₃). Thus, there is no significant change in HC and Smoke emissions, but NOx emission is increased, as the engine improves power, torque, specific fuel consumption and CO emissions in the tests made with sample A3.

Keywords: Ceramic coating, material characterization, engine performance, exhaust emissions.

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Authors: S. Ghorbani, N. I. Polushin

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Vibration during machining process is crucial since it affects cutting tool, machine, and workpiece leading to a tool wear, tool breakage, and an unacceptable surface roughness. This paper applies a nonparametric statistical method, single decision tree (SDT), to identify factors affecting on vibration in machining process. Workpiece material (AISI 1045 Steel, AA2024 Aluminum alloy, A48-class30 Gray Cast Iron), cutting tool (conventional, cutting tool with holes in toolholder, cutting tool filled up with epoxy-granite), tool overhang (41-65 mm), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev) and depth of cut (0.05-0.15 mm) were used as input variables, while vibration was the output parameter. It is concluded that workpiece material is the most important parameters for natural frequency followed by cutting tool and overhang.

Keywords: Cutting condition, vibration, natural frequency, decision tree, CART algorithm.

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Authors: Da-Hye Kim, Won-Hyung Park, In-Ho Yun, Jeong Cheol Kim, Sang-Youn Kim

Abstract:

This paper presents an authoring tool which makes a user easily and intuitively design vibrotactile sensation. A mobile hardware platform powered by ANDROID, a multi-purpose haptic driver and a linear resonance actuator are used to implement the system of the presented authoring tool. The tool allows users to easily and simply create a vibrotactile sensation by drawing vibrotactile images and to feel the sensation by rubbing drawn images on the touch screen of a mobile device. The tool supports a graphical interface for designing, editing and playing vibrotactile images as well as a pre-defined file format for save and open.

Keywords: authoring tool, mobile device, vibrotactile pattern, vibrotactile sensation

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Authors: Balwinder Singh

Abstract:

The present research is a paper on the characterization of aluminum alloy-6063 hybrid metal matrix composites using three different reinforcement materials (SiC, red mud, and fly ash) through stir casting method. The red mud was used in solid form, and particle size range varies between 103-150 µm. During this investigation, fly ash is received from Guru Nanak Dev Thermal Plant (GNDTP), Bathinda. The study has been done by using Taguchi’s L9 orthogonal array by taking fraction wt.% (SiC 5%, 7.5%, and 10% and Red Mud and Fly Ash 2%, 4%, and 6%) as input parameters with their respective levels. The study of the mechanical properties (tensile strength, impact strength, and microhardness) has been done by using Analysis of Variance (ANOVA) with the help of MINITAB 17 software. It is revealed that silicon carbide is the most significant parameter followed by red mud and fly ash affecting the mechanical properties, respectively. The fractured surface morphology of the composites using Field Emission Scanning Electron Microscope (FESEM) shows that there is a good mixing of reinforcement particles in the matrix. Energy-dispersive X-ray spectroscopy (EDS) was performed to know the presence of the phases of the reinforced material.

Keywords: Reinforcement, silicon carbide, fly ash, red mud.

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Authors: Alan Vaško, Juraj Belan, Lenka Hurtalová, Eva Tillová

Abstract:

The aim of this study is to evaluate the influence of raw material composition on the microstructure, mechanical and fatigue properties and micromechanisms of failure of nodular cast iron. In order to evaluate the influence of charge composition, the structural analysis, mechanical and fatigue tests and microfractographic analysis were carried out on specimens of ten melts with different charge compositions. The basic charge of individual melts was formed by different ratio of pig iron and steel scrap and by different additive for regulation of chemical composition (silicon carbide or ferrosilicon). The results show differences in mechanical and fatigue properties, which are connected with the microstructure. SiC additive positively influences microstructure. Consequently, mechanical and fatigue properties of nodular cast iron are improved, especially in the melts with higher ratio of steel scrap in the charge.

