The cutting performance of sialon ceramic tools

The thesis deals with a research programme in which the cutting performance of a new generation of ceramic cutting tool material is evaluated using the turning process. In part one, the performance of commercial Kyon 2000 sialon ceramic inserts is studied when machining a hardened alloy steel under a wide range of cutting conditions. The aim is to formulate a pattern of machining behaviour in which tool wear is related to a theoretical interpretation of the temperatures and stresses generated by the chip-tool interaction. The work involves a correlation of wear measurement and metallographic examination of the wear area with the measurable cutting data. Four main tool failure modes are recognised: (a) flank and crater wear (b) grooving wear (c) deformation wear and (d) brittle failure Results indicate catastrophic edge breakdown under certain conditions. Accordingly in part two, the edge geometry is modified to give a double rake tool; a negative/positive combination. The results are reported for a range of workpiece materials under orthogonal cutting conditions. Significant improvements in the cutting performance are achieved. The improvements are explained by a study of process parameters; cutting forces, chip thickness ratio, chip contact length, temperature distribution, stress distribution and chip formation. In part three, improvements in tool performance are shown to arise when the edge chamfer on a single rake tool is modified. Under optimum edge chamfer conditions a substantial increase in tool life is obtained compared with the commercial cutting geometry.

The mechanics of creep crack growth in a Magnox alloy

Magnox AL80 has been used for a study of creep crack propagation. A number of variables have been considered such as specimen geometry,notch root radius, material thickness, creep prestrain and stress level.The work has covered the material behaving under two values of the creep exponent, n=3.5 and n=7, according to the stress level. As well as observing initiation times and crack growth rates, scribed grids have been used to examine the near crack tip strain levels and distributions. It was shown that estimations of COD from notch flank opening can give misleading indications of material behaviour and that a more informative method was to monitor displacements in the material surrounding the crack tip. Strong evidence was found for crack advance being displacement controlled, however it was shown that the COD approach should be considered geometry dependant. The summation of ∈xx and ∈yy provided the most successful description of crack advance as it produced a single value that described propagation in all the cases concidered. The strain distributions indicates that σyy was related to distance from a point ahead of the crack tip by the exponent - (l/n+l) and that σxx is proportional to σyy. The constraint stresses arising in the DEN and CN specimens were evaluated. Initiation time was found to be principally affected by the stress level but was modified by the constraints arising from specimen geometry. Crack growth was found not to obey either the empirical K or σpett relationships but was reviewed in context of the observed strain behaviour.

Modelling the dynamics of cutting during turning

This thesis presents an approach to cutting dynamics during turning based upon the mechanism of deformation of work material around the tool nose known as "ploughing". Starting from the shearing process in the cutting zone and accounting for "ploughing", new mathematical models relating turning force components to cutting conditions, tool geometry and tool vibration are developed. These models are developed separately for steady state and for oscillatory turning with new and worn tools. Experimental results are used to determine mathematical functions expressing the parameters introduced by the steady state model in the case of a new tool. The form of these functions are of general validity though their coefficients are dependent on work and tool materials. Good agreement is achieved between experimental and predicted forces. The model is extended on one hand to include different work material by introducing a hardness factor. The model provides good predictions when predicted forces are compared to present and published experimental results. On the other hand, the extension of the ploughing model to taming with a worn edge showed the ability of the model in predicting machining forces during steady state turning with the worn flank of the tool. In the development of the dynamic models, the dynamic turning force equations define the cutting process as being a system for which vibration of the tool tip in the feed direction is the input and measured forces are the output The model takes into account the shear plane oscillation and the cutting configuration variation in response to tool motion. Theoretical expressions of the turning forces are obtained for new and worn cutting edges. The dynamic analysis revealed the interaction between the cutting mechanism and the machine tool structure. The effect of the machine tool and tool post is accounted for by using experimental data of the transfer function of the tool post system. Steady state coefficients are corrected to include the changes in the cutting configuration with tool vibration and are used in the dynamic model. A series of oscillatory cutting tests at various conditions and various tool flank wear levels are carried out and experimental results are compared with model—predicted forces. Good agreement between predictions and experiments were achieved over a wide range of cutting conditions. This research bridges the gap between the analysis of vibration and turning forces in turning. It offers an explicit expression of the dynamic turning force generated during machining and highlights the relationships between tool wear, tool vibration and turning force. Spectral analysis of tool acceleration and turning force components led to define an "Inertance Power Ratio" as a flank wear monitoring factor. A formulation of an on—line flank wear monitoring methodology is presented and shows how the results of the present model can be applied to practical in—process tool wear monitoring in • turning operations.

