Axial Depth Research Articles

Surface Quality of AZ91D Magnesium Alloy After Precision Milling with Coated Tools

This study investigates the surface quality of AZ91D magnesium alloy specimens after precision milling. The milling was conducted with the use of TiB2- and TiAlN-coated carbide end mills. The following variables were used in the milling process: cutting speed vc, feed per tooth fz and axial depth of cut ap. The surface quality was analysed based on surface roughness parameters and Abbott-Firestone curves. The results showed that the surface quality after machining depended on the tool coating type and applied machining parameters; the only exception was the axial depth of cut because changes in its value did not have any significant effect on the obtained surface quality. After precision milling, AZ91D specimens were characterized by very low surface roughness parameters. The impact of machining conditions was also evaluated with ANOVA analysis, which confirmed the significant effect of cutting speed and feed per tooth. It also indicated the dependence of the roughness parameters on the tool coating type. The tool coating type and machining conditions did not have any significant effect on the Abbott-Firestone curves. Despite the changes applied, the shape of the curves remained similar. The obtained results provide both theoretical and practical knowledge about the achievable surface roughness of AZ91D magnesium alloy specimens after precision milling.

Investigation of the performance of integrated intelligent models to predict the roughness of Ti6Al4V end-milled surface with uncoated cutting tool

Abstract Titanium alloys are broadly used in the medical and aerospace sectors. However, they are categorized within the hard-to-machine alloys ascribed to their higher chemical reactivity and lower thermal conductivity. This aim of this research was to study the impact of the dry-end-milling process with an uncoated tool on the produced surface roughness of Ti6Al4V alloy. This research aims to study the impact of the dry-end milling process with an uncoated tool on the produced surface roughness of Ti6Al4V alloy. Also, it seeks to develop a new hybrid neural model based on the training back propagation neural network (BPNN) with swarm optimization-gravitation search hybrid algorithms (PSO-GSA). Full-factorial design of the experiment with L27 orthogonal array was applied, and three end-milling parameters (cutting speed, feed rate, and axial depth of cut) with three levels were selected (50, 77.5, and 105 m/min; 0.1, 0.15, and 0.2 mm/tooth; and 1, 1.5, and 2 mm) and investigated to show their influence on the obtained surface roughness. The results revealed that the surface roughness is significantly affected by the feed rate followed by the axial depth. A 0.49 µm was produced as a minimum surface roughness at the optimized parameters of 105 m/min, 0.1 mm/tooth, and 1 mm. On the other hand, a neural network having a single hidden layer with 1–20 hidden neurons, 3 input neurons, and 1 output neuron was trained with both PSO and PSO–GSA algorithms. The hybrid BPNN–PSO–GSA model showed its superiority over the BPNN–PSO model in terms of the minimum mean square error (MSE) that was calculated during the testing stage. The best BPNN–PSO–GSA hybrid model was the 3–18–1 structure, which reached the best testing MSE of 3.8 × 10−11 against 2.42 × 10−5 of the 3–8–1 BPNN–PSO hybrid model.

Axial compression behavior of square CFST short column with triangular-corner gap

In order to investigate the impact of the triangular-corner gap between the outer steel tube and the core concrete on the axial compression behavior of square concrete-filled steel tubular (SCFST) columns, this study conducted axial compression tests on 117 SCFST columns and three reference hollow steel tubes. The main test parameters included steel tube thickness, concrete strength, side length of the triangular gap, and axial gap depth. The test results revealed four typical damage modes in the SCFST columns with triangular-corner gaps. The presence of the gap defect had a significant effect on the ultimate bearing capacity of the SCFST columns, causing a decrease in the range of 1.66 %–17.72 % when the gap ratio ranged from 0.45 % to 12.50 %. Moreover, the influence of the gap ratio on the ductility and initial stiffness of the SCFST with triangular-corner gaps was dependent on the concrete strength and the steel tube thickness. Finally, a simplified formula for calculating the ultimate bearing capacity of SCFST columns with triangular-corner gaps was proposed based on the test data and force analysis. The maximum error between the theoretically calculated value and the test value is within 15 %.

