Development of the microbiological population in water miscible metal working fluids

The deterioration of metal working fluids (MWFs) due to the microbial colonization and degradation is a considerable economic factor in the metal working industry. Microorganisms (MO) are able to metabolize almost all components of MWFs and thus lead to a loss of its function by the reduction or depletion of additives. Microbial growth cannot be avoided completely, although various methods exist to reduce the bacterial load in MWFs. This paper presents a study on the colonization of MWFs by bacteria and fungi in an industrial environment. The cooling lubricants have been periodically examined based on biological and chemical methods. The level of the total bacterial load in the lubricant is considered as well as the composition of the species community and its development over the evaluation period. With regard to the increasing relevance of environment friendly processes, a conventional mineral oil based MWF has been compared to a product based on renewable resources

Experimental and Numerical Analysis of the Surface Integrity resulting from Outer-Diameter Grind-Hardening

AbstractBesides conventional heat treatment operations, an innovative approach for surface hardening is the grind-hardening process. During this process the dissipated heat from grinding is used for a martensitic phase transformation in the subsurface region of machined components. Additionally, compressive residual stresses are induced in the grindhardened surface layer. However, for the implementation of grind-hardening into industrial production extensive experimental tests are required to achieve iterative results of hardening depth. This paper focuses on the identification of parameter sets for a sufficient grind-hardening in outer-diameter grinding. On the one hand, grinding tests were conducted supported by metallographic investigations; on the other hand, a finite-element-based model was used to predict the surface integrity resulting from grind-hardening

Influence of Additives in Metalworking Fluids on the Wear Resistance of Steels

AbstractTheability of metalworking fluids (MWF) to cool and lubricate the contact zone between tool and workpiece is strongly dependent on the surface-active substances such as extreme pressure additives (EP) and passive extreme pressure additive (PEP) as well as the chemical surface properties of steel.Low alloyed steels and stainless steels were examined with a wear resistance test by applying MWF with defined varied concentrations of additivesfeaturing different properties e.g. regarding activity and molecular structure.The wear resistance was assessed and correlated with the chemical properties of the metals. Synergistic and antagonistic effects were obtained and will be discussed. The results gained from the experiments, clearly indicate, why the amount of the additives is less decisive for wear resistance than the relative ratio of polar and unpolar EP/PEP-additives.The optimal result furthermore depends on the chemical properties of the considered surfaces

Tips to Advance Business Writing Skills at EFL Classes (Through the Example of "Letter of Complaint")

Writing is a creative communicative skill to express thoughts. It is cognitively complex, requires much practice and is best learned through experience. Writing is one of the most challenging, time-consuming tasks in acquiring a foreign language. To improve students’ writing skills and accuracy, a teacher should encourage writing-thinking, provide instructions and examples of good writing in the target language, and give feedback focusing both on error correction (cohesion) and organization of writing (clarity, idea development, coherence). This paper explores difficulties of the development of business writing skills and gives recommendations on writing a letter of complaint at English as a foreign language classes

3D Finite Element Modelling of Cutting Forces in Drilling Fibre Metal Laminates and Experimental Hole Quality Analysis

Machining Glass fibre aluminium reinforced epoxy (GLARE) is cumbersome due to distinctively different mechanical and thermal properties of its constituents, which makes it challenging to achieve damage-free holes with the acceptable surface quality. The proposed work focuses on the study of the machinability of thin (~2.5 mm) GLARE laminate. Drilling trials were conducted to analyse the effect of feed rate and spindle speed on the cutting forces and hole quality. The resulting hole quality metrics (surface roughness, hole size, circularity error, burr formation and delamination) were assessed using surface profilometry and optical scanning techniques. A three dimensional (3D) finite-element (FE) model of drilling GLARE laminate was also developed using ABAQUS/Explicit to help understand the mechanism of drilling GLARE. The homogenised ply-level response of GLARE laminate was considered in the FE model to predict cutting forces in the drilling process

Using Barkhausen Noise to Measure Coating Depth of Coated High-Speed Steel

Coated high-speed steel tools are widely used in machining processes as they offer an excellent tool life to cost ratio, but they quickly need replacing once the coated layer is worn away. It would be therefore useful to be able to measure the tool life remaining non-destructively and cheaply. To achieve this, the work presented here aims to measure the thickness of the coated layer of high-speed cutting tools by using Barkhausen noise (BHN) techniques. Coated high-speed steel specimens coated with two different materials (chromium nitride (CrN), titanium nitride (TiN)) were tested using a cost-effective measuring system developed for this study. Sensory features were extracted from the signal received from a pick-up coil and the signal features, Root mean square, peak count, and signal energy, were successfully correlated with the thickness of the coating layer on high-speed steel (HSS) specimens. The results suggest that the Barkhausen noise measuring system developed in this study can successfully indicate the different thickness of the coating layer on CrN/TiN coated HSS specimens

Миграция и эмиграция поволжских немцев

This article presents an overview of current simulation methods describing the interaction of grinding process and grinding machine structure, e.g., vibrations, deflections, or thermal deformations. Innovative process models which describe the effects of the grinding wheel–workpiece interaction inside the contact zone are shown in detail. Furthermore, simulation models representing the static and dynamic behaviour of a grinding machine and its components are discussed. Machine tool components with a high influence on the process results are modelled more detailed than those with low influence. The key issue of the paper is the coupling of process and machine tool models for predicting the interactions of process and machine. Several coupling methods are introduced and the improvements of the simulation results are documented. On the basis of the presented simulation approaches, grinding processes and machines can be designed more effectively resulting in higher workpiece quality and process stability

Residual stress analysis of drive shafts after induction hardening

Typically, for automotive shafts, shape distortion manifests itself in most cases after the induction hardening by an effect known as bending. The distortion results in a boost of costs, especially due to machining parts in the hardened state to fabricate its final tolerances. In the present study, residual stress measurements were carried out on automotive drive shafts made of DIN 38B3 steel. The samples were selected in consequence of their different distortion properties by an industrial manufacturing line. One tested shaft was straightened, because of the considerable dimensional variation and the other one not. Firstly, the residual stress measurements were carried out by using a portable difractometer, in order to avoid cutting the shafts and evaluate the original state of the stresses, and afterwards a more detailed analysis was realized by a conventional stationary diffractometer. The obtained results presented an overview of the surface residual stress profiles after induction hardening and displayed the influence of the straightening process on the redistribution of residual stresses. They also indicated that the effects of the straightening in the residual stresses cannot be neglecte