Abstract: In this report we have discussed the theoretical aspects
of the flow transformation, occurring through a series of bifurcations.
The parameters and their continuous diversion, the intermittent bursts
in the transition zone, variation of velocity and pressure with time,
effect of roughness in turbulent zone, and changes in friction factor
and head loss coefficient as a function of Reynolds number for a
transverse flow across a cylinder have been discussed. An analysis of
the variation in the wake length with Reynolds number was done in
FORTRAN.
Abstract: Vancron 40, a nitrided powder metallurgical tool
Steel, is used in cold work applications where the predominant failure
mechanisms are adhesive wear or galling. Typical applications of
Vancron 40 are among others fine blanking, cold extrusion, deep
drawing and cold work rolls for cluster mills. Vancron 40 positive
results for cold work rolls for cluster mills and as a tool for some
severe metal forming process makes it competitive compared to other
type of work rolls that require higher precision, among others in cold
rolling of thin stainless steel, which required high surface finish
quality. In this project, three roll materials for cold rolling of stainless
steel strip was examined, Vancron 40, Narva 12B (a high-carbon,
high-chromium tool steel alloyed with tungsten) and Supra 3 (a
Chromium-molybdenum tungsten-vanadium alloyed high speed
steel). The purpose of this project was to study the depth profiles of
the ironed stainless steel strips, emergence of galling and to study the
lubrication performance used by steel industries. Laboratory
experiments were conducted to examine scratch of the strip, galling
and surface roughness of the roll materials under severe tribological
conditions. The critical sliding length for onset of galling was
estimated for stainless steel with four different lubricants. Laboratory
experiments result of performance evaluation of resistance capability
of rolls toward adhesive wear under severe conditions for low and
high reductions. Vancron 40 in combination with cold rolling
lubricant gave good surface quality, prevents galling of
metal surfaces and good bearing capacity.
Abstract: Compositions of different molar ratios of
polymethylmethacrylate-co-methacrylic acid (PMMA-co-MAA)
were synthesized via free-radical polymerization. Polymer coated
surfaces have been produced on silicon wafers. Coated samples were
analyzed by atomic force microscopy (AFM). The results have shown
that the roughness of the surfaces have increased by increasing the
molar ratio of monomer methacrylic acid (MAA). This study reveals
that the gradual increase in surface roughness is due to the fact that
carboxylic functional groups have been generated by MAA segments.
Such surfaces can be desirable platforms for fabrication of the
biosensors for detection of the viruses and diseases.
Abstract: Burnishing is increasingly used as a finishing operation to improve surface roughness and surface hardness. This can be achieved by applying a hard ball or roller onto metallic surfaces under pressure, in order to achieve many advantages in the metallic surface. In the present work, the feed rate, speed and force have been considered as the basic burnishing parameters to study the surface roughness and surface hardness of metallic matrix composites. The considered metal matrix composites were made from Aluminum-Magnesium-Graphite with five different weight percentage of graphite. Both effects of burnishing parameters mentioned above and the graphite percentage on the surface hardness and surface roughness of the metallic matrix composites were studied. The results of this investigation showed that the surface hardness of the metallic composites increases with the increase of the burnishing force and decreases with the increase in the burnishing feed rate and burnishing speed. The surface roughness of the metallic composites decreases with the increasing of the burnishing force, feed rate, and speed to certain values, then it starts to increase. On the other hand, the increase in the weight percentage of the graphite in the considered composites causes a decrease in the surface hardness and an increase in the surface roughness.
