Pub Date : 2023-01-01Epub Date: 2023-08-29DOI: 10.1007/s41871-023-00210-9
John O'Hara, Fengzhou Fang
The effective removal of the heat generated during mechanical cutting processes is crucial to enhancing tool life and producing workpieces with superior surface finish. The internal cooling systems used in cutting inserts employ a liquid water-based solvent as the primary medium to transport the excess thermal energy generated during the cutting process. The limitations of this approach are the low thermal conductivity of water and the need for a mechanical input to circulate the coolant around the inner chamber of the cutting tool. In this context, this paper proposes an alternative method in which liquid gallium is used as the coolant in combination with a magnetohydrodynamic (MHD) pump, which avoids the need for an external power source. Using computational fluid dynamics, we created a numerical model of an internal cooling system and then solved it under conditions in which a magnetic field was applied to the liquid metal. This was followed by a simulation study performed to evaluate the effectiveness of liquid gallium over liquid water. The results of experiments conducted under non-cooling and liquid gallium cooling conditions were analyzed and compared in terms of the tool wear rate. The results showed that after six machining cycles at a cutting speed Vc = 250 m min -1, the corner wear VBc rate was 75 µm with the coolant off and 48 µm with the MHD-based coolant on, representing a decrease of 36% in tool wear. At Vc = 900 m min-1, the corner wear VBc rate was 75 µm with the coolant off and 246 µm with the MHD-based coolant on, representing a decrease of 31% in tool wear. When external cooling using liquid water was added, the results showed at Vc = 250 m min-1, the difference between the tool wear rate reduction with the internal liquid gallium coolant relative to the external coolant was 29%. When the cutting speed was increased to Vc = 900 m min-1, the difference observed between the internal liquid gallium coolant relative to the external coolant was 16%. The study proves the feasibility of using liquid gallium as a coolant to effectively remove thermal energy through internally fabricated cooling channels in cutting inserts.
有效去除机械切削过程中产生的热量对于提高刀具寿命和生产具有优异表面光洁度的工件至关重要。切削镶片中使用的内部冷却系统采用液态水基溶剂作为主要介质，以输送切削过程中产生的多余热能。这种方法的局限性在于水的低热导率以及需要机械输入以使冷却剂围绕切割工具的内腔循环。在这种情况下，本文提出了一种替代方法，将液态镓用作冷却剂，并与磁流体动力学（MHD）泵相结合，从而避免了对外部电源的需要。使用计算流体动力学，我们创建了一个内部冷却系统的数值模型，然后在对液态金属施加磁场的条件下对其进行求解。随后进行了模拟研究，以评估液态镓相对于液态水的有效性。根据刀具磨损率分析和比较了在非冷却和液态镓冷却条件下进行的实验结果。结果表明，在切削速度为Vc的六个加工循环之后 = 250 m min-1，在冷却剂关闭的情况下，角磨损VBc率为75µm，在基于MHD的冷却剂打开的情况下为48µm，这意味着刀具磨损减少了36%。在Vc = 900 m min-1，在冷却剂关闭的情况下，角磨损VBc率为75µm，在基于MHD的冷却剂打开的情况下为246µm，这意味着刀具磨损减少了31%。当加入使用液态水的外部冷却时，结果显示在Vc = 250mmin-1，内部液态镓冷却剂相对于外部冷却剂的工具磨损率降低之间的差异为29%。当切割速度增加到Vc时 = 900mmin-1，内部液态镓冷却剂与外部冷却剂之间观察到的差异为16%。该研究证明了使用液态镓作为冷却剂通过内部制造的切削刀片冷却通道有效去除热能的可行性。
{"title":"Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Evalidation.","authors":"John O'Hara, Fengzhou Fang","doi":"10.1007/s41871-023-00210-9","DOIUrl":"10.1007/s41871-023-00210-9","url":null,"abstract":"<p><p>The effective removal of the heat generated during mechanical cutting processes is crucial to enhancing tool life and producing workpieces with superior surface finish. The internal cooling systems used in cutting inserts employ a liquid water-based solvent as the primary medium to transport the excess thermal energy generated during the cutting process. The limitations of this approach are the low thermal conductivity of water and the need for a mechanical input to circulate the coolant around the inner chamber of the cutting tool. In this context, this paper proposes an alternative method in which liquid gallium is used as the coolant in combination with a magnetohydrodynamic (MHD) pump, which avoids the need for an external power source. Using computational fluid dynamics, we created a numerical model of an internal cooling system and then solved it under conditions in which a magnetic field was applied to the liquid metal. This was followed by a simulation study performed to evaluate the effectiveness of liquid gallium over liquid water. The results of experiments conducted under non-cooling and liquid gallium cooling conditions were analyzed and compared in terms of the tool wear rate. The results showed that after six machining cycles at a cutting speed <i>V</i><sub><i>c</i></sub> = 250 m min <sup>-1</sup>, the corner wear VB<sub>c</sub> rate was 75 µm with