Keywords: Nodular cast iron, silicon carbide, microstructure, mechanical properties.

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Authors: Sadílek M., Čep R.

Abstract:

This work deals with problems of tool axis inclination angles in ball-end milling. Tool axis inclination angle contributes to improvement of functional surface properties (surface integrity - surface roughness, residual stress, micro hardness, etc.), decreasing cutting forces and improving production. By milling with ball-end milling tool, using standard way of cutting, when work piece and cutting tool contain right angle, we have zero cutting speed on edge. At this point cutting tool only pushes material into the work piece. Here we can observe the following undesirable effects - chip contraction, increasing of cutting temperature, increasing vibrations or creation of built-up edge. These effects have negative results – low quality of surface and decreasing of tool life (in the worse case even it is pinching out). These effects can be eliminated with the tilt of cutting tool or tilt of work piece.

Keywords: CAD/CAM system, tool axis inclination angle, ballend milling, surface roughness, cutting forces.

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Authors: Samir Khrais, Adel Mahammod Hassan , Amro Gazawi

Abstract:

The aim of this research is to evaluate surface roughness and develop a multiple regression model for surface roughness as a function of cutting parameters during the turning of flame hardened medium carbon steel with TiN-Al2O3-TiCN coated inserts. An experimental plan of work and signal-to-noise ratio (S/N) were used to relate the influence of turning parameters to the workpiece surface finish utilizing Taguchi methodology. The effects of turning parameters were studied by using the analysis of variance (ANOVA) method. Evaluated parameters were feed, cutting speed, and depth of cut. It was found that the most significant interaction among the considered turning parameters was between depth of cut and feed. The average surface roughness (Ra) resulted by TiN-Al2O3- TiCN coated inserts was about 2.44 μm and minimum value was 0.74 μm. In addition, the regression model was able to predict values for surface roughness in comparison with experimental values within reasonable limit.

Keywords: Medium carbon steel, Prediction, Surface roughness, Taguchi method

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Authors: Cem Karacal, Sohyung Cho, William Yu

Abstract:

In metal cutting industries, mathematical/statistical models are typically used to predict tool replacement time. These off-line methods usually result in less than optimum replacement time thereby either wasting resources or causing quality problems. The few online real-time methods proposed use indirect measurement techniques and are prone to similar errors. Our idea is based on identifying the optimal replacement time using an electronic nose to detect the airborne compounds released when the tool wear reaches to a chemical substrate doped into tool material during the fabrication. The study investigates the feasibility of the idea, possible doping materials and methods along with data stream mining techniques for detection and monitoring different phases of tool wear.

Keywords: Tool condition monitoring, cutting tool replacement, data stream mining, e-Nose.

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Authors: Saad Alkhaldi, Fadi Ghammas, Tariq Alghamdi, Stefano Alexandirs

Abstract:

The operating conditions and corrosive nature of the process fluid in the Haradh and Hawiyah areas are subjecting facility piping to undesirable corrosion phenomena. Therefore, production headers inside remote headers have been internally cladded with high alloy material to mitigate the corrosion damage mechanism. Corrosion mitigation in the jump-over lines, constructed between the existing flowlines and the newly constructed facilities to provide operational flexibility, is proposed. This corrosion mitigation system includes the application of fusion bond epoxy (FBE) coating on the internal surface of the pipe and depositing corrosion-resistant alloy (CRA) weld layers at pipe and fittings ends to protect the carbon steel material. In addition, high alloy CRA weld material is used to deposit the girth weld between the 90-degree elbows and mating internally coated segments. A rigorous testing and qualification protocol was established prior to actual adoption at the Haradh and Hawiyah Field Gas Compression Program, currently being executed by Saudi Aramco. The proposed mitigation system, aimed at applying the cladding at the ends of the internally FBE coated pipes/elbows, will resolve field joint coating challenges, eliminate the use of approximately 1700 breakout flanges, and prevent the potential hydrocarbon leaks.

Keywords: Corrosion, FBE coated sour service, cost savings.

