Browsing by Subject "Milling (machining)"
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Item Open Access Effect of milling time on the structure, micro-hardness, and thermal behavior of amorphous/nanocrystalline TiNiCu shape memory alloys developed by mechanical alloying(Elsevier Ltd, 2014) Alijani F.; Amini, R.; Ghaffari, M.; Alizadeh, M.; Okyay, Ali KemalIn the present paper, the effect of milling process on the chemical composition, structure, microhardness, and thermal behavior of Ti-41Ni-9Cu compounds developed by mechanical alloying was evaluated. The structural characteristic of the alloyed powders was evaluated by X-ray diffraction (XRD). The chemical composition homogeneity and the powder morphology and size were studied by scanning electron microscopy coupled with electron dispersive X-ray spectroscopy. Moreover, the Vickers micro-indentation hardness of the powders milled for different milling times was determined. Finally, the thermal behavior of the as-milled powders was studied by differential scanning calorimetery. According to the results, at the initial stages of milling (typically 0-12. h), the structure consisted of a Ni solid solution and amorphous phase, and by the milling evolution, nanocrystalline martensite (B19') and austenite (B2) phases were initially formed from the initial materials and then from the amorphous phase. It was found that by the milling development, the composition uniformity is increased, the inter-layer thickness is reduced, and the powders microhardness is initially increased, then reduced, and afterward re-increased. It was also realized that the thermal behavior of the alloyed powders and the structure of heat treated samples is considerably affected by the milling time.Item Open Access Effects of milling and annealing on formation and structural characterization of nanocrystalline intermetallic compounds from Ni-Ti elemental powders(2012) Ghadimi, M.; Shokuhfar, A.; Rostami H.R.; Ghaffari, M.Nickel and Titanium elemental powders with a nominal composition Ni-50 at.%Ti were mechanical alloyed in a planetary high-energy ball mill in different milling conditions (5, 10, 20, 40 and 60 h). The investigation revealed that increasing milling time leads to a reduction in crystallite size, and after 60 h of milling, the Ti dissolved in Ni lattice and NiTi (B2) phase was obtained. With milling time, morphology of pre-alloyed powders changed from lamella to globular. Annealing of as-milled powders at 1173 K for 900 s led to formation of nanocrystalline NiTi (B19′), grain growth and release of internal strain. The results indicated that this technique is a powerful and high productive process for preparing NiTi intermetallic compound with nanocrystalline structure and appropriate morphology. © 2012 Elsevier B.V. All rights reserved.Item Open Access Effects of thickness on the metal-insulator transition in free-standing vanadium dioxide nanocrystals(American Chemical Society, 2017) Fadlelmula, M. M.; Sürmeli, E. C.; Ramezani, M.; Kasırga, T. S.Controlling solid state phase transitions via external stimuli offers rich physics along with possibilities of unparalleled applications in electronics and optics. The well-known metal-insulator transition (MIT) in vanadium dioxide (VO2) is one instance of such phase transitions emerging from strong electronic correlations. Inducing the MIT using electric field has been investigated extensively for the applications in electrical and ultrafast optical switching. However, as the Thomas-Fermi screening length is very short, for considerable alteration in the material’s properties with electric field induced MIT, crystals below 10 nm are needed. So far, the only way to achieve thin crystals of VO2 has been via epitaxial growth techniques. Yet, stress due to lattice mismatch as well as interdiffusion with the substrate complicate the studies. Here, we show that free-standing vapor-phase grown crystals of VO2 can be milled down to the desired thickness using argon ion-beam milling without compromising their electronic and structural properties. Among our results, we show that even below 4 nm thickness the MIT persists and the transition temperature is lowered in two-terminal devices as the crystal gets thinner. The findings in this Letter can be applied to similar strongly correlated materials to study quantum confinement effects.Item Open Access Influence of tool wear on machining forces and tool deflections during micro milling(Springer, 2016) Oliaei, S. N. B.; Karpat, Y.Tool wear on the cutting edges of micro end mills is an important issue affecting process outputs such as tool deflections and surface roughness, especially when difficult-to-cut materials such as