The Performance Characteristics of a Surface-Modified Cutting Tool

In the past, many papers have been presented which show that the coating of cutting tools often yields decreased wear rates and reduced coefficients of friction. Although different theories are proposed, covering areas such as hardness theory, diffusion barrier theory, thermal barrier theory, and reduced friction theory, most have not dealt with the question of how and why the coating of tool substrates with hard materials such as Titanium Nitride (TiN), Titanium Carbide (TiC) and Aluminium Oxide (Al203) transforms the performance and life of cutting tools. This project discusses the complex interrelationship that encompasses the thermal barrier function and the relatively low sliding friction coefficient of TiN on an undulating tool surface, and presents the result of an investigation into the cutting characteristics and performance of EDMed surface-modified carbide cutting tool inserts. The tool inserts were coated with TiN by the physical vapour deposition (PVD) method. PVD coating is also known as Ion-plating which is the general term of the coating method in which the film is created by attracting ionized metal vapour in this the metal was Titanium and ionized gas onto negatively biased substrate surface. Coating by PVD was chosen because it is done at a temperature of not more than 5000C whereas chemical Vapour Deposition CVD process is done at very high temperature of about 8500C and in two stages of heating up the substrates. The high temperatures involved in CVD affects the strength of the (tool) substrates. In this study, comparative cutting tests using TiN-coated control specimens with no EDM surface structures and TiN-coated EDMed tools with a crater-like surface topography were carried out on mild steel grade EN-3. Various cutting speeds were investigated, up to an increase of 40% of the tool manufacturer’s recommended speed. Fifteen minutes of cutting were carried out for each insert at the speeds investigated. Conventional tool inserts normally have a tool life of approximately 15 minutes of cutting. After every five cuts (passes) microscopic pictures of the tool wear profiles were taken, in order to monitor the progressive wear on the rake face and on the flank of the insert. The power load was monitored for each cut taken using an on-board meter on the CNC machine to establish the amount of power needed for each stage of operation. The spindle drive for the machine is an 11 KW/hr motor. Results obtained confirmed the advantages of cutting at all speeds investigated using EDMed coated inserts, in terms of reduced tool wear and low power loads. Moreover, the surface finish on the workpiece was consistently better for the EDMed inserts. The thesis discusses the relevance of the finite element method in the analysis of metal cutting processes, so that metal machinists can design, manufacture and deliver goods (tools) to the market quickly and on time without going through the hassle of trial and error approach for new products. Improvements in manufacturing technologies require better knowledge of modelling metal cutting processes. Technically the use of computational models has a great value in reducing or even eliminating the number of experiments traditionally used for tool design, process selection, machinability evaluation, and chip breakage investigations. In this work, much interest in theoretical and experimental investigations of metal machining were given special attention. Finite element analysis (FEA) was given priority in this study to predict tool wear and coating deformations during machining. Particular attention was devoted to the complicated mechanisms usually associated with metal cutting, such as interfacial friction; heat generated due to friction and severe strain in the cutting region, and high strain rates. It is therefore concluded that Roughened contact surface comprising of peaks and valleys coated with hard materials (TiN) provide wear-resisting properties as the coatings get entrapped in the valleys and help reduce friction at chip-tool interface. The contributions to knowledge: a. Relates to a wear-resisting surface structure for application in contact surfaces and structures in metal cutting and forming tools with ability to give wear-resisting surface profile. b. Provide technique for designing tool with roughened surface comprising of peaks and valleys covered in conformal coating with a material such as TiN, TiC etc which is wear-resisting structure with surface roughness profile compose of valleys which entrap residual coating material during wear thereby enabling the entrapped coating material to give improved wear resistance. c. Provide knowledge for increased tool life through wear resistance, hardness and chemical stability at high temperatures because of reduced friction at the tool-chip and work-tool interfaces due to tool coating, which leads to reduced heat generation at the cutting zones. d. Establishes that Undulating surface topographies on cutting tips tend to hold coating materials longer in the valleys, thus giving enhanced protection to the tool and the tool can cut faster by 40% and last 60% longer than conventional tools on the markets today.

Turning of compacted graphite iron using commercial tiN coated Si 3N4 under dry machining conditions

Due to their high hardness and wear resistance Si3N4 based ceramics are one of the most suitable cutting tool materials for machining hardened materials. Therefore, their high degree of brittleness usually leads to inconsistent results and sudden catastrophic failures. Improvement of the functional properties these tools and reduction of the ecological threats may be accomplished by employing the technology of putting down hard coatings on tools in the state-of-the-art PVD processes, mostly by improvement of the tribological contact conditions in the cutting zone and by eliminating the cutting fluids. However in this paper was used a Si3N4 based cutting tool commercial with a layer TiN coating. In this investigation, the performance of TiN coating was assessed on turning used to machine an automotive grade compacted graphite iron. As part of the study were used to characterise the performance of cutting tool, flank wear, temperature and roughness. The results showed that the layer TiN coating failed to dry compacted graphite iron under aggressive machining conditions. However, using the measurement of flank wear technique, the average tool life of was increased by VC=160 m/min.The latter was also observed using a toolmakers microscope and scanning electron microscopy (SEM).

