Machining Damage Research Articles

DEM Simulation and Experimental Investigation of Silicon Carbide on Pre-Stressed Machining

In this paper, the technology of pre-stressed machining suitable for ceramic materials was presented. Using the cluster method, the discrete element method (DEM) model of SiC ceramic was established to simulate the crack’s initiation and propagation in cutting processes with different pre-stress value. The scratching tests were carried out to confirm the validity of simulation. Both the DEM simulation and the experimental investigation showed that: with the increasing of pre-stress, the number of radial cracks reduced and the transverse cracks replaced the radial cracks to some extent, and also caused the material removal in the form of smaller fragments. Using pre-stressed machining can decrease the machining damage and improve the surface quality, and further prove that using DEM to simulate the machining process of ceramic materials was feasible.

Prediction of cutting forces in helical end milling fiber reinforced polymers

Machining of fiber reinforced composites is an important activity in the integration of these advanced materials into engineering applications. Machining damage due to excessive cutting forces may result in rejecting the composite components at the last stages of their production cycle. Therefore, the ability to predict the cutting forces is essential for selecting process parameters that would result in minimum machining damage. This work utilizes mechanistic modeling techniques for simulating the cutting of carbon fiber-reinforced polymers (CFRP) with a helical end mill. A methodology is developed for predicting the cutting forces by transforming specific cutting energies from orthogonal cutting to oblique cutting. It is shown that the method developed is capable of predicting the cutting forces in helical end milling of unidirectional and multidirectional composites and over the entire range of fiber orientations from 0° to 180°. This is a significant improvement over previous models that were only capable of addressing orthogonal cutting and/or a limited range of fiber orientations. Model predictions were compared with experimental data and were found to be in good agreement in cutting unidirectional laminate, but with lesser agreement in the case of a multidirectional laminate.

Analysis of dynamic effects relevant for the wear damage in hydraulic machines for wave energy conversion

The present paper deals with a mathematical model of a heaving-buoy Wave Energy Converter (WEC) equipped with high-pressure hydraulic power take-off machinery for energy conversion. This model is based on linear hydrodynamic theory, and a hybrid frequency–time domain model is used to study the dynamics of the heaving-body exposed to an irregular incident wave. For the power take-off system, end-stop devices are provided to protect the hydraulic machinery when the buoy is exposed to severe sea states. The model also takes into account the lubricated friction force and pressure drops of orifice flow through the valves in the hydraulic system. All the forces mentioned in the hydraulic power take-off machinery have non-linear features. A complete non-linear state space model for the WEC system is presented in this study. The WEC system was numerically simulated for different cylinder lengths under a fixed volume. The effect of fluid compressibility in the cylinder has been investigated in the mathematical model. High frequency oscillations (HFOs) caused by the compressibility of the fluid are displayed in the time series and in corresponding power spectra, and variation is shown for different cylinder sizes. Piston ring and cylinder bore wear damage is estimated by using Archard’s equation on the basis of the simulation results. A comparison of these results with a performance of an identical WEC system which neglects fluid compressibility has been done in this work. It shows that although the spectral power is small, HFO can make a large contribution to both the ring and cylinder bore wear. For the purpose of wear prediction, oscillations at or below the wave frequency and HFO may be equally important.

Perencanaan Perawatan Mesin Untuk Menurunkan Biaya Perawatan Dengan Menggunakan Metode Markov Chain

For this time, machine and tools are much wear in some factory to support human in produce something. And so machine and tools it self are an object which be able to damaged, then be needed to take care of those thing in a continue manner. In a logic manner could be arithmeticed that with continued machine treatment will more decrease the cost of factory every periode than the consequence cost of machine damage. Especially in order to get a good productivity, good quality and low cost level, so one of method to prevent this thing is using Markov Chain method. Base on result analyst, then known that the treatment of Root Washer machine are Korective Treatment Planning on weight status and Prohibition treatment on light in weight and average status. Then the treatment cost motion on Root Whasher machine have a cost judgment result Rp. 492.977,-

Machining damage analysis of alumina in relation to thermal shock behavior

Machining damage of alumina disks with two different finishes, C and F, was analyzed with the aim of explaining the differences in their thermal shock responses. Thermal treatments designed to simulate conditions in thermal shock testing were performed on sets of C and F disks. The damage was quantified by several techniques, including the measurement of residual stresses. The mechanical strength of as-machined disks and thermally treated disks was also determined, including fractographic analysis. A decrease in the residual stresses after thermal treatment was observed in F specimens, as was expected. Conversely, unusual behavior was observed in C disks, showing a tendency to increase the residual stresses when the disks were kept at high temperature. Several factors were discussed to explain this fact. Higher mechanical strength and a decrease in the critical flaw size was observed in thermally treated disks compared to as-machined specimens for both types of finishes.

