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.     

Modulation-assisted high speed machining of compacted graphite iron (CGI)

The application of controlled, low-frequency modulation (～100 Hz) superimposed onto the cutting process in the feed-direction – modulation-assisted machining (MAM) – is shown to be quite effective in reducing the wear of cubic boron nitride (CBN) tools when machining compacted graphite iron (CGI) at high machining speeds (>500 m/min). The tool life is at least 20 times greater than in conventional machining. This significant reduction in wear is a consequence of the multiple effects realized by MAM, including periodic disruption of the tool–workpiece contact, formation of discrete chips, enhanced fluid action and lower cutting temperatures. The propensity for thermochemical wear of CBN, the principal wear mode at high speeds in CGI machining, is thus reduced. The tool wear in MAM is also found to be smaller at the higher cutting speeds (730 m/min) tested. The feed-direction MAM appears feasible for implementation in industrial machining applications involving high speeds.     

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.     

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.     

Process modification in the scouring process of textile industry

The effects of scouring parameters on the scouring efficiency, including the weight ratio of de-sizing agent and fabric (5–80 g/g fabric), temperature of de-sizing agent tank (60–90 °C) and dipping time (2–8 s), were investigated. The results demonstrated that weight loss of sizing agent was significantly observed only in the de-sizing agent tank particularly in the first de-sizing tank and was found to a small extent in water tank. The optimum condition in the scouring machine was found at a de-sizing agent to fabric ratio of 20 g/g fabric, with a temperature of the first de-sizing agent tank of 80 °C, a temperature of the second de-sizing agent tank of 90 °C, and dipping time of fabric of 7 s. According to these conditions, more than 89% of the sizing agent was eliminated and only 3.52 mg/g fabric of sizing agent remained in the scoured fabric which was in an acceptable range for feeding to the down stream process known as dyeing process. Application of our results to actual textile plant has shown that there is a cost reduction due to improved utilization of rinse water, chemicals and energy in the process and consequent decreases in the generation of wastewater. Furthermore, the production capacity was increased from 30 m/min to 34.4 m/min.     

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.     

On wear resistance of tool steel

Maintaining a reasonably low cutting tool wear when producing forming tools is a general challenge in the development of new forming tool materials. The tool life of a hot forming tool steel (H13) has been significantly improved by reducing its Si-content from 1.0 to 0.06 wt.%. However, this modified H13 (MH13) also displays a reduced cutting tool life due to higher cutting forces and a stronger tendency to form built up layers (BUE) on the cutting edge. This paper explains why.Gleeble tests of MH13 revealed a significantly higher flow stress in the 820–900 °C temperature interval in MH13 compared to H13. Thermo-Calc simulations showed that when reducing the Si-content from 1.0 to 0.06 wt.% the initial temperature for ferrite-to-austenite transformation (A1) was reduced from 900 °C to 820 °C. Knowing that austenite has totally different mechanical and thermal properties than ferrite, the difference in A1 between the two steels explains the higher cutting forces and higher tendency for BUE-formation. The conclusion is that the difference in machinability between H13 and MH13 is primarily related to their difference in A1.An attempt was also made to find a new tool material composition that can combine the wear resistance of MH13 and the good machinability of H13. Thermo-Calc simulations were performed with slightly modified alloying content without changing its properties as a good forming tool material, with the aim to increase A1. For instance, reducing the Mn content from 0.5 to 0.05 wt.% proved to increase A1 from 820 to 850 °C.     

