Influence of temperature on the anisotropic cutting behaviour of single crystal silicon: A molecular dynamics simulation investigation

Using molecular dynamics (MD) simulation, this paper investigates anisotropic cutting behaviour of single crystal silicon in vacuum under a wide range of substrate temperatures (300 K, 500 K, 750 K, 850 K, 1173 K and 1500 K). Specific cutting energy, force ratio, stress in the cutting zone and cutting temperature were the indicators used to quantify the differences in the cutting behaviour of silicon. A key observation was that the specific cutting energy required to cut the (111) surface of silicon and the von Mises stress to yield the silicon reduces by 25% and 32%, respectively, at 1173 K compared to what is required at 300 K. The room temperature cutting anisotropy in the von Mises stress and the room temperature cutting anisotropy in the specific cutting energy (work done by the tool in removing unit volume of material) were obtained as 12% and 16% respectively. It was observed that this changes to 20% and 40%, respectively, when cutting was performed at 1500 K, signifying a very strong correlation between the anisotropy observed during cutting and the machining temperature. Furthermore, using the atomic strain criterion, the width of primary shear zone was found to vary with the orientation of workpiece surface and temperature i.e. it remains narrower while cutting the (111) surface of silicon or at higher machining temperatures. A major anecdote of the study based on the potential function employed in the study is that, irrespective of the cutting plane or the cutting temperature, the state of the cutting edge of the diamond tool did not show direct diamond to graphitic phase transformation.

Multilayered micro/nanocrystalline CVD diamond coatings for biotribology

In the present work multilayered micro/nanocrystalline (MCD/NCD) diamond coatings were developed by Hot Filament Chemical Vapour Deposition (HFCVD). The aim was to minimize the surface roughness with a top NCD layer, to maximize adhesion onto the Si3N4 ceramic substrates with a starting MCD coating and to improve the mechanical resistance by the presence of MCD/NCD interfaces in these composite coatings. This set of features assures high wear resistance and low friction coefficients which, combined to diamond biocompatibility, set this material as ideal for biotribological applications. The deposition parameters of MCD were optimized using the Taguchi method, and two varieties of NCD were used: NCD-1, grown in a methane rich gas phase, and NCD-2 where a third gas, Argon, was added to the gas mixture. The best combination of surface pre-treatments in the Si3N4 substrates is obtained by polishing the substrates with a 15 μm diamond slurry, further dry etching with CF4 plasma for 10 minutes and final ultrasonic seeding in a diamond powder suspension in ethanol for 1 hour. The interfaces of the multilayered CVD diamond films were characterized with high detail using HRTEM, STEM-EDX and EELS. The results show that at the transition from MCD to NCD a thin precursor graphitic film is formed. On the contrary, the transition of the NCD to MCD grade is free of carbon structures other than diamond, as a result of the richer atomic hydrogen content and of the higher substrate temperature for MCD deposition. At those transitions, WC nanoparticles were found due to contamination from the filament, being also present at the first interface of the MCD layer with the silicon nitride substrate. In order to study the adhesion and mechanical resistance of the diamond coatings, indentation and particle jet blasting tests were conducted, as well as tribological experiments with homologous pairs. Indentation tests proved the superior behaviour of the multilayered coatings that attained a load of 800 N without delamination, when compared to the mono and bilayered ones. The multilayered diamond coatings also reveal the best solid particle erosion resistance, due to the MCD/NCD interfaces that act as crack deflectors. These results were confirmed by an analytical model on the stress field distribution based on the von Mises criterion. Regarding the tribological testing under dry sliding, multilayered coatings also exhibit the highest critical load values (200N for Multilayers with NCD-2). Low friction coefficient values in the range μ=0.02- 0.09 and wear coefficient values in the order of ~10-7 mm3 N-1 m-1 were obtained for the ball and flat specimens indicating a mild wear regime. Under lubrication with physiological fluids (HBSS e FBS), lower wear coefficient values ~10-9-10-8 mm3 N-1 m-1) were achieved, governed by the initial surface roughness and the effective contact pressure.

Análise do comportamento estrutural de uma lancha salva-vidas

Dissertação para obtenção do grau de Mestre em Engenharia Mecânica

Estudo da integridade estrutural da secção-mestra de lanchas de fiscalização rápida da classe “Centauro”

Dissertação para obtenção do Grau de Mestre em Engenharia Mecânica

Determination of displacement, stress- and strain-distribution in the human heart: a FE-model on the basis of MR imaging.