Abstract: In this research, waterglass based aerogel powder was
prepared by sol–gel process and ambient pressure drying. Inspired by
limited dust releasing, aerogel powder was introduced to the PET
electrospinning solution in an attempt to create required bulk and
surface structure for the nanofibers to improve their hydrophobic and
insulation properties. The samples evaluation was carried out by
measuring density, porosity, contact angle, heat transfer, FTIR, BET,
and SEM. According to the results, porous silica aerogel powder was
fabricated with mean pore diameter of 24 nm and contact angle of
145.9º. The results indicated the usefulness of the aerogel powder
confined into nanofibers to control surface roughness for
manipulating superhydrophobic nanowebs with water contact angle
of 147º. It can be due to a multi-scale surface roughness which was
created by nanowebs structure itself and nanofibers surface
irregularity in presence of the aerogels while a layer of fluorocarbon
created low surface energy. The wettability of a solid substrate is an
important property that is controlled by both the chemical
composition and geometry of the surface. Also, a decreasing trend in
the heat transfer was observed from 22% for the nanofibers without
any aerogel powder to 8% for the nanofibers with 4% aerogel
powder. The development of thermal insulating materials has become
increasingly more important than ever in view of the fossil energy
depletion and global warming that call for more demanding energysaving
practices.
Abstract: Machining parameters are very important in
determining the surface quality of any material. In the past decade,
some new engineering materials were developed for the
manufacturing industry which created a need to conduct an
investigation on the impact of the said parameters on their surface
roughness. Polyurethane (PU) block is widely used in the automotive
industry to manufacture parts such as checking fixtures that are used
to verify the dimensional accuracy of automotive parts. In this paper,
the design of experiment (DOE) was used to investigate on the effect
of the milling parameters on the PU block. Furthermore, an analysis
of the machined surface chemical composition was done using
scanning electron microscope (SEM). It was found that the surface
roughness of the PU block is severely affected when PU undergoes a
flood machining process instead of a dry condition. In addition the
stepover and the silicon content were found to be the most significant
parameters that influence the surface quality of the PU block.
Abstract: Solar air heater is a type of heat exchanger which
transforms solar radiation into heat energy. The thermal performance
of conventional solar air heater has been found to be poor because of
the low convective heat transfer coefficient from the absorber plate to
the air. It is attributed to the formation of a very thin boundary layer
at the absorber plate surface commonly known as viscous sub-layer.
Thermal efficiency of solar air heater can be improved by providing
the artificial roughness on absorber plate is the most efficient
technique. In this paper an attempt is made to provide artificial
roughness by incorporating inclined multiple V-ribs in the underside
of the absorber plate. 60˚V – ribs are arranged inclined to the
direction of air flow. Performance of collector estimated theoretically
and experimentally. Results of the investigation reveal that thermal
efficiency of collector with multiple V-ribs increased by 14%.
Abstract: This study presents a cost-effective approach for rapid
fabricating modeling platforms utilized in fused deposition modeling
system. A small-batch production of modeling platforms about 20
pieces can be obtained economically through silicone rubber mold
using vacuum casting without applying the plastic injection molding.
The air venting systems is crucial for fabricating modeling platform
using vacuum casting. Modeling platforms fabricated can be used for
building rapid prototyping model after sandblasting. This study offers
industrial value because it has both time-effectiveness and
cost-effectiveness.
Abstract: Pavement surface unevenness plays a pivotal role on
roughness index of road which affects on riding comfort ability.
Comfort ability refers to the degree of protection offered to vehicle
occupants from uneven elements in the road surface. So, it is
preferable to have a lower roughness index value for a better riding
quality of road users. Roughness is generally defined as an
expression of irregularities in the pavement surface which can be
measured using different equipments like MERLIN, Bump integrator,
Profilometer etc. Among them Bump Integrator is quite simple and
less time consuming in case of long road sections. A case study is
conducted on low volume roads in West District in Tripura to
determine roughness index (RI) using Bump Integrator at the
standard speed of 32 km/h. But it becomes too tough to maintain the
requisite standard speed throughout the road section. The speed of
Bump Integrator (BI) has to lower or higher in some distinctive
situations. So, it becomes necessary to convert these roughness index
values of other speeds to the standard speed of 32 km/h. This paper
highlights on that roughness index conversional model. Using SPSS
(Statistical Package of Social Sciences) software a generalized
equation is derived among the RI value at standard speed of 32 km/h
and RI value at other speed conditions.
