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期刊名称:Mechanics of Advanced Materials and Modern Processes
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Experimental and analytical investigation on resin impregnation behavior in continuous carbon fiber reinforced thermoplastic polyimide composites
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2018-10-24 , DOI: 10.1186/s40759-018-0039-3
ShotaKazano,ToshikoOsada,SatoshiKobayashi,KenGoto
In molding of carbon fiber reinforced thermoplastics (CFRTP), resin impregnation behavior to fiber yarns is very important because higher viscosity of molten thermoplastics inhibites resin impregnation to the interspace among fibers. Resultant resin un-impregnation causes lower mechanical properties of CFRTP. The purpose of this study was to clarify the relation among molding method, molding conditions and resin impregnation to fiber yarns experimentally and analytically. In this study, CFRTPs using continuous carbon fiber yarn as a reinforcement and a thermoplastic polyimide which is excellent in heat resistance as a matrix resin were produced by Micro-Braiding, Film Stacking and Powder method. In addition resin impregnation was modeled based on Darcy’s law and continuity condition. As a result, analytical resin impregnation prediction showed good agreements with the experimental results in all the producing methods and molding conditions. In addition, the void content in the molded CFRP could be greatly reduced by pressurizing cooling.
Estimating the creep behavior of glass-fiber-reinforced polyamide considering the effects of crystallinity and fiber volume fraction
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2018-09-29 , DOI: 10.1186/s40759-018-0038-4
TakenobuSakai,YutoHirai,SatoshiSomiya
The time-temperature superposition principle (TTSP) is often used to estimate the viscoelastic behavior of polymers. It can also be used to evaluate the influence of a given variable, or set of variables, on viscoelastic properties. In this research, the effects of time, temperature, fiber volume fraction and the relative crystallinity of polyamide (PA) and glass fiber-reinforced polyamide (GFRPA) were investigated using the time-temperature superposition principle to estimate viscoelastic behavior under each set of conditions. The crystallinities of PA and GFRPA, which ranged from 33 to 45%, were controlled by adjusting the duration of crystallization as 250 °C. Creep tests were carried out with these materials, and creep compliance curves of each condition were obtained. Using these creep compliance curves, the master curves for temperature, and the grand master curves for crystallinity and for fiber volume fraction were generated to show the relationships between fiber volume fraction, crystallinity, and viscoelastic parameters. Furthermore, the great-grand master curve for crystallinity and fiber volume fraction was generated to predict creep behavior in an arbitrarily condition. The predicted data were in good agreement with experimental results. A method for estimating creep deformation taking into account the effects of influencing variables was developed. The time-temperature superposition principle (TTSP) was applied to the effects of the fiber volume fraction and crystallinity. Grand master curves for crystallinity and fiber volume fraction were obtained by shifting the corresponding master curves. This study demonstrates that the creep behaviors of fiber-reinforced plastics can be estimated using these shift factors and a great-grand master curve. This method yielded estimates of creep deformation that fitted well with experimental results. Based on our findings, it should be possible to control creep deformation in plastics or fiber-reinforced resins by controlling the fiber volume fraction and the crystallinity of the matrix material.
Microstructure and mechanical properties of aluminium-graphene composite powders produced by mechanical milling
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2018-09-06 , DOI: 10.1186/s40759-018-0037-5
JiangshanZhang,ZhixinChen,JingweiZhao,ZhengyiJiang
Graphene has been reported to be a promising nanofiller in fabricating advanced metal matrix composites. Graphene nanosheets (GNSs) have been incorporated into an aluminium matrix composite using mechanical milling and hot pressing in the current study. The SEM observation shows that aluminium particles are firstly flattened into flakes, and then fractured/ rewelded into equiaxed particles as the ball milling progresses. The crystalline size is decreased and the lattice strain is increased during the ball milling, which are also intensified by the added GNSs. The hardness of the composite is increased by 115.1% with the incorporation of 1.0 vol. % GNSs. The local stress induced by the hard GNSs accelerates the milling process. The X-Ray diffraction patterns show that the intensity ratio of (111) to (200) can reflect the preferred orientation of the particle mixture, and the evolution of I(111)/I(200) agrees well with the observed results using SEM. The increased hardness is mainly attributed to the refined microstructure and Orowan strengthening.
