High shock release in ultrafast laser irradiated metals: Scenario for material ejection

We present one-dimensional numerical simulations describing the behavior of solid matter exposed to subpicosecond near infrared pulsed laser radiation. We point out to the role of strong isochoric heating as a mechanism for producing highly non-equilibrium thermodynamic states. In the case of metals, the conditions of material ejection from the surface are discussed in a hydrodynamic context, allowing correlation of the thermodynamic features with ablation mechanisms. A convenient synthetic representation of the thermodynamic processes is presented, emphasizing different competitive pathways of material ejection. Based on the study of the relaxation and cooling processes which constrain the system to follow original thermodynamic paths, we establish that the metal surface can exhibit several kinds of phase evolution which can result in phase explosion or fragmentation. An estimation of the amount of material exceeding the specific energy required for melting is reported for copper and aluminum and a theoretical value of the limit-size of the recast material after ultrashort laser irradiation is determined. Ablation by mechanical fragmentation is also analysed and compared to experimental data for aluminum subjected to high tensile pressures and ultrafast loading rates. Spallation is expected to occur at the rear surface of the aluminum foils and a comparison with simulation results can determine a spall strength value related to high strain rates

Nonterrestrial utilization of materials: Automated space manufacturing facility

Four areas related to the nonterrestrial use of materials are included: (1) material resources needed for feedstock in an orbital manufacturing facility, (2) required initial components of a nonterrestrial manufacturing facility, (3) growth and productive capability of such a facility, and (4) automation and robotics requirements of the facility

Residual stresses in orthogonal cutting of metals: the effect of thermo-mechanical coupling parameters and of friction

21 pages, 13 figures.The generation of residual stresses in orthogonal machining is analysed by using an Arbitrary Lagrangian Eulerian (ALE) finite element approach. It is shown that a substantial level of tensile residual stresses can be obtained in the vicinity of the machined surface without any contribution of thermal effects. This motivates the development of a parametric study to analyse the effects of the thermomechanical coupling parameters on residual stresses. The roles of thermal expansion, of thermal softening and of the Taylor-Quinney coefficient (controlling the heat generated by plastic flow) are considered separately. The influence of friction is also analysed by assuming dry cutting conditions and a Coulomb friction law. The friction coefficient has a complex effect by controlling heat generation (frictional heating) along the tool rake and clearance faces and the propensity for the chip to stick to the tool. Geometrical effects such as the tool rake angle and the tool edge radius are also discussed.The authors are indebted, for the financial support of this work, to the Ministry of Science and Education of Spain (under project DPI2005-08018) and to the Comunidad Autónoma de Madrid and University Carlos III of Madrid (under project CCG07-UC3M/DPI-3396).Publicad

3D Finite Element Simulation of Micro End-Milling by Considering the Effect of Tool Run-Out

Understanding the micro milling phenomena involved in the process is critical and difficult through physical experiments. This study presents a 3D finite element modeling (3D FEM) approach for the micro end-milling process on Al6082-T6. The proposed model employs a Lagrangian explicit finite element formulation to perform coupled thermo-mechanical transient analyses. FE simulations were performed at different cutting conditions to obtain realistic numerical predictions of chip formation, temperature distribution, and cutting forces by considering the effect of tool run-out in the model. The radial run-out is a significant issue in micro milling processes and influences the cutting stability due to chip load and force variations. The Johnson-Cook (JC) material constitutive model was applied and its constants were determined by an inverse method based on the experimental cutting forces acquired during the micro end-milling tests. The FE model prediction capability was validated by comparing the numerical model results with experimental tests. The maximum tool temperature was predicted in a different angular position of the cutter which is difficult or impossible to obtain in experiments. The predicted results of the model, involving the run-out influence, showed a good correlation with experimental chip formation and the signal shape of cutting forces

Manufacturing of coir fibre-reinforced polymer composites by hot compression technique

This present chapter describes the manufacturing technique and properties of coir fibre-reinforced polypropylene composites manufactured using a hot press machine. The effects of basic chromium sulphate and sodium bicarbonate treatment on the physical and mechanical properties were also evaluated. Chemical treatment and fibre loading generally improved the mechanical properties. Five-hour basic chromium sulphate and sodium bicarbonate-treated coir-polypropylene had the best set of properties among all manufactured composites. Chemical treatment also improved water absorption characteristics. This proves that chemical treatment reduced the hydrophilicity of the coir fibre. Overall the hot compression technique was proved to be successful in manufacturing good quality coir reinforced polypropylene composites