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Fracture phenomena in plastics cutting - chip types, deformation of material, magnitude, and direction of cutting forces during cutting, and rheological effects on cutting mechanism
13 Manufacturing & Prototyping A method is based on two unique processing steps that are both based on deterministic machining processes using a single-point diamond turning (SPDT) machine. In the first step, a high-MRR (material removal rate) process is used to machine the part within several microns of the final geometry. In the second step, a low-MRR process is used to machine the part to near optical quality using a novel ductile regime machining (DRM) process. DRM is a deterministic machining process associated with conditions under high hydrostatic pressures and very small depths of cut. Under such conditions, using high negative-rake angle cutting tools, the high-pressure region near the tool corresponds to a plastic zone, where even a brittle material will behave in a ductile manner. In the high-MRR processing step, the objective is to remove material with a sufficiently high rate such that the process is economical, without inducing large-scale subsurface damage. A laser-assisted machining approach was evaluated whereby a CO2 laser was focused in advance of the cutting tool. While CVD (chemical vapor deposition) SiC was successfully machined with this approach, the cutting forces were substantially higher than cuts at room temperature under the same machining conditions. During the experiments, the expansion of the part and the tool due to the heating was carefully accounted for. The higher cutting forces are most likely due to a small reduction in the shear strength of the material compared with a larger increase in friction forces due to the thermal softening effect. The key advantage is that the hybrid machine approach has the potential to achieve optical quality without the need for a separate optical finishing step. Also, this method is scalable, so one can easily progress from machining 50-mm-diameter samples to the 250-mm-diameter mirror that NASA desires.
Instrumented pick installed on cutting drum of coal shearer for longwall mining measures cutting force with strain-gage-bridge load cell. Force signal transmitted to remote recorder. Transmitter located in base of pick assembly. Antenna located in shadow of rotating pick. Changes in characteristics of force signals from pick used to determine whether pick is cutting coal or rock.
A tool makes a cut perpendicular to the cylindrical axis of a core hole at a predetermined depth to free the core at that depth. The tool does not damage the surrounding material from which the core was cut, and it operates within the core-hole kerf. Coring usually begins with use of a hole saw or a hollow cylindrical abrasive cutting tool to make an annular hole that leaves the core (sometimes called the plug ) in place. In this approach to coring as practiced heretofore, the core is removed forcibly in a manner chosen to shear the core, preferably at or near the greatest depth of the core hole. Unfortunately, such forcible removal often damages both the core and the surrounding material (see Figure 1). In an alternative prior approach, especially applicable to toxic or fragile material, a core is formed and freed by means of milling operations that generate much material waste. In contrast, the present tool eliminates the damage associated with the hole-saw approach and reduces the extent of milling operations (and, hence, reduces the waste) associated with the milling approach. The present tool (see Figure 2) includes an inner sleeve and an outer sleeve and resembles the hollow cylindrical tool used to cut the core hole. The sleeves are thin enough that this tool fits within the kerf of the core hole. The inner sleeve is attached to a shaft that, in turn, can be attached to a drill motor or handle for turning the tool. This tool also includes a cutting wire attached to the distal ends of both sleeves. The cutting wire is long enough that with sufficient relative rotation of the inner and outer sleeves, the wire can cut all the way to the center of the core. The tool is inserted in the kerf until its distal end is seated at the full depth. The inner sleeve is then turned. During turning, frictional drag on the outer core pulls the cutting wire into contact with the core. The cutting force of the wire against the core increases with the tension in the wire and, hence, with the frictional drag acting on the outer sleeve. As the wire cuts toward the center of the core, the inner sleeve rotates farther with respect to the outer sleeve. Once the wire has cut to the center of the core, the tool and the core can be removed from the hole. The proper choice of cutting wire depends on the properties of the core material. For a sufficiently soft core material, a nonmetallic monofilament can be used. For a rubber-like core material, a metal wire can be used. For a harder core material, it is necessary to use an abrasive wire, and the efficiency of the tool can be increased greatly by vacuuming away the particles generated during cutting. For a core material that can readily be melted or otherwise cut by use of heat, it could be preferable to use an electrically heated cutting wire. In such a case, electric current can be supplied to the cutting wire, from an electrically isolated source, via rotating contact rings mounted on the sleeves.
Tests on mineral oil slurries show that the potential for workability and low cost is present. However, slurries tested to date which had sufficient lubricity exhibited wafer breakage problems near the end of the run for as-yet unknown reasons. The first test of the large prototype saw under cutting force control was largely successful in that the controller worked perfectly. Unfortunately a technique error (excessive stroke shortening) caused blade breakage and low yield. The latest run of the large saw pointed up the fact that an indication of end-of-stoke vertical motion, or bounce, is necessary. A circuit to provide such indication was fabricated and installed. Preliminary tests show it to be excessively noise sensitive; therefore, work on grounding and shielding to reduce this sensitivity is in progress.
The feasibility of utilizing a sensitized pick to discriminate between cutting coal and roof material during the longwall mining process was investigated. A conventional longwall mining pick was instrumented and cutting force magnitudes were determined for a variety of materials, including Illinois #6 coal, shale type materials, and synthetic coal/shale materials.
