Influência da lubrirrefrigeração na qualidade superficial de metais retificados

Na fabricação de componentes mecânicos precisos, que necessitam de alta resistência mecânica e ao desgaste, utiliza-se o processo de retificação, para conferir o acabamento final desejado e, também, para eliminar as deformações ocorridas durante a têmpera do aço. No entanto, as condições de retificação devem ser adequadas, para que não sejam introduzidas falhas na peça. Novos conceitos de lubrificação e refrigeração, para o processo de retificação, estão sendo pesquisados, de forma a diminuir os custos e os danos ambientais causados pelos fluidos de corte. Nesse trabalho, é analisada a influência das técnicas de mínima quantidade de lubrificante (MQL), refrigeração otimizada e refrigeração convencional, com diferentes vazões e velocidade de aplicação do fluido de corte, na qualidade das peças produzidas com aço ABNT 4340 endurecido, no processo de retificação cilíndrica externa de mergulho com a utilização de rebolos de CBN. O Aço ABNT 4340 apresenta várias aplicações industriais, sendo considerado de uso aeronáutico devido, sua alta resistência mecânica sem aumentar o peso dos componentes que o utilizam. A análise da qualidade das peças foi realizada com a verficação das rugosidades e com a análise de microscopias eletrônicas de varredura. Verificou-se, ainda, a força tangencial de corte. em relação às diferentes formas de aplicação do fluido de corte, notou-se o melhor desempenho da aplicação otimizada, para maiores velocidades, mostrando a eficiência do bocal utilizado. O processo otimizado e o processo MQL foram capazes de manter a integridade superficial das peças produzidas. Exceção somente para a condição MQL com vazão de fluido de corte de 40ml/h, que produziu trincas e queima superficial. Rebolos com baixa concentração de CBN, conseqüentemente mais baratos, proporcionaram bons resultados, quando associados com técnicas mais eficientes de aplicação de fluido de corte apresentando desgaste reduzido.

An improved static model for tool deflection in machining of Ti–6Al–4V acetabular shell produced by selective laser melting

Tool deflection during milling operation leads to dimensional error, decreasing surface quality and increasing rejection rate. In this study, tool deflection during the milling of the inner surfaces of Ti–6Al–4V prosthetic acetabular shell produced by selective laser melting (SLM) was modelled. The first purpose of this research is to provide a general static cutting tool deflection model for ball nose cutters where deviation of machine components and tool holder are so small as to be considered negligible. This is because the values of machine component and tool holder deflection were lower than standard tolerances (10 μm) and found to be lower than 1/15 of tool deflection. The second and third objectives of this work involve calculating contact surfaces by determining workpiece and tool geometry and choosing second moment of inertia using a novel cross section method (CSM). Static models for three quasi-analytical methods (QAM) that are simple cantilever beam model (SCBM), two-section model (TWSM) and our three section model (THSM) are presented. THSM showed high accuracy which was validated by 3D finite element method (FEM3D) and experimental measurements. The accuracy of tool deflection calculation using THSM by computing, shank, flute and ball head deflection and also utilizing CSM to determine second moment of inertia showed notable improvements.

Metallurgical and machinability characteristics of wrought and selective laser melted Ti-6Al-4V

This research work presents a machinability study between wrought grade titanium and selective laser melted (SLM) titanium Ti-6Al-4V in a face turning operation, machined at cutting speeds between 60 and 180 m/min. Machinability characteristics such as tool wear, cutting forces, and machined surface quality were investigated. Coating delamination, adhesion, abrasion, attrition, and chipping wear mechanisms were dominant during machining of SLM Ti-6Al-4V. Maximum flank wear was found higher in machining SLM Ti-6Al-4V compared to wrought Ti-6Al-4V at all speeds. It was also found that high machining speeds lead to catastrophic failure of the cutting tool during machining of SLM Ti-6Al-4V. Cutting force was higher in machining SLM Ti-6Al-4V as compared to wrought Ti-6Al-4V for all cutting speeds due to its higher strength and hardness. Surface finish improved with the cutting speed despite the high tool wear observed at high machining speeds. Overall, machinability of SLM Ti-6Al-4V was found poor as compared to the wrought alloy.

