Surface Integrity Research Articles

An Investigation of the Effects of Cutting Edge Geometry and Cooling/Lubrication on Surface Integrity in Machining of Ti-6Al-4V Alloy

This investigation sought to characterize the combined influence of cutting-edge microgeometry and cooling/lubricating strategies on process thermo-mechanics and the resultant surface integrity in orthogonal machining of the Ti-6Al-4V alloy. Reverse waterfall cutting inserts were prepared with varying cutting-edge geometries, and machining experiments were conducted under cryogenic cooling with liquid nitrogen (LN2), minimum quantity lubrication (MQL), and dry machining conditions, using constant machining parameters. The induced surface integrity was characterized in terms of the developed cutting forces and through-thickness microhardness, grain morphology, dislocation generation, and residual stress formation. The experimental results revealed that the governing process physics are strongly influenced by variation in the implemented machining parameters. As a greater proportion of the cutting edge is distributed on the flank face, competing mechanical ploughing and thermal-based frictional effects both become more pronounced. Utilization of advanced cooling strategies to control cutting interface thermal gradients thus provides a processing route to generate tailored microstructures and surface integrity during the machining of this alloy.

Taguchi optimization of Wire EDM process parameters for machining LM5 aluminium alloy.

LM5 alloy is suitable for metal castings for marine and aesthetic uses due to its admirable resistance to corrosion. In order to make intricate shapes in the LM5 alloy, this study intends to assess the impact of Wire Electric Discharge Machining process variables, like Pulse on Time (Ton), Pulse off Time (Toff), Gap Voltage (GV) and Wire Feed (WF) on responses like Material Removal Rate (MRR), Surface Roughness (SR), and Kerf Width (Kw). The LM5 aluminium alloy plate was produced through stir casting process. SEM, EDAX and XRD images confirm the LM5 Al alloy's microstructure and crystal structure. WEDM studies were conducted using design of experiments approach based on L9 orthogonal array and analysed using Taguchi's Signal to Noise Ratio (S/N) analysis. Pulse on Time has the greatest statistical effects on MRR (68.25%), SR (79.46%) and kerf (81.97%). In order to assess the surface integrity of the WEDM machined surfaces, the SEM study on the topography was conducted using the optimum surface roughness process variables: Ton 110 μs, Toff 50 μs, GV 40 V, and WF 9 m/min. SEM images show the recast layer and its thickness. The average absolute error for MRR is 1.69%, SR is 3.89% and kerf is 0.88%, based on mathematical (linear regression) models. The Taguchi's Signal to Noise ratio analysis is the most appropriate for single objective optimization of responses.

HALOBATES: An autonomous surface vehicle for high-resolution mapping of the sea-surface microlayer and near-surface layer on essential climate variables

Abstract Essential climate variables (ECVs) are physical, chemical, or biological parameters supporting the characterization of the climate system. The oceanic ECVs temperature and salinity have been defined for the sea surface (upper 1 mm) and bulk water (upper 2 meters). Direct observation and sampling of the sea surface from ships and buoys is limited due to the potential loss of integrity of the sea surface and contamination by the research platform. The design, development, and operation of a research vehicle with autonomous capabilities based on commercially available components are described in this study. The autonomous operation and fully automated sampling enable high-resolution mapping of the sea surface microlayer (SML), i.e., the upper < 1mm layer, and near-surface layer (< 1.2 m). Sampling the SML is based on a rotating glass disk sampler. The autonomous surface vehicle HALOBATES has been equipped with multiple conductivity, temperature, and depth sensors (CTDs) in a flow-through system to measure both sea surface and bulk temperature and salinity. The performance of the autopilot under various scenarios is demonstrated. Typical anomalies of ECVs within the SML and near-surface layer are evident and forced by both atmospheric and oceanic processes. Data analyses reveal HALOBATES' ability to resolve thermohaline structure on different spatial and temporal scales, for example, small-scale freshwater lenses and thermohaline changes across oceanic fronts. The integration of an Acoustic Doppler Current Profiler supports the interpretation of thermohaline structures. HALOBATES is a platform with cutting-edge technology for understanding climate-related processes between the ocean and atmosphere and providing high-resolution sea surface data for validating satellite products of ECVs.