Rheonomic phenomenon shrinkage of holes drilled in fibreglass and carbon fibre-reinforced polymer composites
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-11-13 , DOI: 10.1186/s40759-017-0033-1
AleksandrDudarev,KonstantinVolegov,GeorgiyKurzanov
The research is devoted to machining polymer composite materials and reflects a non-trivial, accuracy-affecting phenomenon that occurs while drilling polymer composite materials, i.e. reduction of holes diameter over time after processing. The article contains experimental data obtained in the research of rheonomic shrinkage of holes after drilling various grades of polymer composite materials. The research involved using different types of tools (high-performance Ham solid carbide drill bits and diamond drill bits). The tests were carried out combining different parameters of drilling modes. We adopted the range of spindle speed change n = 10,000-20,000 rev/min and tool feed range Sm = 50-300 mm/min. Measurements of shrinkage were performed with the help of ATOS III Triple Scan XL scanning system immediately after treatment and in 48 h thereafter. Based on the scanned polygonal mesh of each hole, three-dimensional models of holes drilled in the samples were built. Then, these models were verified against nominal drillings using GOM Inspect software. In this way, the values of rheonomic shrinkage were obtained. Verification was carried out according to Gaussian method of measurements by coincidence using variation variables sigma (Gaussian best-fit 3 sigma). Shrinkage of holes does not take place in structural materials. However, in polymer composite materials, shrinkage of the drilled hole of 10 mm nominal diameter may reach reduction in diameter of 0.02-0.03 mm during a period of 48 h and depends on the grade of the polymer composite material. Observations have shown that shrinkage also depends on machining mode parameters. We have developed two hypotheses to explain the influence of processing mode parameters on rheonomic shrinkage: the first one relates to the rate of processing, the second – to the force factors.
Experimental and computational studies of poly-L-lactic acid for cardiovascular applications: recent progress
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-07-25 , DOI: 10.1186/s40759-017-0028-y
RaastiNaseem,LiguoZhao,YangLiu,VadimV.Silberschmidt
Stents are commonly used in medical procedures to alleviate the symptoms of coronary heart disease, a prevalent modern society disease. These structures are employed to maintain vessel patency and restore blood flow. Traditionally stents are made of metals such as stainless steel or cobalt chromium; however, these scaffolds have known disadvantages. An emergence of transient scaffolds is gaining popularity, with the structure engaged for a required period whilst healing of the diseased arterial wall occurs. Polymers dominate a medical device sector, with incorporation in sutures, scaffolds and screws. Thanks to their good mechanical and biological properties and their ability to degrade naturally. Polylactic acid is an extremely versatile polymer, with its properties easily tailored to applications. Its dominance in the stenting field increases continually, with the first polymer scaffold gaining FDA approval in 2016. Still some challenges with PLLA bioresorbable materials remain, especially with regard to understanding their mechanical response, assessment of its changes with degradation and comparison of their performance with that of metallic drug-eluting stent. Currently, there is still a lack of works on evaluating both the pre-degradation properties and degradation performance of these scaffolds. Additionally, there are no established material models incorporating non-linear viscoelastic behaviour of PLLA and its evolution with in-service degradation. Assessing these features through experimental analysis accompanied by analytical and numerical studies will provide powerful tools for design and optimisation of these structures endorsing their broader use in stenting. This overview assesses the recent studies investigating mechanical and computational performance of poly(l-lactic) acid and its use in stenting applications.