An X-ray micro-fluorescence study to investigate the distribution of Al, Si, P and Ca ions in the surrounding soft tissue after implantation of a calcium phosphate-mullite ceramic composite in a rabbit animal model

Synthetic calcium phosphates, despite their bioactivity, are brittle. Calcium phosphate-mullite composites have been suggested as potential dental and bone replacement materials which exhibit increased toughness. Aluminium, present in mullite, has however been linked to bone demineralisation and neurotoxicity: it is therefore important to characterise the materials fully in order to understand their in vivo behaviour. The present work reports the compositional mapping of the interfacial region of a calcium phosphate-20 wt% mullite biocomposite/soft tissue interface, obtained from the samples implanted into the long bones of healthy rabbits according to standard protocols (ISO-10993) for up to 12 weeks. X-ray micro-fluorescence was used to map simultaneously the distribution of Al, P, Si and Ca across the ceramic-soft tissue interface. A well defined and sharp interface region was present between the ceramic and the surrounding soft tissue for each time period examined. The concentration of Al in the surrounding tissue was found to fall by two orders of magnitude, to the background level, within similar to 35 mu m of the implanted ceramic.

A geometrical model for surface roughness prediction when face milling Al 7075-T7351 with square insert tools

Surface quality is important in engineering and a vital aspect of it is surface roughness, since it plays an important role in wear resistance, ductility, tensile, and fatigue strength for machined parts. This paper reports on a research study on the development of a geometrical model for surface roughness prediction when face milling with square inserts. The model is based on a geometrical analysis of the recreation of the tool trail left on the machined surface. The model has been validated with experimental data obtained for high speed milling of aluminum alloy (Al 7075-T7351) when using a wide range of cutting speed, feed per tooth, axial depth of cut and different values of tool nose radius (0.8. mm and 2.5. mm), using the Taguchi method as the design of experiments. The experimental roughness was obtained by measuring the surface roughness of the milled surfaces with a non-contact profilometer. The developed model can be used for any combination of material workpiece and tool, when tool flank wear is not considered and is suitable for using any tool diameter with any number of teeth and tool nose radius. The results show that the developed model achieved an excellent performance with almost 98% accuracy in terms of predicting the surface roughness when compared to the experimental data. © 2014 The Society of Manufacturing Engineers.

Analysis of flexural isostasy of the northern Andes

The mode in which a lithosphere plate supports overlying topography is greatly driven by the strength of the plate. By analyzing the geophysical signature of lithosphere flexure, in the space and spectral domains, the strength of the plates that support the north Andean mountains and adjacent basins, and the topography of Kenya was investigated. In addition, the effect of windowing on elastic thickness estimates obtained via the coherence method was evaluated. ^ The coherence between the topography and Bouguer gravity spectra of northern South America suggests that the average elastic thickness of the lithosphere is 30 km. Although lateral variations were not resolved by the coherence implementation, these became apparent by modeling the foreland stratigraphy of the Llanos, Barinas and Maracaibo sub-Andean basins. Flexural models reveal a zone of lithosphere weakness beneath the eastern flank of the Eastern Cordillera and western flank of the Venezuelan Andes. The gravity anomaly calculated from these models is consistent with the observed Bouguer gravity anomaly. This zone of weakness appears to separate the strong, old Guyana shield lithosphere from the weaker and probably younger Andean lithosphere. The zone of weakness may correspond to a Paleozoic feature at the western margin of cratonic South America, or a Mesozoic rift arm that weakened the proto-Andean lithosphere. ^ Using synthetic data as well as the northern South America topography and gravity, this study demonstrates that lithosphere strength calculated from the coherence of mirrored data may overestimate the true lithosphere strength. As a result, many lithosphere plates may be weaker than currently thought. In light of this observation, gravity and topography data from Kenya were reevaluated using multitaper spectral techniques. The elastic thickness of this plate, currently undergoing rifting, was estimated at 7 to 8 km, a factor of 2 less than previously estimated. These estimates suggest that despite intense fracturing and sustained tensile stresses, continental lithosphere plates undergoing rifting are able to retain some strength. ^

