Effect of Silicon Powder Mixed EDM on Machining Rate of AISI D2 Die Steel

In this paper, the effect of silicon powder mixing into the dielectric fluid of EDM on machining characteristics of AISI D2 (a variant of high carbon high chrome) die steel has been studied. Six process parameters, namely peak current, pulse-on time, pulse-off time, concentration of powder, gain, and nozzle flushing have been considered. The process performance is measured in terms of machining rate (MR). The research outcome will identify the important parameters and their effect on MR of AISI D2 in the presence of suspended silicon powder in a kerosene dielectric of EDM. The study indicated that all the selected parameters except nozzle flushing have a significant effect on the mean and variation in MR (S/N ratio). Optimization to maximize MR has also been undertaken using the Taguchi method. The ANOVA analysis indicates that the percentage contribution of peak current and powder concentration toward MR is maximum among all the parameters. The confirmation runs showed that the setting of peak current at a high level (16 A), pulse-on time at a medium level (100 μs), pulse-off time at a low level (15 μs), powder concentration at a high level (4 g/l), and gain at a low level (0.83 mm/s) produced optimum MR from AISI D2 surfaces when machined by silicon powder mixed EDM.     

Innovative micro hole machining with minimum burr formation by the use of newly developed micro compound tool

The study focuses on the efforts for minimization of burr formation and improvement of hole surface roughness in micro through-hole machining. It deals with the development of micro compound tool which is consisting of a micro flat drill as the drilling part and a micro diamond-electroplated-grinding part for hole finishing. The finishing diameters of each drilling and grinding parts of the fabricated micro compound tool are 90 μm and 100 μm, respectively. The study focuses mainly on the effect of drill point angle and ultrasonic vibration applied during micro hole machining to the hole entrance and exit burrs formation. The used workpiece is made of stainless steel (SUS304) with a thickness of 100 μm. From the experiment, it was found that the tool having drill point angle of 118° resulted in a smaller burr formation although hole machining was conducted for 600 holes. Furthermore, the application of ultrasonic vibration during hole machining could improve the performance of the developed micro compound tool and decreased the burr size, especially the exit burr.     

Nanosecond pulsed laser micromachining of PMMA-based microfluidic channels

This paper reports an investigation into the effects of nanosecond laser processing parameters on the geometry of microchannels fabricated from polymethylmethacrylate (PMMA). The Nd:YAG solid-state pulsed laser has a wavelength of 1064 nm and a measured maximum power of 4.15 W. The laser processing parameters are varied in a scanning speed range of 400–800 pulses/mm, a pulse frequency range of 5–11 Hz, a Q-switch delay time range of 170–180 μs. Main effects plots and microchannel images are utilized to identify the effects of the process parameters for improving material removal rate and surface quality simultaneously for laser micromachining of microchannels in PMMA polymer. It is observed that channel width and depth decreased linearly with increasing Q-switch delay time (hence average power) and increased non-linearly with higher scanning rates and not much affected by the increase in pulse frequency.     

Aero-lap polishing of poly crystalline diamond inserts using Multicon media

Increasing use of poly crystalline diamond (PCD) inserts as cutting tools and wear parts is vividly seen in automobile, aerospace, marine and precision engineering applications. The PCD inserts undergo series of manufacturing processes such as: grinding that forms the required shape and polishing that gives a fine finish. These operations are not straight forward as PCD is extremely resistant to grinding and polishing. Single crystal diamond can easily be polished by choosing a direction of easy abrasion, but polishing a PCD imposes serious difficulties as the grains are randomly oriented. Prior research on polishing of PCD inserts includes electro discharge grinding (EDG), dynamic friction polishing and grinding by a vitrified bonded diamond wheel. The surface textures of PCD produced using an EDG process often contains: micro cavities, particle pullout, micro-grooves, chipped edges, cracks and gouch marks. While applying the dynamic friction polishing method the PCD material undergoes phase transformation and hence increased polishing rate was apparently seen. However the phase transformation of PCD deteriorates the strength of the insert. Furthermore the inserts produced using the dynamic polishing method often exhibits cracks, chip off and edge damage while using as a cutting tool. Therefore, a new method “aero-lap polishing” was attempted as it applies controlled amount of impinging force by which the surface damage can be significantly reduced. The study did establish an improvement of surface finish of PCD from R_a = 0.55 μm, R_t = 4.5 μm to R_a = 0.29 μm, R_t = 1.6 μm within 15–25 min of polishing time along with significant reduction in surface defects.     