Investigation of The Effect of Radial Width and Axial Depth Parameters on Surface Quality in Milling of White Marbles

In this study, surface quality and tangential cutting force and radial width (ae) and axial deep (ap) 
 parameters were investigated in the processing of white marble, which is a natural building material. 
 Five different white marbles were used in the experiments and the taguchi method was applied as the 
 test method. Depending on the number and level of parameters, the L9 orthogonal array was chosen. 
 Cutting forces and surface roughness data were collected for each marble. The optimal level and 
 contribution percentage of each parameter was determined by applying the analysis of variance with 
 the signal-to-noise (S/N) ratio. The Fr and Ra factors for all marbles were found to be ae:1 mm and ap:1 
 mm. Depending on the significance level, axial depth of cut (ap) was the primary effective parameter 
 (65-86% for Fr; 42-78% for Ra), while radial depth of cut was the secondary effective parameter (3-24% 
 for Fr; 16-35% for Ra). It can be said that the feed rate parameter was not an effective parameter in 
 general.As a result of regression analysis, a significant relationship of 83% was observed between Ra 
 surface roughness value and mineral grain size. Grain size has been the mineralogical-petrographic 
 feature affecting the surface quality of marbles.

Numerical investigation of effects of nickel-base alloy overlay size on the welding residual stresses in an austenite stainless steel narrow-gap girth weld

Based on the experimental measurement of the residual stress in the nickel-based alloy overlaid stainless-steel narrow-gap girth weld, an axisymmetric finite element (FE) model was established to simulate the residual stress in the girth weld to verify the model. Then a large number of numerical simulations were carried out with the verified FE model to study the effects of the size (height and length) of the nickel-based alloy weld overlay on the residual stress in the girth weld. The optimal overlay sizes to achieve sufficient depth of the compressive stress were investigated. The results show that as the overlay height increases, the hoop compressive stress depth from the inner wall at the weld centerline increases, while the range of the axial compressive stress distribution decreases. The hoop and axial compressive stress depths at the weld centerline increase as the overlay width increases, while the depth of the hoop compressive stress remains unchanged when the overlay width reaches a critical value. The effect of the overlay height on the hoop stress is greater than that of the overlay width, and it is more difficult to mitigate the axial stress by increasing the width of the overlay layer with a large overlay height. For the narrow-gap 304 stainless-steel pipe girth weld with a size of Ø273 mm × 28 mm, the optimum nickel-based alloy overlay is 14 mm in height and 210 mm in width, which can cause both hoop and axial stresses at the inner wall to be compressive, and the hoop compressive stress depth from the inner wall reaches 88 % of the pipe wall thickness and axial compressive stress depth reaches 78 % of the wall thickness.

Analytical modeling of cutting forces and investigation of the material removal mechanism in milling of HSF/PR composite

High silica fiber reinforced phenolic resin composites (HSF/PR composites) have wide applications in aerospace and electronics owing to their excellent ablative and corrosion resistance. However, there are few papers on the cutting mechanism of this material. In this paper, analytical modeling of cutting forces and investigation of the removal mechanism in the cutting of HSF/PR composite are studied. The machining process was studied in two aspects by using experiments: cutting force and surface quality. The cutting force is most affected by the axial depth of cut ap. The surface quality is most affected by the axial depth of cut ap. Removal mechanism presents different patterns depending on the fiber direction. In the meridional direction, the fibers undergo micro-buckling failure due to the compressive stress exceeding their compression limit. In the normal direction, the fibers are sheared off due to the shear stress exceeding the material's shear strength. In the zonal direction, the fibers are affected by different stresses and exhibit various fracture modes. The main defects on the processed surface are holes, cracks, delamination, matrix crack, and fiber pull-out. The research in this paper provides scientific and technical guidance for the processing and application of this material and similar materials.

Mapping the human parafoveal vascular network to understand flow variability in capillaries.

