Process Parameters Research Articles

Parametric investigation of thermal additive centrifugal abrasive flow machining process for enhancing productivity

Thermal additive centrifugal abrasive flow machining hybrid of abrasive flow machining caters to low material removal issues which enhances the acceptability of the process. The present investigation investigates the different centrifugal force-generating electrode geometry performances in the thermal additive centrifugal abrasive flow machining process. The L27 orthogonal array is used for optimizing the process parameters (electrode type, current supply, and the duty cycle) and their effect on material removal and percentage improvement in surface finish (%Δ Ra) are analyzed. Based on the percentage contribution obtained from Taguchi analysis, electrode type is the prominent parameter for material removal (88.27%) and %Δ Ra (78.54%) followed by current (7.43% for material removal and 13.92% for %Δ Ra) and duty cycle (3.95% for material removal and 6.42% for %Δ Ra). The spline electrode with a curved blade is found optimum with 10 A current and 0.76 duty cycle. The average experimental value based on the design of the experiment and the predicted value for material removal is 10.373 and 10.881 mg, respectively. The average experimental value and the predicted value for percentage improvement in the surface are 42.24% and 43.71%, respectively. The percentage error between the predicted and experimental values for material removal and %Δ Ra is 4.66% and 3.15%, respectively.

Формирование контуров контроля технологического процесса угольного разреза

Mining technological process as a sequence of changing the natural state of the Earth's subsoil to obtain a certain quantity and quality of mineral products is characterized by departures from the specified normative parameter values, which is due to causes of different nature. Most of these causes are man-made, anf they are created during the performance of specific process operations by the personnel. The article presents an original approach to managing the control over the technological process parameters in a coal strip mine. To reduce the magnitude and probability of the process departures from the normative values, the authors propose to create technical and organizational control loops. Each loop is a closed chain of technical means and organizational tools, which secures up-keeping of the normative technological process state. Production risk is proposed to be used as a criterion to assess the efficiency of the control loops. The methodology allowing to calculate the risk is described. The results of the contour approach application to the technological process control at the Solntsevsky coal strip mine are presented.

Crystallographic Texture Evolution in 3D Printed Polyethylene Reactor Blends.

In this work, crystallographic texture evolution in 3D printed trimodal polyethylene (PE) blends and high-density PE (HDPE) benchmark material were investigated to quantify the resulting material anisotropy, and the results were compared to materials made from conventional injection molded (IM) samples. Trimodal PE reactor blends consisting of HDPE, ultrahigh molecular weight PE (UHMWPE), and HDPE_wax have been used for 3D printing and injection molding. Changes in the preferred orientation and distribution of crystallites, i.e., texture evolution, were quantified utilizing the wide angle X-ray diffraction through pole figures and orientation distribution functions (ODFs) for 3D printed and IM samples. Since the change in weight-average molecular weight (Mw) of the blend was expected to significantly affect the resulting crystallinity and orientation, the overall Mw of the trimodal PE blend was varied while keeping the UHMWPE component weight fraction to 10% in the blend. The resulting texture was analyzed by varying the overall Mw of the trimodal blend and the process parameters in 3D printing and compared to the texture of conventional IM samples. The printing speed and orientation (defined with respect to the axis along the length of the samples) were used as the variable process parameters for 3D printing. The degree of anisotropy increases with an increase in the nonuniform distribution of intensities in pole figures and ODFs. All the highest intensity major texture components in IM and 3D printed samples (0° printing orientation) of reactor blends are observed to have crystals oriented in [001] or [001̅]. Overall, for the same throughput, 3D printed samples in the 0° orientation showed greater texture evolution and higher anisotropy compared to IM samples. Most notably, an increase in 3D printing speed increased the crystalline distribution closer to the 0° direction, increasing the anisotropy, while deviation from this printing orientation reduced crystalline distribution closer to the 0° direction, thus increasing isotropy. This demonstrates that tailoring material properties in specific directions can be achieved more effectively with 3D printing than with the injection molding process. Change in the overall Mw of the trimodal PE blend changed the preferential orientation distribution of the crystal planes to some degree. However, the degree of anisotropy remained the same in almost all cases, indicating that the effect of molecular weight distribution is not as significant as the printing speed and printing orientation in tailoring the resulting properties. The 3D printing process parameters (speed and orientation) were shown to have more influence on the texture than the material parameters associated with the blend.