A Comparative Study on the Local Mean Decomposition and Empirical Mode Decomposition and Their Applications to Rotating Machinery Health Diagnosis

Health diagnosis of the rotating machinery can identify potential failure at its early stage and reduce severe machine damage and costly machine downtime. In recent years, the adaptive decomposition methods have attracted many researchers’ attention, due to less influences of human operators in the practical application. This paper compares two adaptive methods: local mean decomposition (LMD) and empirical mode decomposition (EMD) from four aspects, i.e., local mean, decomposed components, instantaneous frequency, and the waveletlike filtering characteristic through numerical simulation. The comparative results manifest that more accurate instantaneous frequency and more meaningful interpretation of the signals can be acquired by LMD than by EMD. Then LMD and EMD are both exploited in the health diagnosis of two actual industrial rotating machines with rub-impact and steam-excited vibration faults, respectively. The results reveal that LMD seems to be more suitable and have better performance than EMD for the incipient fault detection. LMD is thus proved to have potential to become a powerful tool for the surveillance and diagnosis of rotating machinery.

Characteristics of Surface Damage in Micro Electric Discharge Machining of Micro Holes

Micro Electric Discharge Machining is mostly used micromachining technique for manufacturing of micro holes and mini cavities. It is a thermal material removal process achieved by application of recursive electrical sparks between two conductive materials immersed in dielectric liquid. There are many electrical and technological parameters, which are effective in the machining characteristics and machined material surface integrity. In this study, effects of pulse energy on characteristics of surface damage in micro electric discharge machining of micro holes are investigated. To observe the influences of investigated pulse forms, a series of micro-holes were machined and cut from cross sections for metallurgical examinations. Unconventional etching agents were applied to examine the metallurgical transformations using optical and scanning electron microscopy. It was observed that heat-damaged segment is composed of three distinctive layers, have relatively high thicknesses (0.2 to 10 μm) when compared with the size of the micro holes and varies noticeably with respect to drilling dept. Different morphological structures and deformations in the subsurface of micro-hole walls at several sections were illustrated. Finally, analyzed machining parameters and variation of hat damaged layer thicknesses were discussed in terms of drilling depth.

Geometry and surface damage in micro electrical discharge machining of micro-holes

Geometry and subsurface damage of blind micro-holes produced by micro electrical discharge machining (micro-EDM) is investigated experimentally to explore the relational dependence with respect to pulse energy. For this purpose, micro-holes are machined with various pulse energies on plastic mold steel samples using a tungsten carbide tool electrode and a hydrocarbon-based dielectric liquid. Variations in the micro-hole geometry, micro-hole depth and over-cut in micro-hole diameter are measured. Then, unconventional etching agents are applied on the cross sections to examine micro structural alterations within the substrate. It is observed that the heat-damaged segment is composed of three distinctive layers, which have relatively high thicknesses and vary noticeably with respect to the drilling depth. Crack formation is identified on some sections of the micro-holes even by utilizing low pulse energies during machining. It is concluded that the cracking mechanism is different from cracks encountered on the surfaces when machining is performed by using the conventional EDM process. Moreover, an electrically conductive bridge between work material and debris particles is possible at the end tip during machining which leads to electric discharges between the piled segments of debris particles and the tool electrode during discharging.

Anisotropic Analysis on Processed Surface of KDP Single Crystals

Strong anisotropy of physical and mechanical properties of Potassium Dihydrogen Phosphate (KDP) crystals significantly affects surface quality during processing the samples. Different processing direction, along [100], [110], and [120] crystallographic orientations, are chosen on (001) crystal plane in order to evaluate the anisotropic characterizations on the processed surface. Scanning electronic microscopy (SEM) is employed to observe the machined surface damage, defects and profiles. At the same time, surface quality is measured by Zygo surface profiler to estimate the processed surface quality. The results show that the machined surfaces along three different orientations under the same processing conditions behave quite differently from each other. Strong anisotropy and complex slip system of KDP crystals lead to several different asymmetric damages on the machined surface. Surface roughness (Ra) values along [100] are the smallest, that along [120] are in average, and that along [110] are largest. Moreover, many illustrations are given to understand the anisotropic nature during processing, including slip system, mechanical properties during processing, and technical parameters, etc.

