Laser tempering based turning process for efficient machining of hardened AISI 52100 steel

Cost-effective machining of hardened steel components such as a large wind turbine bearing has traditionally posed a significant challenge. This paper presents an approach to machine hardened steel parts efficiently at higher material removal rates and lower tooling cost. The approach involves a two-step process consisting of laser tempering of the hardened workpiece surface followed by conventional machining at higher material removal rates with lower cost ceramic tools to efficiently remove the tempered material. The laser scanning parameters that yield the highest depth of tempered layer are obtained from a kinetic phase change model. Machining experiments are performed to demonstrate the possibility of higher material removal rates and improved tool wear behavior compared to the conventional hard turning process. Tool wear performance, cutting forces, and surface finish of Cubic Boron Nitride (CBN) tools as well as low cost ceramic tools are compared in machining of hardened AISI 52100 steel (~63 HRC). In addition, cutting forces and surface finish are compared for the laser tempering based turning and conventional hard turning processes. Experimental results show the potential benefits of the laser tempering based turning process over the conventional hard turning process.     

Numerical simulation of residual stresses for friction stir welds in copper canisters

In an attempt to map the residual stress distributions after friction stir welding of copper canisters, a three-dimensional thermo-mechanical model has been formulated by coupling heat transfer and elasto-plasticity analyses. The transient temperature field around the tool is simulated by a moving heat source. The simulation shows that the residual stress distribution in a thick-wall copper canister is sensitive to the circumferential angle and asymmetrical to the weld line. Both tensile and compressive stresses emerge along the weld line and its vicinity. The maximum tensile stress appears in the circumferential direction on the outer surface. The maximum tensile stress, whether it is predicted by the finite element method or measured by the hole-drilling technique and the X-ray diffraction method, does not exceed 50 MPa in general.     

Experimental investigation of the machining induced residual stress tensor under mechanical loading

Residual stress induced by machining is complex and difficult to predict, since it involves mechanical loads, temperature gradients or phase transformation in the generation mechanism. In this work, an experiment with a statistical design for the residual stress tensor was performed to investigate the residual stress profile on a machined surface. In order to understand the generation mechanism of residual stress in machining, three variables and workpiece materials were carefully selected to focus on the mechanical loads and avoid the temperature gradients and phase transformation on the machined surface. The mechanical loads considered here included the chip formation force at the primary shear zone and the plowing force at the tool tip–workpiece contact. Depths of cut and rake angles were selected to alter the chip formation force, and the tool tip radius was designed to emphasize the plowing effect. The workpiece material was aluminum 3003. The experimental results showed that the chip formation force provides basic shapes of the residual stress profile for a machined surface. It decides the depth of the peak residual stress below the surface. However, the plowing force was the dominating effect on the surface residual stress, causing high stresses on the surface. The plowing force can shift the surface stress from tensile to compressive. Additionally, the measured stress tensor proved that in-plane shear stress exists for the machined surface.     

Analytical model of metalworking fluid penetration into the flank contact zone in orthogonal cutting

Metalworking fluids (MWFs) are used widely in machining process to dissipate heat, lubricate moving surfaces, and clear chips. They have also been linked to a number of environmental and worker health problems. To reduce these impacts, minimum quantity lubrication (MQL) sprays of MWF delivered in air or CO₂ have been proposed. MQL sprays can achieve performance comparable with conventional water-based or straight oil MWFs while only delivering a small fraction of the fluid. This performance advantage could be explained by the enhanced penetration into the cutting zone that results from delivering MWF in high pressure and precise sprays. To explore this hypothesis, an analytical model of MWF penetration into the flank face of the cutting zone is developed and validated using experimental data. The model is based on a derivation of the Navier–Stokes equation and the Reynolds equation for lubrication and applied to an orthogonal cutting geometry under steady-state conditions. A solution to the model is obtained using a numerical strategy of discretizing the analytical scheme with two-dimensional centered finite difference method. Penetration into the cutting zone is estimated for MQL sprays delivered in air, CO₂ and N₂ as well as two conventional MWFs, straight oil and semi-synthetic emulsion. The model suggests that conventional MWFs, do not penetrate the cutting zone fully and fail to provide direct cooling to the flank zone where wear is most likely to occur. MQL sprays do penetrate the cutting zone completely. Using convective heat transfer coefficients from a previous study, a finite element heat balance is carried out on the tool to understand how each fluid impacts temperature near the flank tip of the tool. The results of the modeling effort are consistent with experimental measurements of tool temperature during turning of titanium (6AL4V) using a K313 carbide tool. The prediction of temperature near the flank indicates that MQL sprays do suppress temperatures near the flank effectively. These results help explain the low levels of tool wear observed for some MQL sprays, particularly those based on high pressure CO₂. This modeling framework provides valuable insight into how lubricant delivery characteristics such as speed, viscosity, and cutting zone geometry can impact lubricant penetration.     