The effect of pitting corrosion on split sleeve cold hole expanded,bare 7075-T651 aluminium alloy

As part of an aircraft fleet fatigue life improvement program, investigation has been carried out into the effect pitting corrosion has on bare 7075-T651 which had undergone split sleeve cold hole expansion. Constant amplitude sinusoidal loading was applied to fatigue test coupons which had pitting corrosion induced upon them by a modified cyclic immersion process using a 3.5% NaCl solution. A pit depth of 39–58 μm was found to significantly reduce the increased fatigue life gains achieved by carrying out cold hole expansion. At 137.9 MPa fatigue life was reduced from achieving run out of ten million cycles to an average 371 × 10³ cycles, while at 165.5 MPa average fatigue life was reduced from 810 × 10³ to 65 × 10³ cycles. The fracture surfaces were analysed under a scanning electron microscope where each displayed an individual crack initiation site located on the material surface within the zone of residual circumferential stress.     

Influence of overlap between the laser beam tracks on surface quality in laser polishing of AISI H13 tool steel

Polishing by laser beam radiation is a novel manufacturing process to modify the initial surface topography in order to achieve a desired level of surface finish. The performance of laser polishing (LP) is determined by an optimum combination of several key process parameters. In this regard, the overlap between two successive laser beam tracks is one of the important LP process parameters, which has a significant effect over the final surface quality. In the current study, influence of overlap between the laser beam tracks on surface quality was experimentally investigated during the laser polishing of AISI H13 tool steel. Surface areas were polished by using four different overlap percentages (e.g. 80%, 90%, 95%, and 97.5%) while applying the same energy density. The improvement of surface quality was estimated through the analysis of line profiling surface roughness R_a, areal topography surface roughness S_a, and material ratio function. Also, individual components of the surface quality, e.g. waviness and roughness, and their evolution during LP were statistically analyzed using the power spectral density and the transfer functions. Finally, as an example of the best achieved LP result, flat surface area was polished using optimum set of the process parameters improving surface quality by 86.7% through the reduction of an areal topography surface roughness S_a from 1.35 μm to 0.18 μm.     

Hermetic joining of 316L stainless steel using a patterned nickel nanoparticle interlayer

This paper evaluates the use of a nickel nanoparticle (NiNP) interlayer for making hermetic joints in 316L stainless steel substrates via diffusion brazing. Different NiNP inks were prepared using commercial nanopowder (～9 nm) and in-house synthesized nanoparticles. Syringe pump deposition of ～9 nm NiNP ink and diffusion brazing at 900 °C for 30 min under 2 MPa resulted in a hermetic joint up to the tested pressure of 70 psi. In-house synthesis of NiNPs was carried out in ethylene glycol by the reduction of NiCl₂·6H₂O in the presence of hydrazine (N₂H₄) as a reducing agent. X-ray diffraction (XRD) analysis and transmission electron microscopy (TEM) results confirm the presence of pure fcc-Ni with an average particle size of 5.4 ± 0.9 nm. An as-synthesized suspension of NiNPs was patterned onto 316L stainless steel laminae via automated dispensing to a thickness of ～3 μm and bonded at 800 °C for 30 min at a pressure of 2 MPa. The diffusion-brazed test article was also found to be hermetic up to 70 psi. An examination of the bond line using scanning electron microscopy (SEM) showed good uniformity and continuity.     

