Wear characteristics of ultra-hard cutting tools when machining austempered ductile iron

Nodularised Ductile Cast Iron, when subjected to heat treatment processes - austenitising and austempering produces Austempered Ductile Iron (ADI). The microstructure of ADI also known as &quot;ausferrite&quot; consists of ferrite, austenite and graphite nodules. Machining ADI using conventional techniques is often a problematic issue due to the microstructural phase transformation from austenite to martensite during machining. This paper evaluates the wear characteristics of ultra hard cutting tools when machining ADI and its effect on machinability. Machining trials consist of turning ADI (ASTMGrade3) using two sets of PCBN tools with 90% and 50% CBN content and two sets of ceramics tools; Aluminium Oxide Titanium Carbide and Silicon Carbide - whisker reinforced Ceramic. The cutting parameters chosen are categorized as roughing and finishing conditions; the roughing condition comprises of constant cutting speed (425 m/min) and depth of cut (2mm) combined with variable feed rates of 0.1, 0.2, 0.3 and 0.4mm/rev. The finishing condition comprises of constant cutting speed (700 m/min) and depth of cut (0.5mm) combined with variable feed rates of 0.1, 0.2, 0.3 and 0.4mm/rev. The benchmark condition to evaluate the performance of the cutting tools was tool wear evaluation, surface texture analysis and cutting force analysis. The paper analyses thermal softening of the workpiece by the tool and its effect on the shearing mechanism under rough and finish machining conditions in term of lower cutting forces and enhanced surface texture of the machined part.<br /

Tool wear and surface integrity analysis of machined heat treated selective laser melted Ti-6Al-4V

In this study, the tool wear and surface integrity during machining of wrought and Selective LaserMelted (SLM) titanium alloy (after heat treatment) are studied. Face turning trails were carried out onboth the materials at different cutting speeds of 60,120 and 180 m/min. Cutting tools and machinedspecimens collected are characterized using scanning electron microscope, surface profiler and opticalmicroscope to study the tool wear, machined surface quality and machining induced microstructuralalterations. It was found that high cutting speeds lead to rapid tool wear during machining of SLMTi-6Al-4V materials. Rapid tool wear observed at high cutting speeds in machining SLM Ti-6Al-4Vresulted in damaging the surface integrity by 1) Deposition of chip/work material on the machinedsurface giving rise to higher surface roughness and 2) Increasing the depth of plastic deformationon the machined sub surface

Thermal Stress Flow Analysis in Fabrication of Acetabular Shells Using SLM

Additive Manufacturing (AM), more popularly known as 3D Printing, is a process for producing functional artifacts by adding layers of materials from data generated directly from 3D solid CAD models. Additive Manufacturing (AM) is the formalized term for what used to be called Rapid Prototyping and what is commonly referred to as 3D Printing. The key to how AM works is that parts are made by adding layers of material; each layer corresponding to a thin cross-section of the part derived from the original CAD data. Although most AM machines produce parts using polymers, there are an increasing number of machines that can directly fabricate in metals. The majority of these machines fabricate from raw material in powder form using a directed energy beam to create a local melt zone. Total hip replacement is recommended for people who have medical issues related to excessive wear of the acetabular, osteoarthritis, accident or age. Researches have shown that large numbers of hip arthroplasties (where the articular surface of a musculoskeletal joint is replaced), hip remodelling, or realignment are carried out annually and will increase in the next few decades. Manufacturing of acetabular shells by using AM is a promising and emerging method that has a great potential to improve public health. Lost wax casting or investment casting is currently used to produce acetabular shells followed by lengthy and complex secondary processes such as machining and polishing. Living organs and medical models have intricate 3D shapes that are challenging to identity in X-ray CT images. These images are used for preparing treatment plans to improve the quality of the surgeries regarding waiting and surgery time per procedure and care regime. For instance, a limited number of hip replacement procedures can be carried out on each acetabulum due to a decrease of bone thickness. Rapid prototyping is a suitable treatment planning tool in complex cases to enhance the quality of surgical procedure and provide long-term stability that can be used to customize the shape and size of the acetabular shell. In this paper, to analyse the manufacturing of a prosthetic acetabular shell, built-up lines resulting from a thermal stress flow and process stopping during the selective laser melting (SLM) AM process, with regarding Gibbs free energy, interfacial energy, and equilibrium temperature will be discussed. Geometrical measurements showed 1.59% and 0.27% differences between the designed and manufactured prototype for inside and outside diameter respectively. Experimental results showed that thermal stress flow in outer surfaces are compressive, but for inner surfaces are tensile, so built-up lines in inner and outer surfaces appear as a groove and dent respectively. The results also indicate that SLM is an accurate and promising method for fabrication of acetabular cup

The Average-Case Area of Heilbronn-Type Triangles

From among ${n \choose 3}$ triangles with vertices chosen from $n$ points in the unit square, let $T$ be the one with the smallest area, and let $A$ be the area of $T$. Heilbronn's triangle problem asks for the maximum value assumed by $A$ over all choices of $n$ points. We consider the average-case: If the $n$ points are chosen independently and at random (with a uniform distribution), then there exist positive constants $c$ and $C$ such that $c/n^3 < \mu_n < C/n^3$ for all large enough values of $n$, where $\mu_n$ is the expectation of $A$. Moreover, $c/n^3 < A < C/n^3$, with probability close to one. Our proof uses the incompressibility method based on Kolmogorov complexity; it actually determines the area of the smallest triangle for an arrangement in ``general position.''Comment: 13 pages, LaTeX, 1 figure,Popular treatment in D. Mackenzie, On a roll, {\em New Scientist}, November 6, 1999, 44--4

Concerted reductive coupling of an alkyl chloride at Pt(IV)

Oxidation of a doubly cyclometallated platinum(II) complex results in two isomeric platinum(IV) complexes. Whereas the trans isomer is robust, being manipulable in air at room temperature, the cis isomer decomposes at −20 °C and above. Reductive coupling of an alkyl chloride at the cis isomer gives a new species which can be reoxidised. The independence of this coupling on additional halide rules out the reverse of an SN2 reaction, leaving a concerted process as the only sensible reaction pathway