Surface modification of die steel materials by EDM method using tungsten powder-mixed dielectric

Surface modification by material transfer during electrical discharge machining (EDM) has emerged as a key research area in the last decade. Material may be provided to the machined surface of the workpiece by the eroding tool electrode or by using powder-mixed dielectric. Breakdown of the hydrocarbon dielectric contributes carbon to the plasma channel which may also cause surface modification. The present work has investigated the response of three die steel materials to surface modification by EDM method with tungsten powder mixed in the dielectric medium. Taguchi experimental design technique was used to conduct the experiments on each work material independently. Peak current, pulse on-time and pulse off-time were taken as variable factors and micro-hardness of the machined surface was taken as the response parameter. X-ray diffraction (XRD) and spectrometric analysis show substantial transfer of tungsten and carbon to the workpiece surface and an improvement of more than 100% in micro-hardness for all the three die steels. Presence of tungsten carbide (WC and W₂C) indicates that its formation is taking place in the plasma channel. Machining parameters for the best value of micro-hardness for each work material were found to be the same.     

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.     

Experimental investigation and characterization of nano-scale dry electro-machining

This paper presents an experimental investigation and characterization of a novel technique of nanoscale electro-machining (EM) in atmospheric air, named dry nano-EM, by using scanning tunneling microscopy (STM) as the platform for nanomachining. The electro-machining has been conducted in near field by maintaining a gap distance of 1–2 nm between the Platinum–Iridium [Pt–Ir (80:20)] tool electrode and atomically flat gold substrate with the air as dielectric medium. An in situ process of evaluating the tool quality before and after machining has been used by monitoring the current–displacement (I–Z) spectroscopy curves. The mechanism of dry nano-EM has been presented as well as the machining performance of the process has been evaluated. Based on the observations, it has been established that field induced evaporation due to intense heat generated at the gap width is the primary mechanism of material removal in dry nano-EM. The experimental results show that dry nano-EM is capable of fabricating consistent nano-features with good repeatability. The volume of material removal increases almost linearly with increasing number of features machined and machining time, indicating the consistency in the dimensions of the nano-features. Finally, dry nano-EM is established as a technique capable of machining 50–100 features in a pre-defined manner with average feature size of 7.5–10 nm in a single pass, thus suitable for nano-patterning in atomically flat electrically conducting surfaces.     

The effect of spindle speed,feed-rate and machining time to the surface roughness and burr formation of Aluminum Alloy 1100 in micro-milling operation

This paper describes the characteristics and the cutting parameters performance of spindle speeds (n, rpm) and feed-rates (f, mm/s) during three interval ranges of machining times (t, minutes) with respect to the surface roughness and burr formation, by using a miniaturized micro-milling machine. Flat end-mill tools that have two-flutes, made of solid carbide with Mega-T coated, with 0.2 mm in diameter were used to cut Aluminum Alloy AA1100. The causal relationship among spindle speeds, feed-rates, and machining times toward the surface roughness was analyzed using a statistical method ANOVA. It is found that the feed-rate (f) and machining time (t) contribute significantly to the surface roughness. Lower feed-rate would produce better surface roughness. However, when machining time is transformed into total cut length, it is known that a higher feed-rate, that consequently giving more productive machining since produce more cut length, would not degrade surface quality and tool life significantly. Burr occurrence on machined work pieces was analyzed using SEM. The average sizes of top burr for each cutting parameter selection were analyzed to find the relation between the cutting parameters and burr formation. In this research, bottom burr was found. It is formed in a longer machining time compare the formation of top burr, entrance burr and exit burr. Burr formation is significantly affected by the tool condition, which is degrading during the machining process. This knowledge of appropriate cutting parameter selection and actual tool condition would be an important consideration when planning a micro-milling process to produce a product with minimum burr.     

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.     

Finite element modeling of microstructural changes in turning of AA7075-T651 Alloy

The surface characteristics of a machined product strongly influence its functional performance. During machining, the grain size of the surface is frequently modified, thus the properties of the machined surface are different to that of the original bulk material. These changes must be taken into account when modeling the surface integrity effects resulting from machining. In the present work, grain size changes induced during turning of AA7075-T651 (160 HV) alloy are modeled using the Finite Element (FE) method and a user subroutine is implemented in the FE code to describe the microstructural change and to simulate the dynamic recrystallization, with the consequent formation of new grains. In particular, a procedure utilizing the Zener–Hollomon and Hall–Petch equations is implemented in the user subroutine to predict the evolution of the material grain size and the surface hardness when varying the cutting speeds (180–720 m/min) and tool nose radii (0.4–1.2 mm). All simulations were performed for dry cutting conditions using uncoated carbide tools. The effectiveness of the proposed FE model was demonstrated through its capability to predict grain size evolution and hardness modification from the bulk material to machined surface. The model is validated by comparing the predicted results with those experimentally observed.     