Full-field infrared phase sensitive thermography for microstructural investigation of giant magnetostrictive materials
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-05-25 , DOI: 10.1186/s40759-017-0026-0
PengYang,ChiuT.Law,RaniF.Elhajjar
Giant magnetostrictive materials are increasingly proposed for smart material applications such as in sensors, actuators, and energy harvesting applications. However, reviewing the literature on this topic, the reader observes a large amount of variability in the reported properties that are typically generated from overall strain or point-value strain measurements obtained with strain gages using the far field estimate to project the internal magnetic field in the specimen. A full-field phase-sensitive thermography method is proposed to correlate the full-field infrared measurements to changes in the microstructure induced by a cyclic magnetic field in a giant magnetostrictive alloy material. The results show the potential of the proposed method in rapidly uncovering the effects of geometry and defects on the magnetostrictive response. The results show responses at the microstructure level from both magnetocaloric and magnetostrictive effects. The effects of the magnetostrictive material’s microstructural spatial variability and the specimen geometry on the localized magnetostrictive response warrant serious considerations but so far have not received significant attention. The method proposed is capable of highlighting magneto-elastic coupling in the composite specimens using the cycle magnetic field.
Wave propagation in a transversely isotropic microstretch elastic solid
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-04-26 , DOI: 10.1186/s40759-017-0023-3
BaljeetSingh,ManishaGoyal
The theory of microstretch elastic bodies was first developed by Eringen (1971, 1990, 1999, 2004). This theory was developed by extending the theory of micropolar elastcity. Each material point in this theory has three deformable directors. The governing equations of a transversely isotropic microstretch material are specialized in x-z plane. Plane wave solutions of these governing equations results into a bi-quadratic velocity equation. The four roots of the velocity equation correspond to four coupled plane waves which are named as Coupled Longitudinal Displacement (CLD) wave, Coupled Longitudinal Microstretch (CLM) wave, Coupled Transverse Displacement (CTD) wave and Coupled Transverse Microrotational (CTM) wave. The reflection of Coupled Longitudinal Displacement (CLD) wave is considered at a stress-free surface of half-space of material. The appropriate displacement components, microrotation component and microstretch potential for incident and four reflected waves in half-space are formulated. These solutions for incident and reflected waves satisfy the boundary conditions at a stress free surface of half-space and we obtain a non-homogeneous system of four equations in four reflection coefficients (or amplitude ratios) along with Snell’s law for the present model. The speeds of plane waves are computed by Fortran program of bi-quadratic velocity equation for relevant physical constants of the material. The reflection coefficients of various reflected waves are also computed by Fortran program of Gauss elimination method. The speeds of plane waves are plotted against angle of propagation direction with vertical axis. The reflection coefficients of various reflected waves are plotted against the angle of incidence. These variations of speeds and reflection coefficients are also compared with those in absence of microstretch parameters. For a specific material, numerical simulation in presence as well as in absence of microstretch shows that the coupled longitudinal displacement (CLD) wave is fastest wave and the coupled transverse microrotational (CTM) is observed slowest wave. The coupled longitudinal microstretch (CLM) wave is an additional wave due to the presence of microstretch in the medium. The presence of microstretch in transversely isotropic micropolar elastic solid affects the speeds of plane waves and the amplitude ratios of various reflected waves. 74J
Linear and non-linear vibration analysis of moderately thick isosceles triangular FGPs using a triangular finite p-element
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-02-01 , DOI: 10.1186/s40759-017-0018-0
SA.Belalia
The geometrically non-linear formulation based on Von-Karman’s hypothesis is used to study the free vibration isosceles triangular plates by using four types of mixtures of functionally graded materials (FGMs - AL/AL2O3, SUS304/Si3N4, Ti- AL-4V/Aluminum oxide, AL/ZrO2). Material properties are assumed to be temperature dependent and graded in the thickness direction according to power law distribution. A hierarchical finite element based on triangular p-element is employed to define the model, taking into account the hypotheses of first-order shear deformation theory. The equations of non-linear free motion are derived from Lagrange's equation in combination with the harmonic balance method and solved iteratively using the linearized updated mode method. Results for the linear and nonlinear frequencies parameters of clamped isosceles triangular plates are obtained. The accuracy of the present results are established through convergence studies and comparison with results of literature for metallic plates. The results of the linear vibration of clamped FGMs isosceles triangular plates are also presented in this study. The effects of apex angle, thickness ratio, volume fraction exponent and mixtures of FGMs on the backbone curves and mode shape of clamped isosceles triangular plates are studied. The results obtained in this work reveal that the physical and geometrical parameters have a important effect on the non-linear vibration of FGMs triangular plates.
