Chip formation mechanism and machinability of wrought duplex stainless steel alloys

This paper investigates the chip formation mechanism and machinability of two-phase materials, such as, wrought duplex stainless steel alloys SAF 2205 and SAF 2507. SEM and optical microscopic details of the frozen cutting zone and chips revealed that the harder austenite phase dissipates in the advancement of the cutting tool, being effectively squeezed out of the softer ferrite phase. Microhardness profiles reveal correlation in hardness from the workpiece material transitioning to the chip. The tool wear (TiAIN + TiN coated solid carbide twist drill) and machining forces were investigated. Tool wear, was dominantly due to the adhesion process which developed from built-up edge formation, is highly detrimental to the flank face. Flute damage was also observed as a major issue in the drilling of duplex alloys leading to premature tool failure. Duplex 2507 shows higher sensitivity to cutting speed during machining and strain hardening at higher velocity and less machinability due to presence of higher percentage of Ni, Mo and Cr.

Weldability and machinability of duplex stainless steel

This chapter investigates two important processing methods, such as welding and machine of duplex stainless steel. The welding process welding generally degrades the properties of these materials by redistributing the phases during melting and solidification. On the other hand, the redistribution during machining mainly take place combined effect of stress, strain rate and temperature. Mechanism of machining process and several welding methods has been analysed in details. It was found that outcomes of welding processes depend on the welding methods. Most of the cases an appropriate annealing process can be used to restore the expected properties of the weld joints though the parameters of annealing process are different in different welding methods. Nonmetallic inclusions and the low carbon content of duplex stainless steel reduce the machinability of duplex stainless steel. SEM and optical microscopic details of the frozen cutting zone and chips revealed that the harder austenite phase dissipates in the advancement of the cutting tool, being effectively squeezed out of the softer ferrite phase. Abrasion and adhesion were the most common wear modes developed on the flank and rake faces. Adhesion wear being the most prevalent on the flank face, appeared to be initiated by built-up edge formation.

Analysis on turning Ti-6Al-4V with different cooling methods

The aim of this paper is to optimize the machining of Ti-6Al-4V alloy, by studying the chip formation, roughness and tool wear for different cooling conditions. The results were compared between cooling methods, minimal quantity of fluid (MQF) and flooding, and also without fluid for the tool H13A. The turning of Ti-6Al-4V has shown good results on roughness (0, 8μm) and tool life, which was 11% lower with MQF than with the flooding method. The tool wear causes variation of the shear angle, which promotes strength hardening of the chip. As a result, the machined surface could be damaged. The use of the cutting fluid helps to save the cutting edge and could reduce the strength hardening. Nevertheless, it could also facilitate the formation of built-up edge. The nucleation of alpha lamellar colonies can occur due to a combination of deformation rates and temperature, mainly when the flooding is used, but it's not conclusive. The lamellar colonies were also found with the MQF in some regions, however, this structure did not show hardness variation compared to equiaxial. For all this reasons, the machining parameters might be carefully chosen.

Torneamento de liga de níquel Pyromet 31V (N07032) com ferramentas de metal duro

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Usinagem da liga de níquel inconel 718 com pastilhas de cerâmica

The machining of super alloys resistant to high temperatures such as nickel alloys, inconel 718 specifically, is a very difficult job to obtain improvements in the process, due to the difficulty of machining at high cutting speeds, the use of these alloys in industries showed great developments in recent years, its application in aeronautical industry spread being used in vane turbo, compressor parts, props and set elements. The automotive, chemical, medical and others also took advantage of the great features of inconel 718 and has used the material. The high temperature resistant alloys have high machining difficulty, a fact that is associated with high cutting forces generated during machining which result in high temperatures. High levels of temperatures can cause deterioration of the cutting edge, with subsequent deformation or breakage, wear most common obtained in machining such materials are flank wear the formation of built-up edge for cutting and notch wear. The experimental part of the work consists in machining of nickel-based alloy Inconel 718 heat treated for hardness, using a tool based ceramic silicon nitride Sandvik (Si3N4) in order to compare the best results obtained in the master's thesis of SANTOS (2010) who used a tool ceramics also the basis of silicon nitride which was developed in the doctoral thesis of SOUZA (2005). Assays were performed on a CNC lathe and was noted for each cutting edge results obtained. Tests were made starting from an initial condition of the tool with cutting speed of 200 m/min, feed 0.5 mm and 0.5 mm depth of cut was reduced cutting speed for the subsequent tests with the same conditions of feed and depth of cut. The tool presented wear instant under two 200 m/min and 100 m/min, premature rupture of 50 m/min and finally cut provided with difficulty... (Complete abstract click electronic access below)

Investigation on the behavior of austenite and ferrite phases at stagnation region in the turning of duplex stainless steel alloys