Achievement of a Parameter Window for the Selective Laser Melting Formation of a GH3625 Alloy.

In the selective laser melting (SLM) process, adjusting process parameters contributes to achieving the desired molten pool morphology, thereby enhancing the mechanical properties and dimensional accuracy of manufactured components. The parameter window characterizing the relationship between molten pool morphology and process parameters serves as an effective tool to improve SLM's forming quality. This work established a mesoscale model of the SLM process for a GH3625 alloy based on the discrete element method (DEM) and computational fluid dynamics (CFD) to simulate the forming process of a single molten track. Subsequently, the formation mechanism and evolution process of the molten pool were revealed. The effects of laser power and scanning speed on the molten pool size and molten track morphology were analyzed. Finally, a parameter window was established from the simulation results. The results indicated that reducing the scanning speed and increasing the laser power would lead to an increase in molten pool depth and width, resulting in the formation of an uneven width in the molten track. Moreover, accelerating the scanning speed and decreasing the laser power cause a reduction in molten pool depth and width, causing narrow and discontinuous molten tracks. The accuracy of the simulation was validated by comparing experimental and simulated molten pool sizes.

OPTIMASI MULTI PARAMETER MESIN 3D PRINTER FDM UNTUK MATERIAL THERMOPLASTIC POLYURETHANE GUNA MENGHASILKAN ERROR DIMENSI TERKECIL MENGGUNAKAN METODE 2K FACTORIAL DESIGN

Fused Deposition Modeling or FDM is a 3D printing technology that is commonly used in manufacturing processes based on Additive Manufacturing Technology. One of the materials that can be used on FDM machines is thermoplastic polyurethane (TPU). One measure of the quality of printed results is the machine's accuracy in producing workpieces that have the smallest possible dimensional error. So this research aims to obtain the printing parameters that have the most influence on print results and find out the optimal combination of printing process parameters on the machine to produce the smallest dimensional error for TPU material. The design of experiment method used is 2k factorial design using 4 process parameters, 2 levels and 3 responses. The parameters used are nozzle temperature, print speed, fill density, and enclosure box. The optimization results obtained an optimal combination of printing process parameters to produce the smallest dimensional error, namely nozzle temperature of 210°C, print speed of 30 mm/s, fill density of 100%, and not using an enclosure box.

Process optimization for the production of fibrinolytic enzyme by a novel marine fungus – Penicillium steckii KU1

The demand for microbial thrombolytic agents is alarmingly increasing, and the discovery of novel microbial species with significant level of fibrinolytic enzyme production are required to cope up with the current circumstances. Surprisingly, marine fungi remain largely unexplored in this regard, presenting an untapped potential for the production of fibrinolytic enzymes.A novel marine fungal strain (Penicillium steckii KU1) was isolated successfully from Kappil beach, Kerala. At the beginning Czapek-dox media was used for the production of fibrinolytic enzyme. Statistical optimization of the enzyme production was achieved initially by Plackett-Burman design (PB). Interactive effect of various process parameters was further scrutinized by Central Composite Design (CCD). Incubation time, inoculum size and concentration of casein were shown significant contribution towards production. Statistical optimization, resulted in a tenfold increment (454.49 ± 14.66 U/mL) [optimized conditions - 30 °C, pH 7, casein 2.7 % (w/v), inoculum 5.75 million spores/mL and 115 h incubation], against the predicted value 441.42 U/mL.

Preparation of solution blow spinning nanofibers and its application in the food field: a review

Abstract Solution blow spinning is a technology that uses high-pressure gas to prepare spinning solution into nanofibers. It has the advantages of high production efficiency and easy operation, and the prepared nanofibers have a large specific surface area, high porosity, and flexible surface functionalization. Therefore, solution blow spinning has received more and more attention in the food field. This paper first introduces the principle of solution blow spinning, the influence of spinning liquid properties, process parameters, and environmental factors on the spinning process. Secondly, it introduces the materials and ways of applying solution blow-spun nanofibers in the food field, such as bacteriostatic food packaging, slow-release food packaging, and intelligent sensors. Finally, the application of solution blow spinning technology in food is summarized and prospected. This paper provides a reference for further research and application of solution blow spinning in the food field at a later stage.

