A finite element simulation for orthogonal cutting of UD-CFRP incorporating a novel fibre - matrix interface model

AbstractThe rapid increase in industrial utilisation of carbon fibre reinforced plastic (CFRP) composites in recent years has led to growing interest in numerical modelling of material behaviour and defect formation when machining CFRP. The inhomogeneous/anisotropic nature of CFRP however presents considerable challenges in accurately modelling workpiece defects such as debonding between the matrix and fibre phase following cutting operations. Much of the published literature has involved the use of zero thickness cohesive elements to represent the fibre-matrix interface, despite the inability of such elements to model compressive stresses. This paper details a new approach for characterising the interface region in a two-dimensional explicit finite element simulation when orthogonal machining unidirectional (UD) CFRP laminates. A cohesive zone model based on a traction-separation law is applied to small thickness (0.25μm) interface elements in order to accommodate compressive failure, which is implemented via a bespoke user subroutine. Fibre fracture is based on a maximum principal stress criterion while elastic-plastic behaviour to failure is used to represent matrix damage. The influence of varying fibre orientations (45°, 90°, 135°) on predicted cutting and thrust forces were validated against published experimental data. While the former was generally within 5% of experimental data for workpieces with 90° and 135° fibre directions, predicted thrust forces were typically underestimated by ∼30-60%. The corresponding chip formation mechanisms and sub-surface damage due to the different material phases were also investigated. The proposed model was able to predict composite behaviour and defect formation that was comparable to experimental high speed camera images outlined in the literature

Optimising surface roughness and density in titanium fabrication via laser powder bed fusion

The Ti6Al4V alloy has many advantages, such as being lightweight, formal, and resistant to corrosion. This makes it highly desirable for various applications, especially in the aerospace industry. Laser Powder Bed Fusion (LPBF) is a technique that allows for the production of detailed and unique parts with great flexibility in design. However, there are challenges when it comes to achieving high-quality surfaces and porosity formation in the material, which limits the wider use of LPBF. To tackle these challenges, this study uses statistical techniques called Design of Experiments (DoE) and Analysis of Variance (ANOVA) to investigate and optimise the process parameters of LPBF for making Ti6Al4V components with improved density and surface finish. The parameters examined in this study are laser power, laser scan speed, and hatch space. The optimisation study results show that using specific laser settings, like a laser power of 175 W, a laser scan speed of 1914 mm/s, and a hatch space of 53 µm, produces Ti6Al4V parts with a high relative density of 99.54% and low top and side surface roughness of 2.6 µm and 4.3 µm, respectively. This promising outcome demonstrates the practicality of optimising Ti6Al4V and other metal materials for a wide range of applications, thereby overcoming existing limitations and further expanding the potential of LPBF while minimising inherent process issues

Hybrid finite element–smoothed particle hydrodynamics modelling for optimizing cutting parameters in CFRP composites

Carbon-fibre-reinforced plastic (CFRP) is increasingly being used in various applications including aerospace, automotive, wind energy, sports, and robotics, which makes the precision modelling of its machining operations a critical research area. However, the classic finite element modelling (FEM) approach has limitations in capturing the complexity of machining, particularly with regard to the interaction between the fibre–matrix interface and the cutting edge. To overcome this limitation, a hybrid approach that integrates smoothed particle hydrodynamics (SPHs) with FEM was developed and tested in this study. The hybrid FEM-SPH approach was compared with the classic FEM approach and validated with experimental measurements that took into account the cutting tool’s round edge. The results showed that the hybrid FEM-SPH approach outperformed the classic FEM approach in predicting the thrust force and bounce back of CFRP machining due to the integrated cohesive model and the element conversion after failure in the developed approach. The accurate representation of the fibre–matrix interface in the FEM-SPH approach resulted in predicting precise chip formation in terms of direction and morphology. Nonetheless, the computing time of the FEM-SPH approach is higher than the classic FEM. The developed hybrid FEM-SPH model is promising for improving the accuracy of simulation in machining processes, combining the benefits of both techniques

Chip formation and orthogonal cutting optimisation of unidirectional carbon fibre composites

This study presents a thorough experimental investigation utilising the design of experiments and analysis of variance (ANOVA) to examine the impact of machining process parameters on chip formation mechanisms, machining forces, workpiece surface integrity, and damage resulting from the orthogonal cutting of unidirectional CFRP. The study identified the mechanisms behind chip formation and found it to significantly impact the workpiece orientation of fibre and the tool’s cutting angle, resulting in increased fibre bounceback at larger fibre orientation angles and when using smaller rake angle tools. Increasing the depth of cut and fibre orientation angle results in an increased damage depth, while using higher rake angles reduces it. An analytical model based on response surface analysis for predicting machining forces, damage, surface roughness, and bounceback was also developed. The ANOVA results indicate that fibre orientation is the most significant factor in machining CFRP, while cutting speed is insignificant. Increasing fibre orientation angle and depth leads to deeper damage, while larger tool rake angles re-duce damage. Machining workpieces with 0° fibre orientation angle results in the least subsurface damage, and surface roughness is unaffected by the tool rake angle for fibre orientations between 0° to 90° but worsens for angles greater than 90°. Optimisation of cutting parameters were subsequently optimised to improve machined workpiece surface quality and reduce forces. The experimental results showed that negative rake angle and cutting at moderately low speeds (366 mm/min) is the optimal conditions for machining laminates with a fibre angle of θ = 45°. On the other hand, for composite materials with fibre angles of θ = 90° and θ = 135°, it is recommended to use a high positive rake angle and cutting speeds