Uvigerina spp. minor element and derived d18Oseawater records over the Mid-Pleistocene Transition (500-1500 kyr), DSDP Hole 94-607

During the Mid-Pleistocene Transition (MPT), the dominant glacial-interglacial cyclicity as inferred from the marine d18O records of benthic foraminifera (d18Obenthic) changed from 41 kyr to 100 kyr years in the absence of a comparable change in orbital forcing. Currently, only two Mg/Ca-derived, high-resolution bottom water temperature (BWT) records exist that can be used with d18Obenthic records to separate temperature and ice volume signals over the Pleistocene. However, these two BWT records suggest a different pattern of climate change occurred over the MPT-a record from North Atlantic DSDP Site 607 suggests BWT decreased with no long-term trend in ice volume over the MPT, while South Pacific ODP Site 1123 suggests that BWT has been relatively stable over the last 1.5 Myr but that there was an abrupt increase in ice volume at ~900 kyr. In this paper we attempt to reconcile these two views of climate change across the MPT. Specifically, we investigated the suggestion that the secular BWT trend obtained from Mg/Ca measurements on Cibicidoides wuellerstorfi and Oridorsalis umbonatus species from N. Atlantic Site 607 is biased by the possible influence of D[CO3]2- on Mg/Ca values in these species by generating a low-resolution BWT record using Uvigerina spp., a genus whose Mg/Ca values are not thought to be influenced by D[CO3]2-. We find a long-term BWT cooling of ~2-3°C occurred from 1500 to ~500 kyr in the N. Atlantic, consistent with the previously generated C. wuellerstorfi and O. umbonatus BWT record. We also find that changes in ocean circulation likely influenced d18Obenthic, BWT, and d18Oseawater records across the MPT. N. Atlantic BWT cooling starting at ~1.2 Ma, presumably driven by high-latitude cooling, may have been a necessary precursor to a threshold response in climate-ice sheet behavior at ~900 ka. At that point, a modest increase in ice volume and thermohaline reorganization may have caused enhanced sensitivity to the 100 kyr orbital cycle.

(Table S1) Calcium isotope ratios of Pacific Ocean sediments

Multiple lines of evidence have shown that the isotopic composition and concentration of calcium in seawater have changed over the past 28 million years. A high-resolution, continuous seawater calcium isotope ratio curve from marine (pelagic) barite reveals distinct features in the evolution of the seawater calcium isotopic ratio suggesting changes in seawater calcium concentrations. The most pronounced increase in the d44/40Ca value of seawater (of 0.3 per mil) occurred over roughly 4 million years following a period of low values around 13 million years ago. The major change in marine calcium corresponds to a climatic transition and global change in the carbon cycle and suggests a reorganization of the global biogeochemical system.

Annotated record of the detailed examination of Mn deposits from COCOTOW Expedition stations in the intersection of the Siqueiros Transform Fault and the East Pacific Rise

A near-bottom geological and geophysical survey was conducted at the western intersection of the Siqueiros Transform Fault and the East Pacific Rise. Transform-fault shear appears to distort the east flank of the rise crest in an area north of the fracture zone. In ward-facing scarps trend 335° and do not parallel the regional axis of spreading. Small-scale scarps reveal a hummocky bathymetry. The center of spreading is not a central peak but rather a 20-40 m deep, 1 km wide valley superimposed upon an 8 km wide ridge-crest horst. Small-scale topography indicates widespread volcanic flows within the valley. Two 0.75 km wide blocks flank the central valley. Fault scarps are more dominant on the western flank. Their alignment shifts from directions intermediate to parallel to the regional axis of spreading (355°). A median ridge within the fracture zone has a fault-block topography similar to that of the East Pacific Rise to the north. Dominant eastward-facing scarps trending 335° are on the west flank. A central depression, 1 km wide and 30 m deep, separates the dominantly fault-block regime of the west from the smoother topography of the east flank. This ridge originated by uplift due to faulting as well as by volcanism. Detailed mapping was concentrated in a perched basin (Dante's Hole) at the intersection of the rise crest and the fracture zone. Structural features suggest that Dante's Hole is an area subject to extreme shear and tensional drag resulting from transition between non-rigid and rigid crustal behavior. Normal E-W crustal spreading is probably taking place well within the northern confines of the basin. Possible residual spreading of this isolated rise crest coupled with shear drag within the transform fault could explain the structural isolation of Dante's Hole from the remainder of the Siqueiros Transform Fault.