Exploration of Ground Penetrating Radar and Time Domain Reflectometry Methods for the Determination of Pavement Dielectric Constant

Traditionally, densities of newly built roadways are checked by direct sampling (cores) or by nuclear density gauge measurements. For roadway engineers, density of asphalt pavement surfaces is essential to determine pavement quality. Unfortunately, field measurements of density by direct sampling or by nuclear measurement are slow processes. Therefore, I have explored the use of rapidly-deployed ground penetrating radar (GPR) as an alternative means of determining pavement quality. The dielectric constant of pavement surface may be a substructure parameter that correlates with pavement density, and can be used as a proxy when density of asphalt is not known from nuclear or destructive methods. The dielectric constant of the asphalt can be determined using ground penetrating radar (GPR). In order to use GPR for evaluation of road surface quality, the relationship between dielectric constants of asphalt and their densities must be established. Field measurements of GPR were taken at four highway sites in Houghton and Keweenaw Counties, Michigan, where density values were also obtained using nuclear methods in the field. Laboratory studies involved asphalt samples taken from the field sites and samples created in the laboratory. These were tested in various ways, including, density, thickness, and time domain reflectometry (TDR). In the field, GPR data was acquired using a 1000 MHz air-launched unit and a ground-coupled unit at 200 and 500 MHz. The equipment used was owned and operated by the Michigan Department of Transportation (MDOT) and available for this study for a total of four days during summer 2005 and spring 2006. The analysis of the reflected waveforms included “routine” processing for velocity using commercial software and direct evaluation of reflection coefficients to determine a dielectric constant. The dielectric constants computed from velocities do not agree well with those obtained from reflection coefficients. Perhaps due to the limited range of asphalt types studied, no correlation between density and dielectric constant was evident. Laboratory measurements were taken with samples removed from the field and samples created for this study. Samples from the field were studied using TDR, in order to obtain dielectric constant directly, and these correlated well with the estimates made from reflection coefficients. Samples created in the laboratory were measured using 1000 MHz air-launched GPR, and 400 MHz ground-coupled GPR, each under both wet and dry conditions. On the basis of these observations, I conclude that dielectric constant of asphalt can be reliably measured from waveform amplitude analysis of GJPR data, based on the consistent agreement with that obtained in the laboratory using TDR. Because of the uniformity of asphalts studied here, any correlation between dielectric constant and density is not yet apparent.

Study of active screen plasma processing conditions for carburising and nitriding austenitic stainless steel

Active screen (AS) is an advanced technology for plasma surface engineering, which offers some advantages over conventional direct current (DC) plasma treatments. Such surface defects and process instabilities as arcing, edge and hollow cathode effects can be minimised or completely eliminated by the AS technique, with consequent improvements in surface quality and material properties. However, the lack of information and thorough understanding of the process mechanisms generate scepticism in industrial practitioners. In this project, AISI 316 specimens were plasma carburised and plasma nitrided at low temperature in AS and DC furnaces, and the treated samples were comparatively analysed. Two diagnostic techniques were used to study the plasma: optical fibre assisted optical emission spectroscopy, and a planar electrostatic probe. Optimum windows of treatment conditions for AS plasma nitriding and AS plasma carburising of austenitic stainless steel were identified and some evidence was obtained on the working principles of AS furnaces. These include the sputtering of material from the cathodic mesh and its deposition on the worktable, the generation of additional active species, and the electrostatic confinement of the plasma within the operative volume of the furnace.

Impact of roof surface runoff on urban water quality

The pollutant impacts of urban stormwater runoff on receiving waters are well documented in research literature. However, it is road surfaces that are commonly identified as the significant pollutant source. This paper presents the outcomes of an extensive program of research into the role of roof surfaces in urban water quality with particular focus on solids, nutrients and organic carbon. The outcomes confirmed that roof surfaces play an important role in influencing the pollutant characteristics of urban stormwater runoff. Pollutant build-up and wash-off characteristics for roads and roof surfaces were found to be appreciably different. The pollutant wash-off characteristics exhibited by roof surfaces show that it influences the first flush phenomenon more significantly than road surfaces. In most urban catchments, as roof surfaces constitutes a higher fraction of impervious area compared to road surfaces, it is important that the pollutant generation role of roof surfaces is specifically taken into consideration in stormwater quality mitigation strategies.

