The Effect of Tool Construction and Cutting Parameters on Surface Roughness and Vibration in Turning of AISI 1045 Steel Using Taguchi Method

This paper presents an experimental investigation focused on identifying the effects of cutting conditions and tool construction on the surface roughness and natural frequency in turning of AISI1045 steel. Machining experiments were carried out at the lathe using carbide cutting insert coated with TiC and two forms of cutting tools made of AISI 5140 steel. Three levels for spindle speed, depth of cut, feed rate and tool overhang were chosen as cutting variables. The Taguchi method L9 orthogonal array was applied to design of experiment. By the help of signal-to-noise ratio and analysis of variance, it was concluded that spindle speed has the significant effect on the surface roughness, while tool overhang is the dominant factor affecting natural frequency for both cutting tools. In addition, the optimum cutting conditions for surface roughness and natural frequency were found at different levels. Finally, confirmation experiments were conducted to verify the effectiveness and efficiency of the Taguchi method in optimizing the cutting parameters for surface roughness and natural frequency.

The Impacts of Climate Change on the Availability of Surface Water Resources in Jordan

Climate change in the Middle East area including Jordan has started to be reflected in decreasing precipitation and increasing temperatures with their impacts on the availability of surface and groundwater. This article aims to evaluate the impacts of decreasing or increasing precipitation by 10% and 20% on the quantities of flood runoff based on recorded precipitation and runoffs of catchments during the past 60 to 70 years of observation, during which the precipitation in individual or a few years increased or decreased by tens of percentages relative to the long-term average precipitation. The results of quantification show that in Jordan as a whole, decreasing precipitation by 10% and 20% has historically (during the recording period) resulted in reductions in flood flows by 26.2% and 52.8% and that increasing precipitation by 10% and 20% has resulted in increases in flood flows by 26.4% and 56.5% respectively. These results look somehow paradox, because the general perception is that flood runoff changes in the same percentage like precipitation although flood flow is not linearly correlated with precipitation but exponentially. Decreasing precipitation in the water-scarce stressed country, Jordan due to climatic changes, will have strong implications on rain-fed and irrigated agriculture and on household water supplies with very severe socio-economic percussions expressed in increasing unemployment and poverty which may lead to social and political unrest. Therefore, proactive measures have to be implemented before disasters hit. Such measures are limited in Jordan to seawater desalination, intensified water harvesting and improved water use efficiency in agriculture.

Difference in Surface Roughness of Ethylene-Vinyl-Acetate Sheet before and after Application of Finishing Liquid: Part 2 Changes over Time in Surface Roughness

Surface texture of the mouthguard affects the sense of adaptation in the athlete and further affects hygiene. The aim of this study was to investigate the changes over time in surface roughness after finish polishing of ethylene vinyl acetate (EVA) sheets and before and after finishing liquid application, and to evaluate its effectiveness. Total of 160 specimens of EVA (3 × 3 mm) were divided into 4 groups according to polishing condition (control = unpolished;RB = Robinson-brush;LF = Lisko-Fine, and MW = Mouthguard-wheel). Polishing was performed at low speed by using a straight headpiece. The rotation speed was 5000, 4000 and 6000 rpm for RB, LF, and MW, respectively. Next, a finishing liquid was applied to each specimen. Changes over time in surface roughness before and after application of the finishing liquid were compared by a non-contact surface shape measuring machine. The arithmetic average height (Sa) was measured. The measurement time points were before application, immediately after application, and at 5, 10, and 15 min after application. The changes over time of the surface roughness of the sheet before and after application of the finishing liquid were analyzed by two-way analysis of variance and Bonferroni’s multiple comparison tests. Surface roughness of the specimen before application became coarse in the order of control;MW, LF and RB, and Sa were about 0.21 μm, 2.03 μm, 2.94 μm, and 4.72 μm, respectively. That showed the same order after finishing liquid application. Significant decrease in Sa for RB and LF were seen at 10 min after application and at 5 min after application, respectively. Sa of MW was not significantly different before and after application. The results of this study showed that a lubricity of about 1.0 μm increases within 5 - 10 min of application of finishing liquid, but in cases where polishing was performed to about 2.0 μm;the application of finishing liquid has no ef-fect.