Some recently achieved results concerning the technological fundamentals of slurry sawing are presented. The specific material removal process and the related kinematic and geometric contact conditions between workpiece and saw blade are described. The result of a functional description of the slurry sawing process is presented, expressing the main process criteria, such as infeed per stroke, specific removal rate, specific tool wear, and vertical stroke intensity, in terms of the dominating process parameters, such as stroke length, width of workpiece, stroke frequency, specific cutting force and slurry specification.
This paper presents a model for a radiation-driven stellar wind in which the driving force is abruptly cut off at an adjustable distance from the star. The model is intended to give a first approximation of the effects of ionizing shocks in a stellar wind on the terminal velocity and mass-loss rate. As expected, the wind velocity is found to decrease after the line force is cut off. The terminal velocity depends directly on the velocity of the wind at the point where the driving force is cut off. The mass-loss rate is found to be unaffected as long as the cutoff is outside the critical point of the flow. The model is applied to the star Tau Sco, a strong X-ray source with an anomalously low terminal velocity. It is shown that this low terminal velocity can be caused by a cutoff of the line force at a distance which is consistent with the idea that the observed X-rate emission is produced by shocks in the wind.
Tool centers itself and cuts precise depth. Tool consists of crosscut carbide bur; sleeve that serves as depth stop and pilot; length of flexible, strong piano wire; and standard drive socket. Parts brazed together. Piano wire transmits torque and axial force to cutting tool.
Published report discusses development of two-component force dynamometer which is used for dynamic measurement of machining forces in cutting and thrust directions. Resulting data suggest that faster metal-cutting machines may be developed that have reduced vibrations.
Testing of low cost low suspension power slurry vehicles is presented. Cutting oils are unlikely to work, but a mineral oil with additives should be workable. Two different abrasives were tested. A cheaper silicon carbide from Norton gave excellent results except for excessive kerf loss: the particles were too big. An abrasive treated for lubricity showed no lubricity improvement in mineral oil vehicle. The bounce fixture was tested for the first time under constant cut rate conditions (rather than constant force). Although the cut was not completed before the blades broke, the blade lifetime of thin (100 micrometer) blades was 120 times the lifetime without the fixture. The large prototype saw completed a successful run, producing 90% cutting yield (849 wafers) at 20 wafers/cm. Although inexperience with large numbers of wafers caused cleaning breakage to reduce this yield to 74%, the yield was high enough that the concept of the large saw is proven workable.
The current climate of budget cuts has forced the space mission operations community to reconsider how it does business. Gone are the days of building one-of-kind control centers with teams of controllers working in shifts 24 hours per day, 7 days per week. Increasingly, automation is used to significantly reduce staffing needs. In some cases, missions are moving towards lights-out operations where the ground system is run semi-autonomously. On-call operators are brought in only to resolve anomalies. Some operations concepts also call for smaller operations teams to manage an entire family of spacecraft. In the not too distant future, a skeleton crew of full-time general knowledge operators will oversee the operations of large constellations of small spacecraft, while geographically distributed specialists will be assigned to emergency response teams based on their expertise. As the operations paradigms change, so too must the tools to support the mission operations team's tasks. Tools need to be built not only to automate routine tasks, but also to communicate varying types of information to the part-time, generalist, or on-call operators and specialists more effectively. Thus, the proper design of a system's user-system interface (USI) becomes even more importance than before. Also, because the users will be accessing these systems from various locations (e.g., control center, home, on the road) via different devices with varying display capabilities (e.g., workstations, home PCs, PDAS, pagers) over connections with various bandwidths (e.g., dial-up 56k, wireless 9.6k), the same software must have different USIs to support the different types of users, their equipment, and their environments. In other words, the software must now adapt to the needs of the users! This paper will focus on the needs and the challenges of designing USIs for mission operations. After providing a general discussion of these challenges, the paper will focus on the current efforts of creatin(y an effective USI for one specific suite of tools, SERS (The Spacecraft Emergency Response System), which has been built to enable lights-out operations. SERS is a Web-based collaborative environment that enables secure distributed fault management.
The Asian financial crisis in the late 20 th century has some long lasting effect on the air transportation industry in Asia, especially in the Great China Area. Starting from 1998, airlines in both China and Taiwan suffered some serious financial losses due to the diminishing travel demand caused by the economic recession. Airlines were forced to cut price to attract passengers and hence crashed the market discipline. A number of airline mergers and acquisitions were then driven by the markets and the governments. After China and Taiwan have both entered the World Trade Organization, some mega-merging cases were finalized in late 2002 for better fitting the world's aviation competitions. This paper reviews the nine merging and acquiring cases in the Great China Area in the past 5 years. Almost all the airlines in the area were involved. The new groups of airlines and the survival airlines are introduced. Market response to the airline mergers will also be examined. A general look over the performance of the new airlines will be discussed. And the future of the market will also be analyzed. Finally, the practices and the impacts of current inter-state mergers in the Great China Area will be examined. The study has expected a highly concentrated domestic market in both China and Taiwan. Each of the market will be dominated by three major airline groups of their own. Cross-holding equity within these 6 leading aviation groups would also be possible after further deregulations.
