Smooth particle hydrodynamics study of surface defect machining for diamond turning of silicon

Acknowledgments The authors would like to thank EPSRC (EP/K018345/1) and Royal Society-NSFC International Exchange Scheme for providing financial support to this research.Peer reviewedPublisher PD

A constitutive model for analyzing martensite formation in austenitic steels deforming at high strain rates

This study presents a constitutive model for steels exhibiting SIMT, based on previous seminal works, and the corresponding methodology to estimate their parameters. The model includes temperature effects in the phase transformation kinetics, and in the softening of each solid phase through the use of a homogenization technique. The model was validated with experimental results of dynamic tensile tests on AISI 304 sheet steel specimens, and their predictions correlate well with the experimental evidence in terms of macroscopic stress–strain curves and martensite volume fraction formed at high strain rates. The work shows the value of considering temperature effects in the modeling of metastable austenitic steels submitted to impact conditions. Regarding most of the works reported in the literature on SIMT, modeling of the martensitic transformation at high strain rates is the distinctive feature of the present paper.The researchers of the University Carlos III of Madrid are indebted to the Comunidad Autónoma de Madrid (Project CCG10-UC3M/DPI-5596)) and to the Ministerio de Ciencia e Innovación de España (Project DPI/2008-06408) for the financial support received which allowed conducting part of this work. The authors express their thanks to Mr. Philippe and Mr. Tobisch from the company Zwick for the facilities provided to perform the tensile tests at high strain rates

The present state of surface conditioning in cutting and grinding

All manufacturing processes have an impact on the surface layer state of a component, which in turn significantly determines the properties of parts in service. Although these effects should certainly be exploited, knowledge on the conditioning of the surfaces during the final cutting and abrasive process of metal components is still only extremely limited today. The key challenges in regard comprise the process-oriented acquisition of suitable measurement signals and their use in robust process control with regard to the surface layer conditions. By mastering these challenges, the present demands for sustainability in production on the one hand and the material requirements in terms of lightweight construction strength on the other hand can be successfully met. In this review article completely new surface conditioning approaches are presented, which originate from the Priority Program 2086 of the Deutsche Forschungsgemeinschaft (DFG)

A constitutive model for analyzing martensite formation in austenitic steels deforming at high strain rates

This study presents a constitutive model for steels exhibiting SIMT, based on previous seminal works, and the corresponding methodology to estimate their parameters. The model includes temperature effects in the phase transformation kinetics, and in the softening of each solid phase through the use of a homogenization technique. The model was validated with experimental results of dynamic tensile tests on AISI 304 sheet steel specimens, and their predictions correlate well with the experimental evidence in terms of macroscopic stress–strain curves and martensite volume fraction formed at high strain rates. The work shows the value of considering temperature effects in the modeling of metastable austenitic steels submitted to impact conditions. Regarding most of the works reported in the literature on SIMT, modeling of the martensitic transformation at high strain rates is the distinctive feature of the present paper.The researchers of the University Carlos III of Madrid are indebted to the Comunidad Autónoma de Madrid (Project CCG10-UC3M/DPI-5596)) and to the Ministerio de Ciencia e Innovación de España (Project DPI/2008-06408) for the financial support received which allowed conducting part of this work. The authors express their thanks to Mr. Philippe and Mr. Tobisch from the company Zwick for the facilities provided to perform the tensile tests at high strain rates

Atomistic aspects of ductile responses of cubic silicon carbide during nanometric cutting

Cubic silicon carbide (SiC) is an extremely hard and brittle material having unique blend of material properties which makes it suitable candidate for microelectromechanical systems and nanoelectromechanical systems applications. Although, SiC can be machined in ductile regime at nanoscale through single-point diamond turning process, the root cause of the ductile response of SiC has not been understood yet which impedes significant exploitation of this ceramic material. In this paper, molecular dynamics simulation has been carried out to investigate the atomistic aspects of ductile response of SiC during nanometric cutting process. Simulation results show that cubic SiC undergoes sp3-sp2 order-disorder transition resulting in the formation of SiC-graphene-like substance with a growth rate dependent on the cutting conditions. The disorder transition of SiC causes the ductile response during its nanometric cutting operations. It was further found out that the continuous abrasive action between the diamond tool and SiC causes simultaneous sp3-sp2 order-disorder transition of diamond tool which results in graphitization of diamond and consequent tool wear

