Evaluation of the Surface Topography and Deformation of Vertical Thin-Wall Milled Samples from the Nickel Alloy Inconel 625.

During the production of components, manufacturers of structures are obliged to meet certain requirements and ensure appropriate quality characteristics. It is especially important during the manufacturing of thin-walled structures, which are subject to many errors during machining due to the reduced rigidity of the products, including the deformation of thin walls, which may be the result of the vibration of the system. The appearance of vibrations reduces the quality of the machined surface affecting the increase in the values of surface topography parameters-waviness and roughness. Thin-wall structures-titanium or nickel alloy, among others-play a key role in the aerospace industry, which constantly strives to reduce the weight of the entire structure while meeting requirements. The present work focuses on the evaluation of the parameters of surface topography, dimensional and shape accuracy during the milling of nickel alloy Inconel 625 samples containing a thin wall in a vertical orientation. The experiment was conducted under controlled cutting conditions using a constant material removal rate. As part of the surface topography section, the distribution of waviness, Wa and Wz, and roughness, Ra and Rz, was determined in selected measurement areas in the direction parallel to the direction of the feed motion. Dimensional deviations, measured with a 3D optical scanner, were determined in selected cross sections in the direction perpendicular and parallel to the bottom of the sample presenting the deflection of the thin-walled structure. The results provide information that the used parameter sets affect the measured quantities to varying degrees.

Dimensional Deviations of Horizontal Thin Wall of Titanium Alloy Ti6Al4V Determined by Optical and Contact Methods.

Thin-walled structures are used in many industries. The need to use such elements is dictated by the desire to reduce the weight of the finished product, as well as to reduce its cost. The most common method of machining such elements is the use of milling, which makes it possible to make a product of almost any shape. However, several undesirable phenomena occur during the milling of thin-walled structures. The main phenomenon is a deformation of the thin wall resulting from its reduced stiffness. Therefore, it is necessary to control the dimensional and shape accuracy of finished products, which is carried out using various measuring instruments. The development of newer measuring methods such as optical methods is being observed. One of the newer measuring machines is the 3D optical scanner. In the present experiment, thin-walled samples in horizontal orientation of Ti6Al4V titanium alloy were machined under controlled cutting conditions. During machining, the cutting speed and feed rate were assumed constant, while the input factors were the tool and cutting strategy. This paper presents graphs of deviations in the determined cross-section planes of thin-walled structures using a 3D optical scanner and a coordinate measuring machine. A correlation was made between the results obtained from the measurement by the optical method and those determined by the contact method. A maximum discrepancy of about 8% was observed between the methods used.

Influence of Tools and Cutting Strategy on Milling Conditions and Quality of Horizontal Thin-Wall Structures of Titanium Alloy Ti6Al4V.

Titanium and nickel alloys are used in the creation of components exposed to harsh and variable operating conditions. Such components include thin-walled structures with a variety of shapes created using milling. The driving factors behind the use of thin-walled components include the desire to reduce the weight of the structures and reduce the costs, which can sometimes be achieved by reducing the machining time. This situation necessitates, among other things, the use of new machining methods and/or better machining parameters. The available tools, geometrically designed for different strategies, allow working with similar and improved cutting parameters (increased cutting speeds or higher feed rates) without jeopardizing the necessary quality of finished products. This approach causes undesirable phenomena, such as the appearance of vibrations during machining, which adversely affect the surface quality including the surface roughness. A search is underway for cutting parameters that will minimize the vibration while meeting the quality requirements. Therefore, researching and evaluating the impact of cutting conditions are justified and common in scientific studies. In our work, we have focused on the quality characteristics of horizontal thin-walled structures from Ti6Al4V titanium alloys obtained in the milling process. Our experiments were conducted under controlled cutting conditions at a constant value of the material removal rate (2.03 cm3/min), while an increased value of the cut layer was used and tested for use in finishing machining. We used three different cutting tools, namely, one for general purpose machining, one for high-performance machining, and one for high-speed machining. Two strategies were adopted: adaptive face milling and adaptive cylindrical milling. The output quantities included the results of acceleration vibration amplitudes, and selected surface topography parameters of waviness (Wa and Wz) and roughness (Ra and Rz). The lowest values of the pertinent quantities were found for a sample machined with a high-performance tool using adaptive face milling. Surfaces typical of chatter vibrations were seen for all samples.

Influence of Grout Properties on the Tensile Performance of Rockbolts Based on Modified Cable Elements.

The grout annulus (GA) has a significant effect on the tensile performance of rockbolts in mining engineering. However, little research has been conducted to use modified cable elements to study this effect quantitatively. This paper used the modified cable elements in FLAC3D to study the effect of the GA on the tensile performance of rockbolts. The two-stage coupling law was used to simulate the behaviour of the GA. The stress had a linear relation with the slippage before the shear strength (SS). After the SS, the stress decreased exponentially. Numerical in situ roadway reinforcement cases were used to study the influence of the grout annulus on the tensile performance of rockbolts. The results showed that, when the SS of the GA increased from 3.2 MPa to 6.4 Mpa, the peak force of rockbolts increased from 247 kN to 425 kN. Moreover, when the SS of the GA increased from 3.2 Mpa to 6.4 Mpa, the distance between the position of the maximum tensile capacity and the external end decreased from 1.17 m to 0.81 m. Last, for the circular roadway, the peak force in rockbolts installed in the lateral side was 171.7 kN, which was significantly larger than the top side of 72.3 kN.