Finite Element Simulation of Ti-6Al-4V Alloy Machining with a Grain-Size-Dependent Constitutive Model Considering the Ploughing Effect Under MQL and Cryogenic Conditions

The finite element modeling method has been widely applied in the modeling of the cutting process to characterize the instantaneous and microscale deformation mechanism that was difficult to obtain using physical experiments. The lubrication and cooling conditions, such as minimum quantity lubrication and cryogenic liquid nitrogen, affect the thermo-mechanical behaviors and machined surface integrity in the cutting process. In this work, a grain-size-dependent constitutive model was used to model orthogonal cutting for Ti-6Al-4V alloy with MQL and LN2 conditions. The cutting forces and chip morphologies that were measured in the cutting experiments of Ti-6Al-4V alloy were used to validate the simulated forces. The relative errors between the measured and simulated principal forces were less than 8%, while the relative errors of thrust forces were less than 19%. The predicted chip morphologies and surface grain refinement agreed well with the experimental results under the conditions with different uncut chip thicknesses and edge radii. Additionally, the relationship between the plastic displacement and grain refinement, as well as the microhardness and residual stresses under MQL and cryogenic conditions, were discussed. This work provides an effective modeling method for the orthogonal cutting of Ti-6Al-4V alloy to understand the mechanism of the plastic deformation and machined surface integrity under the MQL and LN2 conditions.

The Effects of Alloy Composition and Surface Integrity on the Machinability of Austenitic Stainless Steels 304 and 304L

Austenitic stainless steels, such as 304 and 304L, are extensively utilized in diverse industries due to their favorable properties, including biocompatibility, high durability, ductility, toughness at cryogenic temperatures, and excellent corrosion resistance. Additionally, these steels exhibit notable resistance to fatigue and oxidation. Despite these advantages, they are challenging to machine due to characteristics such as high work hardening, built-up edge formation, and low heat conductivity. The material 304L distinguishes itself from material 304 through its lower carbon content, making it more resistance to corrosion. 304L is experiencing a consistent rise in industrial demand. It is anticipated that this advanced material will progressively supersede 304 in various applications. The variability in alloy compositions and surface integrity of blanks can influence the tool wear and may even lead to abrupt tool breakage, necessitating supervision during machining operations. This study delves into the correlation between the alloy compositions, micro structure, surface integrity, and machinability of these special steels, focusing on turning processes. Various blanks of 304 and 304L in the form of bars, sourced from different manufacturers, were utilized in the study. These blanks exhibited slight variations in alloy composition (albeit within the standard range) and differed in the state of surface integrity characterized by variations in microstructure, grain size, microhardness, and residual stress. All blanks (across this array of materials) were subjected to turning using the same tool specifications and sets of machining parameters for comparative analysis. Various machinability indicators, including cutting forces, surface roughness, burr formation, tool wear, and chip morphology, were thoroughly examined. The findings highlight that the key factors influencing machinability include the microhardness of the surface and the residual stress state in the subsurface of the bars before the turning process. In contrast, changing the alloy composition within the standard range has hardly any effect on the machinability of these steels. The machinability of the examined specimens was adversely affected when the hardness exceeded 350 HV from the surface up to 2 mm below the surface and simultaneously the surface compressive residual stress exceeded −130 MPa.

Effect of ultrasonic surface rolling process by disparate static pressure on a carburized layer of 17CrNiMo6 steel

Considering the elevated application requirements for transmission gears in terms of wear and corrosion resistance, this study investigates the impact of different static pressures (0.4 MPa, 0.6 MPa, 0.8 MPa) on the structure and protective properties of vacuum-carburized USRP layers, leveraging the technical advantages offered by vacuum carburizing and USRP. The findings demonstrate that using USRP facilitates fine-grained strengthening, and the thickness of the grain refinement layer increases proportionally with static pressure. The 0.6 MPa static pressure exhibits the most pronounced positive impact on grain refinement. The application of varying static pressures results in different surface integrity and microhardness levels within the carburized layer, thereby impacting the layer's wear and corrosion resistance. The coating exhibits the highest hardness and lowest roughness at a static pressure of 0.6 MPa, thereby demonstrating superior wear resistance. In addition, the 0.6 MPa layer with the lowest roughness has the best corrosion resistance.