Failure Analysis of a Fibrous Composite Half-Space Subjected to Uniform Surface Line Load

Abstract Unidirectional fiber-reinforced plastic (UD-FRP) laminates have been modeled previously as an equivalent quasihomogeneous monoclinic half-space subjected to an inclined line load on the surface using Lekhnitskii’s formulation simulating the orthogonal edge trimming loads in UD-FRPs. In continuation, failure analysis of the aforementioned composite half-space has been carried out in the present investigation based on Tsai–Wu criterion. In particular, the failure behavior of the half-space laminate with respect to the fiber orientation, load inclination angle, and spatial coordinates has been examined in detail. The motivation behind such a study lies in correlating the failure behavior of the half-space laminate with the machining damage observed during orthogonal edge trimming experiments. The present work strives at identifying this relationship and, in the process, understanding the physics of orthogonal cutting of UD-FRP laminates.

High Sensitivity Proteomics Assisted Discovery of a Novel Operon Involved in the Assembly of Photosystem II, a Membrane Protein Complex

Photosystem II (PSII) is a large membrane protein complex that performs the water oxidation reactions of photosynthesis in cyanobacteria, algae, and plants. The unusual redox reactions in PSII often lead to damage, degradation, and reassembly of this molecular machine. To identify novel assembly factors, high sensitivity proteomic analysis of PSII purified from the cyanobacterium Synechocystis sp. PCC 6803 was performed. This analysis identified six PSII-associated proteins that are encoded by an operon containing nine genes, slr0144 to slr0152. This operon encodes proteins that are not essential components of the PSII holocomplex but accumulate to high levels in pre-complexes lacking any of the lumenal proteins PsbP, PsbQ, or PsbV. The operon contains genes with putative binding domains for chlorophylls and bilins, suggesting these proteins may function as a reservoir for cofactors needed during the PSII lifecycle. Genetic deletion of this operon shows that removal of these protein products does not alter photoautotrophic growth or PSII fluorescence properties. However, the deletion does result in decreased PSII-mediated oxygen evolution and an altered distribution of the S states of the catalytic manganese cluster. These data demonstrate that the proteins encoded by the genes in this operon are necessary for optimal function of PSII and function as accessory proteins during assembly of the PSII complex. Thus, we have named the products of the slr0144-slr0152 operon Pap (Photosystem II assembly proteins).

Blood processing

Blood processing

THEORY OF NON-DESTRUCTIVE INSPECTION OF CERAMICS BASED ON FLAW-SIZE DISTRIBUTION

Two kinds of theory for non-destructive inspection of ceramics were reviewed, which were derived by the authors using flaw-size distribution. In the sufficient condition theory (Realistic NDI), we had discussed about the screening flaw-size and a screening region. In the necessary and sufficient condition theory (Ideal NDI), we found that the screening flaw-size should be changed depending on stress state and specimen configuration. It was proved that there is one-to-one correspondence between Ideal NDI and a proof test. Applications to machining damage problems and surface strengthening of ceramics were also presented.

Tokamak machine monitoring and control system for JT-60

The tokamak machine monitoring and control system has been developed to avoid machine damages in JT-60 safety operation. It monitors the JT-60 mechanical structures and other sub-components to maintain their conditions. The system adopts the CAMAC digitizers, the Signal Transfer Unit (STU), and the hard-wired interlocks. Over 20 year, it has never been affected by any major troubles except a water leakage in toroidal field coil (TFC). The TFC monitoring system has been developed for the TFC safety with the water leakage from a cooling water channel. It has improved the reliability and efficiency of the TFC operation.

Precision Machining of Silicon Carbide with Diamond Micro Tool Array (DMTA)

An advanced conditioning technique was developed to precisely and effectively condition the nickel electroplated mono-layer coarse-grained diamond grinding wheel of 46m and 91m grain size with an aim to fabricate Diamond Micro Tool Arrays (DMTA), to meet the high demands of form accuracy, surface quality and low subsurface damage in ductile machining of silicon carbide (SiC). The precision machining experiments on SiC were carried out on a precision grinder to determine the applicability of these fabricated diamond micro tool array (DMTA). The experimental result indicates that the newly developed DMTA is applicable and feasible to realize ductile machining on SiC with high efficiency and low diamond tool wear rate, which shows a good prospect to apply this new concept diamond tool type in precision machining of SiC, as well as the other brittle and hard-to-machine materials.

