Defect Analysis in Microgroove Machining of Nickel-Phosphide Plating by Small Cross-Angle Microgrooving

Crystalline nickel-phosphide (c-Ni-P) plating is a newly developed mold material for precision glass molding (PGM) to fabricate microgrooves. In the ultraprecision cutting process of the c-Ni-P plating material, the neighboring microgrooves are required to adjoin with each other to ensure acute microgroove ridges and miniaturize the microgroove size. Generally, defects of burrs and fracture pits can easily occur on the ridges when the plating layer is grooved. Burrs appear when tears dominate in material removal with a large adjacent amount. With the change of the adjacent amount, the removed material is sheared out from the workpiece, and when the cutting depth of the groove ridge is over the brittle-ductile transition thickness, fracture pits arise. To restrict these defects, a small cross-angle microgrooving method is proposed to test the critical adjacent amount range efficiently. It is found that an acute ridge of the microgroove is formed with a small enough adjacent amount; when this amount is in the range of 570 nm~720 nm in the microgroove machining process, fracture pits begin to arise on the gradient edge. High-quality microgrooves can be obtained based on this methodology

A Mathematical Modeling to Predict the Cutting Forces in Microdrilling

In microdrilling, because of lower feed, the microdrill cutting edge radius is comparable to the chip thickness. The cutting edges therefore should be regarded as rounded edges, which results in a more complex cutting mechanism. Because of this, the macrodrilling thrust modeling is not suitable for microdrilling. In this paper, a mathematical modeling to predict microdrilling thrust is developed, and the geometric characteristics of microdrill were considered in force models. The thrust is modeled in three parts: major cutting edges, secondary cutting edge, and indentation zone. Based on slip-line field theory, the major cutting edges and secondary cutting edge are divided into elements, and the elemental forces are determined by an oblique cutting model and an orthogonal model, respectively. The thrust modeling of the major cutting edges and second cutting edge includes two different kinds of processes: shearing and ploughing. The indentation zone is modeled as a rigid wedge. The force model is verified by comparing the predicted forces and the measured cutting forces

Mechanism-Based FE Simulation of Tool Wear in Diamond Drilling of SiCp/Al Composites

The aim of this work is to analyze the micro mechanisms underlying the wear of macroscale tools during diamond machining of SiCp/Al6063 composites and to develop the mechanism-based diamond wear model in relation to the dominant wear behaviors. During drilling, high volume fraction SiCp/Al6063 composites containing Cu, the dominant wear mechanisms of diamond tool involve thermodynamically activated physicochemical wear due to diamond-graphite transformation catalyzed by Cu in air atmosphere and mechanically driven abrasive wear due to high-frequency scrape of hard SiC reinforcement on tool surface. An analytical diamond wear model, coupling Usui abrasive wear model and Arrhenius extended graphitization wear model was proposed and implemented through a user-defined subroutine for tool wear estimates. Tool wear estimate in diamond drilling of SiCp/Al6063 composites was achieved by incorporating the combined abrasive-chemical tool wear subroutine into the coupled thermomechanical FE model of 3D drilling. The developed drilling FE model for reproducing diamond tool wear was validated for feasibility and reliability by comparing numerically simulated tool wear morphology and experimentally observed results after drilling a hole using brazed polycrystalline diamond (PCD) and chemical vapor deposition (CVD) diamond coated tools. A fairly good agreement of experimental and simulated results in cutting forces, chip and tool wear morphologies demonstrates that the developed 3D drilling FE model, combined with a subroutine for diamond tool wear estimate can provide a more accurate analysis not only in cutting forces and chip shape but also in tool wear behavior during drilling SiCp/Al6063 composites. Once validated and calibrated, the developed diamond tool wear model in conjunction with other machining FE models can be easily extended to the investigation of tool wear evolution with various diamond tool geometries and other machining processes in cutting different workpiece materials

The effect of cutting fluid on high strain rate dynamic mechanical property and cutting force of ultra-high-strength steel