Experimental investigation of turning AISI 1045 steel using cryogenic carbon dioxide as the cutting fluid

The intensive temperatures in high speed machining not only limit the tool life but also impair the machined surface by inducing tensile residual stresses, microcracks and thermal damage. This problem can be handled largely by reducing the cutting temperature. When the conventional coolant is applied to the cutting zone, it fails to remove the extent of the heat effectively. Hence, a cryogenic coolant is highly recommended for this purpose. In this paper, an attempt has been made to use cryogenic carbon dioxide (CO₂) as the cutting fluid. Experimental investigations are carried out by turning AISI 1045 steel in which the efficiency of cryogenic CO₂ is compared to that of dry and wet machining with respect to cutting temperature, cutting forces, chip disposal and surface roughness. The experimental results show that the application of cryogenic CO₂ as the cutting fluid is an efficient coolant for the turning operation as it reduced the cutting temperature by 5%–22% when compared with conventional machining.It is also observed that the surface finish is improved to an appreciable amount in the finished work piece on the application of cryogenic CO₂. The surface finish is improved by 5%–25% in the cryogenic condition compared with wet machining.     

Numerical modelling of electrohydraulic free-forming and die-forming of DP590 steel

Electrohydraulic forming (EHF) is a high energy rate forming process in which the strain rate in the sheet metal can vary from 5 × 10² to 10⁵ s⁻¹ depending on various factors. Several mechanisms have been reported to cause an improvement in formability in EHF such as material deformation mechanisms, inertial effects and the dynamic impact of the sheet against the die. EHF is a complex high speed forming process and experimental work alone is not sufficient to properly understand this process. To understand the variation of some influential variables in EHF, electrohydraulic die-forming (EHDF) and free-forming (EHFF) of DP590 dual phase steel were simulated in ABAQUS/Explicit by considering the fluid/structure interactions. Three-dimensional finite element simulations were conducted by modelling the water with Eulerian elements with a view to investigating the effect of released energy on the sheet deformation profile history, strain distribution, loading path and damage accumulation type. The Johnson–Cook constitutive material model was used to predict the sheet behaviour and the parameters in this model were calibrated based on experimental test results available for DP590 at various strain rates. The Johnson–Cook phenomenological damage model was also used to predict the ductile failure (damage accumulation) in both EHDF and EHFF. Predicted final strain values and damage accumulation type showed good agreement with the experimental observations.     

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.     

High speed ball nose end milling of hardened AISI A2 tool steel with PCBN and coated carbide tools

High speed machining (HSM) of tool steels in their hardened state is emerging as an attractive approach for the mold and die industry due to its potential for significant cost savings and productivity improvement. An experimental study was conducted to investigate the tool wear mechanism and surface integrity in high speed ball nose end milling of hardened AISI A2 tool steel using coated tungsten carbide and polycrystalline cubic boron nitride (PCBN) tools. It is found that coated carbide tools can only be used at low speed (120 m/min) while high content PCBN tools are suitable for HSM range (470 m/min). PCBN tools produce a damage free workpiece with better surface finish and less work hardening. Despite the higher tool cost, HSM with PCBN tools lead to reduction in both total cost and production time per part.     