Impact of nose radius and machining parameters on surface roughness, tool wear and tool life during turning of AA7075/SiC composites for green manufacturing
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2020-08-02 , DOI: 10.1186/s40759-020-00045-7
RajeshKumarBhushan
Green manufacturing demands least wastage. Minimum chip formation reduces adverse effect on environment. Nose radius has a major role in reducing development of chips. Selection of proper nose radius and machining parameters will reduce amount of chip, therefore protect the environment. In finish turning of Al alloy-SiC, nose radius wear mainly affect the surface feature of the final product. It is owing to the direct contact between the area of tool nose and the SiC particles during turning. This paper is focused on influence of tool nose radius and machining parameters on surface quality of AA7075/15 wt.% SiC (20 - 40 μm) composites and tool life of tungsten carbide inserts while dry turning. Response surface method (RSM) was utilized to find the roughness and tool life under numerous turning situations. Considering the single objective optimization of turning parameters, minimum roughness of 2.088 μm, was achieved at nose radius of 1.2 mm and maximum tool life of 6.72 min, was obtained at nose radius of 0.4 mm. Multi objective optimization by desirability analysis for minimum roughness and the maximum life of tool has shown that suitable value of nose radius is 0.4 mm. Multi objective optimization of both roughness of surface and life of tool results in 1.81% increase in surface roughness and 10.11% decrease in tool life. Abrasion was mainly found to be responsible for wear of tungsten carbide inserts, while turning of AA7075/15 wt.% SiC (20 - 40 μm) composites. Novelty of this research work is that so far no one has investigated impact of nose radius and machining parameters on surface roughness, tool wear and tool life during turning of AA7075/15 wt.% SiC composites. Outcome of this research work will be useful for vehicle, aeroplane, space and ship industry.
Taguchi-Grey relation analysis for assessing the optimal set of control factors of thermal barrier coatings for high-temperature applications
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2016-10-12 , DOI: 10.1186/s40759-016-0011-z
MohammedYunus,MohammadS.Alsoufi,ShadiM.Munshi
In an aerospace industry, the efficient use of thermally sprayed coatings for high-temperature applications is achieved by improving the thermal characteristics (TC) such as thermal drop/barrier (TD) and thermal fatigue cycles (TFC). The characterization of ceramic coatings demands a better understanding of TC and their performance. In this paper, an attempt has been made to use hybrid Taguchi design method based grey relation analysis (GRA) for optimizing the control factors such as the thickness of coating, type of coating, bond coating and exposed temperature. The necessary experiments were carried out using Taguchi L16 factorial design of experiments for analysis based on the larger the better signal-to-noise (S/N) ratio. The multi-response/output optimization and grading of control factors were successfully carried out by GRA. The significance of each factor as regards TD and TFC were investigated. The ANOVA results showed that most important parameters at 95 % confidence level and were validated with a confirmation test using optimum process factors. It shows an improvement in the TC of thermal barrier coatings. This work revealed that the hybrid GRA with Taguchi technique had improved the durability and efficient usage of TBC for high-temperature applications.