Investigating surface roughness,material removal rate and corrosion resistance in PMEDM of γ-TiAl intermetallic

Titanium aluminide intermetallics offer an attractive combination of low density and good oxidation, corrosion and ignition resistance with unique mechanical properties. In this study two series of machining tests are designed. Firstly the powder mixed electrical discharge machining (PMEDM) of γ-TiAl by means of different powders such as aluminum, chrome, silicon carbide, graphite and iron is performed to investigate the output characteristics of surface roughness and topography, material removal rate (MRR), electrochemical corrosion resistance of machined samples and also the machined surfaces are investigated by means of EDS and XRD analyses. Secondly after selection the aluminum powder as the most appropriate kind of powder, the current, pulse on time, powder size and powder concentration are changed in different levels for overall comparison between EDM and PMEDM output characteristics. In the first setting of input machining parameters, aluminum powder improves the surface roughness of TiAl sample about 32% comparing with EDM case and also aluminum particles with the size of 2 μm, in the second setting of input parameters lead to 54% enhancement of MRR comparing with EDM case. The electrochemical corrosion results show that, corrosion resistance of the samples which are machined by graphite and chrome powders respectively are about three and two times more than the sample which is machined without powder.     

Evaluation of the effectiveness of low frequency workpiece vibration in deep-hole micro-EDM drilling of tungsten carbide

The application of micro-electrical discharge machining (micro-EDM) in deep-hole drilling is still limited due to the difficulty in flushing of debris and unstable machining. Present study introduces a simplistic analytical model to evaluate the effectiveness of low frequency workpiece vibration during the micro-EDM drilling of deep micro-holes. In addition, experimental investigation has been conducted to validate the model by studying the effects of workpiece vibration on machining performance, surface quality and dimensional accuracy of the micro-holes. The effect of vibration frequency and amplitude for three different settings of aspect ratios has been studied experimentally. Moreover, the vibration experiments have been conducted at different levels of gap voltages and capacitances in order to understand the effect of electrical parameters and effectiveness of low-frequency workpiece-vibration at different levels of discharge energies. It has been shown analytically that the effectiveness of low frequency workpiece vibration during micro-EDM drilling can be evaluated by a parameter ‘K_v’ (ratio of maximum acceleration of the vibrating plate in gravitational direction to gravitational acceleration ‘g’), which can be determined from the vibration frequency, amplitude and phase angle of the vibrating workpiece. The theoretical model reveals that for K_v > 1, the position of debris particles will be above the workpiece; thus can be flushed away from machined zone effectively. The experimental reasons for improved micro-EDM drilling performance at the setting of K_v > 1 are found to be the increased effective discharge ratio, reduced short-circuits and improved dielectric flushing. The experimental results also reveal that the low frequency vibration is more effective at the low discharge energy level, thus making it more suitable for micro-EDM. Considering the effect on both the machining characteristics and micro-hole accuracy parameters, vibration frequency of 750 Hz and amplitude of 1.5 μm was found to provide improved performance for the developed vibration device.     

The role of indicator choice in quantifying the threat of atmospheric ammonia to the ‘Natura 2000’ network

New ‘critical levels’ (CLE) for assessing the effects of atmospheric ammonia on sensitive ecosystems have recently been adopted by the United Nations Economic Commission for Europe (UNECE) of 1 and 3 [2–4] μg NH₃ m^?3 of ambient air (including water vapour), for different species sensitivities and their associated habitats. Based on these values, we examined how indicator choice affects estimates of stock-at-risk in the European ‘Natura 2000’ network.We applied an atmospheric model, FRAME, to estimate surface air concentrations of ammonia at 5 km and 1 km resolution for the UK network of Natura sites, optionally including calibration with the National Ammonia Monitoring Network. As a base indicator, we estimated the overall percentage area of the UK Natura network that exceeded critical level thresholds (‘Area Weighted Indicator’, AWI). We compared this with an alternative approach, estimating the percentage number of Natura sites where the critical level was exceeded (‘Designation Weighted Indicator’, DWI), which we consider more relevant under the terms of the Habitats Directive.Using the AWI (with 1 km calibrated ammonia), we estimate that 11.2%, 1.3% and 0.2% area of the UK Natura network exceeds the critical level values of 1, 2 and 3 μg NH₃ m^?3, respectively. By contrast, using the DWI, the equivalent exceedances are 59.1%, 23.6% and 9.8%. The highest regional exceedance (DWI, critical level 1 μg NH₃ m^?3) was calculated for England (91.9% exceeded), and the lowest for Scotland (24.0% exceeded). High resolution maps show that the larger threat estimated by the DWI approach is explained by (i) an anti-correlation between NH₃ concentration and Natura site area and (ii) the fact that exceedance over part of a Natura site is considered to represent a threat to the integrity of the whole site.     