Toluene decomposition performance and NOx by-product formation during a DBD-catalyst process

Characteristics of toluene decomposition and formation of nitrogen oxide (NOx) by-products were investigated in a dielectric barrier discharge (DBD) reactor with/without catalyst at room temperature and atmospheric pressure. Four kinds of metal oxides, i.e., manganese oxide (MnOx), iron oxide (FeOx), cobalt oxide (CoOx) and copper oxide (CuO), supported on Al₂O₃/nickel foam, were used as catalysts. It was found that introducing catalysts could improve toluene removal efficiency, promote decomposition of by-product ozone and enhance CO₂ selectivity. In addition, NOx was suppressed with the decrease of specific energy density (SED) and the increase of humidity, gas flow rate and toluene concentration, or catalyst introduction. Among the four kinds of catalysts, the CuO catalyst showed the best performance in NOx suppression. The MnOx catalyst exhibited the lowest concentration of O₃ and highest CO₂ selectivity but the highest concentration of NOx. A possible pathway for NOx production in DBD was discussed. The contributions of oxygen active species and hydroxyl radicals are dominant in NOx suppression.     

Study of ultrasonic assisted cryogenically cooled EDM process using sintered (Cu–TiC) tooltip

In most EDM operations, the maximum contribution in the total operation cost is the tool cost. Electrode wear is a major problem in EDM process. Therefore, in this paper, the process performance of sintered copper (Cu)–titanium carbide (TiC) electrode tip in ultrasonic assisted cryogenically cooled electrical discharge machining (UACEDM) has been studied. The performance parameters studied in this paper are electrode wear ratio (EWR), material removal rate (MRR), surface roughness (SR), out of roundness and surface integrity. The process parameters considered in this study are discharge current, pulse on time, duty cycle and gap voltage. Cermet was fabricated, having copper content of 75% and titanium carbide content of 25%, by mixing, pressing, and sintering. The performance of the newly formed cermet electrode tip is compared with conventional copper electrode tip for UACEDM process and analyzed. It has been observed that EWR and out of roundness decreases when cermet electrode tip is used as compared to conventional tooltip. It has also been observed that MRR and SR increase when cermet tooltip is used. The surface cracks density and crack width on workpiece machined by cermet tooltip have been found to be lesser as compared to the specimen machined by conventional tooltip.     

Three-dimensional laser machining of structural ceramics

Three- dimensional laser machining of structural ceramics such as alumina (Al₂O₃), silicon nitride (Si₃N₄), silicon carbide (SiC) and magnesia (MgO) was carried out using a 1.06 μm wavelength pulsed Nd:YAG laser. The rate of machining predicted in terms of material removed per unit time (mg/s) increased with an increase in heating rate (K/s). A thermal model based on temperature dependent absorptivity and thermophysical properties, in addition to conduction, convection and radiation based heat transfer, was developed to predict material removal rate. Predicted values were compared with actual measurements made from machined cavities. Such a study would enable advance predictions of the laser processing conditions required to machine cavities of desired dimensions.     

Formic acid and acetic acid: Emissions,atmospheric formation and dry deposition at two southern California locations

Emission rates, in situ formation rates and removal rates by dry deposition are estimated for formic acid (HCOOH, C1) and acetic acid (CH₃COOH, C2), which are the most abundant acids in southern California air and together account for much of the airborne acidity and are the leading contributors to acid dry deposition. Using data for eight unreactive tracers, direct emission rates during the fall 1987 are estimated to be 5.6 and 12.8 metric tons d⁻¹ for C1 and C2, respectively, at a coastal source-dominated site. These emissions rates increase to 9.6(C1) and 20.4(C2) metric tons d⁻¹ during the summer. In situ formation in the atmosphere via the ozone-olefin reaction is an important source for both acids. This reaction produces an estimated 25.0 and 10.1 metric tons d⁻¹ of C1 and C2, respectively, during the day and 34.5 (C1) and 4.3 (C2) metric tons d⁻¹ at night. More acetic acid than formic acid is emitted by direct sources, with C2/C1 emission rate ratios of 2.1–2.3. The reverse is true of in situ formation, with C1/C2 production rate ratios of 2.5 (day) and 8.0 (night). Dry deposition removal rates depend on season (fall > summer) and location (inland > coastal) and are 22–52 metric tons d⁻¹ for C1, and 32–83 metric tons d⁻¹ for C2. Source (emissions + in situ formation) and sink (dry deposition) terms are of the same magnitude in all six cases studied and balance each other well in three of these cases. Uncertainties in emission, in situ production and removal rates are discussed and reflect uncertaintes in olefin and unreactive tracer emission rates, yields of organic acids from the Criegee biradical (ozone-olefin reaction), and dry deposition velocity, respectively.     