Modelling of thermomechanical behaviour of fibrous polymeric composite materials subject to relaxation transition in the matrix
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2016-11-25 , DOI: 10.1186/s40759-016-0015-8
ValeriyPavlovichMatveenko,NikolayAlexandrovichTrufanov,OlegYurievichSmetannikov,IgorNikolaevichShardakov,IgorNikolaevichVasserman
Fiber–reinforced polymer composite materials are widely used in different branches of industry due to their distinctive features such as high specific strength and stiffness and due to as considerable opportunity to formulate materials with controllable variation of properties in response to the action of external factors (smart-materials). A distinguishing feature of products made of composite materials is that the processes of product and material fabrication are inseparable. Therefore the estimation of composite properties based on the composite architecture and properties of the reinforcing fibers and matrix is a very actual task. The model of polymer behavior at glass transition recently developed by the authors was generalized to the case of fiber-reinforced polymer matrix composites using two approaches: one is base on the concept of free specific energy, the other – on the growth of matrix stiffness. For homogeneous materials these two approaches are of equal worth, whereas for composite materials they give different results under deformation in the transverse direction. The stiffness growth approach is more accurate, but is very expensive computationally and, is highly sensitive to the experimental data errors. Using the finite element method and averaging technique the thermoelastic constants of composites containing different types of fibers in the glassy and high-elastic states were calculated based on the fiber and matrix properties. Softening of the matrix has an insignificant effect on the longitudinal modulus of a composite but leads to a considerable decrease of the transverse and shear moduli. The coefficient of thermal expansion in the transverse direction is much higher than the coefficient of thermal expansion in the longitudinal direction, especially when the composite is in the high-elastic state. The model of polymer behavior at glass transition recently developed by the authors can be generalized to the case of fiber-reinforced polymer matrix composites. The thermoelastic constants of composites containing different types of fibers can be calculated from the fiber and matrix properties using the finite element method and averaging technique.
Nickel nanoparticles inside carbon nanostructures: atomistic simulation
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2019-03-20 , DOI: 10.1186/s40759-019-0042-3
LiliyaR.Safina,JuliaA.Baimova,RadikR.Mulyukov
Ni nanoparticle on a graphene substrate, inside the fullerene and carbon nanotube was studied by molecular dynamics simulation technique. Morse interatomic potential have been used for Ni-Ni and Ni-C interactions, and AIREBO potential has been used for C-C interaction. The pairwise Morse potential was chosen for the description of the Ni–C interaction because of its simplicity. It is shown that Morse potential can satisfactory reproduce the properties of graphene-nickel system. The effect of boundary conditions on the interaction of Ni nanoparticle and graphene sheet are investigated. It is shown, that if the edges of graphene plane are set to be free, coverage of Ni nanoparticle by graphene or just crumpling of graphene is observed depending on the size of nanoparticle. It is found, that Ni nanoparticle tend to attach to the carbon surface - graphene plane or the shell of fullerene and nanotube. Moreover, Ni nanoparticle induce the deformation of the surface of carbon polymorph. The obtained results are potentially important for understanding of the fabrication of metal-carbon composites and interaction between graphene and metal nanoparticles in such a system.
Finite element simulation of the braiding process.
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2019-01-23 , DOI: 10.1186/s40759-019-0041-4
SDelRosso,LIannucci,PTCurtis
Braiding is one of the most common technique employed for the manufacture of fabrics and ropes. It is also commonly used to produce near-net shaped preforms for advanced fibre reinforced composites. This paper presents an explicit finite element approach to create and simulate the braiding process for the virtual manufacture of 2D braids. The process starts from the definition of an analytical function which describes the movement of the carriers on a braiding track plate. Models of idealised Maypole-type braiding machines are built and used to shape virtual yarns into braids. This procedure can be used in a parameter control fashion, to optimise or to create virtual braided structures, which can serve as input for other structural analyses. It is emphasised that multiple cylinders are required for the modelling of a multifilament yarn to achieve better correlation with the experimental results. A parametric study is presented to investigate the effect of the number of virtual cylinders to represent a real yarn and the shape of the final braid. Excellent correlation was found between the virtual models and the experimental results when comparing the braid angle and yarn width.