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Authors: Raida El Mansouri, Elhillali Kerkouche, Allaoua Chaoui

Abstract:

The Petri net tool INA is a well known tool by the Petri net community. However, it lacks a graphical environment to cerate and analyse INA models. Building a modelling tool for the design and analysis from scratch (for INA tool for example) is generally a prohibitive task. Meta-Modelling approach is useful to deal with such problems since it allows the modelling of the formalisms themselves. In this paper, we propose an approach based on the combined use of Meta-modelling and Graph Grammars to automatically generate a visual modelling tool for INA for analysis purposes. In our approach, the UML Class diagram formalism is used to define a meta-model of INA models. The meta-modelling tool ATOM3 is used to generate a visual modelling tool according to the proposed INA meta-model. We have also proposed a graph grammar to automatically generate INA description of the graphically specified Petri net models. This allows the user to avoid the errors when this description is done manually. Then the INA tool is used to perform the simulation and the analysis of the resulted INA description. Our environment is illustrated through an example.

Keywords: INA, Meta-modelling, Graph Grammars, AToM3, Automatic Code Generation.

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Authors: Jui-Pui Hung, Yu-Sheng Lai, Tzuo-Liang Luo, Kung-Da Wu, Yun-Ji Zhan

Abstract:

This study presented the investigation of the influence of the tool holder interface stiffness on the dynamic characteristics of a spindle tool system. The interface stiffness was produced by drawbar force on the tool holder, which tends to affect the spindle dynamics. In order to assess the influence of interface stiffness on the vibration characteristic of spindle unit, we first created a three dimensional finite element model of a high speed spindle system integrated with tool holder. The key point for the creation of FEM model is the modeling of the rolling interface within the angular contact bearings and the tool holder interface. The former can be simulated by a introducing a series of spring elements between inner and outer rings. The contact stiffness was calculated according to Hertz contact theory and the preload applied on the bearings. The interface stiffness of the tool holder was identified through the experimental measurement and finite element modal analysis. Current results show that the dynamic stiffness was greatly influenced by the tool holder system. In addition, variations of modal damping, static stiffness and dynamic stiffness of the spindle tool system were greatly determined by the interface stiffness of the tool holder which was in turn dependent on the draw bar force applied on the tool holder. Overall, this study demonstrates that identification of the interface characteristics of spindle tool holder is of very importance for the refinement of the spindle tooling system to achieve the optimum machining performance.

Keywords: Dynamic stiffness, Drawbar force, Interface stiffness, Spindle-tool holder.

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Authors: Amir Ngah, Masita Abdul Jalil, Zailani Abdullah

Abstract:

The aim of software maintenance is to maintain the software system in accordance with advancement in software and hardware technology. One of the early works on software maintenance is to extract information at higher level of abstraction. In this paper, we present the process of how to design an information extraction tool for software maintenance. The tool can extract the basic information from old programs such as about variables, based classes, derived classes, objects of classes, and functions. The tool have two main parts; the lexical analyzer module that can read the input file character by character, and the searching module which users can get the basic information from the existing programs. We implemented this tool for a patterned sub-C++ language as an input file.

Keywords: Extraction tool, software maintenance, reverse engineering, C++.

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Authors: S. Palaniyappan, P. K. Chennam, M. Trautmann, H. Ahmad, T. Mehner, T. Lampke, G. Wagner

Abstract:

In structural-health monitoring of fiber reinforced plastics (FRPs), every single inorganic fiber sensor that are integrated into the bulk material requires an electrical insulation around itself, when the surrounding reinforcing fibers are electrically conductive. This results in a more accurate data acquisition only from the sensor fiber without any electrical interventions. For this purpose, thin nano-films of aluminium oxide (Al₂O₃)-based electrical-insulation coatings have been fabricated around the Silicon Carbide (SiC) single fiber sensors through reactive DC magnetron sputtering technique. The sputtered coatings were amorphous in nature and the thickness of the coatings increased with an increase in the sputter time. Microstructural characterization of the coated fibers performed using scanning electron microscopy (SEM) confirmed a homogeneous circumferential coating with no detectable defects or cracks on the surface. X-ray diffraction (XRD) analyses of the as-sputtered and 2 hours annealed coatings (825 & 1125 ˚C) revealed the amorphous and crystalline phases of Al₂O₃ respectively. Raman spectroscopic analyses produced no characteristic bands of Al₂O₃, as the thickness of the films was in the nanometer (nm) range, which is too small to overcome the actual penetration depth of the laser used. In addition, the influence of the insulation coatings on the mechanical properties of the SiC sensor fibers has been analyzed.

Keywords: Al2O3 insulation coating, reactive sputtering, SiC single fiber sensor, single fiber tensile test.

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Authors: Mohammed T. Hayajneh

Abstract:

Machining of Metal Matrix Composites (MMCs) is very significant process and has been a main problem that draws many researchers to investigate the characteristics of MMCs during different machining process. The poor machining properties of hard particles reinforced MMCs make drilling process a rather interesting task. Unlike drilling of conventional materials, many problems can be seriously encountered during drilling of MMCs, such as tool wear and cutting forces. Cutting tool wear is a very significant concern in industries. Cutting tool wear not only influences the quality of the drilled hole, but also affects the cutting tool life. Prediction the cutting tool life during drilling is essential for optimizing the cutting conditions. However, the relationship between tool life and cutting conditions, tool geometrical factors and workpiece material properties has not yet been established by any machining theory. In this research work, fuzzy subtractive clustering system has been used to model the cutting tool life in drilling of Al₂O₃ particle reinforced aluminum alloy composite to investigate of the effect of cutting conditions on cutting tool life. This investigation can help in controlling and optimizing of cutting conditions when the process parameters are adjusted. The built model for prediction the tool life is identified by using drill diameter, cutting speed, and cutting feed rate as input data. The validity of the model was confirmed by the examinations under various cutting conditions. Experimental results have shown the efficiency of the model to predict cutting tool life.

Keywords: Composite, fuzzy, tool life, wear.

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Authors: Deepak D, Anjaiah D, Yagnesh Sharma N.

Abstract:

It is well known that the abrasive particles in the abrasive water suspension has significant effect on the erosion characteristics of the inside surface of the nozzle. Abrasive particles moving with the flow cause severe skin friction effect, there by altering the nozzle diameter due to wear which in turn reflects on the life of the nozzle for effective machining. Various commercial abrasives are available for abrasive water jet machining. The erosion characteristic of each abrasive is different. In consideration of this aspect, in the present work, the effect of abrasive materials namely garnet, aluminum oxide and silicon carbide on skin friction coefficient due to wall shear stress and jet kinetic energy has been analyzed. It is found that the abrasive material of lower density produces a relatively higher skin friction effect and higher jet exit kinetic energy.

Keywords: Abrasive water suspension jet, Skin friction coefficient, Jet kinetic energy, Particulate loading, Stokes number.

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Authors: Mohd Shahrom Ismail, B.T. Hang Tuah Baharudin, K.K.B. Hon

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In this paper, a methodology of a model based on predicting the tool forces oblique machining are introduced by adopting the orthogonal technique. The applied analytical calculation is mostly based on Devries model and some parts of the methodology are employed from Amareggo-Brown model. Model validation is performed by comparing experimental data with the prediction results on machining titanium alloy (Ti-6Al-4V) based on micro-cutting tool perspective. Good agreements with the experiments are observed. A detailed friction form that affected the tool forces also been examined with reasonable results obtained.