Modeling and optimization of turning duplex stainless steels

The attractive combination of high mechanical strength, good corrosion resistance and relatively low cost has contributed to making duplex stainless steels (DSSs) one of the fastest growing groups of stainless steels. As the importance of DSSs is increasing, practical information about their successful machining is expected to be crucial. To address this industrial need, standard EN 1.4462 and super EN 1.4410 DSSs are machined under constant cutting speed multi-pass facing operations. A systematic approach which employs different modeling and optimization tools under a three phase investigation scheme has been adopted. In phase I, the effect of design variables such as cutting parameters, cutting fluids and axial length of cuts are investigated using the D-Optimal method. The mathematical models for performance characteristics such as; percentage increase in radial cutting force (%F_r), effective cutting power (P_e), maximum tool flank wear (VB_max) and chip volume ratio (R) are developed using response surface methodology (RSM). The adequacy of derived models for each cutting scenario is checked using analysis of variance (ANOVA). Parametric meta-heuristic optimization using Cuckoo search (CS) algorithm is then performed to determine the optimum design variable set for each performance. In the phase II, comprehensive experiment-based production cost and production rate models are developed. To overcome the conflict between the desire of minimizing the production cost and maximizing the production rate, compromise solutions are suggested using Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). The alternatives are ranked according to their relative closeness to the ideal solution. In the phase III, expert systems based on fuzzy rule modeling approach are adopted to derive measures of machining operational sustainability called operational sustainability index (OSI). Artificial neural network (ANN) based models are developed to study the effect of design variables on computed OSIs. Cuckoo search neural network systems (CSNNS) are finally utilized to constrainedly optimize the cutting process per each cutting scenario. The most appropriate cutting setup to ensure successful turning of standard EN 1.4462 and super EN 1.4410 for each scenario is selected in accordance with conditions which give the maximum OSI.     

Analytical modelling of residual stresses in orthogonal machining of AISI4340 steel

Residual stress profile in a component is often considered as the critical characteristic as it directly affects the fatigue life of a machined component. This work presents an analytical model for the prediction of residual stresses in orthogonal machining of AISI4340 steel. The novelty of the model lies in the physics-based approach focusing on the nature of contact stresses in various machining zones and the effect of machining temperature. The model incorporates: (i) stresses in three contact regions viz. shear, tool-nose-work piece and tool flank and machined surface, (ii) machining temperature, (iii) strain, strain rate and temperature dependent work material properties, (iv) plastic stresses evaluation by two algorithms, S-J and hybrid, (v) relaxation procedure and (iv) cutting conditions. The model benchmarking shows (86–88%) agreement between the experimental and predicted residual stresses in the X- and Y-directions. On the machined surface, the tensile residual stresses decrease with an increase the edge radius and increase with an increase the cutting speed. However, below the surface, the compressive residual stresses increase with an increase the depth of cut. Further, it is observed that the proposed model with hybrid algorithm gives better results at a lower feed rate, whereas with the S-J algorithm, at a higher feed rate.     

温瑞塘河流域水体污染时空分异特征及污染源识别

不同季节主要污染物的空间分布特征及其潜在的污染源分析对水资源管理与污染控制具有重要意义.本研究应用GIS、主成分分析方法对2008-09~2009-10温瑞塘河水的温度、DO、电导率、p H、浊度、NH+4-N、NO-2、NO-3、PO3-4、Si O2-3、H2S、TOC、TN等水质参数进行时空分异特征分析和潜在污染源的识别.结果表明流域内丰水期、平水期、枯水期的典型污染物是TN、NH+4-N、PO3-4,主要来自于工业和生活点源;空间上水质污染程度是三级河道二级河道一级河道,无论几级河道市区的水质都劣于郊区和湿地;时间上水质污染程度是枯水期平水期丰水期;另外河道周边人口密度、土地利用类型及其调水对温瑞塘河的水质产生了不同程度的影响.     