Investigation into micro slotting of Cu-based shape memory alloy via µ-ECM using ethylene glycol mixed aqueous NaCl electrolyte

ABSTRACT Micro-Electrochemical Machining (µECM) presents significant promise as a future micromachining process offering higher machining rates, improved precision and the ability to work with a wide range of materials. Cu-based shape memory alloys (SMAs) have exceptional properties that make them quite difficult to machine using traditional techniques. In this investigation a new electrolyte solution consisting of ethylene glycol (EG) and NaCl has been explored while attempting µECM of Cu-SMA. The Cu-based shape memory alloy used consists primarily of Cu-53.19%, Zn-41.50%, and 5.2% other elements. Four different parameter combinations selected based on pilot experiments were used for the main experimentation conducted in four sub-sets. The influence of micromachining parameters including machining voltage, electrolyte concentration and micro-tool feed rate on µECM characteristics such as material removal rate (MRR) and surface roughness (SR) during micro-slot formation has been investigated. With the identified optimum parameters, a high-quality micro-slot was successfully machined on Cu-based shape memory alloys achieving a material removal rate of 0.323 mg/min and surface roughness of 0.384 μm. The investigation demonstrated that an ethylene glycol electrolyte containing NaCl is more suitable for µECM of micro-slots offering superior surface integrity and shape accuracy compared to a water-based electrolyte.

Sustainable Water Management with Photocatalytic Janus Mesh: Efficient Fog Harvesting, Water Purification, and Microbial Disinfection.

Water scarcity is a critical global challenge, especially in arid and semiarid regions. Fog harvesting has emerged as a promising solution; however, concerns about air pollution and bacterial growth in humid environments have raised doubts about the safety and sustainability of such systems. This study introduces a Janus mesh with asymmetric wettability on its two faces, fabricated through a simple and scalable method. The unique design of the Janus mesh enables the transport of water droplets from the superhydrophobic side to the hydrophilic side in a unidirectional manner, enhancing its fog harvesting efficiency. The mesh's photocatalytic properties not only elevate the fog harvesting rate to 4.7 kg·m-2h-1 but also effectively purify the harvested water by removing organic contaminants (94%) and microbial impurities (99.98%). Additionally, its inherent bactericidal activity prevents biofouling, ensuring sustained efficiency in water collection. The mesh's self-cleaning abilities through photocatalysis maintain its surface integrity, promising long-term stability for fog harvesting applications. This technological advancement in fog harvesting offers a sustainable and economical solution to water scarcity concerns, addressing safety and sustainability issues associated with existing systems. By potentially transforming the livelihoods of communities struggling with water scarcity, this innovation paves the way for a more sustainable future.

Study on the effects of laser shock peening on the microstructure and properties of 17-7PH stainless steel

To investigate the surface integrity of 17-7PH stainless steel welded structural components used in aviation, laser shock peening (LSP) with different power densities was applied to stainless steel welded joints. The microstructural morphology, structural features, full-width at half-maximum, microhardness, and surface roughness of the stainless steel welded joint specimens before and after LSP were characterized and measured using SEM, TEM, XRD, a microhardness tester, and a high-resolution confocal microscope. The effects of different laser power densities on the microstructure and properties of the stainless steel welded joints were explored. Results indicate that the stainless steel welded joints exhibit a typical BCC phase. Laser shock peening promotes grain refinement in the welded joints, leading to the phase transformation of residual austenite into martensite. The surface roughness of the specimen is positively correlated with laser power density. At a power density of 5.17 GW/cm2, the surface roughness increased to 1.919 μm, which is 117.08% higher than that of the non-peened specimen. The microhardness of the specimens shows a decreasing trend with increasing power density. When the power density is 2.79 GW/cm2, the microhardness of the specimen significantly increases to 462.94 HV0.5, which is 22.26% higher than that of the non-peened specimen.