titanium alloys, stainless steel, etc. are machined at micro scale. An understanding of the interactions between tool wear, machining forces, tool deflections, and surface roughness is important in order to maintain component quality requirements. However, in literature, the number of studies concerning tool wear in micro end mills is limited. The goal of the paper is to better understand tool wear patterns (flank wear, edge rounding) of micro end mills and their relationship to machining parameters. In this study, first, the influence of tool wear on micro milling forces and surface roughness parameters is analyzed and favorable micro milling process parameters are identified. It is shown that, when machining with worn end mills, forces are affected by the tool wear patterns. Then, the influence of increased milling forces due to tool wear on tool deflections and tool breakage is studied using both experimental techniques and finite element analysis. The finite element model-based tool deflection and tool breakage predictions are validated through experiments. The results of this study can be used in process parameter selection in pocket micro milling operations and tool condition monitoring systems.Item Open Access Mechanistic force modeling for milling of carbon fiber reinforced polymers with double helix tools(Elsevier, 2013) Karpat, Y.; Polat, N.Carbon fiber reinforced polymers (CFRP) have emerged as the material of choice to satisfy increasing demand for lighter aircrafts. Machinability characteristics of CFRPs are quite different than those of metals; therefore, special tool designs have been developed for CFRP machining. The double helix end mill design compresses the upper and lower sides of the laminate using opposite helix angles that eliminate delamination. A mechanistic force model for double helix tools is developed based on milling force data obtained on flat end mills. The proposed model can be used to improve double helix tool designs and to optimize milling process parameters.Item Open Access Milling force modelling of multidirectional carbon fiber reinforced polymer laminates(Elsevier, 2012) Karpat, Yiğit; Bahtiyar, O.; Deger, B.Carbon fiber reinforced polymer (CFRP) usage in the aerospace industry has been steadily increasing due to its superior material properties such as high strength, low weight, high resistance to corrosion, and a low thermal expansion coefficient. In addition, CFRP parts are produced near-net-shape, a process that eliminates rough machining operations. However, machining operations such as drilling, side milling, and slotting are still necessary to give the CFRP parts their final shape. A majority of the studies on machining of CFRP laminates are on drilling. The number of studies on milling of CFRPs is quite limited. In this study, a mechanistic cutting force model for milling CFRPs is proposed based on experimentally collected cutting force data during slot milling of unidirectional CFRP laminates using a polycrystalline diamond cutter. Cutting force coefficients in radial and tangential directions are calculated as a function of fiber cutting angle. The mechanistic model is shown to be capable of predicting cutting forces during milling of multidirectional CFRP laminates and capable of investigating stability of machining. © 2012 The Authors.Item Open Access On-machine fabrication of PCD and WC micro end mills using micro electro discharge machining(Inderscience Enterprises Ltd., 2014) Oliaei, S.N.B.; Özdemir, C.; Karpat, Y.Micro electro discharge machining (μ -EDM) process can be used to fabricate micro-milling tools of different geometries from tungsten carbide (WC) and polycrystalline diamond (PCD). The non-contact nature of EDM process makes micro tool fabrication a challenging task while offering the advantage of eliminating tool run out and clamping errors since micro tools fabricated on-machine. The tools are fabricated and used on the same spindle. In this study, a combination of block-EDM and wire electro discharge grinding (WEDG) techniques are used to fabricate micro end mills of different geometries. The influences of EDM process parameters on material erosion rate and surface roughness are examined. The performance of the fabricated micro-tools in ductile mode machining of fused silica has been investigated. It is found that micro end mills can be used to fabricate prototypes of microfluidics chips with acceptable quality. © 2014 Inderscience Enterprises Ltd.Item Open Access Phase transformation during mechano-synthesis of nanocrystalline/amorphous Fe–32Mn–6Si alloys(Elsevier, 2013) Amini, R.; Shamsipoor, A.; Ghaffari, M.; Alizadeh, M.; Okyay, Ali KemalMechano-synthesis of Fe-32Mn-6Si