An investigation of cutting forces and surface damage in high-speed turning of Inconel 718

Abstract Knowing the stringent operating conditions to which superalloys are subjected to in automobile, aerospace and gas turbine industries, their efficient machining and generation of machined surfaces with high integrity assumes a lot of importance. Therefore, this paper presents an experimental investigation into the effect of various process and tool-dependent parameters on cutting forces, an indirect measure of machined surface integrity besides a detailed microstructural analysis of the machined surface damage, in high-speed machining of superalloy Inconel 718. Accordingly, the effect of cutting speed, feed rate, depth of cut and tool cutting edge geometry on cutting forces, surface roughness and surface damage in high-speed turning of Inconel 718 using PCBN tools has been discussed. The input parameters were varied as: V = 125–475 m min −1 , f = 0.05–0.15 mm rev −1 , d = 0.50–1.0 mm and edge geometry as: 30° chamfer, 20° chamfer and 30° chamfer plus honed. The results show that the radial and feed force components are almost equal and the main cutting force component is two to three times that of feed and radial force components. The honed plus chamfered cutting edge was influential in reducing cutting forces significantly. It was noted that specimens showing larger cutting forces generated poor surface finish as well as extensive surface damage.

Effect of machining parameters on surface textures in EDM of Fe-Mn-Al alloy

In this work, the surface characteristics caused by EDM were analyzed by means of the atomic force microscopy (AFM) technique. An empirical model of Fe-Mn-Al alloy was proposed based on the experimental data. A qualitative energy dispersive spectroscopic analyzer was used to measure the chemical composition of the specimen. Surface hardness was determined with a microhardness tester. Experimental results indicate that the EDM process causes a ridged surface and induces machining damage in the surface layer, and increases the surface roughness. The depth of micro-cracks, micro-voids and machined damage increase with an increase in the amount of pulsed current and pulse-on duration. The effect of the magnitude of the pulse-on duration on the surface texture of the specimen is more significant than the pulsed current. Furthermore, the AFM method reveals the 3D surface textures of the EDM specimen with a nanometer scale.

Influence of Abrasive Machining and Annealing on Hydrothermal Stability of Zirconia-Alumina Composites as a Hip Joint Head

Two tetragonal (t) zirconia-alumina composites were prepared by adding Al2O3 (20 vol%) into t-ZrO2 solid solutions doped with 3.0 mol% Y2O3, 1.6 mol% Nb2O5, 3.6 mol% CeO2 (Al20Ce) and 5.3 mol% Y2O3, 4.6 mol% Nb2O5 (Al20) as the femoral heads for the total hip replacements. The effect of machining and annealing on the hydrothermal stability and surface roughness of the composites was evaluated by comparing with the commercial 3 mol% Y2O3 stabilized t-ZrO2 (3Y-TZP). Machining was conducted by using the high-precision machine, where the spindle speeds (rpm 9000~18000) and the electroplated wheels (#400, 800) can be easily adjusted. The machined specimens were annealed at temperatures from 900 to 1300 oC and subsequently autoclaved for 5 days at 120oC under 0.3 MPa water vapor pressure. Although the phase stability and surface roughness of the machined composites were found to be inferior, the hydrothermal stability of the annealed and subsequently autoclaved composites was determined to be excellent as compared with that of the commercial 3Y-TZP. The lower phase stability of the machined composites was likely to be due to numerous machining damages (surface defects) of the composites than those of 3Y-TZP.

近年発生した大地震による中小企業の被災状況調査

The purpose of this research is to clarify the damage of the small and medium-sized companies in recent large earthquakes by mailing questionnaires and hearing.The main results are summarized as follows:1) The large building damage broke out from the seismic intensity 5+, and increased from the seismic intensity 6+,2) The building damage loss of the large companies were bigger than the small companies,3) There were a lot of machine damages caused by slide in the case of the manufacturing,4) In the case of small companies, the building damage loss accounted for over 10% of the gross sales.

Characteristics of Machining Damage and Their Influence on Strength in Alumina Ceramics System

Machining damage and its influence on strength was examined for alumina ceramics with various grain sizes, which were prepared by dry-pressing method with spray-dried granules, followed by sintering at 1350-1550°C for 2-27 hours. Grain sizes of the sintered bodies were 1-6μm. After machining at the same grinding force, specimens were placed in an alcohol solution of fluorescent dye and dried. The fracture strength was measured by 4 point bending. The machining flaws in the specimens were observed with a confocal scanning laser fluorescence microscope. Machining flaws appeared continuous, wide and deep in the specimen with small grain size, and discontinuous with large size. On ground surfaces, intra-grain fracture appeared on the surface, whereas inter-grain fracture dominates. The continuous, wide and deep flaws were attributed to the dissipation of stored energy associated with the cracks propagation. The result suggested that the stored energy on the machining process increased with decreasing grain size. The strength of the specimen with 1 μm grain size reduced from 500MPa to 250 MPa with machining damage. The strength depended remarkably on the depth of the machining damage.