Reviewing the class of Al-rich Ti-Al alloys: modeling high temperature plastic anisotropy and asymmetry
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-10-02 , DOI: 10.1186/s40759-017-0031-3
HelalChowdhury,HolmAltenbach,ManjaKrüger,KonstantinNaumenko
In the last decades, the class of Ti-rich TiAl-based intermetallic materials has replaced many contemporary alloys till 900 °C. Due to higher oxidation resistance, 20% lower density and higher (about 150 °C more) operating temperature possibility of Al-rich TiAl alloys over Ti-rich side, phases from the Al-rich region of this alloy system are considered to be highly potential candidates for high temperature structural applications. Although there are a lot of works about Ti-rich alloys, however, investigation from the Al-rich side is very limited. This work reviews the class of Al-rich TiAl alloys in terms of phases, microstructures, morphology, deformation mechanisms, mechanical behaviors along with a possible micromechanical modeling approach. Single crystal like Ti-61.8at.%Al alloy from the Al-rich family has been chosen as an example for modeling high temperature anisotropy and tension-compression asymmetry. A possible comparison with Ti-rich side is also presented.
Modelling low velocity impact induced damage in composite laminates
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-07-26 , DOI: 10.1186/s40759-017-0029-x
YuShi,ConstantinosSoutis
The paper presents recent progress on modelling low velocity impact induced damage in fibre reinforced composite laminates. It is important to understand the mechanisms of barely visible impact damage (BVID) and how it affects structural performance. To reduce labour intensive testing, the development of finite element (FE) techniques for simulating impact damage becomes essential and recent effort by the composites research community is reviewed in this work. The FE predicted damage initiation and propagation can be validated by Non Destructive Techniques (NDT) that gives confidence to the developed numerical damage models. A reliable damage simulation can assist the design process to optimise laminate configurations, reduce weight and improve performance of components and structures used in aircraft construction.
Computational study for reliability improvement of a circuit board
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-06-05 , DOI: 10.1186/s40759-017-0024-2
B.EmekAbali
An electronic device consists of electronic components attached on a circuit board. Reliability of such a device is limited to fatigue properties of the components as well as of the board. Printed circuit board (PCB) consists of conducting traces and vertical interconnect access (via) out of copper embedded in a composite material. Usually the composite material is fiber reinforced laminate out of glass fibers and polyimid matrix. Different reasons play a role by choosing the components of the laminate for the board, one of them is its structural strength and fatigue properties. An improvement of board’s lifetime can be proposed by using computational mechanics. In this work we present the theory and computation of a simplified one layer circuit board conducting electrical signals along its copper via, producing heat that leads to thermal stresses. Such stresses are high enough to perform a plastic deformation. Although the plastic deformation is small, subsequent use of the electronic device causes accumulating plastic deformation, which ends the lifetime effected by a fatigue failure in the copper via. Computer simulations provide a convenient method for understanding the nature of this phenomenon as well as predicting the lifetime. We present a coupled and monolithic way for solving the multiphysics problem of this electro-thermo-mechanical system, numerically, by using finite element method in space and finite difference method in time.