Enhancing surface integrity of additively manufactured Inconel 718 through numerical modeling of hydrostatic ball burnishing parameters using TOPSIS and ANOVA

Abstract Surface enhancement of laser powder bed fusion components is pivotal for their suitability in end-use applications. Hydrostatic ball burnishing, a mechanical surface hardening technique, induces compressive residual stress on the surface by the application of hydraulic force resulting in improved fatigue life of the material. This present study focuses on determining the optimum burnishing parameter combinations for better surface integrity (roughness, hardness, and residual stress) utilizing ANOVA and TOPSIS analysis. The cumulative performance score of the TOPSIS analysis states that the best parameter combination for Inconel 718 is found to be 300 bar pressure, 0.2mm burnishing width, and feed 800mm/min. The adjusted R² values of the ANOVA model for all three responses are 0.96, 0.93, and 0.94, confirming their close agreement with experimental results. With optimum parameters, the roughness decreased from 2.217μm to 0.305μm, Microhardness increased from 318.9HV to 475.9HV and residual stress was converted from tensile 216MPa to Compressive -54MPa demonstrating the significance of this process on surface enhancement.

Comparative evaluation of autologous tissue-engineered ocular and oral mucosal tissue grafts- a prospective randomized controlled trial

BackgroundBilateral ocular surface disease resulting from Stevens Johnson Syndrome (SJS) and chemical injuries are visually debilitating and difficult to treat. Ocular surface reconstruction by various means has been reported with variable results. This study addresses an unmet need for a prospective clinical trial comparing the outcomes of transplanting autologous oral and conjunctival epithelial cell constructs on human amniotic membrane by ex vivo tissue engineering.MethodsA prospective, randomized controlled clinical trial was prospectively applied for registration, with the clinical trial registry of India (CTRI), with the approval of the Institute Ethics Committee number IEC/NP-99/11.04.2014 and CTRI No. REF/2018/10/021791, the study also registered with the WHO-recognized trial registry, International Standard Randomised Controlled Trial Number (ISRCTN) registration reference number 45780. The study was conducted to compare clinical outcomes of two different tissue-engineered cell grafts, Cultivated Oral Mucosal Epithelial Transplantation (COMET) and Conjunctival Cultivated Epithelial Transplantation (CCET) for ocular surface reconstruction in patients with bilateral ocular surface disease due to Stevens-Johnson Syndrome or chemical injuries. Fifty patients were enrolled and randomized to either the COMET or CCET group. A uniform pre-op and post-op protocol using standard medications was followed for all patients Parameters assessed at baseline, day 1, 1 week, 2 weeks, 1 month, 2 months, 3 months and 6 months postoperatively included patient comfort, best corrected visual acuity (BCVA), ocular surface status and corneal clarity. The efficacy was measured in terms of improvement of vision, reduction in vascularization, symblepharon and corneal clarity.ResultsIn the study, 50 patients (50 eyes; mean ages of 29 ± 15.86 years and 26.36 ± 10.85 years, respectively; range, 12–65 years) were enrolled, with 25 patients each in the COMET and CCET groups. Out of them, 36% were female and 64% were male; the causes were Steven Johnson syndrome (48), and chemical injury (2). Mean pre-operative BCVA was log MAR 1.73 ± 0.57 for COMET and 1.99 ± 0.33 for the CCET group. Pre-operatively all 50 enrolled patients had opaque corneas pre-operatively, symblepharon that extended to the cornea categorised as grade 3 and corneal vascularization that went beyond the pupil’s boundary into the central zone encluaching on the visual axis. The minimal follow-up time was six months. Following surgery postoperatively, the BCVA considerably improved in the COMET group by 1.51 ± 0.58 compared to the CCET group by 1.91 ± 0.33 at 3 months. BCVA at 6 months was 1.73 ± 0.56 in the COMET group and 1.99 ± 0.31 in the CCET group, which is not statistically significant and comparable to the BCVA before surgery. The corneal clarity was significantly improved in COMET group 25 eye (100%) at 2 month, 3month and 19 eye (76%), 6eye (24%) at 6 months when compared to CCET group 15 eye improved (60%), 9 eyes (36%) not improved and one eye with opaque cornea (4%) at 2 months. 22 eye (88%) had not improved, 2 eye (8%) opaque cornea and 1 eye (4%) improved at 3 months. At 6 months 21 eye (84%) were not improved, 4 eye (16%) eye became opaqued at 6 months. Compared to preoperative conditions, both groups had improved corneal clarity significantly (p > 0.005). Of the 50 patients with grade 3 symblepharon extended to the cornea, were completely resolved 19 (76%) in COMET group when compared to CCET group 22 eye (88%) not improved. Similarly, 19 eye (76%) had a improvement in corneal vascularization when compared to the CCET group not improved 25 eye (100%) at 6months. No adverse event was observed in any of either group during the follow up periods.ConclusionBoth cell types are effective to restore the ocular surface integrity in bilateral ocular surface disease. Whereas COMET is safe and efficacious in terms of improvement of clinical parameters including, BCVA, corneal clarity, reduction in vascularization and preventing the recurrence of symblepharon postoperatively 3months and 6 months. In addition, the CCET group maintained the stability of the ocular surface and had improvement in corneal clarity and a decrease in vascularization at 3 months compared to their pre-operative characteristics.