Market-based approaches and tools for improving water and air quality

Nitrogen (N) losses from agriculture are negatively impacting groundwater, air, and surface water quality. National, state, and local policies and procedures that can mitigate these problems are needed. Market-based approaches where waste treatment plants (point sources) can purchase nutrient credits from upstream agricultural operations (non-point sources) to meet their National Pollutant Discharge Elimination System permit requirements within the Clean Water Act are being explored. This paper reviews these market-based approaches for enhancing air and water quality at a lower cost than simple command-and-control regulation, and describes new tools that are being developed, such as Nitrogen Trading Tool (NTT), that can be used to assess nitrogen losses to the environment under different management scenarios. The USDA-NRCS, EPA and several other state and local agencies are interested in these new tools. The NTT, though primarily designed for water quality markets, also estimates savings in nitrous oxide (N₂O) emissions that can be traded in carbon markets. For example, an analysis using NTT shows that for 100 ha of crop land, a C sequestration equivalent of approximately 25–38 Mg C y^?1 for a farm in Ohio, and 13–21 Mg C y^?1 for a farm in Virginia could be achieved with better nitrogen management practices. These numbers across a watershed could be much larger with improved N and conservation management practices that contribute to better water quality and lower global warming potential. There is a need to further develop, calibrate, and validate these tools to facilitate nitrogen and carbon trading future markets around the globe to increase environmental conservation across agro-ecosystems worldwide.     

Water jet guided laser as an alternative to EDM for micro-drilling of fuel injector nozzles: A comparison of machined surfaces

To characterize the inner surface of the fuel injector nozzle holes drilled by EDM and water jet guided laser drilling (Laser Micro-Jet) a specifically conceived scanning probe microscopy technique with true non-contact operating mode was used. A difference in morphology of the drilled surfaces is evident from the acquired surface topography along the hole axis for the two compared drilling techniques. Results showed that the surface texture can be characterized by (i) maximum peak-to-valley distance and (ii) periodicity. Acquired maps confirm that electro-eroded surfaces are an envelope of craters randomly distributed with total excursion up to 1.7 μm with a crater size of 15 μm. While, the efficient melt expulsion and immediate cooling of water jet guided laser generates a peak to valley distance of 800 nm with a periodicity of 18 μm. Average R_q derived from the measured cylindrical surfaces was 450 nm and 150 nm for EDM and Laser Micro-Jet, respectively. Water jet guided laser drilling has proved to be a reliable alternative to EDM from the point of view of repeatability of the results and surface quality to facilitate the atomization of the fuel jet.     

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.     

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.     

Scale-up modeling of the twin roll casting process for AZ31 magnesium alloy

In the present study, a 2-D finite-element method (FEM) thermal-fluid-stress model has been developed and validated for the twin roll casting (TRC) of AZ31 magnesium alloy. The model was then used to quantify how the thermo-mechanical history experienced by the strip during TRC would change as the equipment was scaled up from a laboratory size (roll diameter = 355 mm) to a pilot scale (roll diameter = 600 mm) and to an industrial scale (roll diameter = 1150 mm) machine. The model predictions showed that the thermal history and solidification cooling rate experienced by the strip are not affected significantly by caster scale-up. However, the mechanical history experienced by the strip did change remarkably depending on the roll diameters. Casting with bigger rolls led to the development of higher stress levels at the strip surface. The roll separating force/mm width of strip was also predicted to increase significantly when the TRC was scaled to larger sizes. Using the model predicted results, the effect of both casting speed and roll diameter was integrated into an empirical equation to predict the exit temperature and the roll separating force for AZ31. Using this approach, a TRC process map was generated for AZ31 which included roll diameter and casting speed.     

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.     

Development and characterization of microwave composite cladding

The development of cladding through microwave radiation is recently explored and very few, initial studies were reported elsewhere. In order to explore more viability of process, (EWAC (Ni based) + 20% Cr₂₃C₆ powder) composite cladding has been developed on substrate austenitic stainless steel (SS-316). The experiments were conducted in domestic microwave oven and the clad of thickness, approximate 500 m has been developed by the exposure of microwave radiation at frequency 2.45 GHz for duration of 360 s. Typical clads cross sections of composite clads showed good metallurgical bonding with the substrate by partial dilution. The back scattered electron image of clad cross section showed the reinforced chromium carbide (Cr₂₃C₆) particles are uniformly distributed and well embedded in the Ni based matrix. The developed clad is free from visible solidification cracking and has significantly less porosity which is of the order of 0.90%. The XRD pattern of the developed clad showed the presence of FeNi₃, NiSi and Cr₂₃C₆ phases. The average Vicker's microhardness of developed clad was observed as 425 ± 140 Hv.     

