Fully dense Ti/stainless‐steel couples are produced via cold‐spraying and subsequent hot‐rolling at various temperatures. Accordingly, the authors examined the nanoindentation hardness and modulus as well as elemental distributions corresponding to the interfacial regions. Moreover, the electrochemical corrosion behavior of the Ti part prior to and following hot‐rolling is also investigated. Our results shown that the couples hot‐rolled at 950 °C can successfully avoid both prior defects in the Ti and intermetallic compounds at the interface. Hot‐rolling has a significant influence on the interfacial mechanical behavior. The cold‐sprayed and hot‐rolled Ti parts exhibit excellent electrochemical corrosion resistance in 3.5 wt% NaCl solutions, which is identical to that of normal pure Ti.

To provide insight into the microstructural evolution and mechanical behavior of bulk nanostructured Ti, we used cold gas dynamic spraying of Ti particles to synthesize thick coatings (e.g., >10 mm in thickness). Accordingly, the grain size, lattice parameter, lattice strain, residual stress, porosity, microhardness, tensile, and compressive behavior of the bulk Ti deposits before and after annealing were comparatively analyzed. Our results show that the microstructure of the as-sprayed bulk Ti was characterized by a grain size of ~60 nm, lattice expansion (~2 pct for \( a \) and ~3 pct for \( c \)), lattice strain (~1.65 × 10−5), and residual compressive stress (~53 MPa). Moreover, annealing of the as-deposited bulk Ti led to a significant decrease in lattice expansion, lattice strain, and residual stress, whereas porosity remained unchanged (~11 pct). The mechanisms of grain growth, as well as the evolution of particle interfaces during annealing, were also investigated. In terms of mechanical behavior, the as-deposited bulk Ti exhibited a very low modulus (52 GPa) with relatively high tensile and compressive strength values (180 and 850 MPa, respectively). Annealing in the temperature range of 1023 K to 1173 K (750 °C to 900 °C) led to a significant increase of tensile and compressive strength (to 380 MPa and more than 1200 MPa, respectively). Finally, annealing resulted in a slight increase of elastic modulus, which was rationalized on the basis of changes in pore geometry in the bulk Ti deposits.

To understand the nanomechanical properties of nano-grained (NG) Ti produced by combination of asymmetric and symmetric rolling, nanoindentation hardness (H(n)) and elastic modulus (E(n)) of different planes within the NG Ti specimens were measured using continuous stiffness measurement mode at room temperature. For comparison, the nanomechanical properties of the as-received hot-rolled coarse-grained (CG) Ti and ultrafine-grained (UFG) Ti with only asymmetric rolling process were also investigated. It was found that H(n) of the Ti samples increased significantly with the decrease of grain sizes, while E(n) exhibited a slight decrease as the grain sizes decreased from CG to NG regime. The increase of H(n) was expected to be caused by higher density of dislocations and finer grains attained by severer plastic deformation, while the slight decrease of E(n) was considered as a result of the increased density of lattice defects and volume fraction of the grain boundary atoms. Furthermore, the nanomechanical properties of different planes of the Ti specimen exhibited a little difference which can be expressed as H(n(RD-TD)) > H(n(N-RD)) > H(n(TD-ND)) and E(n(RD-TD)) > E(n(ND-RD)) > E(n(TD-ND)). These differences were ascribed to crystallographic textures formed by rolling deformation.

Since the accurate prediction of fatigue life has a significant value, many researchers have attempted to develop a reliable fatigue life model. Recently, rolling contact fatigue life models incorporating machining impact were developed. These models have contributed to a significant improvement in prediction accuracy as compared with earlier models, thus representing a major step forward in the modeling effort. This paper compares the prediction accuracy of these models with that of the prediction method in International Standards. When α is set to 0.25, the observed improvement of prediction accuracy as measured by variance of prediction errors due to these models over that due to prediction method in International Standards is statistically significant. Impact analyses of such improvement are conducted to illustrate its value. It is further noted that while difference was observed between the variance of prediction errors due to the crack initiation life model based on a dislocation model and that due to the crack initiation life model based on a local stress-life curve, the observed difference is not statistically significant.

Co-base refractory alloy coating was prepared on carbon steel substrate by cold spray technology; microstructure and nano-mechenical property were examined by scanning electron microscope (SEM) and nano indenter individually. The results showed that about 250 mu m Co-base refractory alloy coating could be deposited on steel substrate by cold spray technique, interface between coating and substrate was combined well, and the refractory alloy particle had a significant plastic deformation during deposition process; mixing Ni powders into Co-base refractory alloy powders could increase the density and decrease the nano-hardness of coating, the nano-hardness and elastic modulus of refractory alloy coating was higher than 6 GPa and 160 GPa, respectively.