Magnetron-Sputtered Long-Term Superhydrophilic Thin Films for Use in Solid-State Cooling Devices

Pulse-magnetron-sputtered long-term superhydrophilic coatings have been synthesized to functionalize the surfaces of solid-state cooling devices, e.g., electrocaloric heat pumps, where not only a complete wetting of the surface by a fluid is intended, but also fast wetting and dewetting processes are required. The coatings consist of a (Ti,Si)O2 outer layer that provides lasting hydrophilicity thanks to the mesoporous structure, followed by an intermediate WO3 film that enables the reactivation of the wettability through visible light irradiation, and a W underlayer which can work as a top electrode of the electrocaloric components thanks to its suitable electrical and thermal conductivity properties. Process parameter optimization for each layer of the stack as well as the influence of the microstructure and composition on the wetting properties are presented. Finally, water contact angle measurements, surface energy evaluations, and a contact line dynamics assessment of evaporating drops on the coatings demonstrate that their enhanced wetting performance is attributed not only to their intrinsic hydrophilic nature but also to their porous microstructure, which promotes wicking and spreading at the nanometric scale.

Two-dimensional identification of time-varying batch nonlinear processes with input dead-zone nonlinearity

ABSTRACT In the time dimension, the batch process with input dead-zone nonlinearity often has the characteristics of short operation time and time-varying process parameters. A two-dimensional recursive least squares (2D-RLS) identification method for time-varying nonlinear systems with input dead zone is proposed. By mining system dynamic information from the time direction of the same batch and different batch directions, the identification parameters are updated. The proposed two-dimensional identification strategy converts the time-varying parameter estimation problem of time dimension into the equivalent time-invariant parameter estimation problem of batch dimension. Sufficient production data in batch dimension ensure that the proposed identification algorithm can eliminate the influence of random measurement noise. The identification strategy with unequal length of batch data is also given. The convergence of the proposed algorithm is analysed. Finally, numerical simulation and experimental tests are used to verify the effectiveness and superiority of the proposed algorithm.

Yield Stress and Elongation Prediction and Process Parameter Optimization of Two C-Mn Steel Based on XGBoost and Non-dominated Sorting Genetic Algorithm-IIization of C-Mn steel based on XGBoost algorithm

Yield Stress and Elongation Prediction and Process Parameter Optimization of Two C-Mn Steel Based on XGBoost and Non-dominated Sorting Genetic Algorithm-IIization of C-Mn steel based on XGBoost algorithm

Investigation of Micropattern Forming Process on Zr‐4 Alloy Surface Considering Plowing Effects

Micropattern forming process is an efficient and low‐cost process for fabricating multifunctional surfaces in electronics, energy, and biomedical products, but this process of creating microdimples on the surface of zirconium alloys has not been investigated. Currently, there are few models describing the micropattern forming process, and these existing models have not considered the effect of roughness on forming. The influence of roughness on micropattern forming process is not to be neglected due to the size effect, especially the plowing effects caused by asperities in surface roughness during sliding process. In this article, a micropattern forming process model is developed by combining a rough plane indentation model and a plowing effects model, and the experimental study of the forming process is conducted, which can quantitatively evaluate the effects of different process parameters and different roughness of forming die on forming process. The applicability range of the developed model is obtained, and the model is capable of predicting the forming process with various process parameters and surface roughness of forming die by comparing the experiment results with the model results, which is of great significance to the design of the forming die and the improvement of the forming process.

Mimicking the mechanical properties of cortical bone with an additively manufactured biodegradable Zn-3Mg alloy

