Machining of titanium alloy (Ti-6Al-4V)-theory to application

This article correlates laboratory-based understanding in machining of titanium alloys with the industry based outputs and finds possible solutions to improve machining efficiency of titanium alloy Ti-6Al-4V. The machining outputs are explained based on different aspects of chip formation mechanism and practical issues faced by industries during titanium machining. This study also analyzed and linked the methods that effectively improve the machinability of titanium alloys. It is found that the deformation mechanism during machining of titanium alloys is complex and causes basic challenges, such as sawtooth chips, high temperature, high stress on cutting tool, high tool wear and undercut parts. These challenges are correlated and affected by each other. Sawtooth chips cause variation in cutting forces which results in high cyclic stress on cutting tools. On the other hand, low thermal conductivity of titanium alloy causes high temperature. These cause a favorable environment for high tool wear. Thus, improvements in machining titanium alloy depend mainly on overcoming the complexities associated with the inherent properties of this alloy. Vibration analysis kit, high pressure coolant, cryogenic cooling, thermally enhanced machining, hybrid machining and, use of high conductive cutting tool and tool holders improve the machinability of titanium alloy.

Investigation on the effect of cutting fluid pressure on surface quality measurement in high speed thread milling of brass alloy (C3600) and aluminium alloy (5083)

The quality of a machined finish plays a major role in the performance of milling operations, good surface quality can significantly improve fatigue strength, corrosion resistance, or creep behaviour as well as surface friction. In this study, the effect of cutting parameters and cutting fluid pressure on the quality measurement of the surface of the crest for threads milled during high speed milling operations has been scrutinised. Cutting fluid pressure, feed rate and spindle speed were the input parameters whilst minimising surface roughness on the crest of the thread was the target. The experimental study was designed using the Taguchi L32 array. Analysing and modelling the effective parameters were carried out using both a multi-layer perceptron (MLP) and radial basis function (RBF) artificial neural networks (ANNs). These were shown to be highly adept for such tasks. In this paper, the analysis of surface roughness at the crest of the thread in high speed thread milling using a high accuracy optical profile-meter is an original contribution to the literature. The experimental results demonstrated that the surface quality in the crest of the thread was improved by increasing cutting speed, feed rate ranging 0.41-0.45 m/min and cutting fluid pressure ranging 2-3.5 bars. These outcomes characterised the ANN as a promising application for surface profile modelling in precision machining.

Materials machining study of titanium alloy using a high speed camera

The research aim is to study and analyze the shear zone by application of merchant circle during machining of titanium alloy (Ti6Al4V). The thermo-mechanical reaction during machining plays an important role in defining machinability of titanium alloys. The scientific community is concerned about machining of titanium alloy due to problems occurring in the shear zone that affect tool life. Studying the cutting action contributes to understanding and addressing these problems effectively. For this purpose, an experimental setup, utilizing a high speed camera will be used to study the shear zone. The shear zone characteristics are studied by analyzing the images captured by a high speed camera placed near to the shear zone during machining. The experimental design consists of conducting a series of turning trials using combination of cutting parameters namely constant spindle speed (n) 770 rpm; feed rate (f) of 2 and 4 mm/rev; and depth of cut (d) of 1 and 2 mm. The length of cut (L) of 10 mm remains constant and no coolant is used for all trials. The images obtained from the camera are analyzed against the theory of orthogonal cutting using merchants circle.

Reducing yarn hairiness with a modified yarn path in worsted ring spinning

The spinning geometry of a ring frame plays an important role, and the twist triangle is the critical region in ring spinning. Changes in the spinning geometry may affect yarn properties. This paper examines the idea of ring spinning with a "diagonal" yarn path, and the effect of such a path on yam properties, particularly hairiness. Both "left diagonal" and "right diagonal" yam arrangements are tried on a 24-spindle Cognetex FLC worsted ring frame. The hairiness results obtained from the Zweigle hairiness meter show that the right diagonal yam path produces yams of lower hairiness than the conventional ring spun yarn in almost all the hair length groups. Yam evenness and tenacity are not as sensitive to the change in yarn path. The mean spindle speed at break is also tested, and there is some deterioration in spinning efficiency with the right diagonal yarn path, particularly at higher spinning speeds. Results from this study may help explain variations in yarns spun on poorly aligned ring frames.