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.     

Investigation of chipping and wear of silicon wafer dicing

Wafer dicing chipping and blade wear processes in transient and steady stages were investigated. Dicing blades with two different diamond grit sizes were used to cut wafers. In the cutting experiments, the dicing blades with two different diamond grit sizes were used to cut wafers and for a given type of wafer, the cooling water temperature, cutting feed speed, and rotational speed were fixed. The chipping size, blade surface wear area and surface roughness of the wafer were measured at cutting distances of 50, 150, 300, 975, 1350, and 1900 m, respectively. Cutting debris of cutting distances of 300 m and 1900 m was collected and analyzed. The correlation between blade surface properties and chipping size was investigated. Based on this experimental system, attention is to pay to examine the correlation between blade surface properties and chipping size for transient stage and steady stage. In transient stage, the roughness of dicing blade increases rapidly. This will rapidly increase the chipping size. In steady stage, the chipping size decreases slowly with the decreasing roughness of blade surface. This concludes that blade surface condition is an important factor that affects the chipping size. Moreover, in transient stage, diamond grits that are salient or less bonded to the blade detach leave caves on the blade surface which increases surface roughness of the blade and the chipping size. In steady stage, the heights of grits become even and the chipping size decreases accordingly.     

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.     

Simulation of retention and transport of copper,lead and zinc in a paddy soil of the Red River Delta,Vietnam

Heavy metal (HM) contaminations in the topsoil around handicraft villages with non-ferrous heavy metal recycling in the Red River Delta can impose serious threats to the subsoil as well as to the groundwater quality. This feature is very important for paddy soils due to relatively high leaching rates and the dissolution of Fe–Mn oxides under reducing conditions which can accelerate the amount of HM translocated to the subsoil and groundwater.The transport of Cu, Pb and Zn in paddy soils was simulated by numerical modeling of non-equilibrium solute transport with an adaptation of the Hydrus-1D model. For the simulation, a water layer on the soil surface was included, from which HM can infiltrate into the soil depending on the soil hydraulic properties. Sorption coefficients, obtained from batch experiments were used as input data for the simulations. Calculated leaching rates were compared with the binding forms of HM in the samples.The simulations show that leaching rates decrease in the order: Zn > Cu > Pb. This order is confirmed by the results of sequential extractions. Under constant flooded conditions at a water table of 20 cm, Cu, Pb and Zn were estimated to reach the soil depth of 1 m within 470, 495 and 370 days, respectively, emphasizing that reactive pollutants can reach groundwater in a relatively short time. A change of the water layer from 1 to 30 cm can accelerate the leaching rate of HM up to 36%. The hard pan layer was observed to induce a hysteresis in hydraulic conductivity and slow down the movement of HM. Uncertainties in modeling arise as several parameters in the simulation can be determined only with significant errors. However, Hydrus-1D is a suitable tool for simulation of the transport of HM in paddy soils.     

Removal of naphthenic acid by microwave

The conventional deacidification methods have many disadvantages. In this paper, we reported a new method using microwave irradiation to remove the naphthenic acid from the vacuum cut #1 distillate oil of Daqing. When the distilled oil (the volume rate of solvent-to-oil was 0.23:1) was irradiated for 5 min under constant pressure (0.11 MPa), and then rested for 25 min, the acid number was reduced from 0.63 mg KOH/g to 0.0478 mg KOH/g, which was sufficient to meet the specification of Q/SHR001-95 (less than 0.05 mg KOH/g) on lubricating oil, and the recovery rate of the distilled oil was 99.3%. The microwave irradiation method has many advantages, such as, it is highly effective, it consumes less time and it is environmentally friendly.     

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.