Additively manufactured (AM) biodegradable zinc (Zn) alloys have recently emerged as promising porous bone-substituting materials, due to their moderate degradation rates, good biocompatibility, geometrically ordered microarchitectures, and bone-mimicking mechanical properties. While AM Zn alloy porous scaffolds mimicking the mechanical properties of trabecular bone have been previously reported, mimicking the mechanical properties of cortical bone remains a formidable challenge. To overcome this challenge, we developed the AM Zn-3Mg alloy. We used laser powder bed fusion to process Zn-3Mg and compared it with pure Zn. The AM Zn-3Mg alloy exhibited significantly refined grains and a unique microstructure with interlaced α-Zn/Mg2Zn11 phases. The compressive properties of the solid Zn-3Mg specimens greatly exceeded their tensile properties, with a compressive yield strength of up to 601 MPa and an ultimate strain of >60 %. We then designed and fabricated functionally graded porous structures with a solid core and achieved cortical bone-mimicking mechanical properties, including a compressive yield strength of >120 MPa and an elastic modulus of ≈20 GPa. The biodegradation rates of the Zn-3Mg specimens were lower than those of pure Zn and could be adjusted by tuning the AM process parameters. The Zn-3Mg specimens also exhibited improved biocompatibility as compared to pure Zn, including higher metabolic activity and enhanced osteogenic behavior of MC3T3 cells cultured with the extracts from the Zn-3Mg alloy specimens. Altogether, these results marked major progress in developing AM porous biodegradable metallic bone substitutes, which paved the way toward clinical adoption of Zn-based scaffolds for the treatment of load-bearing bony defects. Statement of significanceOur study presents a significant advancement in the realm of biodegradable metallic bone substitutes through the development of an additively manufactured Zn-3Mg alloy. This novel alloy showcases refined grains and a distinctive microstructure, enabling the fabrication of functionally graded porous structures with mechanical properties resembling cortical bone. The achieved compressive yield strength and elastic modulus signify a critical leap toward mimicking the mechanical behavior of load-bearing bone. Moreover, our findings reveal tunable biodegradation rates and enhanced biocompatibility compared to pure Zn, emphasizing the potential clinical utility of Zn-based scaffolds for treating load-bearing bony defects. This breakthrough opens doors for the wider adoption of zinc-based materials in regenerative orthopedics.

Experimental Analysis of Spiral Finishing Process on EDM Drilled Hole in Titanium

It is quite evident that some of the experimental research works have been carried out by researchers in the area of spiral polishing using abrasive for surface finishing improvement but most of the experiment has been employed on Steel or Alloy Steel as a material. Very few number of research works have been performed by researchers across the globe on the Spiral Polishing Method of Titanium holes made by Electrical Discharge Machining (EDM). Therefore, experimental investigations were carried out in the area of Spiral Polishing and Finishing of EDM-drilled holes of various materials to meet the desired goal of demands on the surface quality. This experimentation aims to develop a novel method with spiral polishing using abrasive flow finishing. To explore the search investigation and find out the better surface finishing for through holes made on EDM, the process parameters have been designed using the Taguchi L16 orthogonal array with input parameters such as Current (I), Pulse on time (Ton), and Pulse off time (Toff). The addition of Boron Carbide Powder with Handwash, Glycerine, Shampoo, and Liquid Soap is used to decrease the Surface Roughness (Ra) with a ratio of 5 : 1. The Taguchi technique is used to assess the P/M process parameter setting for a given signal to noise (S/N) ratio.

Design and Fabrication of Multifunctional E-Textiles by Upcycling Waste Cotton Fabrics through Carbonization

The merging of electronic materials and textiles has triggered the proliferation of wearables and interactive surfaces in the ubiquitous computing era. However, this leads to e-textile waste that is difficult to recycle and decompose. Instead, we demonstrate an eco-design approach to upcycle waste cotton fabrics into functional textile elements through carbonization without the need for additional materials. We identify optimal parameters for the carbonization process and develop encapsulation techniques to improve the response, durability, and washability of the carbonized textiles. We then configure these e-textiles into various 'design primitives' including sensors, interconnects, and heating elements, and evaluate their electromechanical properties against commercially available e-textiles. Using these primitives, we demonstrate several applications, including a haptic-transfer fabric, a joint-sensing wearable, and an intelligent sailcloth. Finally, we highlight how the sensors can be composted, re-carbonized and coated onto other fabrics, or repurposed into different sensors towards their end-of-life to promote a circular manufacturing process.

A Practical Method for Synthesizing Iptacopan.