The determination of characteristic cardiac parameters, such as displacement, stress and strain distribution are essential for an understanding of the mechanics of the heart. The calculation of these parameters has been limited until recently by the use of idealised mathematical representations of biventricular geometries and by applying simple material laws. On the basis of 20 short axis heart slices and in consideration of linear and nonlinear material behaviour we have developed a FE model with about 100,000 degrees of freedom. Marching Cubes and Phong's incremental shading technique were used to visualise the three dimensional geometry. In a quasistatic FE analysis continuous distribution of regional stress and strain corresponding to the endsystolic state were calculated. Substantial regional variation of the Von Mises stress and the total strain energy were observed at all levels of the heart model. The results of both the linear elastic model and the model with a nonlinear material description (Mooney-Rivlin) were compared. While the stress distribution and peak stress values were found to be comparable, the displacement vectors obtained with the nonlinear model were generally higher in comparison with the linear elastic case indicating the need to include nonlinear effects.

Exact Nonparametric Two-Sample Homogeneity Tests for Possibly Discrete Distributions.

In this paper, we study several tests for the equality of two unknown distributions. Two are based on empirical distribution functions, three others on nonparametric probability density estimates, and the last ones on differences between sample moments. We suggest controlling the size of such tests (under nonparametric assumptions) by using permutational versions of the tests jointly with the method of Monte Carlo tests properly adjusted to deal with discrete distributions. We also propose a combined test procedure, whose level is again perfectly controlled through the Monte Carlo test technique and has better power properties than the individual tests that are combined. Finally, in a simulation experiment, we show that the technique suggested provides perfect control of test size and that the new tests proposed can yield sizeable power improvements.

Finite Element Analysis of Warship Structures

Warships are generally sleek, slender with V shaped sections and block coefficient below 0.5, compared to fuller forms and higher values for commercial ships. They normally operate in the higher Froude number regime, and the hydrodynamic design is primarily aimed at achieving higher speeds with the minimum power. Therefore the structural design and analysis methods are different from those for commercial ships. Certain design guidelines have been given in documents like Naval Engineering Standards and one of the new developments in this regard is the introduction of classification society rules for the design of warships.The marine environment imposes subjective and objective uncertainties on ship structure. The uncertainties in loads, material properties etc.,. make reliable predictions of ship structural response a difficult task. Strength, stiffness and durability criteria for warship structures can be established by investigations on elastic analysis, ultimate strength analysis and reliability analysis. For analysis of complicated warship structures, special means and valid approximations are required.Preliminary structural design of a frigate size ship has been carried out . A finite element model of the hold model, representative of the complexities in the geometric configuration has been created using the finite element software NISA. Two other models representing the geometry to a limited extent also have been created —- one with two transverse frames and the attached plating alongwith the longitudinal members and the other representing the plating and longitudinal stiffeners between two transverse frames. Linear static analysis of the three models have been carried out and each one with three different boundary conditions. The structural responses have been checked for deflections and stresses against the permissible values. The structure has been found adequate in all the cases. The stresses and deflections predicted by the frame model are comparable with those of the hold model. But no such comparison has been realized for the interstiffener plating model with the other two models.Progressive collapse analyses of the models have been conducted for the three boundary conditions, considering geometric nonlinearity and then combined geometric and material nonlinearity for the hold and the frame models. von Mises — lllyushin yield criteria with elastic-perfectly plastic stress-strain curve has been chosen. ln each case, P-Delta curves have been generated and the ultimate load causing failure (ultimate load factor) has been identified as a multiple of the design load specified by NES.Reliability analysis of the hull module under combined geometric and material nonlinearities have been conducted. The Young's Modulus and the shell thickness have been chosen as the variables. Randomly generated values have been used in the analysis. First Order Second Moment has been used to predict the reliability index and thereafter, the probability of failure. The values have been compared against standard values published in literature.

Percepción del riesgo en trabajadores de la mina de carbón la morena

Los diferentes estudios realizados en el sector de minería de carbón hablan de problemáticas específicas en salud que afectan a la población trabajadora y otros con enfoque del impacto social y económico que tiene este tipo de actividad. Uno de los estudios fue realizado en la zona minera del valle de Ubaté, cuyo objetivo fue determinar los factores de riesgo de carga física y postura forzada, relacionados con alteraciones osteomusculares en mineros. Realizado por Edgar Humberto Velandia Baca, Médico especialista en Salud Ocupacional y Medicina del Trabajo y Juan José Muñoz Robayo, Médico especialista en Epidemiología y Medicina del Trabajo. La metodología que se utilizo para el estudio fue de corte transversal. 49 mineros fueron evaluados de acuerdo con el tipo de manto de las minas de carbón y con el puesto de trabajo. Para la valoración de las condiciones de salud de los trabajadores se diseñaron dos instrumentos de evaluación: el de historia clínica y laboral y el formato de registro de condiciones osteomusculares, los cuales fueron aplicados por un médico fisiatra. Para la valoración de la carga física y la postura se utilizó el método OWAS (Ovako Working Posture Analysis System).

