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.

Development of the sheared edge in the trimming of steel and light metal sheet, part 1 - experimental observations

Trimming experiments were conducted on sheet metals including two drawing steels, an aluminum alloy and a magnesium alloy, using a specially designed die in a mechanical press. The punch-die clearance was varied and data obtained on the rollover and burr height as a function of the clearance. Samples were also partially trimmed to examine crack initiation, the generation of the fracture surface profile and mechanism of burr formation. The results showed that while the burr height and rollover depth generally increased with increasing clearance for all examined materials, there were differences in the fracture surface profile shape, the burr shape, and the mechanism of burr formation, between the two steels and the two light alloys. The major cause of these differences appeared to be the rate of crack propagation through the sheet material.

Development of the sheared edge in the trimming of steel and light metal sheet, part 2 - mechanisms and modelling

The shearing behavior of a drawing-steel and aluminum alloy were investigated using hardness contours of partially deformed samples and a finite element model of the trimming process. Results showed that the stress and strain distributions within the work-piece were more strongly dependent on the punch penetration than the material properties of the work-piece. Differences in the final fracture surface profile and burr formation of the drawing-steel and aluminum alloy were a consequence of the shape of the stress and strain distribution when the crack in the sample became unstable, not when it was initiated. Results and existing literature suggest that a correlation may exist between the strain-rate sensitivity of the work-piece material and the burr mechanism and fracture surface profile of the trimmed part.

The effect of laser power density on the fatigue life of laser-shock-peened 7050 aluminium alloy

Laser shock peening (LSP) is an innovative surface treatment method that can result in significant improvement in the fatigue life of many metallic components. The process produces very little or no surface profile modification while producing a considerably deeper compressive residual stress layer than traditional shot peening operations. The work discussed here was designed to: (a) quantify the fatigue life improvement achieved by LSP in a typical high strength aircraft aluminium alloy and (b) identify any technological risks associated with its use. It is shown that when LSP conditions are optimal for the material and specimen configuration, a —three to four times increase in fatigue life over the as-machined specimens could be achieved for a representative fighter aircraft loading spectrum when applied at a representative load level. However, if the process parameters are not optimal for the material investigated here, fatigue lives of LSP treated specimens may be reduced instead of increased due to the occurrence of internal cracking. This paper details the effect of laser power density on fatigue life of 7050-T7451 aluminium alloy by experimental and numerical analysis.

Comparisons of the two-body abrasive wear behaviour of four different ferrous microstructures with similar hardness levels

The abrasive wear resistance of four distinct metallurgical steel microstructures - bainite, pearlite, martensite and tempered martensite, with similar hardness levels was investigated. A pin-on-disc tribometer was used to simulate the two-body abrasive condition (i.e. the metallic surface abrading against the silicon carbide abrasive particles) and evaluate the specific wear rate of the microstructures. Each microstructure had a unique response towards the abrasion behaviour and this was largely evident in the friction curve. However, the multi-phase microstructures (i.e. bainite and pearlite) demonstrated better abrasion resistance than the single-phase microstructures (i.e. martensite and tempered martensite). Abrasion induced microstructural changes at the deformed surfaces were studied using sub-surface and topographical techniques. The properties of these layers (i.e. surface profile measurements) determined the amount of material loss for each microstructure. These were directly linked to the single-wear track analysis that highlighted a marked difference in their mode of material removal. Ploughing and wedge formation modes were dominant in the case of bainite and pearlite microstructures, whereas the cutting mode could be attributed to the higher material loss in the single-phase microstructures. The combination of brittle and ductile phases in the multi-phase microstructure matrix could be one of the driving factors for their superior abrasion resistance.

Direct measurement of surface forces due to charging of solids immersed in a nonpolar liquid

Direct measurements of a long-range force between charged solid surfaces in a nonpolar liquid are presented for the first time. Measurements were made between mica surfaces in solutions of the anionic surfactant sodium di-2-ethylhexylsulfosuccinate (AOT) at millimolar concentrations in n-decane using a surface force apparatus which has been modified to improve its sensitivity for detecting a weak and long-range force. Modifications include a magnetic drive system, the use of a weak cantilever spring with the apparatus mounted in a vertical configuration, and a detailed consideration of the interference optics to allow accurate measurements of surface separations up to several micrometers. The results show a repulsion that is well fitted by theoretical curves based on a model in which only counterions enter the calculation, in other words, in the absence of a reservoir of ions in the solvent. Fitting the theory to the data allows an estimate of the mica surface charge density of ∼1 mC/m². A mechanism for surface charging of mica in this solution is proposed, which includes a role for trace amounts of water that are inevitably present and adsorbed surface aggregates of AOT. The relevance of the results to previously observed charge stabilization of colloids in nonaqueous solvents is discussed.

Measurement of surface forces between mica sheets immersed in aqueous quaternary ammonium ion solutions

Forces between mica surfaces immersed in Me4NBr, Pr4NBr, and Pe4NBr solutions over a wide concentration range are reported (Me = methyl, Pr = propyl, Pe = pentyl). In each case the cation adsorbs quite strongly onto the negatively charged mica surface and determines the double-layer potential. However, this strong adsorption does not cause complete neutralization of the negative lattice charge apparently because of packing constraints due to the large size of these ions. Adsorption of Me4N+ ions gives rise to a short-range (<2 nm) repulsive force similar to that previously observed between bilayers of CTAB and may be due to the residual hydration of these ions. The large rations also, unexpectedly, give rise to short-range repulsive forces but of a somewhat different nature. In this case, the repulsive forces can be explained by assuming that the large adsorbed ions shift the plane of charge a distance of one ion diameter from the mica surface. At all but very high concentrations these larger ions could be displaced from the mica surfaces on forcing them together. No evidence of any “hydrophobic attraction” was observed between surfaces containing these adsorbed ions. Previous studies on coagulation are discussed in the light of our results.

Direct measurement of surface forces between sapphire crystals in aqueous solutions

Measurements are presented of the electrical double layer and van der Waals forces between the (0001) surfaces of two single-crystal sapphire platelets immersed in an aqueous solution of NaCl at pH values from 6.7 to 11. The results fit the standard Deryaguin-Landau-Verwey-Overbeek (DLVO) theory, with a Hamaker constant of 6.7 × 10−20 J. These are the first measurements made using the Israelachvili surface forces apparatus without mica as a substrate material, and they demonstrate the possibility of using this technique to explore the surface chemistry of a wider range of materials.