the coolant off and 48 µm with the MHD-based coolant on, representing a decrease of 36% in tool wear. At <i>V</i><sub><i>c</i></sub> = 900 m min<sup>-1</sup>, the corner wear VB<sub>c</sub> rate was 75 µm with the coolant off and 246 µm with the MHD-based coolant on, representing a decrease of 31% in tool wear. When external cooling using liquid water was added, the results showed at <i>V</i><sub><i>c</i></sub> = 250 m min<sup>-1</sup>, the difference between the tool wear rate reduction with the internal liquid gallium coolant relative to the external coolant was 29%. When the cutting speed was increased to <i>V</i><sub><i>c</i></sub> = 900 m min<sup>-1</sup>, the difference observed between the internal liquid gallium coolant relative to the external coolant was 16%. The study proves the feasibility of using liquid gallium as a coolant to effectively remove thermal energy through internally fabricated cooling channels in cutting inserts.</p>","PeriodicalId":52345,"journal":{"name":"Nanomanufacturing and Metrology","volume":"6 1","pages":"33"},"PeriodicalIF":0.0,"publicationDate":"2023-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10462532/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"10501397","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-12-15DOI: 10.3390/nanomanufacturing2040017
K. I. Baskakova, A. Okotrub, L. G. Bulusheva, O. Sedelnikova
3D printing is a promising technology for creating polymer objects of a given architecture with specified functional properties. In fact, the choice of filaments for 3D printing is quite limited. Here, we report a process for producing polystyrene filaments with 0.0025–2 wt.% single-walled carbon nanotubes (SWCNTs) by extruding crushed polystyrene composites. The resulting filaments are characterized by a high uniformity of filler distribution and the absence of air pores. Comparison of microscopy data and electromagnetic properties of base composites and composite materials printed from filaments showed that extrusion and printing improve SWCNT dispersion. The proposed method can be used to create filaments for 3D printing of objects from various base polymers containing functional fillers up to the electrical percolation threshold and above.
{"title":"Manufacturing of Carbon Nanotube-Polystyrene Filament for 3D Printing: Nanoparticle Dispersion and Electromagnetic Properties","authors":"K. I. Baskakova, A. Okotrub, L. G. Bulusheva, O. Sedelnikova","doi":"10.3390/nanomanufacturing2040017","DOIUrl":"https://doi.org/10.3390/nanomanufacturing2040017","url":null,"abstract":"3D printing is a promising technology for creating polymer objects of a given architecture with specified functional properties. In fact, the choice of filaments for 3D printing is quite limited. Here, we report a process for producing polystyrene filaments with 0.0025–2 wt.% single-walled carbon nanotubes (SWCNTs) by extruding crushed polystyrene composites. The resulting filaments are characterized by a high uniformity of filler distribution and the absence of air pores. Comparison of microscopy data and electromagnetic properties of base composites and composite materials printed from filaments showed that extrusion and printing improve SWCNT dispersion. The proposed method can be used to create filaments for 3D printing of objects from various base polymers containing functional fillers up to the electrical percolation threshold and above.","PeriodicalId":52345,"journal":{"name":"Nanomanufacturing and Metrology","volume":"30 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"84157767","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-12-05DOI: 10.3390/nanomanufacturing2040016
Md Abdus Subhan, Newton Neogi, K. Choudhury
Nanomaterials (NMs) that are created with zinc oxide are very valuable for a wide variety of applications. There is a present interest in ZnO nanoparticles in a wide range of industries. This interest may be attributed to the fact that ZnO NPs have many important features. It will be necessary for ZnO NPs to possess certain qualities in order for them to rapidly find uses in industry and for these applications to have an effect on the expansion of the economy. A large surface area, a large bandgap, photocatalytic property, biosensing, bioimaging, and other qualities are included in this list. In this article, the extraordinary characteristics of ZnO NPs, as well as their novel applications in industrial settings and the challenges that come along with their utilization, will be discussed.