Comparing the hairiness of solospun and ring spun worsted yarns

This paper compares the hairiness of Solospun yarns with conventional ring spun worsted yams of the same specifications. A 24-spindles worsted ring spinning frame is used to spin the Solospun and conventional ring spun yarns at the same time, and yarn hairiness is measured. The total hairiness number (Tp), the number of hairs longer than or equal to 3mm (S3), the percentage of longer hairs in total hairs (100S3/Tp), and the total hair length per unit yarn length (K' ) are used to compare the hairiness of these yams. The results indicate that the Solospun yarn exhibits less hairiness in each of the hair length groups and has lower variations in yarn hairiness. The hair-length distribution of the Solospun yarn follows an exponential law just like conventional ring spun yams. There is a statistically significant difference between the Solospun and conventional ring spun yams for T p, S3, and K', but the difference in 1 00S 3/Tp is not statistically significant for these yams. In addition, the Tp, S3, and K' values of the Solospun yarn decrease with twist increase and increase with spindle speed increase, but the 100S3/Tp values of the Solospun and conventional ring spun yarns in this study behave differently in that they are affected by twist level and spindle speed.

Effect of yarn hairiness on energy consumption in rotating a ring-spun yarn package

The effect of yarn hairiness on energy consumption when rotating a ring-spun yarn package is investigated theoretically and experimentally. A theoretical model is developed to calculate the energy required to rotate hair fibers, based on hair length and number as well as package speed and size. A single spindle test rig is used to verify the theoretical prediction. The experimental results confirm the theoretical prediction that the package power increases with increased yarn hairiness level and spindle speed.

Minimizing energy consumption of yarn winding in ring spinning

Ring spinning has been and will continue to be an important system for making staple yarns from different fibers in the textile industry. But high power consumption and low productivity remain the two outstanding problems with ring spinning. Based on an analysis of power distribution during yarn winding in ring spinning, models for the ratio of energy consumption to yarn production over a full yarn package are established. Spindle speed, yarn count, and package diameter are the three key parameters affecting this ratio. The effects on energy consumption of these parameters are discussed through a case study. The energy-to-production ratio increases with increased package diameter but decreases with increased spindle speed and/or yarn count (tex). The results will help guide spinners in minimizing energy consumption in ring spinning.

Skin friction coefficient on a yarn package surface in ring spinning

The skin friction coefficient on the surface of a rotating yarn package affects the power required to drive the package. This paper examines the relationship between the skin friction coefficient on the package surface and its diameter and rotating speed, based on the fundamentals of aerodynamics and the experimental results of power consumption. Skin friction coefficients on the surfaces of an airplane, car top, and yarn package are discussed. The results indicate that the skin friction coefficient on the package surface without hairiness depends on the package diameter and spindle speed only. The skin friction coefficient on the yarn package surface is about three times that on the top surface of a car, and is about twenty times that on an airplane surface. The power consumed to overcome skin friction drag is more than that consumed to drive the spindle if the spindle speed is very slow. However, the situation reverses when the spindle speed is fast.

Investigation of yarn hairiness

Yarn hairiness affects not only the quality of products, but also the productivity in spinning and weaving. Too much yarn hairiness is undesirable for many end uses as well as the spinning and post spinning processes. The main aims of this project are to examine the hairiness features of various yarns and to reduce yarn hairiness. The thesis covers five related areas – hairiness assessment, factors affecting yarn hairiness, the hairiness of newly developed yarns, yarn hairiness reduction, and effect of yarn hairiness on the energy consumption in ring spinning. The worsted cashmere, pure wool and wool/cashmere blend yarns were employed to investigate the effect of some fibre parameters on the yarn hairiness. A single exponential distribution of the hair-length was confirmed first, using the data from the Zweigle G565 Hairiness Meter. A linear relationship was observed between the blend ratio and the hairiness indexes. In particular, the effect of fibre crimp or curvature on yarn hairiness is examined. The theory of yarn hairiness composition was also developed further. The effect of draft ratio and spindle speed on the hairiness of worsted wool yarn was examined next with a factorial experiment design. Several new hairiness indexes, namely the relative hairiness indexes, have been used to explain the results obtained. In the investigation of the hairiness of newly developed yarns, the hairiness of the Compact Spun and Roller-Jet-Spun yarns was examined first. The composition of the yarn hairiness, the hair-length distribution, and the effect of test speed on yarn hairiness were then studied. An important finding is that for both yarns, the predominant hairiness feature is the looped hairs. A comparison of the hairiness of Solospun yarns and the equivalent ring spun wool yarns was undertaken. The hair-length distribution of the Solospun yarn was examined first. The Solospun yarns used had fewer hairs in most hair-length groups and lower variations in hairiness. In addition, the effect of twist level and spindle speed on the hairiness of Solospun and conventional ring spun yarns has also been discussed. A novel approach of reducing yarn hairiness – spinning with a ‘Diagonal’ yarn path was examined next. Both ‘Left Diagonal’ and ‘Right Diagonal’ yarn arrangements were studied. A new finding is that the ‘Right Diagonal’ yarn path leads to reduced hairiness for the Z-twist yarn, while yarn evenness and tenacity are not as sensitive to the modified yarn path. The mechanism of hairiness reduction with the ‘Diagonal’ yarn path has been discussed. The spinning performance of “Right Diagonal” yarn arrangement has also been evaluated. Finally, the effect of yarn hairiness on the energy consumption in ring spinning has been investigated theoretically and experimentally. A theoretical model has been developed, which represents the first attempt at theoretically investigating the influence of yarn hairiness on energy consumption during the winding stage of ring spinning. The experimental results have generally confirmed predictions of this model. Recommendations for further research in this area have also been made in the concluding chapter of this thesis.