Iptacopan, the first orally available small-molecule complement factor B inhibitor, was developed by Novartis AG of Switzerland. Iptacopan for the treatment of PNH was just approved by the FDA in December 2023. Other indications for treatment are still in phase III clinical trials. Iptacopan is a small-molecule inhibitor targeting complement factor B, showing positive therapeutic effects in the treatment of PNH, C3 glomerulonephritis, and other diseases. Although Iptacopan is already on the market, there has been no detailed synthesis process or specific parameter report on the intermediates during the synthesis of its compounds except for the original research patent. In this study, a practical synthesis route for Iptacopan was obtained through incremental improvement while a biosynthesis method for ketoreductase was used for the synthesis of the pivotal intermediate 12. Moreover, by screening the existing enzyme library of our research group on the basis of random as well as site-directed mutagenesis methods, an enzyme (M8) proven to be of high optical purity with a high yield for biocatalectic reduction was obtained. This enzyme was used to prepare the compound benzyl (2S,4S)-4-hydroxy-2-(4-(methoxycarbonyl)-phenyl)-piperidine-1-carboxylate) white powder (36.8 g HPLC purity: 98%, ee value: 99%). In the synthesis of intermediate 15, the reaction was improved from two-step to one-step, which indicated that the risk of chiral allosterism was reduced while the scale was expanded. Finally, Iptacopan was synthesized in a seven-step reaction with a total yield of 29%. Since three chiral intermediate impurities were synthesized directionally, this paper lays a solid foundation for the future of pharmaceutical manufacturing.

Multimethod cross-sectional characterization approaching the limits of diamond monophase multilayers

Chemical vapour deposited diamond draws significant scientific interest due to its wide range of mechanical and functional properties, which can be easily tuned by the applied deposition conditions. Here, hot filament chemical vapour deposition was used to synthesize four monophase multilayer diamond thin films with individual layer thickness down to ∼ 300 nm. Extensive structural characterization by scanning electron microscopy and Raman spectroscopy on the cross-section confirmed the different diamond morphologies originating from the different applied process parameters of the individual sublayers, where Raman spectroscopy could give a clear distinction between nano- and microcrystalline diamond down to a layer thickness of ∼ 1 μm. Cross-sectional X-ray nanodiffraction identified exclusively the diamond crystal structure throughout the cross-section of the multilayered diamond thin films. Cross-sectional phase and FWHM analysis allowed to discriminate between the diamond morphologies down to ∼ 500 nm, thus identifying the limitations of monophase diamond multilayers. While the microcrystalline diamond sublayers all exhibit pronounced structural gradients expressed in (i) increasing intensity of the 111 Debye-Scherrer ring, (ii) ⟨110⟩ fibre texture, and periodic variations of (iii) grain size and (iv) residual stress, the nanocrystalline diamond sublayers showed no pronounced cross-sectional variations. In summary, the experimental results provide insights into the cross-sectional evolution of microstructure and residual stress and the limitations of monophase multilayered diamond thin films.

Microbiological safety of dry-aged meat: a critical review of data gaps and research needs to define process hygiene and safety criteria

Dry-aged meat is gaining popularity among food business operators and private consumers. The process is carried out in aerobic conditions by hanging beef carcasses or placing subprimal or primal cuts in a dedicated cabinet for several weeks or even months while controlling the environment through the management of process parameters such as temperature, relative humidity, and airflow. In this review, we present a critical evaluation of the literature to evaluate tools to manage the process to guarantee food safety and identify critical control points, as well as good hygienic and manufacturing practices. In controlled aging conditions, only Listeria monocytogenes and Yersinia enterocolitica can multiply, while a reduction in the number of Salmonella spp. and Escherichia coli O157:H7 is generally reported. Enterobacteriaceae usually decrease on the surface of the meat during maturation; thus, for the purpose of the hygienic evaluation of the production process, a count no higher than that of unmatured meat is expected. Besides, various studies report that the total bacterial count and the spoilage microorganisms significantly increase on the surface of the meat, up to 5-6 Log CFU/g in the absence of visible spoilage. Bacteria of the Pseudomonas genus tend to progressively replace other microorganisms during maturation; thus, the total mesophilic or psychrophilic bacterial load is not a good indicator of process hygiene for matured meat. Critical parameters for the control of the process are temperature, relative humidity, and ventilation, which should be monitored during the process. For this reason, equipment designed and certified for dry aging must be used, and the manufacturer must validate the process. Food business operators must apply general good manufacturing practices (GMP) and good hygiene practices (GHP) for meat processing and some GMP and GHP specific for dry aging. Several research needs were identified, among them the evolution of the populations of L. monocytogenes and Y. enterocolitica and the microbiology of the inner parts of the dry-aged meat.