Shallow geophysical techniques to investigate the groundwater table at the Great Pyramids of Giza, Egypt

The near-surface groundwater aquifer that threatened the Great Pyramids of Giza, Egypt, was investigated using integrated geophysical surveys. A total of 10 electrical resistivity imaging, 26 shallow seismic refraction, and 19 ground-penetrating radar surveys were conducted in the Giza Plateau. Collected data for each method were evaluated by state-of-the art processing and modeling techniques. A three-layer model depicts the subsurface layers and better delineates the groundwater aquifer and water table elevation. The resistivity of the aquifer layer and seismic velocity vary between 40 and 80&thinsp;Ωm and between 1500 and 2500&thinsp;m&thinsp;s−1, respectively. The average water table elevation is about +15&thinsp;m, which is safe for the Great Sphinx, but it is still subjected to potential hazards from the Nazlet El-Samman suburb where the water table elevation reaches 17&thinsp;m. A shallower water table at the Valley Temple and the tomb of Queen Khentkawes, with a low topographic relief, represents severe hazards. It can be concluded that a perched groundwater table is detected in the elevated topography to the west and southwest that might be due to runoff and capillary seepage.</p

Cortical depth dependent functional responses in humans at 7T: improved specificity with 3D GRASE

Ultra high fields (7T and above) allow functional imaging with high contrast-to-noise ratios and improved spatial resolution. This, along with improved hardware and imaging techniques, allow investigating columnar and laminar functional responses. Using gradient-echo (GE) (T2* weighted) based sequences, layer specific responses have been recorded from human (and animal) primary visual areas. However, their increased sensitivity to large surface veins potentially clouds detecting and interpreting layer specific responses. Conversely, spin-echo (SE) (T2 weighted) sequences are less sensitive to large veins and have been used to map cortical columns in humans. T2 weighted 3D GRASE with inner volume selection provides high isotropic resolution over extended volumes, overcoming some of the many technical limitations of conventional 2D SE-EPI, whereby making layer specific investigations feasible. Further, the demonstration of columnar level specificity with 3D GRASE, despite contributions from both stimulated echoes and conventional T2 contrast, has made it an attractive alternative over 2D SE-EPI. Here, we assess the spatial specificity of cortical depth dependent 3D GRASE functional responses in human V1 and hMT by comparing it to GE responses. In doing so we demonstrate that 3D GRASE is less sensitive to contributions from large veins in superficial layers, while showing increased specificity (functional tuning) throughout the cortex compared to GE

Recognising facial expressions in video sequences

We introduce a system that processes a sequence of images of a front-facing human face and recognises a set of facial expressions. We use an efficient appearance-based face tracker to locate the face in the image sequence and estimate the deformation of its non-rigid components. The tracker works in real-time. It is robust to strong illumination changes and factors out changes in appearance caused by illumination from changes due to face deformation. We adopt a model-based approach for facial expression recognition. In our model, an image of a face is represented by a point in a deformation space. The variability of the classes of images associated to facial expressions are represented by a set of samples which model a low-dimensional manifold in the space of deformations. We introduce a probabilistic procedure based on a nearest-neighbour approach to combine the information provided by the incoming image sequence with the prior information stored in the expression manifold in order to compute a posterior probability associated to a facial expression. In the experiments conducted we show that this system is able to work in an unconstrained environment with strong changes in illumination and face location. It achieves an 89\% recognition rate in a set of 333 sequences from the Cohn-Kanade data base

The Role of Women in Economic Transformation: Market Women in Sierra Leone.

yesVarious research has concluded that economic life did not die out during the conflict in Sierra Leone, but took on different forms. Different stakeholders at all levels were engaged in economic activities during the war. The specific roles of women in the shadow economy are under-researched with the result that most analysis and policy-options are inadequate. While some of Sierra Leone¿s Market Women strategically participated in war economies to `do well out of war¿, most did so out of the need to survive. With the end of the war, market women have been able to make a successful transformation to peace economies through micro-credit assistance

Effect of stress relieving heat treatment on surface topography and dimensional accuracy of incrementally formed grade 1 titanium sheet parts

The forming of parts with an optimized surface roughness and high dimensional accuracy is important in many applications of incremental sheet forming (ISF). To realize this, the effect of stress relieving heat treatment of grade-1 Ti parts performed before and after forming on the surface finish and dimensional accuracy was studied. It was found that heat treatment at a temperature of 540 °C for 2 h improves the surface finish of formed parts resulting in a surface with little or no visible tool marks. Additionally, it improves the dimensional accuracy of parts after unclamping from the rig used for forming, in particular, that of parts with shallow wall angles (typically <25°). It was also noted that post-forming heat treatment improves the surface finish of parts. The surface topography of formed parts was studied using interferometry to yield areal surface roughness parameters and subsequently using secondary electron imaging. Back-scatter electron microscopy imaging results coupled with energy-dispersive X-ray (EDX) analysis showed that heat treatment prior to forming leads to tool wear as indicated by the presence of Fe in samples. Furthermore, post-forming heat treatment prevents curling up of formed parts due to compressive stresses if the formed part is trimmed