Individual variation in thermal performance curves: swimming burst speed and jumping endurance in wild-caught tropical clawed frogs

The importance of studying individual variation in locomotor performance has long been recognized as it may determine the ability of an organism to escape from predators, catch prey or disperse. In ectotherms, locomotor performance is highly influenced by ambient temperature (Ta), yet several studies have showed that individual differences are usually retained across a Ta gradient. Less is known, however, about individual differences in thermal sensitivity of performance, despite the fact that it could represent adaptive sources of phenotypic variation and/or additional substrate for selection to act upon. We quantified swimming and jumping performance in 18 wild-caught tropical clawed frogs (Xenopus tropicalis) across a Ta gradient. Maximum swimming velocity and acceleration were not repeatable and individuals did not differ in how their swimming performance varied across Ta. By contrast, time and distance jumped until exhaustion were repeatable across the Ta gradient, indicating that individuals that perform best at a given Ta also perform best at another Ta. Moreover, thermal sensitivity of jumping endurance significantly differed among individuals, with individuals of high performance at low Ta displaying the highest sensitivity to Ta. Individual differences in terrestrial performance increased with decreasing Ta, which is opposite to results obtained in lizards at the inter-specific and among-individual levels. To verify the generality of these patterns, we need more studies on individual variation in thermal reaction norms for locomotor performance in lizards and frogs.

High-precision five-axis machine for high-speed material processing using linear motors and parallel-serial kinematics

The paper describes some details of the mechanical and kinematics design of a five-axis mechanism. The design has been utilized to physically realize an industrial-scale five-axis milling machine that can carry a three KW spindle. However, the mechanism could be utilized in other material processing and factory automation applications. The mechanism has five rectilinear joints/axes. Two of these axes are arranged traditionally, i.e. in series, and the other three axes utilize the concept of parallel kinematics. This combination results in a design that allows three translational and two rotational two-mode degrees of freedom (DOFs). The design provides speed, accuracy and cost advantages over traditional five-axis machines. All axes are actuated using linear motors.

Variation in body condition during the post-moult foraging trip of southern elephant seals and its consequences on diving behaviour

Mature female southern elephant seals (Mirounga leonina) come ashore only in October to breed and in January to moult, spending the rest of the year foraging at sea. Mature females may lose as much as 50% of their body mass, mostly in lipid stores, during the breeding season due to fasting and lactation. When departing to sea, post-breeding females are negatively buoyant, and the relative change in body condition (i.e. density) during the foraging trip has previously been assessed by monitoring the descent rate during drift dives. However, relatively few drift dives are performed, resulting in low resolution of the temporal reconstruction of body condition change. In this study, six post-breeding females were equipped with time-depth recorders and accelerometers to investigate whether changes in active swimming effort and speed could be used as an alternative method of monitoring density variations throughout the foraging trip. In addition, we assessed the consequences of density change on the swimming efforts of individuals while diving and investigated the effects on dive duration. Both descent swimming speed and ascent swimming effort were found to be strongly correlated to descent rate during drift dives, enabling the fine-scale monitoring of seal density change over the whole trip. Negatively buoyant seals minimized swimming effort during descents, gliding down at slower speeds, and reduced their ascent swimming effort to maintain a nearly constant swimming speed as their buoyancy increased. One per cent of seal density variation over time was found to induce a 20% variation in swimming effort during dives with direct consequences on dive duration.