Surface effects of hybrid vibration-assisted femtosecond laser system for micro-hole drilling of copper substrate

The ultrafast laser based hybrid machining system was studied and a novel approach was demonstrated to improve laser machining quality on metals by vibrating the optical objective lens with a low frequency (500 Hz) and various displacements (0-16.5 μm) during a femtosecond laser machining process.The laser used in this experiment is an amplified Ti:sapphire femtosecond (10-15 s) laser system that generates 100 femtosecond pulses having an energy of 3.5 mJ/pulse with a 5 kHz repetition rate at a central wavelength of 790 nm.It is found that both the wall surface finish of the machined structures and the aspect ratio obtained using the frequency vibration assisted laser machining are improved compared with those derived via laser machining without vibration assistance.

Surface Roughness of Flux Film in Continuous Casting Mold

The corundum plates with a groove were used to freeze molten flux into solid slice to simulate the flux film formed in continuous casting mold,and thereby to study the formation mechanism of flux film with different surface roughness.The effect of some factors on the surface roughness of flux film,such as reheating rate,cooling rate,flux film thickness and crystallization ratio,was discussed.

Changes in Surface Energy Partitioning in China over the Past Three Decades

Surface energy balance and the partitioning of sensible heat flux(SHF) and latent heat flux(LHF) play key roles in land–atmosphere feedback. However,the lack of long-term observations of surface energy fluxes,not to mention spatially extensive ones,limits our understanding of how the surface energy distribution has responded to a warming climate over recent decades(1979–2009) at the national scale in China. Using four state-of-the-art reanalysis products with long-term surface energy outputs,we identified robust changes in surface energy partitioning,defined by the Bowen ratio(BR = SHF/LHF),over different climate regimes in China. Over the past three decades,the net radiation showed an increasing trend over almost the whole of China. The increase in available radiative energy flux,however,was balanced by differential partitioning of surface turbulent fluxes,determined by local hydrological conditions. In semi-arid areas,such as Northeast China,the radiative energy was transferred largely into SHF. A severe deficiency in near-surface and soil moistures led to a significant decreasing trend in LHF. The combined effect of increased SHF and decreased LHF resulted in significant upward trends in the BR and surface warming over Northeast China. In contrast,in the wet monsoon regions,such as southern China,increased downward net radiation favored a rise in LHF rather than in SHF,leading to a significant decreasing trend in the BR. Meanwhile,the increased LHF partly cancelled out the surface warming. The warming trend in southern China was smaller than that in Northeast China. In addition to impacts on heat-related events,the changes in the BR also reflected recent cases of extreme drought in China. Our results indicate that information regarding the BR may be valuable for drought monitoring,especially in regions prone to such conditions.

Effect of water absorption ratio on tensile strength of red sandstone and morphological analysis of fracture surfaces

Brazilian disc tests were undertaken on a number of red sandstone samples with different water absorption ratios.The tensile strength of the red sandstone decreases as the water absorption ratio increases.The fracture surfaces of failed red sandstone discs were scanned by Talysurf CLI 2000.With the aid of Talymap Gold software,based on ISO25178,a set of statistical parameters was obtained for the fracture surfaces.The maximum peak height(S_p),maximum pit height(S_v) and maximum height(S_z) of the fracture surfaces exhibited the same decreasing trend with increasing water absorption.Sa and Sku values for the fracture surfaces showed a downward trend as the water absorption ratio increased.The fractal dimensions of fracture surfaces were calculated and found to decrease as the water absorption ratio increased.Through analysis of PSD curves,the smallest dominant wavelength was observed to reflect the roughness of the fracture surfaces.Additionally,the results suggest that the roughness of fracture surfaces becomes small as the water absorption ratio increases.