Water-induced surface ordering facilitating the microcutting of ductile metals

Metal cutting is a crucial process in modern manufacturing. Enhancing the machinability of metals can significantly improve their production efficiency and surface integrity. Coating surface-active media (SAM) on the free surface of the metals before cutting is an easy method to improve machinability, which usually pertains to the category of the renowned Rehbinder effect. However, the existing SAM is usually hazardous and complex materials. Besides, the effect of SAM on the local structure of the metal surface remains unclear. In this study, water is employed as a simple yet often overlooked SAM in the microcutting of copper. Using water as SAM also allows the employment of X-ray absorption fine structure spectroscopy (XAFS) to study the local structure of copper with and without water coating. Results show that water coating on the free surface of copper can significantly reduce the cutting force and chip thickness, and improve the surface finish. Interestingly, removing the water coating enables the recovery of the cutting force, demonstrating a reversible effect. Based on the XAFS results and molecular dynamics simulation, a water-induced surface ordering mechanism is proposed to explain the findings from the microcutting experiments. This mechanism suggests that water molecules can induce surface ordering in copper, resulting in reduced surface energy and fracture toughness of copper, thus enhancing machinability. This work provides valuable insights into the comprehension of the Rehbinder effect and shows that picometer-scale modifications of the surface atom arrangement can considerably alter the deformation mode of metals, paving the way for the development of new manufacturing processes.

Effect of laser shock peening on the surface integrity and fretting fatigue properties of high-strength titanium alloy TC21

High-strength titanium alloy TC21 is often used to make aircraft load-bearing components in the aviation field. However, due to vibration, load-bearing components often suffer from fretting fatigue (FF), which greatly reduces their actual service life. Nowadays, laser shock peening (LSP) is being recognized as an effective strengthening process for many materials. Therefore, in this study, the effectiveness of LSP on the strengthening of high-strength titanium alloy TC21 is studied, in terms of surface integrity and FF properties. TC21 fretting specimens and tests are designed. Before fretting tests, the specimens are processed by LSP with varying laser pulse energies, number of shocks and overlap rate, and their surface integrity and FF properties are analyzed. It is found that the greater the laser pulse energy and number of shocks, the higher the surface hardness and compressive residual stress, the more the grain refinement, the greater the improvement in FF life. Under 32J-50%-T1, the FF life is improved by 191.3% compared with BM. But the overlap rate has little effect on surface integrity and FF life. Meanwhile, there forms amorphous structures, which tended to be transformed into nanograins during fretting process. This transformation is helpful for prolonging FF life due to its action of energy absorption. This study reveals the strengthening mechanism of LSP on TC21 and its effect on the FF properties of TC21 specimens.