Soil-profile organic carbon and total nitrogen during 12 years of pasture management in the Southern Piedmont USA

Soil organic C (SOC) and total soil N (TSN) sequestration estimates are needed to improve our understanding of management influences on soil fertility and terrestrial C cycling related to greenhouse gas emission. We evaluated the factorial combination of nutrient source (inorganic, mixed inorganic and organic, and organic as broiler litter) and forage utilization (unharvested, low and high cattle grazing pressure, and hayed monthly) on soil-profile distribution (0–150 cm) of SOC and TSN during 12 years of pasture management on a Typic Kanhapludult (Acrisol) in Georgia, USA. Nutrient source rarely affected SOC and TSN in the soil profile, despite addition of 73.6 Mg ha^?1 (dry weight) of broiler litter during 12 years of treatment. At the end of 12 years, contents of SOC and TSN at a depth of 0–90 cm under haying were only 82 ± 5% (mean ± S.D. among treatments) of those under grazed management. Within grazed pastures, contents of SOC and TSN at a depth of 0–90 cm were greatest within 5 m of shade and water sources and only 83 ± 7% of maximum at a distance of 30 m and 92 ± 14% of maximum at a distance of 80 m, suggesting a zone of enrichment within pastures due to animal behavior. During 12 years, the annual rate of change in SOC (0–90 cm) followed the order: low grazing pressure (1.17 Mg C ha^?1 year^?1) > unharvested (0.64 Mg C ha^?1 year^?1) = high grazing pressure (0.51 Mg C ha^?1 year^?1) > hayed (?0.22 Mg C ha^?1 year^?1). This study demonstrated that surface accumulation of SOC and TSN occurred, but that increased variability and loss of SOC with depth reduced the significance of surface effects.     

Integrated environmental assessment of biodiesel production from soybean in Brazil

This paper presents the results of an environmental impact assessment of biodiesel production from soybean in Brazil. In order to achieve this objective, environmental impact indicators provided by Emergy Accounting (EA), Embodied Energy Analysis (EEA) and Material Flow Accounting (MFA) were used. The results showed that for one liter of biodiesel 8.8 kg of topsoil are lost in erosion, besides the cost of 0.2 kg of fertilizers, about 5.2 m² of crop area, 7.33 kg of abiotic materials, 9.0 tons of water and 0.66 kg of air and about 0.86 kg of CO₂ were released. About 0.27 kg of crude oil equivalent is required as inputs to produce one liter of biodiesel, which means an energy return of 2.48 J of biodiesel per Joule of fossil fuel invested. The transformity of biodiesel (3.90E + 05 seJ J^?1) is higher than those calculated for fossil fuels as other biofuels, indicating a higher demand for direct and indirect environmental support. Similarly, the biodiesel emergy yield ratio (1.62) indicates that a very low net emergy is delivered to consumers, compared to alternatives. Obtained results show that when crop production and industrial conversion to fuel are supported by fossil fuels in the form of chemicals, goods, and process energy, the fraction of fuel that can actually be considered renewable is very low (around 31%).     

Self-registration methods for increasing membrane utilization within compression-sealed microchannel hemodialysers

More than 1.2 million people worldwide require regular hemodialysis therapy to treat end stage renal failure. Current hemodialysis systems are too expensive to support at-home hemodialysis where more frequent and longer duration treatment can lead to better patient outcomes. The key cost driver for hemodialysers is the cost of the hemodialysis membrane. Microchannel hemodialysers are smaller providing the potential to use significantly less membrane. Prior work has demonstrated the use of sealing bosses to form compression seals in microchannel hemodialysers. In this paper, estimates show that the percentage of the membrane utilized for mass transfer is highly dependent on the design and registration accuracy of adjacent blood and dialysate laminae. Efforts here focus on the development of a self-registration method to align polycarbonate laminae compatible with compression sealing schemes for membrane separation applications. Self-nesting registration methods were demonstrated with average registration accuracies of 11.4 ± 7.2 μm measured over a 50 mm scale. Analysis shows that the registration accuracy is constrained by tolerances in the embossing process. A dialysis test article was produced using the self-nesting registration method showing a measured average one-dimensional misregistration of 18.5 μm allowing a potential 41.4% of the membrane to be utilized for mass transfer when considering both microchannel and header regions. Mass transfer results provide evidence of a twofold to threefold increase in membrane utilization over other designs in the existing literature.     