Capillary flow is known to be non-homogenous between vessels and variable over time, for reasons that are poorly understood. The local properties of individual vessels have been shown to have limited explanatory power in this regard. This exploratory study investigates the association of network-level properties such as vessel depth, branch order, and distance from the feeding arteriole with capillary flow. Detailed network connectivity analysis was undertaken in 3 healthy young subjects using flood-illuminated adaptive optics retinal imaging, with axial depth of vessels determined via optical coherence tomography angiography. Forty-one out of 70 vessels studied were of terminal capillary type, i.e. fed from an arterial junction and drained by a venous junction. Approximately half of vessel junctions were amenable to fitting with a model of relative branch diameters, with only a few adhering to Murray's Law. A key parameter of the model (the junction exponent) was found to be inversely related to the average velocity (r = -0.59, p = 0.015) and trough velocity (r = -0.67, p = 0.004) in downstream vessels. Aspects of cellular flow, such as the minimum velocity, were also moderately correlated (r = 0.46, p = 0.009) with distance to the upstream feeding arteriole. Overall, this study shows that capillary network topology contributes significantly to the flow variability in retinal capillaries in human eyes. Understanding the heterogeneity in capillary flow is an important first step before pathological flow states can be properly understood. These results show that flow within capillary vessels is not affected by vessel depths but significantly influenced by the upstream feeder distance as well as the downstream vessel junction exponents, but there remains much to be uncovered regarding healthy capillary flow.

Research on design and milling performance of unequal gradient helix and variable pitch end mill

It is difficult to obtain excellent surface quality and dimensional accuracy of the low-rigidity frame and beam parts made by titanium alloy, due to the obvious vibration and large elastic deformation during side milling. The variable helix and pitch cutting tool is usually used to reduce vibration, which does not consider the unequable stiffness in the milling area. Therefore, the concept of Unequal Gradient Helix and Variable Pitch (UGHVP) is proposed in this research. The helix angles of the UGHVP vary with the stiffness of the milling area position, which will lead to milling forces and vibration decreasing as the stiffness weakens. As a result, the surface quality and dimensional accuracy will be increased, of which the advantages are analyzed. The mathematical models of the UGHVP circumferential cutting edges and groove sections are derived, which provide theoretical support for tool grinding. The models are visualized by numerical simulation. Finally, the comparison experiment with the conventional variable helix and pitch end mill was completed by side-milling the designed feature samples. The results showed that the milling forces perpendicular to the milling surface by the UGHVP were smaller and less fluctuating, which could obtain less elastic deformation theoretically. The milling vibration was smoother, especially when cutting in and out. Besides, the larger the axial depth of cut, the more obvious the superior performance of the UGHVP tool. Better surface quality and dimensional accuracy were obtained, which proved the excellent performance of the UGHVP.

A geometric approach to milling stability uncertainty

Deterministic solutions for the milling stability boundary are provided by frequency-domain, time-domain, and semi-discretization methods. While these deterministic solutions are valuable, it is essential to consider the uncertainty in the predicted stability boundary to enable optimum milling parameter selection. Prior efforts have implemented Type A (statistical) uncertainty evaluations. This paper provides a Type B (other means) analysis, where the stability uncertainty is represented by offset boundaries based on user-selected uncertainties in spindle speed and axial depth. The geometric approach is demonstrated for a selected milling system using a frequency-domain stability solution.

Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

Trochoidal milling has been developed to enhance tool life during slot machining. It is characterized by reduced cutting forces, cutting temperature, and tool wear as compared to conventional milling processes. It is effective in machining difficult-to-cut materials, high-speed machining, and groove corners. However, this process has not been deeply investigated enough to discover its advantages and optimize its parameters. A full factorial design of 144 experiments has been applied in this paper to investigate extensively the effects of axial depth of cut, feed rate, and trochoidal step on material removal rate, cutting forces, and specific energy in trochoidal milling. Trochoidal step and axial depth of cut almost have the same contributions on cutting forces by 32% and 31% respectively, followed by feed rate by 25%. Feed rate, trochoidal step, and axial depth of cut influence the material removal rate by 37%, 30%, and by 19% respectively. The contributions of feed rate, trochoidal step, and axial depth of cut on relative specific energy are 57%, 24%, and 8% respectively. The increase of axial depth of cut increases the maximum resultant force till a threshold value, then it stabilizes. This behavior occurred due to the increase of the maximum engagement angle to a certain limit, then it does not increase any more. Both feed rate and trochoidal step linear affect maximum resultant force and material removal rate, while the relationships are non-linear for specific energy. It is recommended to machine slots in full depth with the highest possible trochoidal step and feed rate, considering the increase of tool wear and surface roughness. It is preferred to use a cutting tool of a large helix angle and small diameter to reduce the threshold axial depth of cut. Overall, this study is significant in characterizing, designing, and optimizing of trochoidal milling through experimental work.