Abstract: This paper presents the findings of an experimental investigation of important machining parameters for the horizontal boring tool modified to mouth with a horizontal lathe machine to bore an overlength workpiece. In order to verify a usability of a modified tool, design of experiment based on Taguchi method is performed. The parameters investigated are spindle speed, feed rate, depth of cut and length of workpiece. Taguchi L9 orthogonal array is selected for four factors three level parameters in order to minimize surface roughness (Ra and Rz) of S45C steel tubes. Signal to noise ratio analysis and analysis of variance (ANOVA) is performed to study an effect of said parameters and to optimize the machine setting for best surface finish. The controlled factors with most effect are depth of cut, spindle speed, length of workpiece, and feed rate in order. The confirmation test is performed to test the optimal setting obtained from Taguchi method and the result is satisfactory.
Abstract: In this study, Electrical Discharge Machining (EDM) is used to modify the surface of high carbon steel En31 with the help of tool electrode (Copper-Chromium-Nickel) manufactured by powder metallurgy (PM) process. The effect of EDM on surface roughness during surface alloying is studied. Taguchi’s Design of experiment (DOE) and L18 orthogonal array is used to find the best level of input parameters in order to achieve high surface finish. Six input parameters are considered and their percentage contribution towards surface roughness is investigated by analysis of variances (ANOVA). Experimental results show that an hard alloyed surface (1.21% carbon, 2.14% chromium and 1.38% nickel) with surface roughness of 3.19µm can be generated using EDM with PM tool. Additionally, techniques like Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS) are used to analyze the machined surface and EDMed layer composition, respectively. The increase in machined surface micro-hardness (101%) may be related to the formation of carbides containing chromium.
Abstract: Blood gamma irradiation is the only available method
to prevent transfusion associated graft versus host disease (TAGVHD).
However, when blood is irradiated, determine blood shelf
time is crucial. Non irradiated blood have a self-time from 21 to 35
days when is preserved with anticoagulated solution and stored at
4°C. During their storage, red blood cells (RBC) undergo a series of
biochemical, biomechanical and molecular changes involving what is
known as storage lesion (SL). SL include loss of structural integrity
of RBC, decrease of 2,3-diphosphatidylglyceric acid levels, and
increase of both ion potassium concentration and hemoglobin (Hb).
On the other hand, Atomic force Microscopy (AFM) represents a
versatile tool for a nano-scale high resolution topographic analysis in
biological systems. In order to evaluate SL in irradiated and nonirradiated
blood, RBC topography and morphometric parameters
were obtained from an AFM XE-BIO system. Cell viability was
followed using flow cytometry. Our results showed that early
markers as nanoscale roughness, allow us to evaluate blood quality
since other perspective.
Abstract: Ultrasonic shot peening (USP) on AALY12 sheet was studied. Several parameters (arc heights, surface roughness, surface topography and micro hardness) with different USP process parameters were measured. The research proposes that radius of curvature of shot peened sheet increases with time and electric current decreasing, while increases with pin diameter increasing, and radius of curvature reaches a saturation level after a specific processing time and electric current. An empirical model of the relationship between radius of curvature and pin diameter, electric current, time was also obtained. The research shows that the increment of surface and vertical micro hardness of material is more obvious with longer time and higher value of electric current, which can be up to 20% and 28% respectively.
Abstract: This research studies the electroplating of zinc coating
in the zinc chloride bath mixed with supercritical CO2. The sodium
fluoride (NaF) was used as the bath additive to change the structure
and property of the coating, and therefore the roughness and corrosion
resistance of the zinc coating was investigated. The surface
characterization was performed using optical microscope (OM), X-ray
diffractometer (XRD), and α-step profilometer. Moreover, the
potentiodynamic polarization measurement in 3% NaCl solution was
employed in the corrosion resistance evaluation. Because of the
emulsification of the electrolyte mixed in Sc-CO2, the electroplated
zinc produced the coating with smoother surface, smaller grain, better
throwing power and higher corrosion resistance. The main role played
by the NaF was to reduce the coating’s roughness and grain size. In
other words, the CO2 mixed with the electrolyte under the supercritical
condition performed the similar function as brighter and leveler in zinc
electroplating to enhance the throwing power and corrosion resistance
of the coating.
