The objective of the present work is to carry out analytical and finite element analysis for commonly used coating materials for micro-milling applications on high-speed steel substrate and evaluate the effects of different parameters. Four different coating materials were selected for micro-milling applications: titanium nitride (TiN), diamond-like carbon (DLC), aluminium titanium nitride (AlTiN) and titanium silicon nitride (TiSiN). A 3D finite element model of coating and substrate assembly was developed in Abaqus to find the Hertzian normal stress when subjected to normal load of 4 N, applied with the help of a rigid ball. The radius of the rigid ball was 200 µm. For all the coating materials, the length was 3 mm, the width was 1 mm, and the thickness was 3 µm. For the high-speed steel substrate, the length was 3 mm, the width was 1 mm, and the thickness was 50 µm. Along the length and width, coating and substrate both were divided into 26 equal parts. The deformation behaviour of all the coating materials was considered as linear–elastic and that of the substrate was characterized as elastic–plastic. The maximum normal stress developed in the FEA model was 12,109 MPa. The variation of the FEA result from the analytical result (i.e., 12,435.97 MPa is 2.63%) which is acceptable. This confirms that the FEA model of coating–substrate assembly is acceptable. The results shows that the TiSiN coating shows least plastic equivalent strain in the substrate, which serves the purpose of protecting the substrate from plastic deformation and the TiSiN of 3 micron thickness is the most optimum coating thickness for micro-milling applications.
The main objective of this article is to perform the turning operation on an EN36B steel work-billet with a tungsten carbide tool, to study the optimal cutting parameters and carry out an analysis of flank-wear. Experimental and simulation-based research methodology was opted in this study. Experimental results were obtained from the lab setup, and optimisation of parameters was performed using RSM (response surface methodology). Using RSM, cutting-tool flank-wear was optimised, and the cutting parameters which affect the flank wear were determined. In results main effect plot, contour plot, the surface plot for flank-wear and forces (Fx, Fy and Fz) were successfully obtained. It was concluded that tool flank-wear is affected by depth of cut, and that flank-wear generally increases linearly with increasing cutting-speed, depth of cut and feed-rate. To validate the obtained results, predicated and measured values were plotted and were in very close agreement, having an accuracy level of 96.33% to 98.92%.
The synthetic fibres are having high stiffness and strength still high manufacturing cost with environmental issues limited the use of synthetic fibres. This encourages towards thinking of intense research of natural fibres having similar property as synthetic fibres. To obtain the better mechanical and thermal property, hybridization of fibres is mostly preferred and that leads to minimize the use of synthetic fibres. As natural fibres are strong and having more ductile property, though moisture absorption is the primary limitation. So fibres is subjected to various treatments such as physical, thermal, chemical and laser treatments etc., to improve the surface characteristics with better interfacial bonding. Nano particle addition also helps in improving the performance of composites and develops cross linking in bonding of matrix and fibre. This research work mostly focuses on hybridization of short mercerized sisal and glass fibre filled with nano silica and marble dust particles, by injection moulding process with polypropylene matrix. It is noticed that among the addition of different fillers, marble dust added composite gave the better result than SiO2 added composite. Incorporation of SiO2 particles as filler material improves the flexural strength and thermal property of the composite.
The main objective of this study is to perform an abrasive wear resistance study of UMHWPE and XLPE by using different grades of abrasive paper (grade 100 (190 µm), grade 220 (50 µm), and grade 400 (40 µm)) with minor (10 N) and major (15 N) loading conditions. In this article, wear performance of the UMHWPE and XLPE materials compared to the bio-tribological data as reported earlier in the clinical studies has been investigated. The experimental result shows that the loss of materials for the XLPE was much higher than the UHMWPE under similar loading conditions. UHMWPE shows a 34% reduction in wear at minor loading conditions and a 53% reduction in wear at major loading conditions. From experimental results it was concluded that Cross-link PE has better wear resistance than UHMWPE in minor wear conditions, whereas UHMWPE shows better wear resistance under major loading conditions. Based upon these results, UHMWPE and XLPE have been recommended for use as bearing materials in orthopedics. The experimental results of this study were validated using results from the available literature.
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