Stable isotope and Cd/Ca ratios of Neogloboquadrina pachyderma in high-latitude sediments

Recent studies have stressed the role of high latitude nutrient levels and productivity in controlling the carbon isotopic composition of the deep sea and the CO2 content of the atmosphere. We undertook a study of the chemical composition of the polar planktonic foraminifer Neogloboquadrina pachyderma (s., sinistral coiling) from 30 late Holocene samples and 49 down core records from the high-latitude North and South Atlantic Oceans to evaluate the history of sea surface chemical change from glacial to interglacial time. Stable isotopic analysis of coretop samples from the Atlantic, Pacific and Southern Oceans shows no significant correlation between the delta13C of N. pachyderma and either delta13C or PO4 in seawater. Conversely, Cd/Ca ratios in planktonic foraminifera are consistent with the PO4 content of surface waters. The level of maximum glaciation (18,000 yr B.P.), identified by CLIMAP and delta18O, was chosen for mapping. Isopleths of delta18O on N. pachyderma (s.) in the North Atlantic reveal a pattern largely influenced by sea surface temperature (S.S.T.) and generally support the S.S.T. reconstruction of CLIMAP. Differences between the two suggest significantly lower salinity in North Atlantic surface waters at high latitudes than in lower latitudes. Down core delta13C records of N. pachyderma confirm that low delta13C values occurred in the northeast Atlantic during the latest glacial maximum (Labeyrie and Duplessy, 1985, doi:10.1016/0031-0182(85)90069-0). However, a map of delta13C for the 18,000 yr B.P. level for a much larger region in the North Atlantic shows that minimum N. pachyderma delta13C occurred in temperate waters. N. pachyderma delta13C decreased toward the southwest, reaching a minimum of -1 per mil at 37°N. Despite the variability seen in delta13C records of N. pachyderma, none of our cores show significant temporal variability in Cd/Ca. From the combined Cd/Ca and delta13C data we can see no evidence for an upwelling gyre in the eastern North Atlantic during the latest glacial maximum, nor evidence that the southern and northern oceans had significantly different levels of preformed nutrients than today.

Benthic foraminifera in eastern equatorial Indian Ocean surface sediments

Study of Recent abyssal benthic foraminifera from core-top samples in the eastern equatorial Indian Ocean has identified distinctive faunas whose distribution patterns reflect the major hydrographic features of the region. Above 3800 m, Indian Deep Water (IDW) is characterized by a diverse and evenly-distributed biofacies to which Globocassidulina subglobosa, Pyrgo spp., Uvigerina peregrina, and Eggerella bradyi are the major contributors. Nuttalides umbonifera and Epistominella exigua are associated with Indian Bottom Water (IBW) below 3800 m. Within the IBW fauna, N. umbonifera and E. exigua are characteristic of two biofacies with independent distribution patterns. Nuttalides umbonifera systematically increases in abundance with increasing water depth. The E. exigua biofacies reaches its greatest abundance in sediments on the eastern flank of the Ninetyeast Ridge and in the Wharton-Cocos Basin. The hydrographic transition between IDW and IBW coincides with the level of transition from waters supersaturated to waters undersaturated with respect to calcite and with the depth of the lysocline. Carbonate saturation levels, possibly combined with the effects of selective dissolution on the benthic foraminiferal populations, best explain the change in faunas across the IDW/IBW boundary and the bathymetric distribution pattern of N. umbonifera. The distribution of the E. exigua fauna cannot be explained with this model. Epistominella exigua is associated with the colder, more oxygenated IBW of the Wharton-Cocos Basin. The distribution of this biofacies on the eastern flank of the Ninetyeast Ridge agrees well with the calculated bathymetric position of the northward flowing deep boundary current which aerates the eastern basins of the Indian Ocean.