Influence of cutting parameters on surface characteristics of cut section in cutting of Inconel 718 sheet using CW Nd:YAG laser

Recently, laser cutting technologies begin to use for manufacturing mechanical parts of Inconel super-alloy sheet due to difficulties of machining of the Inconel material as a results of its extremely tough nature. The objective of this work is to investigate the influence of cutting parameters on surface characteristics of the cut section in the cutting of Inconel 718 super-alloy sheet using CW Nd:YAG laser through laser cutting experiments. Normal cutting experiments were performed using a laser cutting system with six-axis controlled automatic robot and auto-tracking system of the focal distance. From the results of the experiments, the effects of the cutting parameters on the surface roughness, the striation formation and the microstructure of the cut section were examined. In addition, an optimal cutting condition, at which the surface roughness is minimized and both the delayed cutting phenomenon and the micro-cracking are not initiated, is estimated to improve both the part quality and the cutting efficiency.

Fundamental of Inclusion Removal from Molten Steel by Rising Bubble

The corundum plates with a groove were used to freeze molten flux into solid slice to simulate the flux film formed in continuous casting mold, and thereby to study the formation mechanism of flux film with different surface roughness. The effect of some factors on the surface roughness of flux film, such as reheating rate, cooling rate, flux film thickness and crystallization ratio, was discussed.

Influence of tool deflection on micro channel pattern of 6:4 brass with rectangular tool

Machining experiment of micro channel structure with 6:4 brass was carried out by shaping process using a single crystal diamond tool. FEM simulation using solid cantilever beam model was analyzed. In result of experiment, tool deflection is observed as machining characteristics through result of experiments such as surface roughness, cutting force and burr formations. And the influence of tool deflection is experimentally proved.

Grinding Characteristics Of Directionally Aligned SiC Whisker Wheel - Comparison With A12O3 Fiber Wheel

A unique SiC whisker wheel was invented,in which the whiskers were aligned normally to the grinding wheel surface.In this paper,grindabilities of the SiC whisker wheel are investigated and compared with those of other wheels of SiC grains,Al2O3 grains,as well as Al2O3 long and short fibres which were also aligned normally to the grinding wheel surface,respectively.The main research contents concern grinding characteristics of a directionally aligned SiC whisker wheel such as material-removal volume,wheel-wear rates,integrity of the ground surfaces,grinding ratios and grinding efficiency.Furthermore,grinding wheels of whiskers and fibres have a common disadvantage:they tend to load easily.The authors have proposed a simple method of loading-free grinding to overcome this propensity and investigate some related grinding characteristics under loading-free grinding conditions.

颗粒表面粗糙度对材料小应变动力特性的影响

土体的小应变剪切模量和阻尼比是表征土体动力学特性的重要参数,不仅受到土体密实度和应力状态的影响,还受到土体颗粒级配、形状等颗粒特征的影响。颗粒表面粗糙度是重要的土体颗粒特征之一,然而关于颗粒表面粗糙度对土体小应变动力特性影响的研究较为匮乏。利用能量注入式虚拟质量共振柱设备,系统地测试了颗粒表面粗糙度不同的玻璃珠所成试样的小应变剪切模量和阻尼比;采用三维干涉显微镜测量了玻璃珠的表面粗糙度,并量化表征粗糙度对试样小应变剪切模量和阻尼比的影响。试验结果表明,在相同孔隙比和有效应力条件下,试样的小应变剪切模量随颗粒表面粗糙度增大而减小,而小应变阻尼比受颗粒表面粗糙度影响的规律不明显。研究结果表明,当材料的颗粒形状、级配等因素相近时,颗粒表面粗糙度对材料小应变剪切模量的影响不应被忽略。

基于综合熵权-信噪比的球轴承外圈沟道ELID磨削加工参数优化

为提高球轴承外圈沟道表面的加工质量,实现对电解在线砂轮修整ELID磨削加工试验中摆动参数、磨削参数的精确控制,设计正交试验并基于试验数据建立表面质量与加工参数之间的二阶响应模型和指数回归模型;通过熵权理论确定表面粗糙度与轮廓度的综合权重,最终获得最优加工参数,并结合信噪比的基本特性分析加工参数对表面质量的影响程度。结果表明:指数回归模型对表面粗糙度预测较为精确,二阶响应模型对轮廓度预测较为精确,误差均在5%以下;表面粗糙度、轮廓度综合权重分别为0.4568,0.5432,最优加工参数为摆动幅度11°、摆动速度6°/s、砂轮转速19500 r/min、工件转速50 r/min;加工参数的影响程度由大到小依次为摆动幅度、摆动速度、工件转速、砂轮转速。