Keywords: dynamics machining, micro cutting tool, Tool forces

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Authors: Merve Küçük, M. Lütfi Öveçoğlu

Abstract:

Zinc oxide particles were synthesized using the sol-gel method and dip coated on polyester fabric. X-ray diffraction (XRD) analysis revealed a single crystal phase of ZnO particles. Chemical characteristics of the polyester fabric surface were investigated using attenuated total reflection-Fourier transform infrared (ATR-FTIR) measurements. Morphology of ZnO coated fabric was analyzed using field emission scanning electron microscopy (FESEM). After particle analysis, the aqueous ZnO solution resulted in a narrow size distribution at submicron levels. The deposit of ZnO on polyester fabrics yielded a homogeneous spread of spherical particles. Energy dispersive X-ray spectroscopy (EDX) results also affirmed the presence of ZnO particles on the polyester fabrics.

Keywords: Dip coating, polyester fabrics, sol-gel, zinc oxide.

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Authors: Jaharah A. Ghani, Muhammad Rizal, Ahmad Sayuti, Mohd Zaki Nuawi, Mohd Nizam Ab. Rahman, Che Hassan Che Haron

Abstract:

This study presents a new method for detecting the cutting tool wear based on the measured cutting force signals using the regression model and I-kaz method. The detection of tool wear was done automatically using the in-house developed regression model and 3D graphic presentation of I-kaz 3D coefficient during machining process. The machining tests were carried out on a CNC turning machine Colchester Master Tornado T4 in dry cutting condition, and Kistler 9255B dynamometer was used to measure the cutting force signals, which then stored and displayed in the DasyLab software. The progression of the cutting tool flank wear land (VB) was indicated by the amount of the cutting force generated. Later, the I-kaz was used to analyze all the cutting force signals from beginning of the cut until the rejection stage of the cutting tool. Results of the IKaz analysis were represented by various characteristic of I-kaz 3D coefficient and 3D graphic presentation. The I-kaz 3D coefficient number decreases when the tool wear increases. This method can be used for real time tool wear monitoring.

Keywords: mathematical model, I-kaz method, tool wear

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Authors: G.Vinitha, A.Ramalingam

Abstract:

TiO2 nanoparticles were synthesized by hydrothermal method at 180°C from TiOSO4 aqueous solution with1m/l concentration. The obtained products were coated with silica by means of a seeded polymerization technique for a coating time of 1440 minutes to obtain well defined TiO2@SiO2 core-shell structure. The uncoated and coated nanoparticles were characterized by using X-Ray diffraction technique (XRD), Fourier Transform Infrared Spectroscopy (FT-IR) to study their physico-chemical properties. Evidence from XRD and FTIR results show that SiO2 is homogenously coated on the surface of titania particles. FTIR spectra show that there exists an interaction between TiO2 and SiO2 and results in the formation of Ti-O-Si chemical bonds at the interface of TiO2 particles and SiO2 coating layer. The non linear optical limiting properties of TiO2 and TiO2@SiO2 nanoparticles dispersed in ethylene glycol were studied at 532nm using 5ns Nd:YAG laser pulses. Three-photon absorption is responsible for optical limiting characteristics in these nanoparticles and it is seen that the optical nonlinearity is enhanced in core-shell structures when compared with single counterparts. This effective three-photon type absorption at this wavelength, is of potential application in fabricating optical limiting devices.

Keywords: hydrothermal method, optical limiting devicesseeded polymerization technique, three-photon type absorption

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Authors: M.Jalali Azizpour, S.norouzi, H.mohammadi majd, H.Talebi, A.Ghamari

Abstract:

In this paper, the application of thermal spray coatings in high speed shafts by a revolution up to 23000 RPM has been studied. Gas compressor shafts are worn in contact zone with journal therefore will be undersized. Wear mechanisms of compressor shaft were identified. The predominant wear mechanism is abrasion wear. The worn surface was coated by hard WC-Co cermets using high velocity oxy fuel (HVOF) after preparation. The shafts were in satisfactory service in 8000h period. The metallurgical and Tribological studies has been made on the worn and coated shaft using optical microscopy, scanning electron microscopy (SEM) and X-ray diffraction.

Keywords: Thermal spray, Residual stress, Wear mechanism, HVOF, Gas compressor shafts.

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