Tool condition monitoring (TCM) is an important aspect of condition based maintenance (CBM) in all manufacturing processes. Recent work on TCM has generated significant successes for a variety of cutting operations. In particular, lower cost and on-board sensors in conjunction with enhanced signal processing capabilities and improved networking has permitted significant enhancements to TCM capabilities. This paper presents an overview of TCM for drilling, turning, milling, and grinding. The focus of this paper is on the hardware and algorithms that have demonstrated success in TCM for these processes. While a variety of initial successes are reported, significantly more research is possible to extend the capabilities of TCM for the reported cutting processes as well as for many other manufacturing processes. Furthermore, no single unifying approach has been identified for TCM. Such an approach will enable the rapid expansion of TCM into other processes and a tighter integration of TCM into CBM for a wide variety of manufacturing processes and production systems.

Molecular Dynamics (MD) simulations of nanometric cutting of single-crystal copper were conducted to predict cutting forces and investigate the mechanism of chip formation at the nano-level. The MD simulations were conducted at a conventional cutting speed of 5 m/s and different depths of cut (0.724–2.172 nm), and cutting forces and shear angle were predicted. The effect of tool rake angles and depths of cut on the mechanism of chip formation was investigated. Tools with different rake angles, namely 0°, 5°, 10°, 15°, 30°, and 45°, were used. It was found that the cutting force, thrust force, and the ratio of the thrust force to cutting force decrease with increasing rake angle. However, the ratio of the thrust force to the cutting force is found to be independent of the depth of cut. In addition, the chip thickness was found to decrease with an increase in rake angle. As a consequence, the cutting ratio and the shear angle increase as the rake angle increases. The dislocation and subsurface deformation in the workpiece material were observed in the cutting region near the tool rake face. The adhesion of copper atoms to the diamond tool was clearly seen. The same approach can be used to simulate micromachining by significantly increasing the number of atoms in the MD model to represent cutting depths in the order of microns.

Dimensional measurement feedback in manufacturing systems is critical in order to consistently produce quality parts. Considering this, methods and techniques by which to accomplish this feedback have been the focus of numerous studies in recent years. More-over, with the rapid advances in computing technology the complexity and computational overhead that can be feasibly incorporated in any developed technique have dramatically improved. Thus, techniques that would have been impractical for implementation just a few years ago can now be realistically applied. This rapid growth has resulted in a wealth of new capabilities for improving part and process quality and reliability. In this paper, overviews of recent advances that apply to machining are presented. More specifically, research publications pertaining to the use of coordinate measurement machines to improve the machining process are discussed.

In order to consistently produce quality parts, many aspects of the manufacturing process must be carefully monitored, controlled, and measured. The methods and techniques by which to accomplish these tasks has been the focus of numerous studies in recent years. With the rapid advances in computing technology, the complexity and overhead that can be feasibly incorporated in any developed technique has dramatically improved. Thus, techniques that would have been impractical for implementation just a few years ago can now be realistically applied. This rapid growth has resulted in a wealth of new capabilities for improving part and process quality and reliability. In this paper, overviews of recent advances that apply to machining are presented. Moreover, due to the relative significance of two particular machining aspects, this review focuses specifically on research publications pertaining to using tool condition monitoring and coordinate measurement machines to improve the machining process. Tool condition has a direct effect on part quality and is discussed first. The application of tool condition monitoring as it applies to turning, drilling, milling, and grinding is presented. The subsequent section provides recommendations for future research opportunities. The ensuing section focuses on the use of coordinate measuring machines in conjunction with machining and is subdivided with respect to integration with machining tools, inspection planning and efficiency, advanced controller feedback, machine error compensation, and on-line tool calibration, in that specific order and concludes with recommendations regarding where future needs remain.

Fatigue life of nominally identical structures under nominally identical loading conditions can scatter widely. This study has investigated the impact of machining processes on such scatters. After Ti 6Al-4V samples were surface ground and face turned, they were subject to constant amplitude four-point bending fatigue tests under room temperature. The best case scenario of process capability ratios of fatigue for these samples were evaluated with assumed tolerances of fatigue life. Based on these ratios, the numbers of nonconforming parts were estimated. Under the machining conditions from a handbook, up to 39% of samples due to one process are expected to be nonconforming while only up to 0.6% of samples due to the other process are expected to be nonconforming. The ramifications in terms of cost for machining quality control due to the different capability ratios have been discussed. The current findings indicate an urgent need to further the study of this issue in a scientific manner.