Analysis of the mechanical characteristics and plasticity-hazardous zones development of natural gas pipeline under overload

The problem of natural gas pipeline overload failure is of great significance, and the development law of critical mechanical properties of pipelines is of great importance to the safety design of natural gas pipelines. This study establishes a three-dimensional finite element computational model of the pipeline that integrates the changes in axial and circumferential mechanical characteristics, and uses the yield strength, safety factor and ellipticity indexes as criteria to dimensionless the axial depth and circumferential angle of the plastic zone to explore the characteristics of the plastic damage stage of the pipeline. By solving the plastic hazardous zones based on the safety factor, the applicability of the dimensionless parameters is extended to investigate the development laws of the hazardous zones and the correlation mechanism between failure criteria and hazardous zones. The results show that as the ground load increases, the pipeline deformation gradually develops into the plastic stage (P = 16 MPa) and then goes through three deformation stages. With the increase of safety factor, the change trend of the proportion of stage I in the whole loading process decreases to 4 %, the change trend of the proportion of stage III increases significantly to 52 %, while the proportion of stage II shows a change trend of decreasing and then increasing, the proportion of this stage ranges from 30 % to 38 %. Based on the law of variation of axial ellipticity of pipeline section, a high-risk section of pipeline was identified in the range of 0–2 m from the point of maximum local compression strain. The results of the study can serve as a basis for accurate evaluation of the safety status of natural gas pipelines under overload.

Condition assessment of underground corroded pipelines subject to hydrogen damage and combined internal pressure and axial compression

In this work, a 3D finite element (FE) based model was developed to assess the condition of an underground hydrogen transmission pipeline containing a corrosion defect under combined internal pressure and soil movement-induced axial compression. The use of mechanical properties of X100 pipeline steel under different hydrogen charging time models the degree of hydrogen damage in pipelines. Parameter effects, i.e., axial compressive stress, hydrogen damage, defect geometries, and pipeline diameter-to-thickness ratio, were determined. The results demonstrated that the synergistic effect of axial compression, internal pressure, corrosion, and hydrogen damage can lead to a significant decrease in the failure pressure of pipelines. The failure pressure decreased with the wall thickness reduction and increased hydrogen damage, axial compressive stress, defect length, defect depth, and pipe diameter. The competitive effect was observed between the degree of metal loss and hydrogen damage in determining the burst capacity of pipelines. In situations where the pipeline integrity was severely compromised, the failure pressure exhibited minimal reduction despite the increasing severity of hydrogen damage. The stress distribution at the defect zone was influenced by axial compressive stress but remained unaffected by hydrogen damage under normal operating conditions (i.e., an internal pressure of 10 MPa). This work is expected to help operators understand the applicability of elder and in-service pipelines for hydrogen transmission.

Design of a Metasurface with Long Depth of Focus Using Superoscillation.

Longitudinal optical field modulation is very important for applications such as optical imaging, spectroscopy, and optical manipulation. It can achieve high-resolution imaging or manipulation of the target object, but it is also limited by its depth of focus. The depth of focus determines whether the target object can be clearly imaged or manipulated at different distances, so extending the depth of focus can improve the adaptability and flexibility of the system. However, how to extend the depth of focus is still a significant challenge. In this paper, we use a super-oscillation phase modulation optimization method to design a polarization-independent metalens with extended focal depth, taking the axial focal depth length as the optimization objective. The optimized metalens has a focal depth of 13.07 μm (about 22.3 λ), and in the whole focal depth range, the transverse full width at half maximum values are close to the Rayleigh diffraction limit, and the focusing efficiency is above 10%. The results of this paper provide a new idea for the design of a metalens with a long focal depth and may have application value in imaging, lithography, and detection.

Milling Mechanism and Chattering Stability of Nickel-Based Superalloy Inconel 718.