Siting restrictions and proximity of Concentrated Animal Feeding Operations to surface water

Proximity and connections to surface waters may play significant roles in determining impacts of manure spills. As occurred in many U.S. states, Minnesota adopted in 2000 more stringent regulations on Concentrated Animal Feeding Operations (CAFOs) including restrictions on siting new facilities near surface waters. The objectives of this study were to determine whether CAFO proximity to surface waters decreased following the siting restrictions and to evaluate implications of siting restrictions. Permit dates, locations, and distances to nearest surface water bodies for 111 west central Minnesota CAFOs were determined based on satellite imagery, historical records, and correspondence with regulatory officials. Average distance between surface waters and facilities permitted after 2000 was greater than for facilities permitted before 2000. The increase in average distance between CAFOs and public surface waters was significant for open water (1790 m, p = 0.03), but not for streams (280 m, p = 0.47). Decreased CAFO proximity to surface waters should benefit water quality, but after 2000 facilities continued to be permitted close to hydraulic connections not covered by the siting restriction. Comprehensive manure spill tracking and long term targeted water quality monitoring are needed to evaluate effectiveness of siting restrictions and other strategies for protecting surface waters from manure spills.     

Reduction of hexavalent chromium by polypyrrole-modified steel mesh electrode

Adherent polypyrrole (ppy) films were electropolymerized from a para-toluenesulfonic sodium (PTS) solution on stainless steel mesh (SSM). Reduced ppy-modified SSM electrode can transfer Cr(VI) to Cr(III) effectively. Lower pH (<2) or higher temperature (>35 °C) is beneficial for the removal of Cr(VI). Electro-reduction achieved 90% removal efficiency after 21 min by cyclic voltammetry. The removal efficiency is 96–56% for one–six contact cycles between ppy and Cr(VI). SEM shows that ppy films on SSM have regular morphology with small nucleus of less than 1 μm in diameter.     

Microwave cladding: A new approach in surface engineering

Cladding is generally characterized by partial dilution of the substrate and hence formation of metallurgical bonding between the substrate and the deposits. Laser cladding is one of the most widely practiced surface engineering techniques. The present work mainly focuses on a novel development in surface engineering techniques in the form of microwave cladding. Clads of tungsten carbide (WC) based WC10Co2Ni powder on austenitic stainless steel were produced using microwave hybrid heating. Microwave clads were developed by exposing the preplaced, preheated powder for a duration of 120 s to microwave radiation at 2.45 GHz frequency and 900 W power in a home microwave system. Characterization of the clads was carried out in the form of microstructural and elemental composition studies. Investigations show crack-free interface revealing good metallurgical bond associated with partial dilution of the stainless steel substrate and full melting of WC particles. Typical X-ray diffraction results confirm presence of metallic carbides in the clad which is primarily responsible for significantly higher microhardness of the clad. Process mechanism has been discussed.     