Abstract: The influence of transverse surface roughness on EHL characteristics has been investigated numerically using an extensive set of full EHL line contact simulations for shear-thinning lubricants under pure sliding condition. The shear-thinning behavior of lubricant is modeled using Carreau viscosity equation along with Doolittle-Tait equation for lubricant compressibility. The surface roughness is assumed to be sinusoidal and it is present on the stationary surface. It is found that surface roughness causes sharp pressure peaks along with reduction in central and minimum film thickness. With increasing amplitude of surface roughness, the minimum film thickness decreases much more rapidly as compared to the central film thickness.
Abstract: In addition to the increase of the material removal rate or surface rate, or the improvement of the surface quality, which are the main aims of the development of manufacturing technology, a growing number of other manufacturing requirements have appeared in the machining of workpiece surfaces. Among these it is becoming increasingly dominant to generate a surface topography in finishing operations which meets more closely the needs of operational requirements.
These include the examination of the surface periodicity and/or ensuring that the twist-structure values are within the limits (or even preventing its occurrence) in specified cases such as on the sealing surfaces of rotating shafts or on the inside working surfaces of needle roller bearings. In the view of the measurement the twist has different parameters from surface roughness, which must be determined for the machining procedures. Therefore in this paper the alteration of the theoretical values of the parameters determining twist structure are studied as a function of the kinematic properties.
Abstract: Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.
Abstract: Nowadays, with the increasing of the wafer's size and
the decreasing of critical size of integrated circuit manufacturing in
modern high-tech, microelectronics industry needs a maximum
attention to challenge the contamination control. The move to 300
[mm] is accompanied by the use of Front Opening Unified Pods for
wafer and his storage. In these pods an airborne cross contamination
may occur between wafers and the pods. A predictive approach using
modeling and computational methods is very powerful method to
understand and qualify the AMCs cross contamination processes.
This work investigates the required numerical tools which are
employed in order to study the AMCs cross-contamination transfer
phenomena between wafers and FOUPs. Numerical optimization and
finite element formulation in transient analysis were established.
Analytical solution of one dimensional problem was developed and
the calibration process of physical constants was performed. The least
square distance between the model (analytical 1D solution) and the
experimental data are minimized. The behavior of the AMCs
intransient analysis was determined. The model framework preserves
the classical forms of the diffusion and convection-diffusion
equations and yields to consistent form of the Fick's law. The
adsorption process and the surface roughness effect were also
traduced as a boundary condition using the switch condition Dirichlet
to Neumann and the interface condition. The methodology is applied,
first using the optimization methods with analytical solution to define
physical constants, and second using finite element method including
adsorption kinetic and the switch of Dirichlet to Neumann condition.
Abstract: The quality of machined surfaces is an important characteristic of cutting processes and surface roughness has strong effects on the performance of sliding, moving components. The ability to forecast these values for a given process has been of great interests among researchers for a long time. Different modeling procedures and algorithms have been worked-out, and each has its own advantages and drawbacks. A new method will be introduced in this paper which will make it possible to calculate both the profile (2D) and surface (3D) parameters of theoretical roughness in the face milling of plain surfaces. This new method is based on an expediently developed CAD model, and uses a professional program for the roughness evaluation. Cutting experiments were performed on 42CrMo4 specimens in order to validate the accuracy of the model. The results have revealed that the method is able to predict surface roughness with good accuracy.
Abstract: This investigation proposes a grey-based Taguchi method to solve the multi-response problems. The grey-based Taguchi method is based on the Taguchi’s design of experimental method, and adopts grey relational analysis (GRA) to transfer multi-response problems into single-response problems. In this investigation, an attempt has been made to optimize the drilling process parameters considering weighted output response characteristics using grey relational analysis. The output response characteristics considered are surface roughness, burr height and hole diameter error under the experimental conditions of cutting speed, feed rate, step angle, and cutting environment. The drilling experiments were conducted using L27 orthogonal array. A combination of orthogonal array, design of experiments and grey relational analysis was used to ascertain best possible drilling process parameters that give minimum surface roughness, burr height and hole diameter error. The results reveal that combination of Taguchi design of experiment and grey relational analysis improves surface quality of drilled hole.