Study and scaling-up of multi-tip pulsed-corona air discharges for degradation of paracetamol

Abstract This study investigates the paracetamol removal efficiency by multi-tip pulsed corona discharges, highlighting the conditions avoiding mutual effects between two consecutive streamer branching discharges generated by each tip. The results show that the production of reactive oxygen and nitrogen species (RONS) in the liquid phase and the efficiency of paracetamol removal are influenced by the distance between two contiguous tips due to the mutual effects for small inter-tip distances between 4 mm and 8 mm in the case of a fixed inter-electrode distance of 5 mm (i.e. distance between the tip summit and the water surface). Beyond an inter-tip distance of 12 mm (over twice the gap distance), the mutual effects of branching discharges were no longer observed since the field lines did not overlap, making the production and absorption of liquid-phase species more efficient. Furthermore, RONS production was almost linear when moving from one to four tip electrodes: [H2O2]1tip: 0.52 mg l–1 versus [H2O2]4tips: 1.99 mg l–1, a ratio of 3.82. Optimum values were reached for an inter-tip distance of 16 mm. In this case, the enhancement factor in this reactor configuration is the surface integration between the plasma and the liquid surface to be treated. Furthermore, the results show a quasi-exponential increase in the percentage of paracetamol degradation as a function of the number of electrodes, from 4% with a mono-tip configuration to over 78% for a treatment with a four tip one.

Electromagnetic force calculation within finite volume framework

ABSTRACT In this research, the comparison of force calculation methods in magnetostatic simulations within a cell-centered finite volume framework is presented. Various procedures for postprocessing of the magnetic vector potential field are laid out to obtain the surface and volume integrals of Maxwell’s stress tensor and the Lorentz force density. Two different magnetostatic problems with multiple operating points were modeled with the AVL FIRETM M. The force results have been verified by comparing them to the Ansys Maxwell and were validated on a benchmark case from a Testing Electromagnetic Analysis Methods (TEAM) workshop. The interpolation of the magnetic flux density on a multi-material interface is presented, and it is used in conjunction with the surface integral of Maxwell’s stress tensor for an efficient global force computation. For all observed cases, the calculated results correspond well to the results found in the literature. It was found that the accuracy of the volume integral of Maxwell’s stress tensor is dependent on the mesh quality and gradient calculation scheme. Employing the semi-structured mesh with Gauss’s gradient scheme results in force discrepancies of less than 3% between the surface and volume integral of Maxwell’s stress tensor. The convergence of the iterative solver is observed to be slower in the case of the materials with permeability jump, where discontinuities between the tangential component of the magnetic flux density and the normal component of the magnetic field intensity occur.

Loaded tooth contact analysis for helical gears with surface waviness error

Meshing characteristics are crucial for the transmission performance of vibration noise and strength of gear systems. Gear transmission error has been acknowledged as a prominent excitation in vibration systems, but the surface waviness deviations that directly affect it in contact analysis are generally ignored. This study proposes a comprehensive model for quasi-static analysis of tooth surfaces with waviness error. The model reconstructs the actual tooth surface in reverse based on the gear Fourier measurement principle. Instead of solving the meshing equations to pre-assume contact position, the problem of normal contact between surfaces with deviations is solved by an innovative multiscale grid and a local iterative numerical algorithm. Combining the finite element numerical method and surface integral of the Boussinesq solution determines gear deformation and develops a loaded contact model. The validity of the model is verified through numerical examples. Furthermore, the proposed model is applied to discuss the tooth surfaces with different waviness amplitudes, frequencies, and distribution angles for the first time. It explains the interaction between local microscale and global scale introduced by waviness error on tooth surfaces and reveals the mechanism of the waviness error on meshing performance.

Enhancing microhardness and surface integrity of Ti–6Al–4V alloy using WC–Cu composite electrode aided electrical discharge coating

Titanium alloy can be found in numerous applications, such as chemical, aerospace, and energy industries, among other sectors, due to its excellent performance. Nevertheless, the possible uses of a variety of titanium-based alloys have been greatly restricted by their low hardness and inadequate resistance to wear. Therefore, in this research work, WC–Cu composite electrode assisted electrical discharge coating (EDC) is used for improving microhardness (MH) and surface integrity of Ti–6Al–4V alloy. By utilizing powder composite electrode, the conductivity of the electrode can be increased, which provides controlled electric spark, resulting in uniform deposition. In order to increase the rate of deposition, the terminal of the EDM has been changed as WC–Cu composite electrode as anode and workpiece as cathode. Response surface methodology is used for studying the variables including compacting pressure (MPa), discharge current (I), pulse on time (T on). In addition, microstructure, elemental analysis and coating interface of deposited Ti–6Al–4V alloy are investigated through scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS). The surface roughness of 8.86 µm was achieved at 400 MPa, 6 A, and 40 µs. The maximum MH of 988 HV was obtained at 400 MPa, 10 A, and 80 µs. The MH of the deposited layer is around 2–3 times harder than base material. Moreover, a greater adhesion strength coated layer was ∼118 N, which permits the alloy to have improved wear resistance. It was concluded that using a high-pressure electrode with lower settings resulted in an improved surface finish, while higher settings led to increased MH.