Achieving a High Thermally Conductive One Micron AlN Deposition by High Power Impulse Magnetron Sputtering plus Kick.

High-power impulse magnetron sputtering (HiPIMS) plus kick is a physical vapor deposition method that employs bipolar microsecond-scale voltage pulsing to precisely control the ion energy during sputter deposition. HiPIMS plus kick for AlN deposition is difficult since nitride deposition is challenged by low surface diffusion and high susceptibility to ion damage. In this current study, a systematic examination of the process parameters of HiPIMS plus kick was conducted. Under optimized main negative pulsing conditions, this study documented that a 25 V positive kick biasing for AlN deposition is ideal for optimizing a high quality film, as shown by X-ray diffraction and transmission electron microscopy as well as optimal thermal conductivity while increasing high speed deposition (25 nm/min) and obtaining ultrasmooth surfaces (rms roughness = 0.5 nm). HiPIMS plus kick was employed to deposit a single-texture 1 μm AlN film with a 7.4° rocking curve, indicating well oriented grains, which correlated with high thermal conductivity (121 W/m·K). The data are consistent with the optimal kick voltage enabling enhanced surface diffusion due to ion-substrate collisions without damaging the AlN grains.

Study of the Dynamic Recrystallization Behavior of Mg-Gd-Y-Zn-Zr Alloy Based on Experiments and Cellular Automaton Simulation

The exploration of the relationship between process parameters and grain evolution during the thermal deformation of rare-earth magnesium alloys using simulation software has significant implications for enhancing research and development efficiency and advancing the large-scale engineering application of high-performance rare-earth magnesium alloys. Through single-pass hot compression experiments, this study obtained high-temperature flow stress curves for rare-earth magnesium alloys, analyzing the variation patterns of these curves and the softening mechanism of the materials. Drawing on physical metallurgical theories, such as the evolution of dislocation density during dynamic recrystallization, recrystallization nucleation, and grain growth, the authors of this paper establish a cellular automaton model to simulate the dynamic recrystallization process by tracking the sole internal variable—the evolution of dislocation density within cells. This model was developed through the secondary development of the DEFORM-3D finite element software. The results indicate that the model established in this study accurately simulates the evolution process of grain growth during heat treatment and the dynamic recrystallization microstructure during the thermal deformation of rare-earth magnesium alloys. The simulated results align well with relevant theories and metallographic experimental results, enabling the simulation of the dynamic recrystallization microstructure and grain size prediction during the deformation process of rare-earth magnesium alloys.

Synergy between Fe-Co oxide catalysts supported over HZSM-5 for direct conversion of methane to methanol

The direct conversion of methane to methanol over iron and cobalt oxide based composite catalysts supported over HZSM-5 was carried out in a fixed-bed micro reactor under changing process parameters and catalyst compositions. The prepared catalysts were well characterized by various techniques including N2 adsorption desorption, X-ray diffraction (XRD), Fourier transformed infrared spectroscopy (FTIR), pyridine FTIR, X-ray photoelectron spectroscopy (XPS), UV–vis spectroscopy and temperature programmed reduction (H2-TPR). The characterization results revealed the presence of various reducible iron and cobalt oxide species depending on the Fe/Co molar ratio and total metal oxide loading. Moreover, the XPS and UV–vis spectroscopic results also confirmed the variation of Fe2+/Fe3+ and Co2+/Co3+ species depending on the Fe-Co molar ratio which had strong influence on the performance of the composite catalysts. It was found that the cobalt species favours the formaldehyde formation whereas the iron species promotes the formic acid formation in their respective pure supported oxide catalysts. However, the synergistic effect of iron and cobalt oxide in equimolar ratio in composite catalysts appeared as effective for achieving highest yield of methanol. The methanol selectivity was also influenced by the alteration of various studied process parameters. The higher reaction temperature favoured the overoxidation of methanol to CO2 whereas the methanol selectivity increased with increasing the methane to oxygen ratio. The lattice to adsorbed oxygen ratio also had strong influence on the activity of composite catalysts and methanol selectivity. The highest methanol yield of 1.87% was achieved at the methane conversion of 42.81 % with the 20Fe1Co1Z catalyst at 873 K reaction temperature with CH4/O2 ratio of 2:1 and WHSV of 1030 ml hr−1 gcat−1.