Study on machinability of a stellite alloy with uncoated and coated carbide tools in turning

Stellite alloys, which have been widely used in the aerospace, automotive and chemical industries, are hard-to-cut cobalt-based materials. This study investigates the machinability of stellite 12 alloys with uncoated carbide cutting tool grades YG610 (K01-K10) and YT726 (K05-K10/M20) and SANDVIK coated carbide tool SNMG150612-SM1105 under dry cutting conditions. Both wear mechanisms and failure modes of the uncoated and coated tools were investigated with turning experiments. The results show that the coated tool SM1105 remarkably outperforms the uncoated tools; and the cutting tool YG610 generally outperforms YT726 under all cutting conditions. Built-up edge was found with YG610 in some cutting conditions and with SM1105 at cutting speed of 16 m/min. Tool surface burning marks were observed on YT726 at relatively higher cutting speeds. Wear develops slowly with coated tools SM1105 until VB reaches 0.2 mm at most conditions (except at v = 43 m/min, f = 0.25 mm/r). Excessive tool flank typically resulted in tool breakage at the cutting edge for uncoated tools. Abrasive and adhesive wear of cutting tools were observed at low cutting speeds while diffusion and chemical wear occurred at higher cutting speeds.     

Carbon footprint of sugar produced from sugarcane in eastern Thailand

Carbon footprint (CFP) of sugar produced from sugarcane in eastern Thailand was estimated from greenhouse gas emissions (CO₂, CH₄, and N₂O) during the sugarcane cultivation and milling process. The use of fossil fuels, chemical and organic fertilizer and sugarcane biomass data during cultivation were collected from field surveys, questionnaires and interviews. Sugar mill emissions, fossil fuel utilization and greenhouse gas emission from wastewater treatments were included. The results show that sugar production has a carbon footprint of 0.55 kg CO₂e kg^?1 sugar. This carbon footprint was a sum of 0.49 kg CO₂e kg^?1 sugar from sugarcane cultivation and 0.06 kg CO₂e kg^?1 sugar from the milling process. For the cultivation part, most of the GHGs emissions were from fertilizer, fossil fuel use and biomass burning. The CFP in eastern Thailand is sensitive to the type of data selected for calculation and of variations of farm inputs during sugarcane cultivation. There was no significant difference of CFP among farm sizes, although small farms tended to give a relatively higher CFP than that of medium and large farms.     

Comparing carbon fluxes between different stages of secondary succession of a karst grassland

Abandonment of marginal agricultural areas with subsequent secondary succession is a widespread type of land use change in Mediterranean and mountain areas of Europe, leading to important environmental consequences such as change in the water balance, carbon cycling, and regional climate. Paired eddy flux measurement design with grassland site and tree/shrub encroached site has been set-up in the Slovenian Karst (submediterranean climate region) to investigate the effects of secondary succession on ecosystem carbon cycling. The invasion of woody plant species was found to significantly change carbon balance shifting annual NEE from source to an evident sink. According to one year of data succession site stored ?126 ± 14 g C m^?2 y^?1 while grassland site emitted 353 ± 72 g C m^?2 y^?1. In addition, the seasonal course of CO₂ exchange differed between both succession stages, which can be related to differences in phenology, i.e. activity of prevailing plant species, and modified environmental conditions within forest fragments of the invaded site. Negligible effect of instrument heating was observed which proves the Burba correction in our ecosystems unnecessary. Unexpectedly high CO₂ emissions and large disagreement with soil respiration especially on the grassland site in late autumn indicate additional sources of carbon which cannot be biologically processes, such as degassing of soil pores and caves after rain events.     

Material flows in the life cycle of leather

This paper presents a study on the resource and environmental profile of leather for communicating to the consumers about the environmental burdens of leather products. The results indicate that significant environmental impacts were caused during the tanning and finishing of leather as well as the electricity production and transportation required in the life cycle. The use of fossil fuels in the production of energy has greater impact with increased emissions leading to about 15190 kg CO₂ equivalent of global warming and about 73 kg SO₂ equivalent of acidification while producing 100 m² of leather for shoe uppers. Further resource use of 174 kg of coal, 6.5 kg of fuel oil, 17.4 m³ of water and 348 kg of chemicals of which about 204 kg are hazardous are consumed, and wastewater of about 17 m³, BOD of 55 kg, COD of about 146 kg, TDS of 732 kg and solid waste of about 1445 kg are generated during the life cycle for the production of 100 m² of leather. The total solid waste generated is 1317 kg, out of which about 80% is biodegradable contributed by slaughtering, tanning and finishing stage, 14% is non-biodegradable contributed by tanning, finishing and electricity production stages and 6% is hazardous mainly from tanning and finishing stage of leather.