Wear behavior of novel CVD-coated wiper inserts’ with various chip-breakers and resulting surface integrity during dry drilling of Ti-6Al-4V

In this paper, a comprehensive investigation in terms of tool wear/life, chip morphology, surface roughness/damage, diametric error, burr height, and microstructure is conducted by using an innovative integration of peripheral wiper and central stepped inserts when drilling Ti-6Al-4V alloy in a dry-cutting environment. Two geometries of peripheral wiper inserts termed as LM (groove width-1000 mm, groove depth-65 mm) and GT (groove width-720 mm, groove depth-20 mm) are evaluated at two levels of cutting speeds (50 m/min and 60 m/min) and three levels of feed rates (0.10 mm/rev, 0.15 mm/rev, and 0.20 mm/rev) while keeping the geometry of central stepped insert constant. The GT wiper configuration is found to be more suitable in terms of tool life, drilling maximum number of holes (75) at a cutting speed of 50 m/min and feed rate of 0.10 mm/rev which is ∼3-fold higher than that of the LM geometry. With respect to majority of the drilled hole attributes, better performance of LM geometry is observed in comparison to its GT counterpart due to its improved chip breakability. In addition, all holes are oversized ranging from 30 µm to100 µm. Minor plastic deformation of grain boundaries in the machined sub-surface is noticed to a depth of 10–15 µm in the direction of cutting.

Air Fixation and AFM: A Comparative Study of Nanoparticle-Induced Topographical Changes in Lung Cells

Gold nanoparticles (AuNPs) have emerged as promising agents in biomedical applications due to their unique physicochemical properties. This study investigates the cellular interactions of AuNPs with A549 (non-small cell lung adenocarcinoma) and BEAS-2B (normal bronchial epithelial) cell lines. AuNPs were synthesized via the citrate reduction method, resulting in 20, 50, and 70 nm particles. Cells were incubated with AuNPs for increasing durations (30 minutes, 4 hours, and 24 hours). Post-incubation, cells were washed with PBS, air-fixed, and subsequently analyzed using Atomic Force Microscopy (AFM) to obtain detailed topographical maps. AFM imaging revealed distinct interactions between AuNPs and the two cell lines. A549 cells displayed darker regions on the cell surface, indicative of topographical depressions likely resulting from nanoparticle-induced membrane collapse. In contrast, BEAS-2B cells did not exhibit such depressions, which is consistent with the literature that suggests cancer cells are mechanically softer than normal cells. The surface roughness analysis results indicated that the preservation of surface integrity post-fixation validates the air-fixation methodology for obtaining reliable mechanical data from AFM analyses.

Influences of size effect and workpiece temperature during cryogenic micro milling of soft viscoelastic polymer: an experimental assessment

Application of tool-based micromachining in soft polymer has been limited due to high adhesion and low elastic modulus of this material at room temperature. This study aims to evaluate the machinability of a typical viscoelastic soft polymer and understand the effect of material and process parameters on machining performances. In this study, a micro-milling process using cryogenic-assisted cooling is proposed and the importance of temperature control toward glass transition zone was particularly addressed. To identify insight of machinability in micro domain, this article also determines minimum uncut chip thickness (MUCT) and size effects by considering the variations of cutting force and surface integrity with the ratio of h/re (uncut chip thickness (h) to cutting edge radius (re)). The experimental results reveal that consideration of size effect during micromilling of soft viscoelastic polymer helps in reduction of machined surface roughness (Sa) value. Based on the cutting force pattern, it is evaluated that higher machining stability can be achieved during cryogenic machining by reduction of specific cutting force value. Moreover, temperature range around glass transition zone yields more promising experimental outcomes, outperforming other cooling zones.