{"title":"Industrial Manufacturing Applications of Zinc Oxide Nanomaterials: A Comprehensive Study","authors":"Md Abdus Subhan, Newton Neogi, K. Choudhury","doi":"10.3390/nanomanufacturing2040016","DOIUrl":"https://doi.org/10.3390/nanomanufacturing2040016","url":null,"abstract":"Nanomaterials (NMs) that are created with zinc oxide are very valuable for a wide variety of applications. There is a present interest in ZnO nanoparticles in a wide range of industries. This interest may be attributed to the fact that ZnO NPs have many important features. It will be necessary for ZnO NPs to possess certain qualities in order for them to rapidly find uses in industry and for these applications to have an effect on the expansion of the economy. A large surface area, a large bandgap, photocatalytic property, biosensing, bioimaging, and other qualities are included in this list. In this article, the extraordinary characteristics of ZnO NPs, as well as their novel applications in industrial settings and the challenges that come along with their utilization, will be discussed.","PeriodicalId":52345,"journal":{"name":"Nanomanufacturing and Metrology","volume":"42 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"90053193","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-12-01DOI: 10.1007/s41871-022-00165-3
G. Dai, K. Hahm, Lipfert Sebastian, M. Heidelmann
{"title":"Correction: Comparison of EUV Photomask Metrology Between CD-AFM and TEM","authors":"G. Dai, K. Hahm, Lipfert Sebastian, M. Heidelmann","doi":"10.1007/s41871-022-00165-3","DOIUrl":"https://doi.org/10.1007/s41871-022-00165-3","url":null,"abstract":"","PeriodicalId":52345,"journal":{"name":"Nanomanufacturing and Metrology","volume":"4 1","pages":"440"},"PeriodicalIF":0.0,"publicationDate":"2022-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"80071697","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-12-01DOI: 10.1007/s41871-022-00160-8
Y. Mizutani, S. Kataoka, T. Uenohara, Y. Takaya
{"title":"Correction: Ghost Imaging with Deep Learning for Position Mapping of Weakly Scattered Light Source","authors":"Y. Mizutani, S. Kataoka, T. Uenohara, Y. Takaya","doi":"10.1007/s41871-022-00160-8","DOIUrl":"https://doi.org/10.1007/s41871-022-00160-8","url":null,"abstract":"","PeriodicalId":52345,"journal":{"name":"Nanomanufacturing and Metrology","volume":"37 1","pages":"435"},"PeriodicalIF":0.0,"publicationDate":"2022-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"90688208","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-12-01DOI: 10.1007/s41871-022-00167-1
R. Sakakibara, I. Yoshida, Yuki Kondo, M. Numada, Kenichi Yamashita
{"title":"Correction: A Proposal of Hyperbolic Fitting Method by Applying the Properties of Functions for Plateau Surface Analysis in ISO 13565–3","authors":"R. Sakakibara, I. Yoshida, Yuki Kondo, M. Numada, Kenichi Yamashita","doi":"10.1007/s41871-022-00167-1","DOIUrl":"https://doi.org/10.1007/s41871-022-00167-1","url":null,"abstract":"","PeriodicalId":52345,"journal":{"name":"Nanomanufacturing and Metrology","volume":"57 1","pages":"442"},"PeriodicalIF":0.0,"publicationDate":"2022-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"73719454","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-12-01DOI: 10.1007/s41871-022-00163-5
K. Nakazawa, S. Ozawa, F. Iwata
{"title":"Correction: Additive Manufacturing of Metal Micro-ring and Tube by Laser-Assisted Electrophoretic Deposition with Laguerre–Gaussian Beam","authors":"K. Nakazawa, S. Ozawa, F. Iwata","doi":"10.1007/s41871-022-00163-5","DOIUrl":"https://doi.org/10.1007/s41871-022-00163-5","url":null,"abstract":"","PeriodicalId":52345,"journal":{"name":"Nanomanufacturing and Metrology","volume":"172 1","pages":"438"},"PeriodicalIF":0.0,"publicationDate":"2022-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"73160472","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-12-01DOI: 10.1007/s41871-022-00164-4
H. Matsukuma, K. Adachi, Takuma Sugawara, Y. Shimizu, Wei Gao, Eiji Niwa, Yoshihiro Sasaki