Evaluation of the Vibration Signal during Milling Vertical Thin-Walled Structures from Aerospace Materials.

The main functions of thin-walled structures-widely used in several industries-are to reduce the weight of the finished product and to increase the rigidity of the structure. A popular method for machining such components, often with complex shapes, is using milling. However, milling involves undesirable phenomena. One of them is the occurrence of vibrations caused by the operation of moving parts. Vibrations strongly affect surface quality and also have a significant impact on tool wear. Cutting parameters, machining strategies and tools used in milling constitute some of the factors that influence the occurrence of vibrations. An additional difficulty in milling thin-walled structures is the reduced rigidity of the workpiece-which also affects vibration during machining. We have compared the vibration signal for different approaches to machining thin-walled components with vertical walls made of Ti6Al4V titanium alloy and Inconel 625 nickel alloy. A general-purpose cutting tool for machining any type of material was used along with tools for high-performance machining and high-speed machining adapted for titanium and nickel alloys. A comparison of results was made for a constant material removal rate. The Short-Time Fourier Transform (STFT) method provided the acceleration vibration spectrograms for individual samples.

Investigation of Selected Surface Topography Parameters and Deformation during Milling of Vertical Thin-Walled Structures from Titanium Alloy Ti6Al4V.

Thin-walled elements are widely used in the aerospace industry, where the aim is to reduce the process time and the weight of the structure while ensuring the sufficient quality of the finished product. Quality is determined by geometric structure parameters and dimensional and shape accuracy. The main problem encountered during the milling of thin-walled elements is the deformation of the product. Despite the various methods available for measuring deformation, more are still being developed. This paper presents selected surface topography parameters and deformation of vertical thin-walled elements during an experiment under controlled cutting conditions for samples from titanium alloy Ti6Al4V. Constant parameters of feed (f), cutting speed (Vc,) and tool diameter (D) were used. Samples were milled using a tool for general-purpose and a tool for high-performance machining, as well as two different machining approaches: with greater involvement of face milling, and cylindrical milling with a constant material removal rate (MRR). For samples with vertical thin walls, the parameters of waviness (Wa, Wz,) and roughness (Ra, Rz) were measured using a contact profilometer in the selected areas on both processed sides. Deformations were determined in selected cross-sections perpendicular and parallel to the bottom of the sample using GOM measurement (GOM-Global Optical Measurement). The experiment showed the possibility of measuring deformations and deflection arrows of thin-walled elements proceeded from titanium alloy using GOM measurement. Differences in selected surface topography parameters and deformations were observed for the machining methods used with an increased cross-section of the cut layer. A sample with a deviation of 0.08 mm from the assumed shape was obtained.

Self-Excited Acoustical Measurement System for Rock Mass Stress Mapping.

This paper presents the results of a preliminary study of a self-excited acoustical system (SAS) for nondestructive testing (NDT). The SAS system was used for mine excavation stresses examination. The principle of operation of the SAS system based on the elastoacoustical effect is presented. A numerical analysis of the excavation was carried out considering the stress factor. An equivalent model based on a two-degree-of-freedom system with a delay has been developed. This model allowed to determine the relation which relates the frequency of the self-excited system to the stress level in the studied ceiling section. This relationship is defined by the elastoacoustic coefficient. The test details for anchorages in laboratory conditions and Wieliczka Salt Mine were presented. This research details of a method for creating actual stress maps in the ceiling of a mine excavation. The results confirmed the possibility of using the new measurement system to monitor the state of stresses in the rock mass.

A Comprehensive Study on Processing Ti-6Al-4V ELI with High Power EDM.

Electrical Discharge Machining (EDM) consists of a non-conventional machining process, which is widely used in modern industry, and especially in machining hard-to-cut materials. By employing EDM, complex shapes and geometries can be produced, with high dimensional accuracy. Titanium alloys, due to their unique inherent properties, are extensively utilized in high end applications. Nevertheless, they suffer from poor machinability, and thus, EDM is commonly employed for their machining. The current study presents an experimental investigation regarding the process of Ti-6Al-4V ELI with high power EDM, using a graphite electrode. Control parameters were the pulse-on current (Ip) and time (Ton), while Machining performances were estimated in terms of Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR). The machined Surface Roughness was calculated according to the Ra and the Rt values, by following the ISO 25178-2 standards. Furthermore, the EDMed surfaces were observed under optical and SEM microscopy, while their cross sections were also studied in order the Average White Layer Thickness (AWLT) and the Heat Affected Zone (HAZ) to be measured. Finally, for the aforementioned indexes, Analysis Of Variance was performed, whilst for the MRR and TMRR, based on the Response Surface Method (RSM), semi-empirical correlations were presented. The scope of the current paper is, through a series of experiments and by employing statistical tools, to present how two main machining parameters, i.e., pulse-on current and time, affect major machining performance indexes and the surface roughness.