In proposed coal-cutting machine, piston forces water through nozzle, expelling pulsed jet that cuts into coal face. Spring-loaded piston reciprocates at end of travel to refill water chamber. Machine a onecylinder, two-cycle, internal-combustion engine, fueled by gasoline, diesel fuel, or hydrogen. Fuel converted more directly into mechanical energy of water jet.
An instrument for biochemical studies, called the rotating spectrometer, separates previously inseparable cell cultures. The rotating spectrometer is intended for use in pharmacological studies which require fractional splitting of heterogeneous cell cultures based on cell morphology and swimming behavior. As a method to separate and concentrate cells in free solution, the rotating method requires active organism participation and can effectively split the large class of organisms known to form spontaneous patterns. Examples include the biochemical star, an organism called Tetrahymena pyriformis. Following focusing in a rotated frame, the separation is accomplished using different radial dependencies of concentrated algal and protozoan species. The focusing itself appears as concentric rings and arises from the coupling between swimming direction and Coriolis forces. A dense cut is taken at varying radii and extraction is replenished at an inlet. Unlike standard separation and concentrating techniques such as filtration or centrifugation, the instrument is able to separate motile from immotile fractions. For a single pass, typical split efficiencies can reach 200 to 300 percent compared to the inlet concentration.
An instrument for biochemical studies, called the rotating spectrometer, separates previously inseparable cell cultures. The rotating spectrometer is intended for use in pharmacological studies which require fractional splitting of heterogeneous cell cultures based on cell morphology and swimming behavior. As a method to separate and concentrate cells in free solution, the rotating method requires active organism participation and can effectively split the large class of organisms known to form spontaneous patterns. Examples include the biochemical star, an organism called Tetrahymena pyriformis. Following focusing in a rotating frame, the separation is accomplished using different radial dependencies of concentrated algal and protozoan species. The focusing itself appears as concentric rings and arises from the coupling between swimming direction and Coriolis forces. A dense cut is taken at varying radii, and extraction is replenished at an inlet. Unlike standard separation and concentrating techniques such as filtration or centrifugation, the instrument is able to separate motile from immotile fractions. For a single pass, typical split efficiencies can reach 200 to 300 percent compared to the inlet concentration.
A hand held hydraulic cutting tool was developed which is particularly useful in deactivating ejection seats in military aircraft rescue operations. The tool consists primarily of a hydraulic system composed of a fluid reservoir, a pumping piston, and an actuator piston. Mechanical cutting jaws are attached to the actuator piston rod. The hydraulic system is controlled by a pump handle. As the pump handle is operated the actuator piston rod is forced outward and thus the cutting jaws are forced together. The frame of the device is a flexible metal tubing which permits easy positioning of the tool cutting jaws in remote and normally inaccessible locations. Bifurcated cutting edges ensure removal of a section of the tubing or cable to thereby reduce the possibility of accidental reactivation of the tubing or cable being severed.
This innovation comprises a compact drill that uses low-axial preload, via vibrations, that fractures the rock under the bit kerf, and rotates the bit to remove the powdered cuttings while augmenting the rock fracture via shear forces. The vibrations fluidize the powered cuttings inside the flutes around the bit, reducing the friction with the auger surface. These combined actions reduce the consumed power and the heating of the drilled medium, helping to preserve the pristine content of the produced samples. The drill consists of an actuator that simultaneously impacts and rotates the bit by applying force and torque via a single piezoelectric stack actuator without the need for a gearbox or lever mechanism. This reduces the development/fabrication cost and complexity. The piezoelectric actuator impacts the surface and generates shear forces, fragmenting the drilled medium directly under the bit kerf by exceeding the tensile and/or shear strength of the struck surface. The percussive impact action of the actuator leads to penetration of the medium by producing a zone of finely crushed rock directly underneath the struck location. This fracturing process is highly enhanced by the shear forces from the rotation and twisting action. To remove the formed cuttings, the bit is constructed with an auger on its internal or external surface. One of the problems with pure hammering is that, as the teeth become embedded in the sample, the drilling efficiency drops unless the teeth are moved away from the specific footprint location. By rotating the teeth, they are moved to areas that were not fragmented, and thus the rock fracturing is enhanced via shear forces. The shear motion creates ripping or chiseling action to produce larger fragments to increase the drilling efficiency, and to reduce the required power. The actuator of the drill consists of a piezoelectric stack that vibrates the horn. The stack is compressed by a bolt between the backing and the horn in order to prevent it from being subjected to tensile stress that will cause it to fail. The backing is intended to transfer the generated mechanical vibrations towards the horn. In order to cause rotation, the horn is configured asymmetrically with helical segments and, upon impacting the bit, it introduces longitudinal along the axis of the actuator and tangential force causing twisting action that rotates the bit. The longitudinal component of the vibrations of the stack introduces percussion impulses between the bit and the rock to fracture it when the ultimate strain is exceeded under the bit.