Aerosol-soil fractionation for Namib Desert samples

Four soil samples, collected in the central Namib Desert, were fractionated by dry sieving and aerosol generation into 16 size fractions in the range 0.15–300 μm diameter. The mass-size function of each soil and the dust (mineral aerosol) generated from the soil were studied. Due to the preferential lifting of smaller soil particles by the air stream, the soil underwent strong physical fractionation resulting in the bulk of the dust being found in the range of 1.3–10.3 μm, whereas the bulk of the soil was found in the range 63–300 μm. The concentrations of 11 elements in eight soil size fractions (from <45 to >300 μm) obtained by dry sieving were measured by X-ray fluorescence analysis while the concentration for these elements in eight size ranges (from <0.15 to >10.3 μm) obtained by aerosol generation were determined by particle-induced X-ray emission. The concentrations of the elements Al, Si, K, Rb and Sr were found to vary by less than a factor of two throughout the particle size range studied. However, the concentration of the elements Ca, Ti, Mn, Fe, Y and Zr increased when the particle size decreased below 150 μm to reach a maximum around 63-45 μm and then to decrease. The concentrations of the elements in the generated aerosol particles were found to be more similar to those in the bulk soil than any particular size fraction. For the aerosol size fraction, elemental enrichment factors were calculated with respect to the composition of average crustal rock, average soil, the bulk Namib soil and the small size fraction of the Namib soil. For several elements, the enrichment factors varied quite significantly, depending on the choice of the reference material. The elemental ratios in the mineral aerosol were also compared to those in the atmospheric aerosol from the Namib Desert. It was confirmed that there is a marine contribution for S, Cl and Sr in the Namib natural aerosol. The composition of the mineral aerosol generated in this study should be useful in source apportionment studies for the Namib Desert and sorrounding regions.     

典型城市河流表层沉积物中汞污染特征与生态风险

以北京市凉水河为研究对象,研究了典型城市河流表层沉积物中汞污染特征与生态风险.采用王水水浴消解法和BCR三步提取法分析沉积物中汞总量及其赋存形态特征,并利用潜在生态风险指数法和风险评估指数法评价汞的生态风险.结果表明,凉水河表层沉积物中总汞含量范围是0.018~3.48 mg·kg~(-1),平均值是0.974 mg·kg~(-1),多数样点高于北京市土壤背景值;表层沉积物中汞主要以残渣态(B4态)存在,平均含量为0.841 mg·kg~(-1),各形态汞所占比例顺序为:残渣态(B4态)可氧化态(B3态)可还原态(B2态)弱酸可溶解态(B1态),其中生物有效态汞占总汞的比例为23.21%.基于汞总量的潜在生态风险评价可知,凉水河各个河段表层沉积物中汞的潜在生态风险程度都处于很高水平(Ei平均值为565);但基于汞形态的生态风险评价可知,汞的生态风险都处于较低水平(B1所占比例平均值为4.80%).     

Problems and perspectives of sludge utilization in agriculture

Sewage sludge utilization in agriculture leads to several advantages through the recycling of nutrient and organic matter to the land.Inorganic nitrogen as NO₃⁻¹and NH₄⁺ becomes immediately available; organic nitrogen becomes available after mineralization, which depends on soil type and tends largely to diminish with time.The soluble forms of phosphorus are H₂P0₄⁻ and HPO₄²⁻ and the percentage P-utilization can easily be predicted from the amount extracted by ammonium chloride.Potassium concentration in sewage sludge is negligible, but crop requirements for it are high and often comparable to those for nitrogen.Organic matter mainly affects soil structure by increasing soil porosity, stability of aggregates and water retention; other properties affected by organic matter addition are pH and cation exchange capacity, which tend to increase.Negative effects due to heavy metals (toxic and phytotoxic) and pathogens can arise following sludge addition to soil. Epidemiological studies in the U.K. indicate that infections can arise, in particular from the presence of Taenia saginata and Salmonella.A recent survey in the European Economic Community (E.E.C.) revealed that nowadays 75% of sewage is treated and 40% of the residual sludges are used in agriculture (about 2 million t (2 M t) of dry solids year⁻¹), affording a saving in mineral fertilizers of about 206 000 M L It. year⁻¹ (£82AM; DM 295M; 100M FF). This economic advantage covers the cost of transport over a distance of 8 km and that of spreading the liquid sludge.This paper also compares the legislations of some countries concerning sewage sludge utilization in agriculture and shows that generally the countries with more experience in sludge utilization (France, Germany and the U.K.) permit disposal of higher concentrations of heavy metals.     