Experimental evaluation of an autonomous surface vehicle for water quality and greenhouse gas emission monitoring

This paper describes the experimental evaluation of a novel Autonomous Surface Vehicle capable of navigating complex inland water reservoirs and measuring a range of water quality properties and greenhouse gas emissions. The 16 ft long solar powered catamaran is capable of collecting water column profiles whilst in motion. It is also directly integrated with a reservoir scale floating sensor network to allow remote mission uploads, data download and adaptive sampling strategies. This paper describes the onboard vehicle navigation and control algorithms as well as obstacle avoidance strategies. Experimental results are shown demonstrating its ability to maintain track and avoid obstacles on a variety of large-scale missions and under differing weather conditions, as well as its ability to continuously collect various water quality parameters complimenting traditional manual monitoring campaigns.

An autonomous surface vehicle for water quality monitoring

This paper describes a novel Autonomous Surface Vehicle capable of navigating throughout complex inland water storages and measuring a range of water quality properties and greenhouse gas emissions. The 16 ft long solar powered catamaran can collect this information throughout the water column whilst the vehicle is moving. A unique feature of this ASV is its integration into a storage scale floating sensor network to allow remote mission uploads, data download and adaptive sampling strategies. This paper provides an overview of the vehicle design and operation including control, laser-based obstacle avoidance, and vision-based inspection capabilities. Experimental results are shown illustrating its ability to continuously collect key water quality parameters and compliment intensive manual monitoring campaigns.

Source characterisation of urban road surface pollutants for enhanced water quality predictions

This study developed a comprehensive research methodology for identification and quantification of sources responsible for pollutant build-up and wash-off from urban road surfaces. The study identified soil and asphalt wear, and non-combusted diesel fuel as the most influential sources for metal and hydrocarbon pollution respectively. The study also developed mathematical models to relate contributions from identified sources to underlying site specific factors such as land use and traffic. Developed mathematical model will play a key role in urban planning practices, enabling the implementation of effective water pollution control strategies.

Improving Nucleation in the Fabrication of High-Quality 3D Macro-Porous Copper Film through The Surface-Modification of A Polystyrene Colloid-Assembled Template

A new approach is developed to the fabrication of high-quality three-dimensional macro-porous copper films. A highly-ordered macroporous copper film is successfully produced on a polystyrene sphere (PS) template that has been modified by sodium dodecyl sulfate (SDS). It is shown that this procedure can change a hydrophobic surface of PS template into a hydrophilic surface. The present study is devoted to the influence of the electrolyte solution transport on the nucleation process. It is demonstrated that the permeability of the electrolyte solution in the nanochannels of the PS template plays an important role in the chemical electrodeposition of high-quality macroporous copper film. The permeability is drastically enhanced in our experiment through the surface modi. cation of the PS templates. The method could be used to homogeneously produce a large number of nucleations on a substrate, which is a key factor for the fabrication of the high-quality macroporous copper film.

Interim report on surface water resources and quality of waters in Lee County, Florida

Report seeks to address following questions: 1. Where within Lee County are surface supplies of water located? 2. What are the variations in this supply? 3. What can be done to provide better answers to questions 1 and 2 than are available at the present time? (PDF contains 76 pages.)

Coupling model uncertainty for coupled rainfall/runoff and surface water quality models in river problems

Coupled hydrology and water quality models are an important tool today, used in the understanding and management of surface water and watershed areas. Such problems are generally subject to substantial uncertainty in parameters, process understanding, and data. Component models, drawing on different data, concepts, and structures, are affected differently by each of these uncertain elements. This paper proposes a framework wherein the response of component models to their respective uncertain elements can be quantified and assessed, using a hydrological model and water quality model as two exemplars. The resulting assessments can be used to identify model coupling strategies that permit more appropriate use and calibration of individual models, and a better overall coupled model response. One key finding was that an approximate balance of water quality and hydrological model responses can be obtained using both the QUAL2E and Mike11 water quality models. The balance point, however, does not support a particularly narrow surface response (or stringent calibration criteria) with respect to the water quality calibration data, at least in the case examined here. Additionally, it is clear from the results presented that the structural source of uncertainty is at least as significant as parameter-based uncertainties in areal models. © 2012 John Wiley & Sons, Ltd.

NEW TYPE OF SILICON MATERIAL WITH VERY HIGH-QUALITY SURFACE-LAYER ON INSULATING DEFECT LAYER

A new-type silicon material, silicon on defect layer (SODL) was proved to have a very high quality surface microstructure which is necessary for commercially feasible high-density very large scale integrated circuits (VLSI). The structure of the SODL material was viewed by transmission electron microscopy. The SODL material was also proved to have a buried defect layer with an insulating resistivity of 5.7 x 10(10) OMEGA-cm.