A novel haptic model and environment for maxillofacial surgical operation planning and manipulation

This paper presents a practical method and a new haptic model to support manipulations of bones and their segments during the planning of a surgical operation in a virtual environment using a haptic interface. To perform an effective dental surgery it is important to have all the operation related information of the patient available beforehand in order to plan the operation and avoid any complications. A haptic interface with a virtual and accurate patient model to support the planning of bone cuts is therefore critical, useful and necessary for the surgeons. The system proposed uses DICOM images taken from a digital tomography scanner and creates a mesh model of the filtered skull, from which the jaw bone can be isolated for further use. A novel solution for cutting the bones has been developed and it uses the haptic tool to determine and define the bone-cutting plane in the bone, and this new approach creates three new meshes of the original model. Using this approach the computational power is optimized and a real time feedback can be achieved during all bone manipulations. During the movement of the mesh cutting, a novel friction profile is predefined in the haptical system to simulate the force feedback feel of different densities in the bone

Methods of measuring residual stresses in components

Residual stresses occur in many manufactured structures and components. Large number of investigations have been carried out to study this phenomenon and its effect on the mechanical characteristics of these components. Over the years, different methods have been developed to measure residual stress for different types of components in order to obtain reliable assessment. The various specific methods have evolved over several decades and their practical applications have greatly benefited from the development of complementary technologies, notably in material cutting, full-field deformation measurement techniques, numerical methods and computing power. These complementary technologies have stimulated advances not only in measurement accuracy and reliability, but also in range of application; much greater detail in residual stresses measurement is now available. This paper aims to classify the different residual stresses measurement methods and to provide an overview of some of the recent advances in this area to help researchers on selecting their techniques among destructive, semi destructive and non destructive techniques depends on their application and the availabilities of those techniques. For each method scope, physical limitation, advantages and disadvantages are summarized. In the end this paper indicates some promising directions for future developments

Smooth particle hydrodynamics study of surface defect machining for diamond turning of silicon

This paper presents the feasibility study of potential application of recently developed surface defect machining (SDM) method in the fabrication of silicon and similar hard and brittle materials by using Smooth Particle Hydrodynamics (SPH) simulation approach. Inverse parametric analysis simulation study was carried out to determine the Drucker-Prager (DP) constitutive model parameters of silicon by analysing the deformed material response behaviour using various DP model parameters. Indentation test simulations were carried out to perform inverse parametric study. SPH approach was exploited to machine silicon using conventional and surface defect machining methods. To this end we delve into opportunities of exploiting SDM through optimized machining quality, reduced machining time and lowering cost. The results of conventional simulation were compared with the results of experimental diamond turning of silicon. In the SPH simulations, various types of surface defects were introduced on the work-piece prior to machining. Surface defects were equally distributed on the front face of the workpiece. The simulation study encompasses the investigation of chip formation, resultant machining forces, stresses and hydrostatic pressure with and without SDM. The study reveals the SDM process is an effective technique to manufacture hard and brittle materials as well as facilitate increased tool life. The study also divulges the importance of SPH evading the mesh distortion problem and offer natural chip formation during machining of hard and brittle materials

A process-reliable tailoring of subsurface properties during cryogenic turning using dynamic process control

Considering the current demands for resource conservation and energy efficiency, innovative machining concepts and increased process reliability have a significant role to play. A combination of martensitic hardening of the subsurface and near-net-shape manufacturing represent a great potential to produce components with wear-resistant subsurfaces in an energy- and time-saving way. Within the scope of the present study, the influence of cryogenic machining of metastable austenitic steel on the martensitic transformation and surface quality was investigated. Different cooling strategies were used. A soft sensor based on eddy current in-process measurements was used to determine and subsequently affect the martensitic transformation of the subsurface. The feed rate and component temperature were identified as significant factors influencing the martensitic transformation. However, a high feed rate leads to an increase in surface roughness, and thus to a reduction in component quality. For this reason, a roughing process for achieving maximum martensitic transformation was carried out first in the present study and then a reduction in the surface roughness by maintaining the martensitic subsurface content was aimed for by a subsequent finishing process. With the knowledge generated, a dynamic process control was finally set up for designing the turning process of a required subsurface condition and surface quality