This study aims to investigate wire electrical discharge machining of copper alloys. Extensive research was done to design an optimum cutting method with adequate wire balance to achieve the ...requisite surface smoothness and geometrical dimensional correctness. Parameters were used in this work to simulate the process pulse-on time, pulse-off time, peak current, servo feed-rate, servo-volt, wire-feed rate, wire tension, and water pressure. For each given treatment requirement, the primary impacting elements are highlighted. The results are the best standard settings that have been designed to satisfy the client’s varied developing needs. A low pulse achieves superior surface polish on time and a high pulse off time. According to the (ANOVA) findings, the most significant cutting parameter is the pulse on-time (Ton), which affects surface roughness by (42.922)%, followed by pulse off time (Toff), which affects surface roughness by (24.860)%, and servo feed (SF), which affects surface roughness by (6.850)%. The impact of the process variables was wire tension on response characteristics, dimensional deviation, cutting rate, and surface roughness.
Sequel to the fact that hybrid nanofluidic systems (e.g. scalable micro-/nanofluidic device) exhibit greater thermal resistance with increasing nanoparticle concentration, little is known on the ...significance of thermal radiation, surface roughness and linear stability of water conveying alumina and copper oxide nanoparticles. This study presents the effects of thermal radiation and surface roughness on the complex dynamics of water conveying alumina and copper oxide nanoparticles, in the case where the thermophysical properties of the resulting mixture vary meaningfully with the volume fraction of solid nanomaterials, as well as with the Brownian motion and thermophoresis microscopic phenomena. Based on the linear stability theory and normal mode analysis method, the basic partial differential equations governing the transport phenomenon were non-dimensionalized to obtain the simplified stability equations. The optimum values of the critical thermal Rayleigh number depicting the onset of thermo-magneto-hydrodynamic instabilities were obtained using the power series method and the Chock–Schechter numerical integration. The increase in the strength of Lorentz forces, thermal radiation and surface roughness has a stronger stabilizing impact on the appearance of convection cells. On the contrary, the stability diminishes with the increasing values of the volumetric fraction and diameter of nanomaterials. The partial substitution of the alumina nanoparticles by the copper oxide nanomaterials in the mixture stabilizes importantly the hybrid nanofluidic medium.
Additive manufacturing (AM) is chosen for its ability to streamline production processes and design freedom. This reduces material waste, enables rapid prototyping, and facilitates intricate ...geometries, ultimately offering cost-effective and customizable solutions for manufacturing complex components in diverse industries. Overlapping melting trajectories result in a low-quality surface (Ra=∼13.34 µm) in the laser metal deposition (LMD) of the Ti64 alloy. Therefore, post-processing is often essential for AMed parts for engineering applications. Milling trials were conducted on AMed specimens under four environmental conditions: dry, flood, minimum quantity lubrication (MQL), and cryogenic medium. The machinability was evaluated in terms of the cutting temperature, machined surface roughness, tool wear, chip morphology, and microhardness. The flank wear under cryogenic CO2 condition is 52.78–54.29 % lower than dry condition, 33.86–36.24 % lower than flood cutting, and 23.64–26.86 % lower than MQL. The outcomes show that cryogenic cooling augments the tool life and the surface integrity of milling LMD parts. Moreover, the hardness under cryogenic CO2 was higher, indicating dimensional stability and maintenance of shape integrity under applied loads.
Selective Laser Melting (SLM) is an increasingly employed additive manufacturing process for the production of medical, aerospace, and automotive parts. Despite progresses in material flexibility and ...mechanical performances, relatively poor surface finish still presents a major limitation in the SLM process.
In this study an investigation of surface roughness and morphology is presented for Steel 316L alloy parts made by SLM. In order to characterise the actual surfaces at different sloping angles, truncheon samples have been produced and an analysis has been conducted at different scales, by surface profilometer and scanning electron microscope (SEM). The surface analysis has showed an increasing density of spare particles positioned along the step edges, as the surface sloping angle increases. When layer thickness is comparable to particle diameter, the particles stuck along step edges can fill the gaps between consecutive layers, thus affecting the actual surface roughness.
Classic models for roughness prediction, based on purely geometrical consideration of the stair step profile, fail to describe the observed trend of the experimental data. A new mathematical model is developed to include the presence of particles on top surfaces, in addition to the stair step effect, for the accurate prediction of surface roughness. Results show that surface roughness predicted by this model has a good agreement with the experimentally observed roughness. The paper investigates the key contributing factors influencing surface morphology, and a theoretical model for roughness prediction that provides valuable information to improve the surface quality of SLM parts, thus minimising the need of surface finishing.
A mechanistic understanding of adhesion in soft materials is critical in the fields of transportation (tires, gaskets, and seals), biomaterials, microcontact printing, and soft robotics. Measurements ...have long demonstrated that the apparent work of adhesion coming into contact is consistently lower than the intrinsic work of adhesion for the materials, and that there is adhesion hysteresis during separation, commonly explained by viscoelastic dissipation. Still lacking is a quantitative experimentally validated link between adhesion and measured topography. Here, we used in situ measurements of contact size to investigate the adhesion behavior of soft elastic polydimethylsiloxane hemispheres (modulus ranging from 0.7 to 10 MPa) on 4 different polycrystalline diamond substrates with topography characterized across 8 orders of magnitude, including down to the angstrom scale. The results show that the reduction in apparent work of adhesion is equal to the energy required to achieve conformal contact. Further, the energy loss during contact and removal is equal to the product of the intrinsic work of adhesion and the true contact area. These findings provide a simple mechanism to quantitatively link the widely observed adhesion hysteresis to roughness rather than viscoelastic dissipation.
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