Nickel-based superalloy Inconel 718 is widely used in the aerospace industry for its excellent high-temperature strength and thermal stability. However, milling Inconel 718 presents challenges because of the significantly increased cutting force and vibration, since Inconel 718 is a typical difficult-to-machine material. This paper takes the milling process of Inconel 718 as the research object, initially, and a milling force model of Inconel 718 is established. Subsequently, the finite element analysis method is used to analyze the stress field, temperature field, and milling force in the milling process of Inconel 718. Building upon this, a dynamic equation of the milling of Inconel 718 is established, and based on the modal experiment, stability lobe diagrams are drawn. Furthermore, milling experiments on Inconel 718 are designed, and the results calculated using the milling force model and finite element analysis are verified through comparison to the experimental results; then, the fmincon optimization algorithm is used to optimize the processing parameters of Inconel 718. Eventually, the results of the multi-objective optimization illustrate that the best processing parameters are a spindle speed of 3199.2 rpm and a feed speed of 80 mm/min with an axial depth of cut of 0.25 mm. Based on this, the best machining parameters are determined, which point towards an improvement of the machining efficiency and quality of Inconel 718.

Cumulative effect of Shearing parameters and Ramp angle on Hole surface quality in Ti6Al4V by Helical milling strategy

Hole creation is a common contour in drilling and milling. However, drilling big holes in Ti6Al4V is difficult. It is due to the thermally increased metallurgical behavior of Ti6Al4V, which mortifies drill bits and degrades hole quality. To solve this issue, the current research investigates Helical milling through Computer Aided Tool Path as a viable option for Hole production by functionally managing shearing parameters. This approach drives the process parameters helically at a certain Ramp angle to achieve improved surface quality in the Hole. The analysis of variance reveals that the Cutting Speed and Feed/tooth affect the Circularity of the Hole. Furthermore, Axial DOC and Ramp angle significantly impactHole surface texture. The cumulative impact of Cutting Speed at 60 m/min, Feed/tooth at 0.06 mm, and Axial Depth of Cut at 0.6 mm applied at a Ramp angle of 1.50 through theHelical milling tool path under Hybrid nano Flood lubrication catch the outstanding Hole Quality.

Experimental study on rockburst of surrounding rock in an elliptical tunnel with different axial ratios

The effect of the ratio of long and short axes on the rockburst of an elliptical tunnel structure was investigated by performing a series of true triaxial tests on red sandstone cuboid samples containing seven types of elliptical holes with different long–short axial ratios, using a self-developed true triaxial compression equipment. The entire process of spalling was monitored and recorded using a miniature camera. According to the test results, the failure stress, geometrical characteristics of the rockburst notch, fragment characteristics, and ejection velocity field characteristics of the rockburst are summarized, and the influence of the axial ratios of the elliptical hole on the failure characteristics and stability of the tunnel are discussed in detail. The test results indicate that the rockburst process of elliptical tunnels with different axial ratios experiences four processes; namely, calm period, small particle ejection period, spalling, and rockburst. The shape of the failure area after the rockburst presents a V-shaped feature. With the increase of the axial ratio, the area, angle, and depth of the V-shaped area show a decreasing trend, the initial failure stress of the cavern and the rockburst failure stress exhibit a trend of first decreasing and then increasing; the tangential stress of the cavern shows an increasing trend; the mass percentage of micro, fine, and medium grain decreases; and the average ejection velocity first decreases and then increases. Under the same stress conditions, rockbursts are more likely to occur on circular sections. Under the same section conditions, the ellipse can bear larger loads when its major axis is parallel to the disturbance stress. These conclusions are helpful to the efficient design of the tunnel structure.