The production of ultrafine ferrite during hot torsion testing of a 0.11 Wt Pct C steel

Ultrafine ferrite grain sizes were produced in a 0.11C-1.6Mn-0.2Si steel by torsion testing isothermally at 675 °C after air cooling from 1250 °C. The ferrite was observed to form intragranularly beyond a von Mises equivalent tensile strain of approximately 0.7 to 0.8 and the number fraction of intragranular ferrite grains continued to increase as the strain level increased. Ferrite nucleated to form parallel and closely spaced linear arrays or “rafts” of many discrete ultrafine ferrite grains. It is shown that ferrite nucleates during deformation on defects developed within the austenite parallel to the macroscopic shear direction (i.e., dynamic strain-induced transformation). A model austenitic Ni-30Fe alloy was used to study the substructure developed in the austenite under similar test conditions as that used to induce intragranular ferrite in the steel. It is shown that the most prevalent features developed during testing are microbands. It is proposed that high-energy jogged regions surrounding intersecting microbands provide potential sites for ferrite nucleation at lower strains, while at higher strains, the walls of the microbands may also act as nucleation sites.

Deep drawing behaviour of ultrafine grained copper : modelling and experiment

Ultrafine grained materials produced by severe plastic deformation methods possess attractive mechanical properties such as high strength compared with traditional coarse grained counterparts and reasonable ductility. Between existing severe plastic deformation methods the Equal Channel Angular Pressing is the most promising for future industrial applications and can produce a variety of ultrafine grained microstructures in materials depending on route, temperature and number of passes during processing. Driven by a rising trend of miniaturisation of parts these materials are promising candidates for microforming processes. Considering that bi-axial deformation of sheet (foil) is the major operation in microforming, the investigation of the influence of the number of ECAP passes on the bi-axial ductility in micro deep drawing test has been examined by experiments and FE simulation in this study. The experiments have showed that high force was required for drawing of the samples processed by ECAP compare to coarse grained materials. The limit drawing ratio of ultrafine grained samples was in the range of 1.9–2.0 with ECAP pass number changing from 1 to 16, while a higher value of 2.2 was obtained for coarse grained copper. However, the notable decrease in tensile ductility with increase in strength was not as pronounced for bi-axial ductility. The FE simulation using standard isotropic hardening model and von Mises yielding criterion confirmed these findings.

Analytic study on pure bending of metal sheets

In this work, analytical models of pure bending are developed to simulate a particular type of bend test and to determine possible errors arising from approximations used in analyzing experimental data. Analytical models proposed for steels include a theoretical solution of pure bending and a series of finite element models, based on the von Mises yield function, are subjected to different stress and strain conditions. The results show that for steel sheets the difference between measured and calculated results of the moment-curvature behaviour is small and the numerical results from the finite element models indicate that experimental results obtained from the test are acceptable in the range of the pure bending operation. Further for magnesium alloys, which exhibit unsymmetrical yielding, the algorithm of the yield function with a linear isotropic hardening model is implemented by programming a user subroutine in Abaqus for bending simulations of magnesium. The simulations using the proposed user subroutine extract better results than those using the von Mises yield function.

A study on compressive anisotropy and nonassociated flow plasticity of the AZ31 Magnesium Alloy in hot rolling

Effect of anisotropy in compression is studied on hot rolling of AZ31 magnesium alloy with a three-dimensional constitutive model based on the quadratic Hill48 yield criterion and nonassociated flow rule (non-AFR). The constitutive model is characterized by compressive tests of AZ31 billets since plastic deformations of materials are mostly caused by compression during rolling processes. The characterized plasticity model is implemented into ABAQUS/Explicit as a user-defined material subroutine (VUMAT) based on semi-implicit backward Euler's method. The subroutine is employed to simulate square-bar rolling processes. The simulation results are compared with rolled specimens and those predicted by the von Mises and the Hill48 yield function under AFR. Moreover, strip rolling is also simulated for AZ31 with the Hill48 yield function under non-AFR. The strip rolling simulation demonstrates that the lateral spread generated by the non-AFR model is in good agreement with experimental data. These comparisons between simulation and experiments validate that the proposed Hill48 yield function under non-AFR provides satisfactory description of plastic deformation behavior in hot rolling for AZ31 alloys in case that the anisotropic parameters in the Hill48 yield function and the non-associated flow rule are calibrated by the compressive experimental results.