压缩率和施胶量对毛白杨重组木干状和湿状表面粗糙度的影响

表面粗糙度是评价木质材料表面质量和加工性能的重要指标之一。以毛白杨(Populus tomentosa)单板和酚醛树脂为原料,采用单因素试验制备重组木,探讨压缩率(50%、55%、59%)和施胶量(10%、15%、20%)对重组木干状和湿状表面粗糙度的影响。结果表明,压缩率对干状和湿状表面粗糙度影响显著,且对干状表面粗糙度的影响大于湿状;随着压缩率的增大,重组木的干状表面粗糙度逐渐降低,湿状表面粗糙度逐渐增大;施胶量对干状和湿状表面粗糙度影响显著,且对湿状表面粗糙度的影响大于干状;随着施胶量的增加,重组木干状和湿状表面粗糙度均逐渐降低。与毛白杨单板相比,在压缩率为59%和施胶量为15%时,重组木干状粗糙度参数Ra和Rz分别降低了79.64%和73.07%,湿状粗糙度参数Ra和Rz分别降低了62.85%和50.00%。在实际生产过程中,可通过控制压缩率和施胶量调控重组木干状和湿状表面粗糙度,以满足不同应用场景对重组木材料表面粗糙度的需求。

水流冲刷作用下单体土工袋稳定特性试验研究

【目的】为探究水流冲刷作用下单体土工袋在河流护岸结构中护底处的稳定规律,【方法】基于塔里木河土工袋护岸工程,搭建水槽模型试验平台,制作了不同规格土工袋模型。讨论Robin体积公式在实际工程应用中的不足。基于土工袋试验结果,分析了土工袋充填率、长宽比、下垫面糙率、摆放形式等实际工程中重点关注因素与稳定性的响应规律。【结果】试验结果显示:土工袋所受推力FD随充填率的增加而逐渐增大,升力FL随充填率的增大先增大后减小;长宽比大于2.33时,土工袋顺水流放置时稳定性逐渐降低,而垂直水流放置时,土工袋稳定性随长宽比的增加一直降低;通过改变土工袋与下垫面的糙率可有效提高土工袋的稳定性。【结论】结果表明:充填率通过直接影响装填后土工袋有效受力面积,进而影响使土工袋失稳的FD和FL的大小;土工袋的稳定不仅与充填率有关,还受土工袋长宽比设计的影响,较大的长宽比不利于土工袋的稳定,且顺水流、垂直水流放置时稳定能力差别很大;实际工程中可在护底处土工袋下方铺设土工布,一方面可提高土工袋的摩擦稳定能力,另一方面也可起到一定的反滤作用。

粉末润滑粗糙界面的摩擦特性数值模拟及光学原位观测

固体粉末润滑剂可用于航空航天和高温成型等恶劣环境,润滑剂的润滑特性已成为制约大型锻件成形的关键因素。建立离散元数值模型分析不同粉末层厚度和粗糙度的初压力链和配位数,再利用面接触原位观察试验机分析30个行程中粉末层形态、摩擦特性参数和真实接触面积比。结果表明:粉末层厚度为15μm时,易发生擦伤、点状剥落和分层剥落等,部分区域金属基体初始裸露,摩擦因数先增加后趋于定值,主要为微凸体直接接触承载,接触界面颗粒数少、配位数迅速下降、力链持续时间短,摩擦磨损状态恶劣。粉末层厚度为30μm时,粉末完全覆盖接触区域,摩擦因数先增加后降低,真实接触面积比大,界面颗粒数多、配位数降低缓慢、力链持续时间长,载荷波动较小且真实接触面积比大,摩擦磨损状态良好。选取较大粉末层厚度(30μm)和适当的表面粗糙度(Ra 0.409μm)时,粉末平整性好且碳元素含量高,接触界面的力链分布均匀,配位数大且持续时间长,能形成平整、稳定的粉末润滑膜。基于离散元数值模拟和光学原位观测研究不同粗糙度和粉末层厚度的摩擦接触界面摩擦特性,可为机械工程领域的接触界面形成平整、稳定且润滑性能良好的粉末润滑膜提供理论指导和机理分析。