Observation of manganese nodules and crusts recovered during the CHAIN 115 cruise from Nov 1973 until June 1974 in the Atlantic Ocean

Investigations of piston cores from the Vema Channel and lower flanks of the Rio Grande Rise suggest the presence of episodic flow of deep and bottom water during the Late Pleistocene. Cores from below the present-day foraminiferal lysocline (at ~4000 m) contain an incomplete depositional record consisting of Mn nodules and encrustations, hemipelagic clay, displaced high-latitude diatoms, and poorly preserved heterogeneous microfossil assemblages. Cores from the depth range between 2900 m and 4000 m contain an essentially complete Late Pleistocene record, and consist of well-defined carbonate dissolution cycles with periodicities of ~100,000 years. Low carbonate content and increased dissolution correspond to glacial episodes, as interpreted by oxygen isotopic analysis of bulk foraminiferal assemblages. The absence of diagnostic high-latitude indicators (Antarctic diatoms) within the dissolution cyclss, however, suggests that AABW may not have extended to significantly shallower elevations on the lower flanks of the Rio Grande Rise during the Late Pleistocene. Therefore episodic AABW flow may not necessarily be the mechanism responsible for producing these cyclic events. This interpretation is also supported by the presence of an apparently complete Brunhes depositional record in the same cores, suggesting current velocities insufficient for significant erosion. Fluctuations in the properties and flow characteristics of another water mass, such as NADW, may be involved. The geologic evidence in core-top samples near the present-day AABW/NADW transition zone is consistent with either of two possible interpretations of the upper limit of AABW on the east flank of the channel. The foraminiferal lysocline, at ~4000 m, is near the top of the benthic thermocline and nepheloid layer, and may therefore correspond to the upper limit of relatively corrosive AABW. On the other hand, the carbonate compensation depth (CDD) at ~4250 m, which corresponds to the maximum gradient in the benthic thermocline, is characterized by rapid deposition of relatively fine-grained sediment. Such a zone of convergence and preferential sediment accumulation would be expected near the level of no motion in the AABW/NADW transition zone as a consequence of Ekman-layer veering of the mean velocity vector in the bottom boundary layer. It is possible that both of these interpretations are in part correct. The "level of no motion'' may in fact correspond to the CCD, while at the same time relatively corrosive water of Antarctic origin may mix with overlying NADW and therefore elevate the foraminifera] lysocline to depths above the level of no motion. Closely spaced observations of the hydrography and flow characteristics within the benthic thermocline will be required in order to use sediment parameters as more precise indicators of paleo-circulation.

Multi-proxy records of Two-Yurts Lake

Within the scope of Russian-German palaeoenvironmental research, Two-Yurts Lake (TYL, Dvuh-Yurtochnoe in Russian) was chosen as the main scientific target area to decipher Holocene climate variability on Kamchatka. The 5x2 km large and 26 m deep lake is of proglacial origin and situated on the eastern flank of Sredinny Ridge at the northwestern end of the Central Kamchatka Valley, outside the direct influence of active volcanism. Here, we present results of a multi-proxy study on sediment cores, spanning about the last 7000 years. The general tenor of the TYL record is an increase in continentality and winter snow cover in conjunction with a decrease in temperature, humidity, and biological productivity after 5000-4500 cal yrs BP, inferred from pollen and diatom data and the isotopic composition of organic carbon. The TYL proxy data also show that the late Holocene was punctuated by two colder spells, roughly between 4500 and 3500 cal yrs BP and between 1000 and 200 cal yrs BP, as local expressions of the Neoglacial and Little Ice Age, respectively. These environmental changes can be regarded as direct and indirect responses to climate change, as also demonstrated by other records in the regional terrestrial and marine realm. Long-term climate deterioration was driven by decreasing insolation, while the short-term climate excursions are best explained by local climatic processes. The latter affect the configuration of atmospheric pressure systems that control the sources as well as the temperature and moisture of air masses reaching Kamchatka.