Machining characteristics of 316L stainless steel in hybrid manufacturing via a three-dimensional thermal-mechanical coupled model

The residual stress distribution obtained by coupling the laser metal deposition residual stress and the milling residual stress is one of the crucial factors affecting the quality and performance of hybrid manufacturing parts. However, it is challenging to explore directly through experiments. A three-dimensional thermal-mechanical fully coupled model for hybrid manufacturing of 316L stainless steel was established, taking into account the multi-physics during laser metal deposition and milling. The accuracy of the hybrid manufacturing model is validated from multiple dimensions using temperature, deformation, and milling force. A height deviation normalization method is proposed to eliminate the influence of printing height deviation caused by randomly fluctuated process parameters on the measuring deformation of the part. The minimum root-mean-square relative error of model temperature is 4 %, the minimum error of printing height deviation is 8 %, and the minimum relative error of milling force in the feed direction is 26 %. The simulated milling force of hybrid manufacturing shows that the factors affecting the milling force rank as the axial depth of cut, the radial depth of cut, milling speed, and spindle speed. The simulated residual stress distribution zone along the depth direction of hybrid manufacturing divides into the work hardening layer, the elastic recovery zone, and the elastic stability zone. The hybrid manufacturing residual stress equals the milling residual stress in the work hardening layer, superimposes linearly with the product of the milling residual stress and depth in the elastic recovery zone, and equals the residual stress of laser metal deposition in the elastic stability zone.

Robust stability prediction in milling process considering the correlations of input parameters

Because of the uncertainties of the input parameters in dynamic milling model, robust stability prediction is a technology to effectively avoid the occurrence of regenerative chatter. However, the existing robust stability prediction methods generally consider the potential interval of each input parameter as their uncertainty measurements directly, without taking into account the correlations between input parameters. In this regard, a novel robust stability prediction method considering the correlations between input parameters is proposed in this paper. To consider the correlations between input parameters, high-dimensional random variables composed of input parameters are constructed, and their probability density functions are estimated according to the observation data. Based on the obtained probability density functions, the confidence regions of these random variables are determined and used to describe the uncertainty boundaries of input parameters. The problem of judging the robust stability of milling at a given speed and axial depth is transformed into an optimization problem, and the confidence regions are used to construct the constraints for the optimization variable. The experimental results have shown that the robust stability boundary generated by the proposed method can effectively avoid the occurrence of regenerative chatter and ensure the stability of milling operation.

A computational geometric learning approach for person axial and slanting depth prediction using single RGB camera

A computational geometric learning approach for person axial and slanting depth prediction using single RGB camera

Manual aspiration of a pneumothorax after CT-guided lung biopsy: outcomes and risk factors.

Quantify the outcomes following pneumothorax aspiration and influence upon chest drain insertion. This was a retrospective cohort study of patients who underwent aspiration for the treatment of a pneumothorax following a CT percutaneous transthoracic lung biopsy (CT-PTLB) from January 1, 2010 to October 1, 2020 at a tertiary center. Patient, lesion and procedural factors associated with chest drain insertion were assessed with univariate and multivariate analyses. A total of 102 patients underwent aspiration for a pneumothorax following CT-PTLB. Overall, 81 patients (79.4%) had a successful pneumothorax aspiration and were discharged home on the same day. In 21 patients (20.6%), the pneumothorax continued to increase post-aspiration and required chest drain insertion with hospital admission. Significant risk factors requiring chest drain insertion included upper/middle lobe biopsy location [odds ratio (OR) 6.46; 95% CI 1.77-23.65, p = 0.003], supine biopsy position (OR 7.06; 95% CI 2.24-22.21, p < 0.001), emphysema (OR 3.13; 95% CI 1.10-8.87, p = 0.028), greater needle depth ≥2 cm (OR 4.00; 95% CI 1.44-11.07, p = 0.005) and a larger pneumothorax (axial depth ≥3 cm) (OR 16.00; 95% CI 4.76-53.83, p < 0.001). On multivariate analysis, larger pneumothorax size and supine position during biopsy remained significant for chest drain insertion. Aspiration of a larger pneumothorax (radial depths ≥3 cm and ≥4 cm) had a 50% rate of success. Aspiration of a smaller pneumothorax (radial depth 2-3 cm and <2 cm) had an 82.6% and 100% rate of success, respectively. Aspiration of pneumothorax after CT-PTLB can help reduce chest drain insertion in approximately 50% of patients with larger pneumothoraces and even more so with smaller pneumothoraces (>80%). Aspiration of pneumothoraces up to 3 cm was often associated with avoiding chest drain insertion and allowing for earlier discharge.