{"title":"Correction: Closed-Loop Control of an XYZ Micro-Stage and Designing of Mechanical Structure for Reduction in Motion Errors","authors":"H. Matsukuma, K. Adachi, Takuma Sugawara, Y. Shimizu, Wei Gao, Eiji Niwa, Yoshihiro Sasaki","doi":"10.1007/s41871-022-00164-4","DOIUrl":"https://doi.org/10.1007/s41871-022-00164-4","url":null,"abstract":"","PeriodicalId":52345,"journal":{"name":"Nanomanufacturing and Metrology","volume":"38 2","pages":"439"},"PeriodicalIF":0.0,"publicationDate":"2022-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"72407007","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-11-29DOI: 10.3390/nanomanufacturing2040015
C. Barbero, D. Acevedo
Direct laser interference patterning (DLIP) involves the formation of patterns of light intensity using coherent laser light beams that interfere between them. Light on the ultraviolet (<350 nm) and NIR (800–2000 nm) is absorbed in chromophores present in the polymer structure or in loaded absorbing species (dyes, polymers, nanoparticles). The absorbed light induces photothermal/photochemical processes, which alter permanently the topography of the polymer surface. The success of DLIP at different wavelengths is discussed in relation to the optical/thermal properties of the polymers and previous data on laser ablation of polymers. The size of the pattern is related directly to the wavelength of the light and inversely to the sine of the angle between beams and the refractive index of the external medium. In that way, nanometric structures (<100 nm) could be produced. Since the patterning occurs in a single short pulse (<10 ns), large surfaces can be modified. Both bacterial biofilm inhibition and human cell differentiation/orientation have been achieved. Large improvements in technological devices (e.g., thin film solar cells) using DLIP structured surfaces have also been demonstrated. Prospective application of DLIP to common polymers (e.g., Teflon®) and complex polymeric systems (e.g., layer-by-layer multilayers) is discussed on the basis of reported polymer data.
{"title":"Manufacturing Functional Polymer Surfaces by Direct Laser Interference Patterning (DLIP): A Polymer Science View","authors":"C. Barbero, D. Acevedo","doi":"10.3390/nanomanufacturing2040015","DOIUrl":"https://doi.org/10.3390/nanomanufacturing2040015","url":null,"abstract":"Direct laser interference patterning (DLIP) involves the formation of patterns of light intensity using coherent laser light beams that interfere between them. Light on the ultraviolet (<350 nm) and NIR (800–2000 nm) is absorbed in chromophores present in the polymer structure or in loaded absorbing species (dyes, polymers, nanoparticles). The absorbed light induces photothermal/photochemical processes, which alter permanently the topography of the polymer surface. The success of DLIP at different wavelengths is discussed in relation to the optical/thermal properties of the polymers and previous data on laser ablation of polymers. The size of the pattern is related directly to the wavelength of the light and inversely to the sine of the angle between beams and the refractive index of the external medium. In that way, nanometric structures (<100 nm) could be produced. Since the patterning occurs in a single short pulse (<10 ns), large surfaces can be modified. Both bacterial biofilm inhibition and human cell differentiation/orientation have been achieved. Large improvements in technological devices (e.g., thin film solar cells) using DLIP structured surfaces have also been demonstrated. Prospective application of DLIP to common polymers (e.g., Teflon®) and complex polymeric systems (e.g., layer-by-layer multilayers) is discussed on the basis of reported polymer data.","PeriodicalId":52345,"journal":{"name":"Nanomanufacturing and Metrology","volume":"1 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"90251073","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-11-24DOI: 10.1007/s41871-022-00155-5
F. Ji, Y. Yao, T. Xin, J. Seidel
{"title":"Correction: A Comprehensive FIB Lift-out Sample Preparation Method for Scanning Probe Microscopy","authors":"F. Ji, Y. Yao, T. Xin, J. Seidel","doi":"10.1007/s41871-022-00155-5","DOIUrl":"https://doi.org/10.1007/s41871-022-00155-5","url":null,"abstract":"","PeriodicalId":52345,"journal":{"name":"Nanomanufacturing and Metrology","volume":"48 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-11-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"90225125","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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