Experimental investigation of surface roughness, flank wear, chip morphology and cost estimation during machining of hardened AISI 4340 steel with coated carbide insert
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-05-04 , DOI: 10.1186/s40759-017-0025-1
SudhansuRanjanDas,AsutoshPanda,DebabrataDhupal
Now-a-days, newer hardened steel materials are coming rapidly into the market due to its wide applications in various fields of engineering. So the machinability investigation of these steel materials is one of the prime concern for practicing engineers, prior to actual machining. The present study addresses surface roughness, flank wear and chip morphology during dry hard turning of AISI 4340 steel (49 HRC) using CVD (TiN/TiCN/Al2O3/TiN) multilayer coated carbide tool. Three factors (cutting speed, feed and depth of cut) and three-level factorial experiment designs with Taguchi’s L9 Orthogonal array (OA) and statistical analysis of variance (ANOVA) were performed to investigate the consequent effect of these cutting parameters on the tool and workpiece in terms of flank wear and surface roughness. For better understanding of the cutting process, surface topography of machined workpieces, wear mechanisms of worn coated carbide tool and chip morphology of generated chips were observed by scanning electron microscope (SEM). Consequently, multiple regression analysis was adopted to develop mathematical model for each response, along with various diagnostic tests were performed to check the validity and efficacy of the proposed model. Finally, to justify the economical feasibility of coated carbide tool in hard turning application, a cost analysis was performed based on Gilbert’s approach by evaluating the tool life under optimized cutting condition (suggested by response optimization technique). The results shows that surface roughness and flank wear are statistically significant influenced by feed and cutting speed. In fact, increase in cutting speed resulted in better surface finish as well as increase in flank wear. Tool wear describes the gradual failure of cutting tool, caused grooves by abrasion due to rubbing effect of flank land with hard particles in the machined surface and high cutting temperature. Chip morphology confirms the formation of saw-tooth type of chip with severity of chip serration due to cyclic crack propagation caused by plastic deformation. The total machining cost per part is found to be $0.13 (i.e. in Indian rupees Rs. 8.21) for machining of hardened AISI 4340 steel with coated carbide tool. From the study, the effectiveness and potential of multilayer TiN/TiCN/Al2O3/TiN coated carbide tool for hard turning process during dry cutting condition possesses high yielding and cost-effective benefit to substitute the traditional cylindrical grinding operation. Apart, it also contributes reasonable option to costlier CBN and ceramic tools.
Parametric optimization of powder mixed electrical discharge machining for nickel-based superalloy inconel-800 using response surface methodology
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-04-17 , DOI: 10.1186/s40759-017-0022-4
SatishKumar,AshwaniKumarDhingra,SanjeevKumar
Electrical Discharge Machining (EDM) is a well-established non-conventional machining process for the machining of electrically conductive and difficult-to-machine materials. But its applications are limited because of the slow machining rate and poor surface finish. Powder mixed EDM (PMEDM) is unitary of the recent progresses in the EDM process in which powder particles mixed in the dielectric fluid results in higher machining rate and better surface quality. In the past, limited work has been found on PMEDM of Inconel-800 material. Researchers have reported about machining with different powder particles like aluminum powder, silicon carbide, graphite etc. in the dielectric fluid of EDM, but the effect of powder particles, i.e. Tungsten carbide, cobalt and boron carbide along with tool material i.e. copper, copper-chromium and graphite on Inconel-800 material has not been explored. The purpose of the present work is to look into the issue of tool material (Cu, copper-chromium, and graphite) along with powder particles (tungsten carbide, cobalt and boron carbide) suspended in EDM oil on Inconel-800 material. The present work includes optimization of Material Removal Rate (MRR) and Tool Wear Rate (TWR) for the machining of Inconel-800 material using Powder Mixed Elctric Discharge Machining (PMEDM). Different input parameters such as peak current, pulse on-time, pulse off-time, tool and powder materials along with effect of three micro powder particles, i.e. tungsten carbide, cobalt and boron carbide and three electrodes i.e. copper, copper-chromium, and graphite have been considered for the experimentation. The box-Behnken method of Response Surface Methodology (RSM) has been used for designing the experiments along with the Desirability Approach for multiple response parameters optimization. The adequacy of the proposed mathematical models have also been tested using analysis of variance (ANOVA). Microstructure analysis and transfer of different factors on the machined surface has also been investigated using Scanning Electron Microscope (SEM), Energy Dispersive Spectrometer (EDS) and X - Ray Diffraction (XRD). The results showed that peak current, pulse on-time, and tool material significantly affects the Material Removal Rate (MRR) while peak current, pulse on-time, tool material and powder materials affected the Tool Wear Rate (TWR). Pulse off-time has a trifling effect on both MRR and TWR, while powder particles on MRR. From desirability approach, the optimal combination of parameters found to be current 1 amp, pulse on-time 0.98 μs, pulse off-time 0.03 μs, tool material 0.31 and the powder (suspended particles) 0.64. The analysis of the experimental observations highlights that the current, pulse on-time and tool material have found to be the most decisive factors for MRR, while current, pulse on-time, tool material and powder particles for TWR.