ABSTRACT It is well known that a large variance can be associated with the fatigue life of nominally identical components. It may be intuitively true for some experts in surface integrity that different processes may produce different variances of fatigue life. However, little is known in the literature about the potential level of impact of different manufacturing processes on the variation of fatigue life, thus this study. Holes have been made on Ti 6Al-4V samples and finished by drilling and internal grinding using handbook recommended conditions. Tension fatigue tests of constant amplitude under load control have been conducted subsequently. Statistical analysis of the results showed a very significant impact of the hole making processes on the variance of the fatigue life. This finding proves the importance and urgency for further studying the issue in a scientific way.

Friction modeling in metal cutting has been recognized as one of the most important and challenging tasks facing researchers engaged in modeling of machining operations. To address this issue from the perspective of predicting machining induced residual stresses, a new stress-based polynomial model of friction behavior in machining is proposed. The feasibility of this methodology is demonstrated by performing finite element analyses. A sensitivity study is performed by comparing the cutting force and residual stress predicted based on this new model with those based on a model using an average coefficient of friction deduced from cutting forces and a model using an average coefficient of friction deduced from stresses. The average coefficient of friction computed based on the measured cutting forces is the conventional approach and is still widely used. The average coefficient of friction due to stresses can be considered as a simplified version of the proposed model. Simulation results show significant difference among the predicted residual stresses. As the proposed model is able to capture the relationship between the normal stress and shear stress on the tool rake face better than the conventional approach can, it has a potential for improving the quality of the prediction of the residual stresses induced by machining.

It is well known that there is a large variance of fatigue life associated with the data of fatigue tests under nominally identical conditions. Understanding and controlling this variance are essential to enhance the safety and competitiveness of designing and manufacturing fatigue critical products. However no analytical model quantitatively linking input variables with the variance of fatigue life has been found in current literature. To address this issue, a methodology for analytically predicting the variance of fatigue life is proposed. Using this methodology, the variance of fatigue life can be decomposed into individual components. The significance of this decomposition is two-fold. First, it provides a tool for pinpointing key driving factors of the variance of fatigue life, which is essential for the variance reduction of fatigue life. Second, the time consuming and costly fatigue tests to obtain critical variance information for reliability design may be divided into less time consuming tests for obtaining variance information for individual variables contributing to fatigue variance. Based on the variance prediction tool, a methodology for systematically incorporating manufacturing influence into the prediction of variance and average value of fatigue life is proposed. A verification model is built to predict the variance and average value of fatigue life of a structure with a central hole in the high cycle fatigue regime. The predicted fatigue life matches the actual average fatigue life well. Statistical analysis shows that the predicted variances of the fatigue life are equal to those estimated from actual fatigue life.

It is well known that there is a large variance associated with fatigue life. However in literature little is found on the relationship between manufacturing processes and fatigue variance of the manufactured components. In this research, the influence of machining processes on the fatigue variance of the machined Ti 6Al-4V samples is studied experimentally. The impact is evaluated by comparing the safety ratios of face-turned samples with those of ground samples. The safety ratio is defined as the average fatigue life over the fatigue life with a reliability of 95%. In the computation, it is assumed that fatigue life follows Weibull distribution. Two sets of faced samples and two sets of ground samples are tested for bending fatigue. The test is under constant amplitude in high cycle fatigue regime under room temperature. The results show that the safety ratios of face-turned samples are significantly smaller than are those of ground samples. Consequently, it is suggested that fatigue life variance be considered as a new process capability This capability serves as a basis in choosing manufacturing processes for making fatigue critical products such as aircraft. Another finding is the positive correlation between the residual stress variation and fatigue life variation. This correlation suggests that a better understanding and prediction of residual stress lead to a better prediction of fatigue life.

This chapter contains sections titled: Introduction Design and Design Alternatives Drawings General Principles for Design for Manufacturability Processes and Materials for Producing the Design Design for Basic Processes-Metal Design for Secondary Operation Design for Basic Processes-Plastics Design for Assembly Computer Software Tools: Object-Oriented Programming and Knowledge-Based Systems Organizational Issues References Additional Reading

Residual stress is one of the most important factors affecting product surface integrity. Every machining operation produces a distinctive residual stress in the surface layer. The surface residual stress produced by grinding and face turning were measured in very small surface areas at several locations of each sample using X-Ray diffraction technique. Significant point-to-point residual stress variations were found in the ground surfaces, which poses a potential hazard to applications requiring high surface integrity. On the other hand, only small point-to-point residual stress variations were found in the face turned surface. An explanation to this phenomenon has been given. Residual stress on seven samples undergone multiple-pass grinding were also measured, the results of which show that final residual stress distribution on a ground workpiece depends on the initial residual stress, the number of grinding pass, as well as grinding conditions. It is suggested that single-point cutting be used in place of abrasive grinding.