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.     

Investigation on the changes effected by tool profile on mechanical and tribological properties of friction stir processed AZ31B magnesium alloy

The present study investigates the effect of tool shoulder profile on the mechanical and tribological properties of friction stir processed AZ31B magnesium alloy. The tool rotational speed and feed rate are the chosen process parameters. The experiments were conducted with 3 level 2 factors full factorial design. The recorded responses were tensile strength, wear losses and corrosion rate. The results were analyzed with the help microstructures of the processed samples. The study reveals that, for concave shoulder tool, the strain hardening effect was playing a major role in determining the properties of the processed materials and for the step shoulder tool, the grain size plays a major role in determining the properties of the processed materials.     

Phenomenological compensation of thermally caused position and orientation errors of rotary axes

Thermal errors of machine tools are one of the major sources of inaccuracy. Therefore, the reduction of temperature induced deviations or the compensation of the resulting tool center point (TCP) errors have been of strong interest to the manufacturing industry for a couple of years. Up to now, the observation of the environment, the main spindle, the linear axes and the machine bed were in the focus of research, but with the rising demand for 5-axis machine tools and the increasing requirements regarding their accuracy, the analysis of the thermal behavior of rotary axes becomes more and more important. This paper gives an overview of corresponding thermal measurements of machine tools. The thermal behavior of rotary and swiveling axes is analyzed in detail. A simulation model and an approach for a phenomenological compensation of the TCP error are introduced and verified by measurements.     

Coastal flooding,climate change and environmental justice: identifying obstacles and incentives for adaptation in two metropolitan Boston Massachusetts communities

We explored the possible future impacts of increased coastal flooding due to sea level rise and the potential adaptation responses of two urban, environmental justice communities in the metropolitan Boston area of Massachusetts. East Boston is predominantly a residential area with some industrial and commercial activities, particularly along the coastal fringe. Everett, a city to the north of Boston, has a diversified industrial and commercial base. While these two communities have similar socioeconomic characteristics, they differ substantially in the extent to which residents would be impacted by increased coastal flooding. In East Boston, a large portion of residents would be flooded, while in Everett, it is the commercial/industrial districts that are primarily vulnerable. Through a series of workshops with residents in each community, we found that the target populations do not have an adaptation perspective or knowledge of any resources that could assist them in this challenge. Furthermore, they do not feel included in the planning processes within their communities. However, a common incentive for both communities was an intense commitment to their communities and an eagerness to learn more and become actively engaged in decisions regarding climate change adaptation. The lessons that can be applied to other studies include 1) images are powerful tools in communicating concepts, 2) understanding existing cultural knowledge and values in adaptation planning is essential to the planning process and 3) engaging local residents at the beginning of the process can create important educational opportunities and develop trust and consensus that is necessary for moving from concept to implementation.     

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.     

Greenhouse gas mitigation and offset options for suckler cow farms: an economic comparison for the Swiss case

We assessed the economic suitability of 4 greenhouse gas (GHG) mitigation options and one GHG offset option for an improvement of the GHG balance of a representative Swiss suckler cow farm housing 35 Livestock units and cultivating 25 ha grassland. GHG emissions per kilogram meat in the economic optimum differ between the production systems and range from 18 to 21.9 kg CO₂-eq./kg meat. Only GHG offset by agroforestry systems showed the potential to significantly reduce these emissions. Depending on the production system agroforestry systems could reduce net GHG emissions by 66% to 7.3 kg CO₂-eq./kg meat in the most intensive system and by 100% in the most extensive system. In this calculation a carbon sequestration rate of 8 t CO₂/ha/year was assumed. The potential of a combination of the addition of lipids to the diet, a cover of the slurry tank and the application of nitrification inhibitors only had the potential to reduce GHG emissions by 12% thereby marginal abatement costs are increasing much faster than for agroforestry systems. A reduction of the GHG emissions to 7.5 kg CO₂-eq./kg meat—possible with agroforestry only—raised costs between 0.03 CHF/kg meat and 0.38 CHF/kg meat depending on the production system and the state of the system before the reduction. If GHG emissions were reduced maximally average costs ranged between 0.37 CHF/kg meat, if agroforestry had the potential to reduce net GHG emissions to 0 kg CO₂-eq., to 1.17 CHF/kg meat if also other options had to be applied.     

Incorporating stakeholder decision support needs into an integrated regional Earth system model

A new modeling effort exploring the opportunities, constraints, and interactions between mitigation and adaptation at regional scale is utilizing stakeholder engagement in an innovative approach to guide model development and demonstration, including uncertainty characterization, to effectively inform regional decision making. This project, the integrated Regional Earth System Model (iRESM), employs structured stakeholder interactions and literature reviews to identify the most relevant adaptation and mitigation alternatives and decision criteria for each regional application of the framework. The information is used to identify important model capabilities and to provide a focus for numerical experiments. This paper presents the stakeholder research results from the first iRESM pilot region. The pilot region includes the Great Lakes Basin in the Midwest portion of the United States as well as other contiguous states. This geographic area (14 states in total) permits cohesive modeling of hydrologic systems while also providing strong gradients in climate, demography, land cover/land use, and energy supply and demand. The results from the stakeholder research indicate that, for this region, iRESM should prioritize addressing adaptation alternatives in the water resources, urban infrastructure, and agriculture sectors, including water conservation, expanded water quality monitoring, altered reservoir releases, lowered water intakes, urban infrastructure upgrades, increased electric power reserves in urban areas, and land use management/crop selection changes. For mitigation in this region, the stakeholder research implies that iRESM should focus on policies affecting the penetration of renewable energy technologies, and the costs and effectiveness of energy efficiency, bioenergy production, wind energy, and carbon capture and sequestration.     

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.     

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.