Simulations and experiments in punching spring-steel devices with sub-millimeter features

This work demonstrates the feasibility of meso-scale (100 μm to mm) punching of multiple holes of intricate shapes in metals. Analytical modeling, finite element (FE) simulation, and experimentation are used in this work. Two-dimensional FE simulations in ABAQUS were done with an assumed material modeling and plane-strain condition. A known analytical model was used and compared with the ABAQUS simulation results to understand the effects of clearance between the punch and the die. FE simulation in ABAQUS was done for different clearances and corner radii of the punch, die, and holder. To complement modeling with real experiments and for the purpose of comparison, a set of punches and dies were made to punch out a miniature spring-steel gripper. Comparison of compliant grippers made by wire-cut electro discharge machining (EDM) and punching shows that realizing sharp interior and re-entrant corners by punching is not easy to achieve. However, the promise of realizing meso-scale parts with complicated shapes through punching is demonstrated in this work; and further work is identified and some strategies are suggested for improvement. The main contribution of this paper is in adapting the well-established punching and blanking operations to the meso-scale as a viable alternative to making miniature devices currently dominated by lithography-based techniques.     

Meeting emission targets under uncertainty—the case of Finnish non-emission-trading sector

The European Union (EU) has set a target to reduce its greenhouse gas (GHG) emissions at least 10 % below the 2005 levels by 2020 in the non-Emission Trading Sector (non-ETS). As part of this, each Member State has a binding national emission limitation target for the non-ETS sector. Finland’s target, examined as a case study in this paper, is to reduce emissions at least 16 % below 2005 levels by 2020. The objective of this study is to find cost optimal mitigation portfolios that meet Finland’s reduction target and to analyze the risks of not attaining the emission target or exceeding the assumed costs. The question was addressed with a stochastic optimization model, Stochastic Optimization of non-ETS Emissions (SONETS) selecting separate mitigation measures that meet the target on expectation. The results show that optimal portfolios include relatively high uncertainty both in costs and achieved reductions. The prices of crude oil and diesel, and the abatement cost of reducing hydrofluorocarbon (HFC) emissions seem to account for the majority of uncertainty regarding total costs. The baseline predictions for various non-ETS subsectors (such as transport and agriculture) were found to have the greatest contribution to the uncertainty of attaining emission target. The results also show that some abatement actions are chosen in nearly all efficient portfolios, while other actions are seldom chosen. For example replacing oil burners in the end of technical life time or recovery of methane (CH₄) from waste are often chosen whereas ban of landfilling of organic waste is chosen extremely seldom. It also seems that the results are somewhat sensitive to the inclusion or exclusion of the interdependencies of mitigation measures.     

Presence of Torque Teno Virus (TTV) in Tap Water in Public Schools from Southern Brazil

Torque teno virus (TTV) was surveyed in tap water collected in schools from three municipalities located in the south of Brazil. TTV genomes were found in 11.7 % (4/34) of the samples. TTV DNA was detected in 10.5 % (2/19) of the samples collected at the city of Caxias do Sul and in 25 % (2/8) of the samples from Pelotas. Those cities have a low rate of sewage treatment. All samples from Santa Cruz do Sul, which has nearly 92 % of its sewage treated, were negative. These results suggest that the amount of sewage treated may have an effect on the detection rates of TTV DNA in drinking water in a given urban area, showing a mild negative correlation (r = ?0.76), when comparing the percentage of sewage treatment to the detection of TTV genomes. The detection rate of TTV was also compared with Escherichia coli, showing a strong correlation (r = 0.97), indicating that TTV may be a suitable marker of fecal contamination.     

Dimensional analysis and scaling in mechanical mixing for fabrication of metal matrix nanocomposites

For a successful enhancement of mechanical properties of metal matrix nanocomposites, a homogeneous nanoparticle dispersion and distribution in the solidified metal is required. Mechanical mixing can be used for initial break-up of agglomerates, and its study can be simplified with dimensional analysis. Using this technique, mixing time and vortex height were assessed while varying fluid properties, impeller angle, and angular speed. Three relevant dimensionless numbers were recognized: the Reynolds (Re), Froude and Galilei (Ga) numbers. Based on blade and impeller shaft angles, a modified Froude number (Fr*) was defined. These parameters were calculated experimentally, varying angular speed from 200 to 1000 rpm for three different impeller angles: 0°, 15° and 30°. This procedure was performed with three fluids: water, and two aqueous glycerin solutions (25% and 50% by volume). Digital images were taken and processed to measure vortex height. Mixing time was measured for water at 0° impeller angle, angular speed ranging from 200 to 1200 rpm. Results showed an optimal dimensionless mixing time with respect to Re. A linear relationship was found between dimensionless vortex height and Fr*. The first had a second order polynomial relationship with the product ReFr*, regardless of impeller angle. This relationship, together with the Ga, specific for each fluid, allows scaling the results to other fluids such as molten pure aluminum. This study allows experimenting in simpler systems that involve transparent fluids, room temperature and low cost, to then elaborate a prediction of vortex height in fluids where measurements are difficult and costly, such as molten metals.     