A microscopic investigation of machining behavior in μED-milling process

The discussion presented in this work is about evaluation of physical behavior of μED-milling process based on channel shape, form and surface quality. μED-milling process is gaining lot of interest in recent times in micro manufacturing to generate complex shapes. Tool rotation and traverse which are not an inherent part of EDM process become important for μED-milling where it significantly influence the molten metal flow, debris flushing and redeposition. The effect of tool rotation not only disturbs the plasma but also affects the final shape and form of channel. Using scanning electron micrographs of μ-channel at different instant and conditions of machining, the physical nature of the process is understood and the results are presented. This study will provide a better understanding of the working phenomenon of μED-milling process.     

Abrasive jet machining by means of velocity shear instability in plasma

The material removal within different machining process can be performed in distinct modalities. One of the modality is based on the erosion phenomena. In this paper, theoretical model of abrasive jet machining based on erosion phenomenon is discussed. The material is removed from the surface due to erosion. In abrasive jet machining process, the output parameter is achieved by controlling various input parameters. This paper discusses the effects of various input parameters in abrasive jet machining (AJM) on the material removal rate (as the output parameter). The results presented in the paper are obtained from a theoretical study carried out with the help of mathematical model and computational technique. Theoretical investigation indicates that magnetic field, electric field and inhomogeneity in DC electric field have significant effect on metal removal by abrasive jet machining process.     

Analysis of micro-cracks on machined surfaces in dry electrical discharge machining

Micro-crack formation in the heat affected zone in EDM is a common phenomenon and many measures have been perceived to minimize their occurrence. This paper presents a comprehensive and quantitative analysis of micro-crack formation, in terms of length, number and orientation of micro-cracks formed on the machined surfaces. The influence of processing conditions on crack formation is studied using the observations under scanning electron microscope (SEM). The results indicate that the micro-crack formation is the best represented in terms of average crack length. Statistical analysis of the results shows that pulse off-time (T_off), current (I), voltage (V) and electrode rotation speed (N) significantly influence the average crack length in both wall and bottom regions of the machined hole. In dry EDM, micro-crack formation occurs due to segregation of elements in the work surface and inter-diffusion of elements between work, and shield. A comparison of crack formation with the liquid dielectric EDM shows that average length and number density of micro-cracks were lower in the dry EDM than those in the liquid dielectric EDM.     

Modeling of residual chlorine in water distribution system

Water quality within water distribution system may vary with both location and time.Water quality models are used to predict the spatial and temporal variation of water quality throughout water system.A model of residual chlorine decay in water pipe has been developed, given the consumption of chlorine in reactions with chemicals in bulk water,bio-films on pipe wall, in corrosion process, and the mass transport of chlorine from bulk water to pipe wall.Analytical methods of the flow path from water sources to the observed point and the water age of every observed node were proposed .Model is used to predict the decay of residual chlorine in an actual distribution system.Good agreement between calculated and measured values was obtained.     

PCR-DGGE分析技术在环境检测中的应用

多聚酶链式反应结合变性梯度凝胶电泳（PCR-DGGE）分析技术是一项基于分子生物学技术的分析方法。文章综述了PCR—DGGE分析技术的产生背景、基本原理和在环境微生物检测中的应用现状，并对该技术的优缺点和今后的应用前景进行了探讨。     

环境样品中多氯联苯的分析技术

作为一种持久性有机污染物,多氯联苯在地球上的分布十分广泛。然而由于多氯联苯在环境样品中残留浓度低、干扰物质多且组成复杂,必须对环境样品进行预处理。目前较为常用的含多氯联苯样品的前处理技术有：溶剂萃取技术、固相萃取技术、固相微萃取技术、超临界萃取技术、微波萃取技术和加速溶剂萃取技术等,分析经过技术处理以后的样品常用的方法有化学分析方法和生物分析方法,化学方法包括气相色谱法,气相色谱质谱分析法等;生物方法有生物传感器测定法、表面胞质团共振检测、以Ah受体为基础的生物分析法和酶联免疫检测法。中国在这方面的研究投入不够,应加大人力、财力和物力的支持,提高环境样品中多氯联苯的检测水平。     