This paper investigates the deformation mechanisms and plastic behavior of austenite and ferrite phases in duplex stainless steel alloys 2205 and 2507 under chip formation from a machine turning operation. SEM images and EBSD phase mapping of frozen chip root samples detected a build-up of ferrite bands in the stagnation region, and between 65 and 85 pct, more ferrite was identified in the stagnation region compared to austenite. SEM images detected micro-cracks developing in the ferrite phase, indicating ferritic build-up in the stagnation region as a potential triggering mechanism to the formation of built-up edge, as transgranular micro-cracks found in the stagnation region are similar to micro-cracks initiating built-up edge formation. Higher plasticity of austenite due to softening under high strain is seen responsible for the ferrite build-up. Flow lines indicate that austenite is plastically deforming at a greater rate into the chip, while ferrite shows to partition most of the strain during deformation. The loss of annealing twins and activation of multiple slip planes triggered at high strain may explain the highly plastic behavior shown by austenite.

Impacts of wear and geometry response of the cutting tool on machinability of super austenitic stainless steel

This paper presents a study of tool wear and geometry response whenmachinability tests were applied under milling operations onthe Super Austenitic Stainless Steel alloy AL-6XN. Eight milling trials were executed under two cutting speeds, two feed rates, andtwo depths of cuts. Cutting edge profile measurements were performed to reveal response of cutting edge geometry to the cuttingparameters and wear. A scanning electron microscope (SEM) was used to inspect the cutting edges. Results showed the presenceof various types of wear such as adhesion wear and abrasion wear on the tool rake and flank faces. Adhesion wear represents theformation of the built-up edge, crater wear, and chipping, whereas abrasion wear represents flank wear.Thecommonly formed wearwas crater wear. Therefore, the optimum tool life among the executed cutting trails was identified according to minimum lengthand depth of the crater wear.The profile measurements showed the formation of new geometries for the worn cutting edges due toadhesion and abrasion wear and the cutting parameters.The formation of the built-up edge was observed on the rake face of thecutting tool. The microstructure of the built-up edge was investigated using SEM. The built-up edge was found to have the austeniteshear lamellar structure which is identical to the formed shear lamellae of the produced chip.

Influence of leading edge imperfections on the aerodynamic characterictics of NACA 632-215 laminar aerofoils at low Reynolds number

This article deals with the effect of leading edge imperfections on the aerodynamic characteristics of a NACA 632-215 laminar aerofoil at low Reynolds numbers. Wind tunnel tests have been performed at different Reynolds numbers and angles of attack and global aerodynamic loads were measured. To perform these tests, a NACA 632-215 aerofoil was built up in two halves (corresponding to the upper side and to the lower side), the leading edge imperfection here considered being a slight displacement of half aerofoil with respect to the other. From experimental results, a quantitative measure of the influence of the leading edge displacement on the degradation of the aerofoil aerodynamic performances has been obtained. This allows the establishment of a criterion for an acceptance limit for this kind of imperfection

Differentiating between pollutants build-up on roads and roofs: Significance of roofs as a stormwater pollutant source

Impervious surfaces in an urban catchment are the primary stormwater pollutant contributing areas. Appropriate treatment of stormwater runoff from these impervious surfaces is essential to safeguard the urban water environment. While urban roads have received significant research attention in this regard, roofs have not been well investigated. Key pollutant processes such as build-up on roads and roofs can be different due to the different surface characteristics. This entails different treatment strategies being needed for road and roofs. The research study characterized roof pollutants build-up by differentiating with road surfaces. It was noted that pollutants are more highly concentrated on particles and particularly finer particles in the case of roof surfaces, compared to road surfaces. Additionally, pollutants built-up on roof surfaces tend to be relatively more variable from one day to another in terms of pollutant loads. These results highlight the significance of roofs as a stormwater pollutant source and the important need for a specific stormwater treatment strategy rather than the application of a combined approach for treating stormwater runoff from both, roads and roofs.

HNbWO6 and HTaWO6: Novel layered oxides related to the rutile structure. Synthesis and investigation of ion-exchange and intercalation behaviour

New protonated layered oxides, HMWO6·1.5H2O (M=Nb or Ta), have been synthesized by topotactic exchange of lithium in trirutile LiMWO6 with protons by treatment with dilute HNO3. The tetragonal cell constants are a=4.71 (2) and c=25.70 (8)Å for HNbWO6·1.5H2O and a=4.70 (2) and c=25.75 (9) Å for HTaWO6·1.5H2O. Partially hydrated compounds, HMWO6·0.5H2O and anhydrous compounds, HMWO6 retain the layered structure. The structure of these oxides consists of MWO6 sheets built up of M/W-oxygen octahedra with rutile type corner- and edge-sharing. Interlayer protons in HMWO6 are exchanged with Li+, Na+, K+ and Tl+. HMWO6 exhibit Brønsted acidity intercalating n-alkylamines and pyridine.