Design and evaluation of an atomization-based cutting fluid spray system in turning of titanium alloy

Tool life has been a vital issue in machining titanium alloys. Recently, an atomization-based cutting fluid (ACF) application has been found to be an effective approach for cooling and lubrication in micromachining operations. In this study, an ACF spray system is developed for macro-scale turning of Ti–6Al–4V. The spray system is designed to minimize interaction between the fluid droplets, and the gas nozzle to control the divergence of the fluid droplets. Experiments are conducted to study the effect of five specific ACF spray parameters including fluid flow rate, spray distance, impingement angle, and type and pressure level of the droplet carrier gas on cutting forces, tool life, and chip characteristics. It has been observed that the combination of lower pressure (150 psi) air-mixed CO₂ with a higher flow rate (20 ml/min) and a larger spray distance (35 mm) produces a significantly longer tool life and broken chips. The results also reveal that the ACF spray system can extend tool life up to 40–50% over flood cooling.     

Modeling and interpretation of fiber orientation-based failure mechanisms in machining of carbon fiber-reinforced polymer composites

The development and implementation of a microstructure-based finite element model for the machining of carbon fiber-reinforced polymer composites is presented. A new approach to interfacial modeling is introduced where the material interface is modeled using continuum elements, allowing failure to take place in either tension or compression. The model is capable of describing the fiber failure mode occurring throughout the chip formation process. Characteristic fiber length in the chips, and machining forces for microstructures with fibers orientated at 0°, 45°, 90°, and 135° are examined. For model validation purposes, the model-based machining performance predictions are compared to the machining responses from a set of orthogonal machining experiments. A parametric study is presented that identifies a robust tool geometry, which minimizes the effects of fiber orientation and size on the machining forces.     

Prompting safety-belt use in the context of a belt-use law: the flash-for life revisited

PROBLEM: Safety-belt use reduces motor vehicle crash-related morbidity and mortality, yet an estimated 18% of drivers do not consistently buckle up (NHTSA, 2005). In 1985, Geller and colleagues developed an interpersonal Flash-for-Life prompt that increased belt use among 22% of 1,087 unbuckled drivers (Geller, Bruff, & Nimmer, 1985). METHOD: The Flash-for-Life intervention was re-introduced at a large university with high safety-belt use (i.e., 80%). College students stood at parking-lot entrance/exits and "flashed" signs with the message, "Please Buckle Up, I Care" to unbuckled drivers. RESULTS: Of 427 unbuckled drivers observed, 30% of these complied with the prompt. Male drivers were significantly more likely to comply with prompts delivered by females. DISCUSSION: Compliance was higher than in the 1985 study, indicating a high baseline rate of safety-belt use does not negate potential beneficial influence of a prompting intervention. This intervention is particularly effective with college-aged males, a sub-group of the driving population least likely to buckle-up. IMPACT ON INDUSTRY: A simple behavioral prompt could be used at most industrial complexes to increase safety-belt use among vehicle occupants who are not buckled-up.     

Does safety climate moderate the influence of staffing adequacy and work conditions on nurse injuries?

PROBLEM: Hospital nurses have one of the highest work-related injury rates in the United States. Yet, approaches to improving employee safety have generally focused on attempts to modify individual behavior through enforced compliance with safety rules and mandatory participation in safety training. We examined a theoretical model that investigated the impact on nurse injuries (back injuries and needlesticks) of critical structural variables (staffing adequacy, work engagement, and work conditions) and further tested whether safety climate moderated these effects. METHOD: A longitudinal, non-experimental, organizational study, conducted in 281 medical-surgical units in 143 general acute care hospitals in the United States. RESULTS: Work engagement and work conditions were positively related to safety climate, but not directly to nurse back injuries or needlesticks. Safety climate moderated the relationship between work engagement and needlesticks, while safety climate moderated the effect of work conditions on both needlesticks and back injuries, although in unexpected ways. DISCUSSION AND IMPACT ON INDUSTRY: Our findings suggest that positive work engagement and work conditions contribute to enhanced safety climate and can reduce nurse injuries.