Study of Micro Rotary Ultrasonic Machining

Product miniaturization for applications in fields such as biotechnology, medical devices, aerospace, optics and communications has made the advancement of micromachining techniques essential. Machining of hard and brittle materials such as ceramics, glass and silicon is a formidable task. Rotary ultrasonic machining (RUM) is capable of machining these materials. RUM is a hybrid machining process which combines the mechanism of material removal of conventional grinding and ultrasonic machining. Downscaling of RUM for micro scale machining is essential to generate miniature features or parts from hard and brittle materials. The goal of this thesis is to conduct a feasibility study and to develop a knowledge base for micro rotary ultrasonic machining (MRUM). Positive outcome of the feasibility study led to a comprehensive investigation on the effect of process parameters. The effect of spindle speed, grit size, vibration amplitude, tool geometry, static load and coolant on the material removal rate (MRR) of MRUM was studied. In general, MRR was found to increase with increase in spindle speed, vibration amplitude and static load. MRR was also noted to depend upon the abrasive grit size and tool geometry. The behavior of the cutting forces was modeled using time series analysis. Being a vibration assisted machining process, heat generation in MRUM is low which is essential for bone machining. Capability of MRUM process for machining bone tissue was investigated. Finally, to estimate the MRR a predictive model was proposed. The experimental and the theoretical results exhibited a matching trend.

Interaction Between Roughages and Corn Milling Byproducts in Finishing Cattle Diets

During ethanol production, starch is the primary nutrient fermented and the remaining byproducts are excellent sources of fiber and protein. In addition, inclusion of byproducts in finishing diets may reduce the incidence of acidosis. As a result, roughage level and quality could potentially be reduced in finishing diets containing byproducts. Three experiments were conducted to examine the effects of roughage and wet corn gluten feed (WCGF) in finishing cattle diets containing corn distillers grains plus solubles. Cattle fed finishing diets containing wet distillers grains plus solubles (WDGS) with no roughage had decreased DMI and ADG compared to cattle fed roughage. Within roughage level, ADG was similar for cattle fed alfalfa hay, corn silage or corn stalks when included on an equal NDF basis. Apparent total tract digestibility of OM, NDF, and CP linearly decreased and ruminal pH variables increased linearly due to increasing roughage levels. Roughage sources can be exchanged on an equal NDF basis in beef finishing diets containing 30% WDGS (DM basis). In finishing diets containing modified distillers grains plus solubles (MDGS), DMI linearly increased due to increasing roughage levels but ADG responded quadratically and was lowest for cattle fed diets without roughage. There was also a quadratic response for DMI and ADG due to WCGF inclusion level. Gain:feed decreased linearly with increasing roughage and WCGF inclusion levels. Feeding 15% WCGF resulted in similar cattle performance and carcass traits to cattle fed no WCGF in diets containing 30% MDGS, but cattle fed diets with 60% total byproduct inclusion made up of 30% WCGF and 30% MDGS had reduced performance (DM basis). Additionally, reducing corn silage inclusion level to 7.5% resulted in similar finishing cattle performance and carcass traits to cattle fed 15% corn silage in diets containing 30% MDGS with or without inclusion of WCGF. Elimination of roughage in diets containing either WDGS or MDGS resulted in negative impacts on finishing cattle performance, ruminal metabolism, and carcass traits.