Otimização topológica de estruturas bidimensionais contínuas submetidas a restrições de flexibilidade e tensão

Neste trabalho é resolvido o problema da minimização do volume de estruturas bidimensionais contínuas submetidas a restrições sobre a flexibilidade (trabalho das forças externas) e sobre as tensões, utilizando a técnica chamada otimização topológica, que visa encontrar a melhor distribuição de material dentro de um domínio de projeto pré-estabelecido. As equações de equilíbrio são resolvidas através do método dos elementos finitos, discretizando a geometria e aproximando o campo de deslocamentos. Dessa forma, essas equações diferenciais são transformadas em um sistema de equações lineares, obtendo como resposta os deslocamentos nodais de cada elemento. A distribuição de material é discretizada como uma densidade fictícia constante por elemento finito. Esta densidade define um material isotrópico poroso de uma seqüência pré-estabelecida (SIMP). A otimização é feita através da Programação Linear Seqüencial. Para tal, a função objetivo e as restrições são sucessivamente linearizadas por expansão em Série de Taylor. A análise de sensibilidade para a restrição de flexibilidade é resolvida utilizando o cálculo da sensibilidade analítico adaptado para elementos finitos de elasticidade plana. Quando as restrições consideradas são as tensões, o problema torna-se mais complexo. Diferente da flexibilidade, que é uma restrição global, cada elemento finito deve ter sua tensão controlada. A tensão de Von Mises é o critério de falha considerado, cuja sensibilidade foi calculada de acordo com a metodologia empregada por Duysinx e Bendsøe [Duysinx e Bendsøe, 1998] Problemas como a instabilidade de tabuleiro e dependência da malha sempre aparecem na otimização topológica de estruturas contínuas. A fim de minimizar seus efeitos, um filtro de vizinhança foi implementado, restringindo a variação da densidade entre elementos adjacentes. Restrições sobre as tensões causam um problema adicional, conhecido como singularidade das tensões, fazendo com que os algoritmos não convirjam para o mínimo global. Para contornar essa situação, é empregada uma técnica matemática de perturbação visando modificar o espaço onde se encontra a solução, de forma que o mínimo global possa ser encontrado. Esse método desenvolvido por Cheng e Guo [Cheng e Guo, 1997] é conhecido por relaxação-ε e foi implementado nesse trabalho.

Otimização Topológica com Termo-elasticidade Utilizando Elementos Tri3

This work proposes a formulation for optimization of 2D-structure layouts submitted to mechanic and thermal shipments and applied an h-adaptive filter process which conduced to computational low spend and high definition structural layouts. The main goal of the formulation is to minimize the structure mass submitted to an effective state of stress of von Mises, with stability and lateral restriction variants. A criterion of global measurement was used for intents a parametric condition of stress fields. To avoid singularity problems was considerate a release on the stress restriction. On the optimization was used a material approach where the homogenized constructive equation was function of the material relative density. The intermediary density effective properties were represented for a SIMP-type artificial model. The problem was simplified by use of the method of finite elements of Galerkin using triangles with linear Lagrangian basis. On the solution of the optimization problem, was applied the augmented Lagrangian Method, that consists on minimum problem sequence solution with box-type restrictions, resolved by a 2nd orderprojection method which uses the method of the quasi-Newton without memory, during the problem process solution. This process reduces computational expends showing be more effective and solid. The results materialize more refined layouts with accurate topologic and shape of structure definitions. On the other hand formulation of mass minimization with global stress criterion provides to modeling ready structural layouts, with violation of the criterion of homogeneous distributed stress

Otimização de forma aplicando B-splines sob critério integral de tensões

This work proposes a computational methodology to solve problems of optimization in structural design. The application develops, implements and integrates methods for structural analysis, geometric modeling, design sensitivity analysis and optimization. So, the optimum design problem is particularized for plane stress case, with the objective to minimize the structural mass subject to a stress criterion. Notice that, these constraints must be evaluated at a series of discrete points, whose distribution should be dense enough in order to minimize the chance of any significant constraint violation between specified points. Therefore, the local stress constraints are transformed into a global stress measure reducing the computational cost in deriving the optimal shape design. The problem is approximated by Finite Element Method using Lagrangian triangular elements with six nodes, and use a automatic mesh generation with a mesh quality criterion of geometric element. The geometric modeling, i.e., the contour is defined by parametric curves of type B-splines, these curves hold suitable characteristics to implement the Shape Optimization Method, that uses the key points like design variables to determine the solution of minimum problem. A reliable tool for design sensitivity analysis is a prerequisite for performing interactive structural design, synthesis and optimization. General expressions for design sensitivity analysis are derived with respect to key points of B-splines. The method of design sensitivity analysis used is the adjoin approach and the analytical method. The formulation of the optimization problem applies the Augmented Lagrangian Method, which convert an optimization problem constrained problem in an unconstrained. The solution of the Augmented Lagrangian function is achieved by determining the analysis of sensitivity. Therefore, the optimization problem reduces to the solution of a sequence of problems with lateral limits constraints, which is solved by the Memoryless Quasi-Newton Method It is demonstrated by several examples that this new approach of analytical design sensitivity analysis of integrated shape design optimization with a global stress criterion purpose is computationally efficient