Influence Of Al203 Particle Mixed Dielectric Fluid on Machining Performance of Ti6Al4V

In this research work, an attempt was made to machine Ti6Al4V titanium alloy utilizing AA6061/10Gr composite tool. The composite tool was fabricated using stir casting technique and Al2O3 particles of size 5µm were incorporated in the dielectric fluid to enhance the machining performance. Experiments were conducted by varying Al203 concentration, pulse on time, current, and pulse off time, and the responses Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (Ra) were recorded. Experiments runs were planned using Taguchi orthogonal array. The results revealed that adding powder increases MRR and TWR owing to the excessive heat generation and bridging effect respectively. The best surface finish was attained due to the increase in spark gap and complete flushing of machined debris. Coating of materials over the machined specimen was observed when the parametric value of Ton was higher than 60s under PMEDM conditions. Pits, craters and cracks were observed on the machined topography which was eliminated when 5g/l of Al2O3 particles were added to dielectric fluid. MEIOT technique was utilized for optimization and it was observed that Ton 15µs, Toff 4µs and current 7A and powder concentration of 10g/l results in best machining performance.

A DIY Fabrication Approach for Ultra-Thin Focus-Tunable Liquid Lens Using Electrohydrodynamic Pump

Demand for variable focus lens is increasing these days due to the rapid development of smart mobile devices and drones. However, conventional mechanical systems for lenses are generally complex, cumbersome, and rigid (e.g., for motors and gears). This research proposes a simple and compact liquid lens controlled by an electro hydro dynamics (EHD) pump. In our study, we propose a do-it-yourself (DIY) method to fabricate the low-cost EHD lens. The EHD lens consists of a polypropylene (PP) sheet for the exterior, a copper sheet for the electrodes, and an acrylic elastomer for the fluidic channel where dielectric fluid and pure water are filled. We controlled the lens magnification by changing the curvature of the liquid interface between the dielectric fluid and pure water. We evaluated the magnification performance of the lens. Moreover, we also established a numerical model to characterize the lens performance. We expect to contribute to the miniaturization of focus-tunable lenses.

Hydrophilic and Hydrophobic Nanostructured Copper Surfaces for Efficient Pool Boiling Heat Transfer with Water, Water/Butanol Mixtures and Novec 649

Increasing heat dissipation requirements of small and miniature devices demands advanced cooling methods, such as application of immersion cooling via boiling heat transfer. In this study, functionalized copper surfaces for enhanced heat transfer are developed and evaluated. Samples are functionalized using a chemical oxidation treatment with subsequent hydrophobization of selected surfaces with a fluorinated silane. Pool boiling tests with water, water/1-butanol mixture with self-rewetting properties and a novel dielectric fluid with low GWP (Novec™ 649) are conducted to evaluate the boiling performance of individual surfaces. The results show that hydrophobized functionalized surfaces covered by microcavities with diameters between 40 nm and 2 µm exhibit increased heat transfer coefficient (HTC; enhancements up to 120%) and critical heat flux (CHF; enhancements up to 64%) values in comparison with the untreated reference surface, complemented by favorable fabrication repeatability. Positive surface stability is observed in contact with water, while both the self-rewetting fluids and Novec™ 649 gradually degrade the boiling performance and in some cases also the surface itself. The use of water/1-butanol mixtures in particular results in surface chemistry and morphology changes, as observed using SEM imaging and Raman spectroscopy. This seems to be neglected in the available literature and should be focused on in further studies.

Impact of orbiting electrode motion on the accuracy of electrical discharge machining

The present study is designed to study processes occurring during the electrical discharge machining (EDM) of tool steels, the influence of orbiting electrode motion on its accuracy, as well as to justify the application of individual orbiting trajectories and implement these data into production. To that end, a trajectory program was written in machine codes for a Mitsubishi EA-28 die-sinking electrical discharge machine using the CIMCO EDIT software package. Also, a prototype punch and ejector of the blanking die were produced and measured. The standard modes of Mitsubishi EA-28 were used to carry out machining in Blasospark GT 250 dielectric fluid to a roughness of Ra 0.6 in 9 passes. The experiments revealed the influence of electrode geometry on the machining of sharp corners, i.e., the formation of unwanted radii on the workpiece. However, this phenomenon is not observed when the corners are drilled with small diameter holes (0.4–0.6 mm). Depending on the machining process along the inner or outer trajectory, inverse electrode motion is also observed. The production part (punch of the blanking die) was machined using a new orbit adjusted to the geometry of the product. The part was found to be consistent with the requirements and the engineering drawing, thus allowing the assembled die to enter the main production. The results of the performed tests, as well as the study of domestic and foreign experience, were used to develop recommendations on the use of individual orbits in the EDM of tool steels, hard alloys, and other hard-to-machine conductive materials. The method of orbiting motion along a particular trajectory was implemented at Cheboksary Electrical Apparatus Plant (Cheboksary).