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.     

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.     

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.     

Opportunities to reduce greenhouse gas emissions from households in Nigeria

Efforts to mitigate climate threats should not exclude the household as the household is a major driver of greenhouse gas (GHG) emissions through its consumption patterns. This paper derives an emission index that could be used to estimate inventories of carbon dioxide (CO₂) emissions from kerosene combustion for lighting in Nigeria and also looks at the implications of solar pv lighting replacing kerosene lamp in Nigeria. Findings indicate that (1) average CO₂ emissions from kerosene combustion for lighting in Nigeria is about 0.06 kg per hour per lamp, which can be taken as the kerosene lamp CO₂ emission index for Nigeria. (2) about 3 × 10W_p solar pv will be required to replace a kerosene lamp, while about 0.124 tonnes of CO₂ will be avoided per lamp per year, operating at 6 h daily. At the national level, under the kerosene lamp replacement projection assumptions made, between 0.4 and 1.0 million tonnes of CO₂ will be avoided per year. The household investment required to owe a solar pv, including the capital cost of switching from kerosene lamp, is about US356, while the national capital investment outlay is between 1,138.265 and US356, while the national capital investment outlay is between 1,138.265 and US2,848 million. (3) Certified Emission Reduction (CER) units, assuming CO₂ is traded, will generate significant annual revenues on the order of 6.96 to almost US17.4 million per year, while earnings from unspent household kerosene fuel could amount to between 2,520 and US17.4 million per year, while earnings from unspent household kerosene fuel could amount to between 2,520 and US6,300 million over the life span of the solar pv. The micro-economic assessment carried out indicates the non-attractiveness of solar pv use at the household level, and (4) to promote solar pv use, both long and short term policy measures that aim at cost reduction were suggested. The paper concludes that, factoring the suggested measures into the climate, energy, and financial policy decision discourse in Nigeria could empower the households to play a significant role in achieving global CO₂ emission reduction, but at the local level.     

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.     

Evidence for a male-produced pheromone in <Emphasis Type="Italic">Tetropium fuscum</Emphasis> (F.) and <Emphasis Type="Italic">Tetropium cinnamopterum</Emphasis> (Kirby) (Coleoptera: Cerambycidae)

(E)-6,10-dimethyl-5,9-undecadien-2-ol (geranyl acetol), termed here fuscol, was identified as a male-produced pheromone emitted by Tetropium fuscum (F.) and Tetropium cinnamopterum Kirby. In field experiments, traps baited with synthetic fuscol alone were not significantly attractive, but the combination of fuscol plus host volatiles (a synthetic blend of monoterpenes plus ethanol) attracted significantly more male and female T. fuscum and female T. cinnamopterum than did host volatiles alone. This is the first homoterpenoid alcohol to be described in the Cerambycidae, and the first pheromone reported from the sub-family Spondylidinae.     

Last Glacial mammals in South America: a new scenario from the Tarija Basin (Bolivia)

The chronology, sedimentary history, and paleoecology of the Tarija Basin (Bolivia), one of the richest Pleistocene mammalian sites in South America, are revised here based on a multidisciplinary study, including stratigraphy, sedimentology, geomorphology, paleontology, isotope geochemistry, and ¹⁴C geochronology. Previous studies have indicated a Middle Pleistocene age for this classic locality. We have been able to obtain a series of ¹⁴C dates encompassing all the fossil-bearing sequences previously studied in the Tarija Basin. The dated layers range in age from about 44,000 to 21,000 radiocarbon years before present (BP), indicating that the Tarija fauna is much younger than previously thought. Glacial advances correlated to marine isotopic stages (MIS) 4 and 2 (ca. 62 and 20 ka BP, respectively) are also documented at the base and at the very top of the Tarija–Padcaya succession, respectively, indicating that the Bolivian Altiplano was not dry but sustained an ice cap during the Last Glacial Maximum. The results of this multidisciplinary study enable us to redefine the chronological limits of the Tarija sequence and of its faunal assemblage and to shift this paleontological, paleoclimatological, and paleoecological framework to the time interval from MIS 4 to MIS 2.