Multi-scale simulation of the nano-metric cutting process

Molecular dynamics (MD) simulation and the finite element (FE) method are two popular numerical techniques for the simulation of machining processes. The two methods have their own strengths and limitations. MD simulation can cover the phenomena occurring at nano-metric scale but is limited by the computational cost and capacity, whilst the FE method is suitable for modelling meso- to macro-scale machining and for simulating macro-parameters, such as the temperature in a cutting zone, the stress/strain distribution and cutting forces, etc. With the successful application of multi-scale simulations in many research fields, the application of simulation to the machining processes is emerging, particularly in relation to machined surface generation and integrity formation, i.e. the machined surface roughness, residual stress, micro-hardness, microstructure and fatigue. Based on the quasi-continuum (QC) method, the multi-scale simulation of nano-metric cutting has been proposed. Cutting simulations are performed on single-crystal aluminium to investigate the chip formation, generation and propagation of the material dislocation during the cutting process. In addition, the effect of the tool rake angle on the cutting force and internal stress under the workpiece surface is investigated: The cutting force and internal stress in the workpiece material decrease with the increase of the rake angle. Finally, to ease multi-scale modelling and its simulation steps and to increase their speed, a computationally efficient MATLAB-based programme has been developed, which facilitates the geometrical modelling of cutting, the simulation conditions, the implementation of simulation and the analysis of results within a unified integrated virtual-simulation environment

Electromagnetically assisted densification of copper-sheathed in situ MgB2/Cu wires

peer-reviewedThis paper summarizes recent methods of improving critical current density of in situ Cu-sheathed MgB2 wires. These methods include using optimum heat treatment schedule, adding copper powder to the wire core and electromagnetic densification of wire core. The large part of work reported here focuses on the latter method applied to the relatively low-density MgB2/Cu wire core. The packing density of unreacted, monofilament wire core was increased by 8 % with oscillating magnetic pressure, reaching a peak value above 700 MPa as calculated by finite element modelling of the forming process. The higher density of the MgB2 core combined with copper powder addition resulted in a critical current density increase of more than fivefold in comparison to purely stoichiometric and cold-drawn-only wire.PUBLISHEDpeer-reviewe

Drying-mediated patterns in colloid-polymer suspensions

Drying-mediated patterning of colloidal particles is a physical phenomenon that must be understood in inkjet printing technology to obtain crack-free uniform colloidal films. Here we experimentally study the drying-mediated patterns of a model colloid-polymer suspension and specifically observe how the deposit pattern appears after droplet evaporation by varying particle size and polymer concentration. We find that at a high polymer concentration, the ring-like pattern appears in suspensions with large colloids, contrary to suppression of ring formation in suspensions with small colloids thanks to colloidpolymer interactions. We attribute this unexpected reversal behavior to hydrodynamics and size dependence of colloid-polymer interactions. This finding would be very useful in developing control of drying-mediated self-assembly to produce crack-free uniform patterns from colloidal fluids.ope

Assessing the accuracy of intracameral phenylephrine preparation in cataract surgery

Purpose: Unpreserved phenylephrine is often used as an off-licence intracameral surgical adjunct during cataract surgery to assist with pupil dilation and/or stabilise the iris in floppy iris syndrome. It can be delivered as a neat 0.2 ml bolus of either 2.5 or 10% strength, or in a range of ad-hoc dilutions. We wished to assess the accuracy of intracameral phenylephrine preparation in clinical practice. Methods: Phenylephrine 0.2 ml was analysed both neat (2.5 and 10%) and in diluted form (ratio of 1:1 and 1:3). Samples were analysed using the validated spectrophotometric method. Results: A total of 36 samples were analysed. The standard curve showed linearity for phenylephrine (R2 = 0.99). Wide variability was observed across all dilution groups. There was evidence of significant differences in the percentage deviations from intended results between dilutions (p < 0.001). Mean percentage deviation for 1:3 dilution was significantly greater than neat (p = 0.003) and 1:1 dilution (p = 0.001). There was no evidence of a significant difference between 1:1 and neat (p = 0.827). Conclusions: Current ad-hoc dilution methods used to prepare intracameral phenylephrine are inaccurate and highly variable. Small volume 1 ml syringes should not be used for mixing or dilution of drug. Commercial intracameral phenylephrine products would address dosage concerns and could improve surgical outcomes in cases of poor pupil dilation and/or floppy iris syndrome

Fatigue life of machined components

A correlation between machining process and fatigue strength of machined components clearly exists. However, a complete picture of the knowledge on this is not readily available for practical applications. This study addresses this issue by investigating the effects of machining methods on fatigue life of commonly used materials, such as titanium alloys, steel, aluminium alloys and nickel alloys from previous literature. Effects of turning, milling, grinding and different non-conventional machining processes on fatigue strength of above-mentioned materials have been investigated in detail with correlated information. It is found that the effect of materials is not significant except steel in which phase change causes volume expansion, resulting in compressive/tensile residual stresses based on the amounts of white layers. It is very complex to identify the influence of surface roughness on the fatigue strength of machined components in the presence of residual stresses. The polishing process improves the surface roughness, but removes the surface layers that contain compressive residual stresses to decrease the fatigue strength of polished specimens. The compressive and tensile residual stresses improve and reduce fatigue strength, respectively. Grinding process induces tensile residual stresses on the machined surfaces due to high temperature generation. On the other hand, milling and turning processes induce compressive residual stresses. High temperature non-conventional machining generates a network of micro-cracks on the surfaces in addition to tensile residual stresses to subsequently reduce fatigue strength of machined components. Embedded grits of abrasive water jet machining degrade the fatigue performance of components machined by this method