Phosphorus retention in forest soils and the functioning of buffer zones used in forestry

Phosphorus (P) retention properties of soils typical for boreal forest, i.e. podzolic soil and peat soils, vary significantly, but the range of this variation has not been sufficiently documented. To assess the usefulness of buffer zones used in forestry in removing P from the discharge by chemical sorption in soil, and to estimate the risk of P leaching after forestry operations, more data is needed on soil P retention properties. P retention properties of soils were studied at clear-cut areas, unharvested buffer zones adjoining the clear-cut and at peatland buffer zone areas. Desorption-sorption isotherms were determined for the humus layer, the mineral soil horizons E, B and C of the Podzol profile and for the surface layer peat (0-15 cm) and the subsurface layer peat (15-30 cm). The efficiency of buffer zones in retaining P was studied at six peatland buffer zone areas by adding P-containing solute in the inflow. A tracer study was conducted at one of the buffer zone areas to determine the allocation of the added P in soil and vegetation. Measured sorption or desorption rather than parameter values of fitted sorption equations described P desorption and sorption behaviour in soil. The highest P retention efficiency was in the B horizon and consequently, if contact occurred or was established between the soluble P in the water and the soil B horizon, the risk of P leaching was low. Humus layer was completely incapable of retaining P after clear-cutting. In the buffer zones, the decrease in P retention properties in the humus layer and the low amount of P sorbed by it indicated that the importance of the layer in the functioning of buffer zones is low. The peatland buffer zone areas were efficient in retaining soluble P from inflow. P sorption properties of the peat soil at the buffer zone areas varied largely but the contribution of P sorption in the peat was particularly important during high flow in spring, when the vegetation was not fully developed. Factors contributing to efficient P retention were large buffer size and low hydrological load whereas high hydrological load combined with the formation of preferential flow paths, especially during early spring or late autumn was disadvantageous. However, small buffer zone areas, too, may be efficient in reducing P load.

Study of cutting forces on machinability properties of gray cast iron using new ceramics cutting tools

During gray cast iron cutting, the great rate of mechanical energy from cutting forces is converted into heat. Considerable heat is generated, principally in three areas: the shear zone, rake face and at the clearance side of the cutting edge. Excessive heat will cause undesirable high temperature in the tool which leads to softening of the tool and its accelerated wear and breakage. Nowadays the advanced ceramics are widely used in cutting tools. In this paper a composition special of Si3N4 was sintering, characterized, cut and ground to make SNGN120408 and applyed in machining gray cast iron with hardness equal 205 HB in dry cutting conditions by using digital controlled computer lathe. The tool performance was analysed in function of cutting forces, flank wear, temperature and roughness. Therefore metal removing process is carried out for three different cutting speeds (300 m/min, 600 m/min, and 800 m/min), while a cutting depth of 1 mm and a feed rate of 0.33 mm/rev are kept constant. As a result of the experiments, the lowest main cutting force, which depends on cutting speed, is obtained as 264 N at 600 m/min while the highest main cutting force is recorded as 294 N at 300 m/min.

Gold Ores Related to Shear Zones, West Santa Comba Fervenza Area (Galicia, NW Spain): A Mineralogical Study

Recent research has discovered high-grade Au ores in NNE-SSW trending shear zones in metamorphic proterozoic and palaeozoic terranes, some 40 km NW of Santiago de Compostela (NW Spain). The orebodies are bound to late-stage Hercynian structures, mainly due to brittle deformation, which are superimposed on earlier ductile shear zones, cutting through various catazonal lithologies, including ortho- and paragneisses, amphibolites, eclogites, and granites. Ore mineralogy, alteration, and ore textures define a frame whose main features are common to all prospects in the area. Main minerals are arsenopyrite and pyrite - accompanied by quartz, adularia, sericite, + (tourmaline, chlorite, carbonates, graphite), as main gangue minerals - with subordinate amounts of boulangerite, bismuthinite, kobellite, jamesonite, chalcopyrite, marcasite, galena, sphalerite, rutile, titanite, scheelite, beryl, fluorite, and minor native gold, electrum, native bismuth, fahlore, pyrrhotite, mackinawite, etc., defining a meso-catathermal paragenesis. Detailed microscopic study allows the author to propose a general descriptive scheme of textural classification for this type of ore. Most of the ores fill open spaces or veins, seal cracks or cement breccias; disseminated ores with replacement features related to alteration (mainly silicification, sericitization, and adularization) are also observed. Intensive and repeated cataclasis is a common feature of many ores, suggesting successive events of brittle deformation, hydrothermal flow, and ore precipitation. Gold may be transported and accumulated in any of these events, but tends to be concentrated in later ones. The origin of the gold ores is explained in terms of hydrotherreal discharge, associated with mainly brittle deformation and possibly related to granitic magmas, in the global tectonic frame of crustal evolution of West Galicia. The mineralogical and textural study suggests some criteria which will be of practical value for exploration and for ore processing. Ore grades can be improved by flotation of arsenopyrite. Non-conventional methods, such as pressure or bacterial leaching, may subsequently obtain a residue enriched in gold.

Tissue engineering of articular cartilage with biomimetic zones

Articular cartilage damage is a persistent and increasing problem with the aging population, and treatments to achieve biological repair or restoration remain a challenge. Cartilage tissue engineering approaches have been investigated for over 20 years, but have yet to achieve the consistency and effectiveness for widespread clinical use. One of the potential reasons for this is that the engineered tissues do not have or establish the normal zonal organization of cells and extracellular matrix that appears critical for normal tissue function. A number of approaches are being taken currently to engineer tissue that more closely mimics the organization of native articular cartilage. This review focuses on the zonal organization of native articular cartilage, strategies being used to develop such organization, the reorganization that occurs after culture or implantation, and future prospects for the tissue engineering of articular cartilage with biomimetic zones.

Cutting edge web

The artwork describes web as a network environment and a space where people are connected and as a result, it can reshape you as an interactive participant who is able to regenerate an object as a new form through a truly collaborative and cooperative interactions with others. The artwork has been created based on the research findings of characteristic of web: 1) Participatory (Slater 2002, p.536), 2) Communicational (Rheingold 1993), 3) Connected (Jordan 1999, 80), and 4) Stylising (Jordan 1999, 69). The artwork has conceptualised and visualised those characteristics of web based on principles of graphic design and visual communication.