Modeling the copper microstructure and elastic anisotropy and studying its impact on reliability in nanoscale interconnects
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2017-03-28 , DOI: 10.1186/s40759-017-0021-5
AdarshBasavalingappa,MingY.Shen,JamesR.Lloyd
Copper is the primary metal used in integrated circuit manufacturing of today. Even though copper is face centered cubic it has significant mechanical anisotropy depending on the crystallographic orientations. Copper metal lines in integrated circuits are polycrystalline and typically have lognormal grain size distribution. The polycrystalline microstructure is known to impact the reliability and must be considered in modeling for better understanding of the failure mechanisms. In this work, we used Voronoi tessellation to model the polycrystalline microstructure with lognormal grainsize distribution for the copper metal lines in test structures. Each of the grains is then assigned an orientation with distinct probabilistic texture and corresponding anisotropic elastic constants based on the assigned orientation. The test structure is then subjected to a thermal stress. A significant variation in hydrostatic stresses at the grain boundaries is observed by subjecting the test structure to thermal stress due to the elastic anisotropy of copper. This introduces new weak points within the metal interconnects leading to failure. Inclusion of microstructures and corresponding anisotropic properties for copper grains is crucial to conduct a realistic study of stress voiding, hillock formation, delamination, and electromigration phenomena, especially at smaller nodes where the anisotropic effects are significant.
Testing, characterization and modelling of mechanical behaviour of poly (lactic-acid) and poly (butylene succinate) blends
Mechanics of Advanced Materials and Modern Processes ( IF 0 ) Pub Date : 2016-11-16 , DOI: 10.1186/s40759-016-0014-9
T.Y.Qiu,M.Song,L.G.Zhao
Significant amount of research, both experimental and numerical, has been conducted to study the mechanical behaviour of biodegradable polymer PL(L)A due to its wide range of applications. However, mechanical brittleness or poor elongation of PL(L)A has limited its applications considerably, particularly in the biomedical field. This study aims to study the potential in improving the ductility of PLA by blending with PBS in varied weight ratios. The preparation of PLA and PBS blends, with various weight ratios, was achieved by melting and mixing technique at high temperature using HAAKE™ Rheomix OS Mixer. Differential Scanning Calorimetry (DSC) was applied to investigate the melting behaviour, crystallization and miscibility of the blends. Small dog-bone specimens, produced by compression moulding, were used to test mechanical properties under uniaxial tension. Moreover, an advanced viscoplastic model with nonlinear hardening variables was applied to simulate rate-dependent plastic deformation of PLA/PBS blends, with model parameters calibrated simultaneously against the tensile test data. Optical Microscopy showed that PBS composition aid with the crystallization of PLA. The elongation of PLA/PBS blends increased with the increase of PBS content, but with a compromise of tensile modulus and strength. An increase of strain rate led to enhanced stress response, demonstrating the time-dependent deformation nature of the material. Model simulations of time-dependent plastic deformation for PLA/PBS blends compared well with experimental results. The crystallinity of PLA/PBS blends increased with the addition of PBS content. The brittleness of pure PLA can be improved by blending with ductile PBS using mechanical mixing technique, but with a loss of stiffness and strength. The tensile tests at different strain rates confirmed the time-dependent plastic deformation nature of the blends, i.e., viscoplasticity, which can be simulated by the Chaboche viscoplastic model with nonlinear hardening variables.
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