Molecular dynamics studies on the dislocation gliding near a tilt boundary

The gliding behavior of edge dislocation near a grain boundary(QB) in copper under pure shear stresses is simulated by using molecular dynamics(MD) method. Many-body potential incorporating the embedded atom method (EAM) is used. The critical shear stresses for a single disocation to pass across GB surface are obtained at values of sigma(c)=23MPa similar to 68 MPa and 137 MPa similar to 274 MPa for Sigma=165 small angle tilt GB at 300 K and 20 K, respectively. The first result agrees with the experimental yield stress sigma(y)(=42 MPa) quite well. It suggests that there might be one of the reasons of initial plastic yielding caused by single dislocation gliding across GB. In addition, there might be possibility to obtain yield strength from microscopic analysis. Moreover, the experimental value of sigma(y) at low temperature is generally higher than that at room temperature. So, these results are in conformity qualitatively with experimental fact. On the other hand, the Sigma=25 GB is too strong an obstacle to the dislocation. In this case, a dislocation is able to pass across GB under relatively low stress only when it is driven by other dislocations. This is taken to mean that dislocation pile-up must be built up in front of this kind of GB, if this GB may take effect on the process of plastic deformation.

From fossil molluscs to salmon

On 9 April 1897 Wilfrid Hudleston, an eminent geologist, purchased the West Holme Estate, comprising some 1500 acres on the edge of the Isle of Purbeck in Dorset, where he could enjoy his sporting interest in shooting and fishing. In doing so, he established a link between himself, The Malacological Society of London, and the Freshwater Biological Association. Hudleston was a keen field geologist who built up a personal collection of several thousand fossils. In 1893 Hudleston took the chair at a meeting, held at the Natural History Museum, which founded The Malacological Society of London. The site on which the Freshwater Biological Association's River Laboratory now stands was formerly part of the West Holme Estate. It purchased the fishing rights to the East Stoke mill stream prior to building the laboratory, in 1957.

The direct field boundary impedance of two-dimensional periodic structures with application to high frequency vibration prediction.

Large sections of many types of engineering construction can be considered to constitute a two-dimensional periodic structure, with examples ranging from an orthogonally stiffened shell to a honeycomb sandwich panel. In this paper, a method is presented for computing the boundary (or edge) impedance of a semi-infinite two-dimensional periodic structure, a quantity which is referred to as the direct field boundary impedance matrix. This terminology arises from the fact that none of the waves generated at the boundary (the direct field) are reflected back to the boundary in a semi-infinite system. The direct field impedance matrix can be used to calculate elastic wave transmission coefficients, and also to calculate the coupling loss factors (CLFs), which are required by the statistical energy analysis (SEA) approach to predicting high frequency vibration levels in built-up systems. The calculation of the relevant CLFs enables a two-dimensional periodic region of a structure to be modeled very efficiently as a single subsystem within SEA, and also within related methods, such as a recently developed hybrid approach, which couples the finite element method with SEA. The analysis is illustrated by various numerical examples involving stiffened plate structures.

Investigation of failures in Irish raised bogs

This paper presents the results of field geophysical testing and laboratory testing of peat from Carn Park and Roosky raised bogs in the Irish Midlands. The motivation for the work was highlight the importance of these areas and to begin to attempt to understand the reasons for the failure of the bogs despite them having surface slopes of some 1°. It was found that the peat is typical of that of Irish raised bogs being up to 8m thick towards the “high” dome of the bogs. The peat is characterised by low density, high water content, high organic content, low undrained shear strength and high compressibility. The peat is also relatively permeable at in situ stress. Geophysical electrical resistivity tomography and ground penetrating radar data shows a clear thinning of the peat in the area of the failures corresponding to a reduction in volume from dewatering by edge drains/peat harvesting. This finding is supported by detailed water content measurements. It was also shown that the peat base topography is relatively flat and indicates that the observed surface movement has come from within the peat rather than from the material below the peat. Potential causes of the failures include conventional slope instability, the effect of seepage forces or the release of built-up gas in the peat mass. Further measurements are required in order to study these in more detail.

Ga Optimized Srr Calculator

Negative magnetic permeability media (NMPM) can be built up by using small resonant metallic particles like Split ring resonator (SRR) which has very high magnetic polarisability. A group of these particles shows a negative permeability region near and above the resonant frequency. The continuous medium parameters describing the SRR array can be predicted from their individual electromagnetic behavior near the resonances. The paper presents an optimizing software using Genetic Algorithm (GA) to design an edge coupled two ring SRR for a particular frequency