Due to the different composition of cutting fluid will affect the failure stress of the material in the shear deformation area, so the rational use of cutting fluid can optimize the cutting force and the surface integrity of parts. Four kinds of hat-shaped samples with shear band widths were designed. The effects of different cutting fluids on mechanical properties of ultrahigh strength steel at different shear strain rates were studied in this paper by SHPB, and verified by cutting experiments. The stress–strain curve, shear failure stress, fracture morphology and cutting force were studied systematically. Experimental results show that the stress remains stable for a period of time with the increases of strain after strain hardening at γs= 10.03 × 104 1/s. All shear fracture is ductile fracture and at γs<1 0.03 ×104 1/s, the dimple will be elongated with the increase of the strain rate. When the shear bandwidth is reduced from 100 μm to 50 μm, size effect occurs, and the failure stress is increased by nearly 30%. The Rehbinder effect of TRIM E709 is more significant, the shear failure stress is the smallest, Fx, Fy and Fz decreases by 23.93%, 33.08% and 50.29% compared with HY-103. This research can guide the high-quality machining of ultra-high strength steel and may also evaluate and develop new cutting fluids to improve cutting performance

On Multi-Objective Based Constitutive Modelling Methodology and Numerical Validation in Small-Hole Drilling of Al6063/SiCp Composites

Discrepancies in capturing material behavior of some materials, such as Particulate Reinforced Metal Matrix Composites, by using conventional ad hoc strategy make the applicability of Johnson-Cook constitutive model challenged. Despites applicable efforts, its extended formalism with more fitting parameters would increase the difficulty in identifying constitutive parameters. A weighted multi-objective strategy for identifying any constitutive formalism is developed to predict mechanical behavior in static and dynamic loading conditions equally well. These varying weighting is based on the Gaussian-distributed noise evaluation of experimentally obtained stress-strain data in quasi-static or dynamic mode. This universal method can be used to determine fast and directly whether the constitutive formalism is suitable to describe the material constitutive behavior by measuring goodness-of-fit. A quantitative comparison of different fitting strategies on identifying Al6063/SiCp’s material parameters is made in terms of performance evaluation including noise elimination, correlation, and reliability. Eventually, a three-dimensional (3D) FE model in small-hole drilling of Al6063/SiCp composites, using multi-objective identified constitutive formalism, is developed. Comparison with the experimental observations in thrust force, torque, and chip morphology provides valid evidence on the applicability of the developed multi-objective identification strategy in identifying constitutive parameters

Alterations in the gut microbiome and metabolism with coronary artery disease severity

Abstract Background Coronary artery disease (CAD) is associated with gut microbiota alterations in different populations. Gut microbe-derived metabolites have been proposed as markers of major adverse cardiac events. However, the relationship between the gut microbiome and the different stages of CAD pathophysiology remains to be established by a systematic study. Results Based on multi-omic analyses (sequencing of the V3-V4 regions of the 16S rRNA gene and metabolomics) of 161 CAD patients and 40 healthy controls, we found that the composition of both the gut microbiota and metabolites changed significantly with CAD severity. We identified 29 metabolite modules that were separately classified as being positively or negatively correlated with CAD phenotypes, and the bacterial co-abundance group (CAG) with characteristic changes at different stages of CAD was represented by Roseburia, Klebsiella, Clostridium IV and Ruminococcaceae. The result revealed that certain bacteria might affect atherosclerosis by modulating the metabolic pathways of the host, such as taurine, sphingolipid and ceramide, and benzene metabolism. Moreover, a disease classifier based on differential levels of microbes and metabolites was constructed to discriminate cases from controls and was even able to distinguish stable coronary artery disease from acute coronary syndrome accurately. Conclusion Overall, the composition and functions of the gut microbial community differed from healthy controls to diverse coronary artery disease subtypes. Our study identified the relationships between the features of the gut microbiota and circulating metabolites, providing a new direction for future studies aiming to understand the host–gut microbiota interplay in atherosclerotic pathogenesis