Abstract: This work is intended to study the post-failure characteristic behaviour of rocks and the techniques of controlling the post-failure regime based on the mechanism of rocks deformation process. It is impossible to determine the post-failure regime of rocks using conventional laboratory testing equipment. This is because most testing machines are soft and therefore no information can be obtained after the peak load. Stress-strain deformation tests were conducted using both conventional and unconventional method (i.e. the closed loop servo-controlled testing machine) in accordance to ISRM standard. Normalised pre-failure curves were constructed to show the stages in the deformation process. The first type contains the Class I and progress to Class II with low strength soft brittle rocks. The second type shows entirely Class II characteristic behaviour. The third type is extremely brittle under axial loading, resulted in explosive failure, so its class could not be determined. The difficulty in obtaining the post-failure curves increases as the total volumetric strain approaches a positive value. The author’s use of normalised pre-failure curves enables identification of additional type of deformation process with very brittle response under axial loading. Testing the third type without confinement could cause equipment damage. Identification of the deformation process with the rock classes using conventional test could guide the personnel conducting tests using closed-loop servo-controlled system, to avoid equipment damage when testing rocks with third type deformation process so that testing is performed safely. It has also improved our understanding on total specimen failure and brittleness of rocks (e.g. brittle for Class II and less brittle or ductile for Class I).
Abstract: Because die drawing requires insertion of a die, a plug, or a mandrel, higher precision and efficiency are demanded for drawing equipment for a tube having smaller diameter. Manufacturing of such tubes is also accompanied by problems such as cracking and fracture. We specifically examine dieless drawing, which is less affected by these drawing-related difficulties. This deformation process is governed by a similar principle to that of reduction in diameter when pulling a heated glass tube. We conducted dieless drawing of SUS304 stainless steel microtubes under various conditions with three factor parameters of heating temperature, area reduction, and drawing speed. We used SEM-EBSD to observe the processing condition effects on microstructural elements. As the result of this study, crystallographic orientation of microtube is clear by using SEM-EBSD analysis.
Abstract: The present work is dealing with 2% Si-steel alloy. The alloy contains 0.05% C as well as 0.85% Al. The alloy under investigation would be used for electrical transformation purposes. A heating (expansion) - cooling (contraction) dilation investigation was executed to detect the a, a+g, and g transformation temperatures at the inflection points of the dilation curve. On heating, primary a was detected at a temperature range between room temperature and 687 oC. The domain of a+g was detected in the range between 687 oC and 746 oC. g phase exists in the closed g region at the range between 746 oC and 1043 oC. The domain of a phase appears again at a temperature range between 1043 and 1105 oC, and followed by secondary a at temperature higher than 1105 oC. A physical simulation of thermo-mechanical processing on the as-cast alloy was carried out. The simulation process took into consideration the hot flat rolling pilot plant parameters. The process was executed on the thermo-mechanical simulator (Gleeble 3500). The process was designed to include seven consecutive passes. The 1st pass represents the roughing stage, while the remaining six passes represent finish rolling stage. The whole process was executed at the temperature range from 1100 oC to 900 oC. The amount of strain starts with 23.5% at the roughing pass and decreases continuously to reach 7.5 % at the last finishing pass. The flow curve of the alloy can be abstracted from the stress-strain curves representing simulated passes. It shows alloy hardening from a pass to the other up to pass no. 6, as a result of decreasing the deformation temperature and increasing of cumulative strain. After pass no. 6, the deformation process enhances the dynamic recrystallization phenomena to appear, where the z-parameter would be high.
Abstract: The results from experimental research of deformation
by upsetting and die forging of lead specimens wit controlled impact
are presented. Laboratory setup for conducting the investigations,
which uses cold rocket engine operated with compressed air, is
described. The results show that when using controlled impact is
achieving greater plastic deformation and consumes less impact
energy than at ordinary impact deformation process.
Abstract: Metal cutting is a severe plastic deformation process
involving large strains, high strain rates, and high temperatures.
Conventional analysis of the chip formation process is based on bulk
material deformation disregarding the inhomogeneous nature of the
material microstructure. A series of orthogonal cutting tests of AISI
1045 and 1144 steel were conducted which yielded similar process
characteristics and chip formations. With similar shear angles and cut
chip thicknesses, shear strains for both chips were found to range
from 2.0 up to 2.8. The manganese-sulfide (MnS) precipitate in the
1144 steel has a very distinct and uniform shape which allows for
comparison before and after chip formation. From close observations
of MnS precipitates in the cut chips it is shown that the conventional
approach underestimates plastic strains in metal cutting.
Experimental findings revealed local shear strains around a value of
6. These findings and their implications are presented and discussed.
Abstract: The analysis of Acoustic Emission (AE) signal
generated from metal cutting processes has often approached
statistically. This is due to the stochastic nature of the emission
signal as a result of factors effecting the signal from its generation
through transmission and sensing. Different techniques are applied in
this manner, each of which is suitable for certain processes. In metal
cutting where the emission generated by the deformation process is
rather continuous, an appropriate method for analysing the AE signal
based on the root mean square (RMS) of the signal is often used and
is suitable for use with the conventional signal processing systems.
The aim of this paper is to set a strategy in tool failure detection in
turning processes via the statistic analysis of the AE generated from
the cutting zone. The strategy is based on the investigation of the
distribution moments of the AE signal at predetermined sampling.
The skews and kurtosis of these distributions are the key elements in
the detection. A normal (Gaussian) distribution has first been
suggested then this was eliminated due to insufficiency. The so
called Beta distribution was then considered, this has been used with
an assumed β density function and has given promising results with
regard to chipping and tool breakage detection.