Prediction of polycrystalline materials texture evolution in machining via Viscoplastic Self-Consistent modeling

The crystallographic orientation or anisotropy is one of the main microstructural attributes strongly affecting the mechanical properties of materials. It is also an influential parameter to be considered during the manufacturing process especially for ultra-precision machining since it affects part quality, tool performance, and process productivity through material properties. In this study, a prediction toolset constituted of a Viscoplastic Self-Consistent model and machining process mechanics model is used to predict the texture evolution on the machined surface. The VPSC (Viscoplastic Self-Consistent) methodology which uses the mechanisms of slip and twinning that are active in single crystals of arbitrary symmetry was used. For this, an analytical model for the process mechanics is derived to understand the forces and stresses generated by the cutting tool at each workpiece point, then the strain and strain rate to capture the rate at which the material is deforming and finally the crystallographic orientations under various machining conditions. Experiments were performed on the orthogonal cutting of aluminum alloy AA-7075-T651 and the texture results were compared to model predictions.     

污水中硫化物分析方法的改进

根据<水和废水监测分析方法>(第三版)中规定的污水中硫化物分析的预处理方法,水样中加1 1的磷酸10ml酸化水样,使水样中的硫化物转变成硫化氢气体,利用高纯氮气,控制好载气流速将硫化氢气体吹出,用乙酸锌-乙酸钠溶液吸收,吹气的时间为45min.同时采用65～80℃的水浴温度加热烧瓶,提高污水中硫化氢的回收率.我们通过平时的对比实验发现,该测定方法时间长,而且存在较大的误差,回收率偏低,影响了实验的速度和测定结果的准确性.为此,针对以上情况,我们对该实验方法进行了改进.实验证明该方法具有准确度高,精密度好,测定周期短等优点,完全能满足污水中硫化物监测的需要.     

连续流动分析测定环境水样中的CODCr

本文介绍了利用新型的连续流动分析仪对环境水样中的化学需氮量(CODCr)进行分析测定,该法的分析速率35个样/h ,检出限1 3mg/L ,加标回收率为96 89%～10 2 4 9%。     

绿色分析技术在环境监测中的应用

环境监测中的样品准备、预处理及分析测试等过程都会产生污染物,采用绿色分析技术有助于从源头减少污染物的产生和排放,保护监测人员身体健康和环境质量。文章介绍了绿色分析技术的概念、目标和主要手段,阐述了各类绿色分析技术的方法原理、特点,分析了在环境监测中的应用现状和前景。     

Analytical reconstruction of three-dimensional weld pool surface in GTAW

The reflective characteristic of mirror surfaces such as a liquid pool surface in arc welding makes many traditional 3D measurement/reconstruction methods fail. The authors proposed to intercept, image, and measure two points in each laser ray reflected from a mirror surface with two diffusive planes and cameras to analytically calculate the equation of the ray. The samples of the points on the mirror surface where the incident laser rays are reflected can thus be analytically calculated as the intersections of the reflection rays with the corresponding incident rays. In this paper, the proposed method is applied to reconstruct the samples on the specular three-dimensional weld pool surface in GTAW (gas tungsten arc welding). Since two diffusive planes are used and must be placed with considerable distance to assure the accuracy of the calculated equations of the reflected rays, focusing reflected laser rays on these two planes becomes an issue. A trade-off among the size of the projected laser pattern, the distances of the arc light with the two diffusive planes, the focus range of the laser rays and the quality of the reflected laser dot images on the diffusive planes has been made to resolve this issue successfully. Further, calibration errors in the locations of the diffusive planes directly affect the accuracy of the calculated equations of reflected rays and an accurate calibration appears to impractical. To resolve this issue, the authors found the least deformation principle and successfully applied it to minimize the calculation errors through calibration rectification. Several weld pool surfaces have been sampled and reconstructed and experimental results verified the effectiveness of the proposed analytical method.