alloy by mechanical alloying of the elemental powder mixtures was evaluated by running the ball milling process under an inert argon gas atmosphere. In order to characterize the as-milled powders, powder sampling was performed at predetermined intervals from 0.5 to 192 h. X-ray florescence analyzer, X-ray diffraction, scanning electron microscope, and high resolution transmission electron microscope were utilized to investigate the chemical composition, structural evolution, morphological changes, and microstructure of the as-milled powders, respectively. According to the results, the nanocrystalline Fe-Mn-Si alloys were completely synthesized after 48 h of milling. Moreover, the formation of a considerable amount of amorphous phase during the milling process was indicated by quantitative X-ray diffraction analysis as well as high resolution transmission electron microscopy image and its selected area diffraction pattern. It was found that the α-to-γ and subsequently the amorphous-to-crystalline (especially martensite) phase transformation occurred by milling development.Item Open Access Quantitative phase evolution during mechano-synthesis of Ti-Ni-Cu shape memory alloys(Elsevier, 2012-05-29) Amini, R.; Alijani, F.; Ghaffari, M.; Alizadeh, M.; Okyay, Ali KemalTi-41Ni-9Cu shape memory alloy was synthesized by mechanical alloying of pure elemental Ti, Ni, and Cu powders using high-energy ball milling. The qualitative and quantitative phase analyses of the as-milled powders were done by X-ray diffraction (XRD) using Rietveld refinement and the alloys microstructure was studied by scanning electron microscopy (SEM) and high resolution transmission electron microscopy (HRTEM). Concerning the results, by milling evolution, the dissolution of the primary materials occurred at different rates and a considerable amount of the amorphous phase as well as B19′-martensite and B2-austenite was created. The formation of Ni solid solution was also evidenced prior to its dissolution. It was found that at sufficient milling time, the mechano-crystallization of the amorphous phase occurred and at the end of milling, the B19′-martensite is the dominant phase of the structure.Item Open Access Structural and phase evolution in mechanically alloyed calcium copper titanate dielectrics(2013) Alizadeh, M.; Ardakani H.A.; Amini, R.; Ghazanfari, M.R.; Ghaffari, M.Nanocrystalline calcium-copper-titanate (CCTO) dielectric powders were prepared by mechanical alloying. Phase transformations and structural evolution of the mechanically activated powders were investigated through the Rietveld refinement of the X-ray diffraction results. The crystallite size, lattice strain, and weight fraction of individual phases were estimated based on crystal structure refinement. Furthermore, the microstructural properties and thermal behavior of the milled powders were investigated by Transmission Electron Microscopy (TEM) and Differential Thermal Analysis (DTA), respectively. It was found that CCTO nanocrystals can be successfully synthesized after the amorphization of the initial crystalline materials. Semi-spherical nano-size particles were developed after sufficient milling time. Formation of an amorphous phase during the milling cycle was confirmed by the presence of the glass transition and crystallization peaks in the thermal analysis profiles. © 2012 Elsevier Ltd and Techna Group S.r.l.Item Open Access Structural, microstructural and thermal properties of lead-free bismuth-sodium-barium-titanate piezoceramics synthesized by mechanical alloying(2013) Amini, R.; Ghazanfari, M.R.; Alizadeh, M.; Ardakani H.A.; Ghaffari, M.Bismuth-sodium-barium-titanate piezoceramics with a composition of (Bi 0.5Na0.5)0.94Ba0.06TiO3 (BNBT) were prepared by mechanical alloying (MA). Structural analysis and phase identification were performed by X-ray diffraction (XRD). Microstructural studies and chemical composition homogeneity were performed by scanning electron microscope (SEM) coupled with energy dispersive X-ray analysis (EDX). Furthermore, thermal properties of the as-milled powders were evaluated by thermogravimetry/differential thermal analysis (TG/DTA). During the initial milling, the constituents were transformed to the perovskite, pyrochlore, and BNT phases; in addition, partial amorphization of the structure appeared during the milling cycle. As MA progressed, transformation of pyrochlore-to-perovskite and crystallization of the amorphous phase occurred and also, the BNBT phase was significantly developed. It was found that the MA process has the ability to synthesize the BNBT powders with a submicron particle size, regular morphology, and uniform elemental distribution. © 2012 Elsevier Ltd.