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Full Text Available Compacted Graphite Iron, (CGI is known to have outstanding mechanical strength and weight-to-strength ratio as compared to conventional grey cast iron, (CI. The outstanding characteristics of CGI is due to its graphite particle shape, which is presented as compacted vermicular particle. The graphite is interconnected with random orientation and round edges, which results in higher mechanical strength. Whereas, graphite in the CI consists of a smooth-surfaced flakes that easily propagates cracks which results in weaker and brittle properties as compared to CGI. Owing to its improved properties, CGI is considered as the best candidate material in substituting grey cast iron that has been used in engine block applications for years. However, the smooth implementation of replacing CI with CGI has been hindered due to the poor machinability of CGI especially at high cutting speed. The tool life is decreased by 20 times when comparing CGI with CI under the same cutting condition. This study investigates the effect of using cryogenic cooling and minimum quantity lubrication (MQL during high-speed milling of CGI (grade 450. Results showed that, the combination of internal cryogenic cooling and enhanced MQL improved the tool life, cutting force and surface quality as compared to the conventional flood coolant strategy during high-speed milling of CGI.
Full Text Available In optical fabrication, brittle-hard materials are used for numerous applications. Especially for high-performance optics for laser or lithography applications, a complex and consistent production chain is necessary to account for the material properties. Particularly in pre-processing, e.g., for shaping optical components, brittle material behavior is dominant which leads to a rough surface layer with cracks that reach far below the surface. This so called subsurface damage (SSD needs to be removed in subsequent processes like polishing. Therefore, it is essential to know the extent of the SSD induced by shaping for an efficient design of precise corrective processes and for process improvement. Within this work the influence of cutting speed on SSD, in fused silica, induced by grinding has been investigated. To analyze the subsurface crack distribution and the maximum crack depth magnetorheological finishing has been appointed to polish a wedge into the ground surface. The depth profile of SSD was analyzed by image processing. For this purpose a coherent area of the polished wedge has been recorded by stitching microscopy. Taking the form deviation of the ground surface in to account to determine the actual depth beneath surface, the accuracy of the SSD-evaluation could be improved significantly. The experiments reveal a clear influence of the cutting speed on SSD, higher cutting speeds generate less SSD. Besides the influence on the maximum crack depth an influence on the crack length itself could be verified. Based on image analysis it was possible, to predict the maximum depth of cracks by means of crack length.
We elucidate here the deformation behaviour and delamination phenomenon in a high-strength low-alloy bainitic steel, in terms of microstructure, texture and stress evolution during deformation via in situ electron back-scattered diffraction and electron microscopy. Furthermore, the selective role of bainitic lath boundary on slip systems was studied in terms of dislocation pile-up and grain boundary energy models. During tensile deformation, the texture evolution was concentrated at 1 1 0 and the laths were turn parallel to loading direction. The determining role of lath on the deformation behaviour is governed by length/thickness (l/t) ratio. When l/t > 28, the strain accommodates along the bainite lath rather than along the normal direction. The delamination crack initiated normal to (0 1 1) plane, and become inclined to (0 1 1) plane with continued strain along (0 1 1) plane and lath plane. This indicated that the delamination is not brittle process but plastic process. The lack of dimples at the delaminated surface is because of lack of strain normal to the direction of lath. The delaminated (0 1 1) planes were associated with cleavage along the (1 0 0) plane.
The Hall-Petch relationship was used to investigate the role of martensite lath on fracture toughness (K IC ) during ductile fracture in a low-carbon EA4T axle steel. The hierarchical structures of lath martensite was clarified by means of optical microscope (OM), field emission scanning electron microscopy (FESEM), transmission electron microscopy (TEM) and electron backscattering diffraction (EBSD). Firstly, in such hierarchical structures, packet size (d p ) and block size (d b ) increase significantly with the size of prior austenite (d r ), while the martensite lath width (d l ) decreases. Subsequently, K IC was measured and follows the Hall-Petch relationship with d l . It depends on the rotation, bending and direct shear during crack propagation of laths, confirmed by EBSD. Besides, fracture toughness (K IC ) is proportional to a parameter ε v , the matrix strain, which is related to the plastic deformation of laths. Therefore, the martensite lath in hierarchical structures is the effective control unit of K IC during ductile fracture controlled by the strain.
The Hall-Petch relationship was used to investigate the role of martensite lath on fracture toughness (Ksub IC) during ductile fracture in a low-carbon EA4T axle steel. The hierarchical structures of lath martensite was clarified by means of optical microscope (OM), field emission scanning electron microscopy (FESEM), transmission electron microscopy (TEM) and electron backscattering diffraction (EBSD). Firstly, in such hierarchical structures, packet size (dsub p) and block size (dsub b) increase significantly with the size of prior austenite (dsub r), while the martensite lath width (dsub l) decreases. Subsequently, Ksub IC was measured and follows the Hall-Petch relationship with dsub l. It depends on the rotation, bending and direct shear during crack propagation of laths, confirmed by EBSD. Besides, fracture toughness (Ksub IC) is proportional to a parameter εsub v, the matrix strain, which is related to the plastic deformation of laths. Therefore, the martensite lath in hierarchical structures is the effective control unit of Ksub IC during ductile fracture controlled by the strain.
Ductile cutting are most widely used in fabricating high-quality optical glass components to achieve crack-free surfaces. For ultra-precision machining of brittle glass materials, critical undeformed chip thickness (CUCT) commonly plays a pivotal role in determining the transition point from ductile cutting to brittle cutting. In this research, cutting characteristics in nanometric cutting of BK7 and fused silica glasses, including machined surface morphology, surface roughness, cutting force and specific cutting energy, were investigated with nanometric plunge-cutting experiments. The same cutting speed of 300 mm/min was used in the experiments with single-crystal diamond tool. CUCT was determined according to the mentioned cutting characteristics. The results revealed that 320 nm was found as the CUCT in BK7 cutting and 50 nm was determined as the size effect of undeformed chip thickness. A high-quality machined surface could be obtained with the undeformed chip thickness between 50 and 320 nm at ductile cutting stage. Moreover, no CUCT was identified in fused silica cutting with the current cutting conditions, and brittle-fracture mechanism was confirmed as the predominant chip-separation mode throughout the nanometric cutting operation.
Vibrations of dental handpieces may contribute to symptoms of hand-arm vibration syndrome in dental personnel and iatrogenic enamel cracking in teeth. However, methods for measuring dental handpiece vibrations have previously been limited and information about vibration characteristics is sparse. This preliminary study aimed to use a novel approach to assess the vibrations of unloaded high-speed handpieces in vitro. Maximum vibration displacement amplitudes of five air turbines and two speed-increasing handpieces were recorded whilst they were operated with and without a rotary cutting instrument (RCI) using a scanning laser vibrometer (SLV). RCI rotation speeds, calculated from frequency peaks, were consistent with expected values. ANOVA statistical analysis indicated significant differences in vibrations between handpiece models (p0.11). Operating handpieces with a RCI resulted in greater vibrations than with no RCI (pmeasurement exceeded 4 microm for the handpieces in the current test setup (implying that these vibrations may be unlikely to cause adverse effects), this study has formed the basis for future work which will include handpiece vibration measurements whilst cutting under clinically representative loads. 2ff7e9595c