Monitoring the dry deposition of SO2 in the Netherlands: Results for grassland and heather vegetation

An automated system based on the micrometeorological gradient technique has been developed to measure the dry deposition of SO₂ on a routine basis. Measurements were made at two locations in the Netherlands. From these results dry deposition fluxes, dry deposition velocities and surface resistances for a heathland and for an agricultural grassland site were estimated using a selected set of data and a calculation procedure based on micrometeorological considerations. An extensive analysis was made to determine uncertainties in the resulting deposition parameters. From this analysis it has been concluded that the uncertainty in these parameters is almost completely determined by the random errors in measured concentrations. The meteorological surface exchange parameters can be estimated sufficiently accurately (<20% uncertainty). At the grassland site, average surface resistances to deposition of 6(±8) and 13(±12) s m⁻¹ were calculated for wet and dry conditions, respectively. At the heathland site, a similar distinct difference between R_c values for wet and dry conditions was found. These values are 20(±21) and 70(±90) s m⁻¹, respectively. The yearly average dry deposition flux for SO₂ at the grassland site amounts to 585(±330) mol ha⁻¹ yr⁻¹, while at the heathland site the yearly average flux was 300(±270) mol ha⁻¹ yr⁻¹. The yearly average dry deposition velocity at 4 m height was 1.2(±0.3) cm s⁻¹ at the grassland site and 0.8(±0.4) cm s⁻¹ at the heathland site.     

赤水河流域水体抗生素污染特征及风险评价

为了初步探究贵州赤水河流域地表水的抗生素浓度分布特征及潜在生态风险,利用固相萃取-液相色谱串联质谱法(SPE-LC-MS)对地表水样品中21种抗生素进行检测分析.结果表明,赤水河地表水共检出12种抗生素,总浓度水平为ND～1 166.97 ng·L-1,氧氟沙星、甲氧苄啶和磺胺嘧啶的检出率均为100％.平均检出浓度最高...     

Modeling of acute cadmium toxicity in solution to barley root elongation using biotic ligand model theory

Protons（H⁺）as well as different major and trace elements may inhibit cadmium（Cd）uptake in aquatic organisms and thus alleviate Cd toxicity.However,little is known about such interactions in soil organisms.In this study,the independent effects of the cations calcium(Ca²⁺),magnesium(Mg²⁺),potassium（K⁺）,H+and zinc(Zn²⁺)on Cd toxicity were investigated with 5-day long barley root elongation tests in nutrient solutions.The tested concentrations of selected cations and trace metal ions were based on the ranges that occur naturally in soil pore water.The toxicity of Cd decreased with increasing activity of Ca²⁺,Mg²⁺,H⁺and Zn²⁺,but not K⁺.Accordingly,conditional binding constants were obtained for the binding of Cd²⁺,Ca²⁺,Mg²⁺,H⁺,and Zn²⁺ with the binding ligand:log K_CdBL5.19,logK_CaBL2.87,logK_MgBL2.98,logK_HBL5.13 and logK_ZnBL5.42,respectively.Furthermore,it was calculated that on average 29% of the biotic ligand sites needed to be occupied by Cd to induce a 50% decrease in root elongation.Using the estimated constants,a biotic ligand model was successfully developed to predict the Cd toxicity to barley root elongation as a function of solution characteristics.The feasibility and accuracy of its application for predicting Cd toxicity in soils were discussed.     

Effect of process parameters on the performance of EDM process with ultrasonic assisted cryogenically cooled electrode

In this work the parametric study on EDM process using ultrasonic assisted cryogenically cooled copper electrode (UACEDM) during machining of M2 grade high speed steel has been performed. Electrode wear ratio (EWR), material removal rate (MRR) and surface roughness (SR) was the three parameters observed. Discharge current, pulse on time, duty cycle and gap voltage were the controllable process variables. The effect of process variables on EWR, MRR and SR has been analyzed. The MRR, EWR and SR obtained in EDM process with normal electrode, cryogenically cooled electrode and ultrasonic assisted cryogenically cooled electrode have been compared. EWR and SR were found to be lower in UACEDM process as compared to conventional EDM for the same set of process parameters, while MRR was at par with conventional EDM process. The surface integrity of work piece machined by UACEDM process has been found to be better as compared to conventional EDM process. The shape of the electrode has also been measured and it was found that the shape retention was better in UACEDM process as compared to conventional EDM process. Thus in the present work UACEDM process has been established to be better than conventional EDM process due to better tool life, tool shape retention ability and better surface integrity.