Surface and Subsurface Quality of Titanium Grade 23 Machined by Electro Discharge Machining.

Electrical Discharge Machining (EDM) is a non-traditional cutting technology that is extensively utilized in contemporary industry, particularly for machining difficult-to-cut materials. EDM may be used to create complicated forms and geometries with great dimensional precision. Titanium alloys are widely used in high-end applications owing to their unique intrinsic characteristics. Nonetheless, they have low machinability. The current paper includes an experimental examination of EDM's Ti-6Al-4V ELI (Extra Low Interstitials through controlled interstitial element levels) process utilizing a graphite electrode. The pulse-on current (IP) and pulse-on time (Ton) were used as control parameters, and machining performance was measured in terms of Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR). The Surface Roughness (SR) was estimated based on the mean roughness (SRa) and maximum peak to valley height (SRz), while, the EDMed surfaces were also examined using optical and SEM microscopy and cross-sections to determine the Average White Layer Thickness (AWLT). Finally, for the indices above, Analysis of Variance (ANOVA) was conducted, whilst semi-empirical correlations for the MRR and TMRR were given using the Response Surface Method (RSM). The results show that the pulse-on time is the most significant parameter of the machining process that may increase the MRR up to 354%. Pulse-on current and pulse-on time are shown to have an impact on the surface integrity of the finished product. Furthermore, statistics, SEM, and EDX images on material removal efficiency and tool wear rate are offered to support the core causes of surface and sub-surface damage. The average microhardness of the White Layer (WL) is 1786 HV.

Transversus abdominis plane block versus quadratus lumborum block type 2 for analgesia in renal transplantation: A randomised trial.

BACKGROUND: Several studies have shown an analgesic efficacy of a transversus abdominis plane block (TAPB) in reducing opioid requirements during and after cadaveric renal transplantation surgery, but the effect of a quadratus lumborum block (QLB) in this type of surgery is unclear. OBJECTIVES: The main objective of this prospective, randomised, double-centre clinical study was to compare the analgesic efficacy of a one-sided lateral approach TAPB with a unilateral QLB type 2 in cadaveric renal transplantation surgery. DESIGN: Randomised, single-blinded trial. SETTING: Two University-affiliated tertiary care hospitals between April 2016 and May 2017. PATIENTS: A total of 101 patients aged more than 18 years, scheduled for cadaveric renal transplantation. INTERVENTIONS: On receiving ethical board approval and individual informed consent, consecutive patients were allocated randomly to receive either an ultrasound-guided single-shot lateral TAPB or an ultrasound-guided single-shot QLB type 2 on the surgical side using 20 ml of bupivacaine 0.25% with adrenaline after a standardised induction of general anaesthesia. All patients on surgical completion and recovery from general anaesthesia were admitted to the postanaesthesia care unit for 24 h. They received standardised intravenous patient-controlled analgesia with fentanyl, and their pain scores were noted at regular intervals. MAIN OUTCOME MEASURES: The primary endpoint was total cumulative fentanyl dose used per kg body mass in the first 24 h after surgery. Secondary outcomes were the need to start a continuous infusion of fentanyl in addition to patient-controlled analgesia boluses during the stay in post-anaesthesia care unit, postoperative pain severity measured using a numerical rating scale, patient satisfaction with analgesic treatment, evidence of postoperative nausea and vomiting, pruritus and sedation level. RESULTS: The 49 patients allocated to the QLB type 2 group used significantly less fentanyl per kg in the first 24 h after surgery than the 52 patients who received a TAPB (median [IQR] 4.2 [2.3 to 8.0] µg kg versus 6.7 [3.5 to 10.7] µg kg, P = 0.042). No statistically significant differences were noted in the secondary endpoints within the study, including the frequency of adverse effects of opioids. CONCLUSION: The reduction of fentanyl consumption in the first 24 h after renal transplantation with no difference in pain intensity and patient satisfaction shows a beneficial effect of one-sided QLB type 2 over a one-sided TAPB in regards to postoperative analgesia. However, the reduction in opioid consumption did not affect the frequency of opioid-related adverse effects. TRIAL REGISTRATION: ClinicalTrials.gov ID: NCT02783586.

Income and Happiness in Time of Post-Communist Modernization.

This paper discusses the relations between economic development, family income, and happiness in post-communist Poland from the point of view of Inglehart's theory of modernization. The happiness is understood as satisfaction with income and life, and as psychological well-being. The analysis of survey data yields the conclusion that economic development reduces the strength of the relations between income and satisfaction as well as between income and psychological well-being. These findings may be explained by changes in the value system from collectivist/materialist to individualist/post-materialist, even when these values are not directly measured. The analyzed data are from a series of representative surveys conducted in Poland during a period of political and economic transformation (i.e., between 1989 and 2008). Official statistical data on Polish economic development during the same period are used as a background for survey results. The relations between income and happiness change in Poland in a way consistent with Inglehart's modernization theory.