金刚石砂轮的磨削整形法研究

为研究金刚石砂轮修整的工艺,采用绿碳化硅砂轮对金刚石砂轮进行磨削整形法修整。通过改变修整量、修整速比、切削进给量、工作台速度得出修整参数对砂轮磨削性能的影响规律。研究结果表明,工件表面粗糙度随着修整量增加而增大,修整量增加到一定次数时粗糙度变化不大;修整速比增大时,工件表面粗糙度值增大;切削进给量增大时,工件磨削表面粗糙度增大;工作台速度增大时,工件表面粗糙度增大。所得结论为绿碳化硅砂轮修整金刚石砂轮的工艺参数选取提供了切实有效的参考价值。

地表糙度与径流水力学参数响应规律模拟

为了明确地表糙度与坡面径流特征及其水力学参数之间的相互作用,通过模拟人工锄耕、人工掏挖、等高耕作和对照组直型坡等4种不同糙度的地表,在室内模拟降雨条件下,对不同糙度坡面上的径流特征和水力学参数(雷诺数、弗劳德数、阻力系数和水流剪切力)以及降雨前后地表糙度的变化进行了测量与计算。结果表明,雨前雨后各措施坡面的地表糙度为:等高耕作>人工掏挖>人工锄耕>直型坡。相同雨强和降雨历时下,不同糙度坡面其径流特征差异显著。初始地表糙度越大的坡面,径流越容易稳定在层流状态;反之,径流越倾向于往紊流发展。对人工锄耕、人工掏挖、等高耕作3种耕作措施来说,在相同雨强和降雨历时下,初始糙度越大的坡面,其断面流量、径流量和产沙量越小。坡面初始地表糙度越大,径流阻力系数也越大,但坡面径流的雷诺数、弗劳德数和径流剪切力则越小,径流对地表糙度具有减小作用,雷诺数和水流剪切力越大,径流对地表糙度的减小作用越弱。研究结果为深入理解坡面地表糙度与其水文特征之间的相互作用提供参考。

纯钛铸件化学抛光的实验研究

目的:探讨纯钛铸件的化学抛光效果。方法:3组板状铸件(15mm×15 mm×1.4 mm)分别给予以下3种处理:A组铸件喷砂后不做其它处理;B组铸件喷砂后常规手工研磨;C组铸件喷砂后化学抛光。测试B、C两组铸件的减重率(-wt％),各处理组铸件的表面粗糙度(Ra值)和表面氧化膜厚度。结果:肉眼观察经化学抛光的纯钛铸件表面呈镜面状。化学抛光组的减重率高于手工研磨组,Ra值小于手工研磨组(P<0.05)。其表面存在约8μm厚的氧化膜,且均匀一致。结论:纯钛铸件化学抛光效果良好,具有临床推广价值。

自锐性金刚石树脂砂轮磨削性能的研究

本文通过对比磨削试验,研究了自锐性金刚石(CSD)树脂砂轮的磨削性能。试验结果表明,由于CSD形状不规则,有许多凹入角和粗糙表面,树脂结合剂对CSD的把持力较普通金刚石强,所以在磨削各参数相同的条件下,自锐性金刚石砂轮与普通金刚石砂轮相比,其磨削比提高60%以上。且由于CSD的内部为许多单个亚晶粒所组成的镶嵌的颗粒,因此在应力作用下,只有很小的不规则的碎片崩掉,从而在每个颗粒的表面上留下许多新的小切削刃,故其加工工件的表面粗糙度值较低。