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Cutting mechanics and surface finish for turning with differently shaped CBN tools

Krzysztof Żak
Archive of Mechanical Engineering | 2017 | vol. 64 | No 3 | 347-357 | DOI: 10.1515/meceng-2017-0021
Keywords hardened steel surface roughness cutting force specific energy corner radius
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Abstract

In this paper, the basic cutting characteristics such as cutting forces, cutting power and its distribution, specific cutting energies were determined taking into account variable tool corner radius ranging from 400 to 1200 μm and constant cutting parameters typical for hard turning of a hardened 41Cr4 alloy steel of 55 ± 1 HRC hardness. Finish turning operations were performed using chamfered CBN tools. Moreover, selected roughness profiles produced for different tool corner radius were compared and appropriate surface roughness parameters were measured. The measured values of Ra and Rz roughness parameters are compared with their theoretical values and relevant material distribution curves and bearing parameters are presented.

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Bibliography

[1] J.P. Davim. Machining of Hard Materials. Springer, London, 2011.
[2] W. Grzesik. Advanced Machining Processes of Metallic Materials. Elsevier Science, 2008.
[3] W. Grzesik. Prediction of the functional performance of machined components based on surface topography: State of the art. Journal of Materials Engineering and Performance, 25(10):4460–4468, 2016. doi: 10.1007/s11665-016-2293-z.
[4] P. Nieslony, G.M. Krolczyk, K. Zak, R.W. Maruda, and S. Legutko. Comparative assessment of the mechanical and electromagnetic surfaces of explosively clad Ti–steel plates after drilling process. Precision Engineering, 47:104–110, Jan. 2017. doi: 10.1016/j.precisioneng.2016.07.011.
[5] R. Chudy and W. Grzesik. Comparison of power and energy consumption for hard turning and burnishing operations of 41CR4 steel. Journal of Machine Engineering, 15, 2015.
[6] Y.K. Chou and H. Song. Tool nose radius effects on finish hard turning. Journal of Materials Processing Technology, 148(2):259–268, 2004. doi: 10.1016/j.jmatprotec.2003.10.029.
[7] R. Meyer, J. Köhler, and B. Denkena. Influence of the tool corner radius on the tool wear and process forces during hard turning. The International Journal of Advanced Manufacturing Technology, 58(9):933–940, 2012. doi: 10.1007/s00170-011-3451-y.
[8] W. Grzesik, B. Denkena, K. Zak, T. Grove, and B. Bergmann. Energy consumption characterization in precision hard machining using CBN cutting tools. The International Journal of Advanced Manufacturing Technology, 85(9):2839–2845, 2016. doi: 10.1007/s00170-015-8091-1.
[9] Sandvik Coromant. Machining Handbook. www.sandvik.coromant.com.
[10] W. Grzesik and K. Zak. Producing high quality hardened parts using sequential hard turning and ball burnishing operations. Precision Engineering, 37(4):849–855, 2013. doi: 10.1016/j.precisioneng.2013.05.001.
[11] W. Grzesik, J. Rech, and K. Zak. Characterization of surface textures generated on hardened steel parts in high-precision machining operations. The International Journal of Advanced Manufacturing Technology, 78(9-12):2049–2056, 2015. doi: 10.1007/s00170-015-6800-4.
[12] H.A. Kishawy, A. Haglund, and M. Balazinski. Modelling of material side flow in hard turning. CIRP Annals – Manufacturing Technology, 55(1):85–88, 2006. doi: 10.1016/S0007-8506(07)60372-2.
[13] W. Grzesik. Generation and modelling of surface roughness in machining using geometrically defined cutting tools. In J.P. Davim, editor, Metal Cutting, chapter 6. Nova Science Publishers, New York, 2010.
[14] N. Schaal, F. Kuster, and K. Wegener. Springback in metal cutting with high cutting speeds. Procedia CIRP, 31:24–28, 2015. doi: 10.1016/j.procir.2015.03.065.
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Authors and Affiliations

Krzysztof Żak
1
  1. Faculty of Mechanical Engineering, Opole University of Technology, Poland

The application of a minimum specific energy concept for a fish ladder design

Michał Kubrak Błażej Smoliński Jaromír Riha Apoloniusz Kodura Paweł Popielski Kamil Jabłoński
Archives of Civil Engineering | 2022 | vol. 68 | No 1 | 555-568 | DOI: 10.24425/ace.2022.140185
Keywords fish ladder dam specific energy critical flow
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Abstract

Structural solutions in terms of fish ladders and the use of natural materials to construct them often raise concerns regarding the possibility of using the standard calculation methods. The fish ladder being designed on the Wisłok river consists of three pools, separated from each other by baffles made of rock boulders. The purpose of this study was to analyze water surface profiles for fish ladder at specific values of flow rates. The paper presents the results of hydraulic calculations under the conditions of constant flow rate based on the concept of a minimum specific energy. According to this method, water flow through boulders is critical. Thus, it does not take into account head losses, which are hard to estimate and which are the integral part of typical calculation methods, e.g. the use of equations to determine the flow rate of a weir. An additional advantage of this method is that there is no need to assume the flow pattern of one specific weir. Verification calculations of the water depths were conducted using the HEC–RAS software, under an assumption of an one-dimensional steady water flow. Water depths in the fish ladder, calculated using both methods, were similar, despite the adopted different calculation concepts, and can be used in ichthyologic analyses.
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Authors and Affiliations

Michał Kubrak
1
ORCID: ORCID
Błażej Smoliński
1
ORCID: ORCID
Jaromír Riha
2
ORCID: ORCID
Apoloniusz Kodura
1
ORCID: ORCID
Paweł Popielski
1
ORCID: ORCID
Kamil Jabłoński
3
  1. Warsaw University of Technology, Faculty of Building Services, Hydro and Environmental Engineering, ul. Nowowiejska 20, 00-653 Warsaw, Poland
  2. Brno University of Technology, Faculty of Civil Engineering, Veverí 331/95, 602 00 Brno, Czech Republic
  3. Energoprojekt-Warszawa SA, Al. Niepodległosci 58, 02-626 Warsaw, Poland

Energy analysis of a laboratory process of water desalination by pervaporation and reverse osmosis

Izabela Gortat Joanna Marszałek Paweł Wawrzyniak
Chemical and Process Engineering: New Frontiers | 2024 | vol. 45 | No 1 | e48 | DOI: 10.24425/cpe.2023.147407
Keywords specific energy consumption water desalination pervaporation reverse osmosis laboratory processes
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Abstract

Fresh water is essential for life. More and more countries around the world are facing scarcity of drinking water, which affects over 50% of the global population. Due to human activity such as industrial development and the increasing greenhouse effect, the amount of drinking water is drastically decreasing. To address this issue, various methods of sea and brackish water desalination are used. In this study, an energy analysis (specific energy consumption, SEC) of two laboratory membrane processes, reverse osmosis (RO) and pervaporation (PV), was conducted. A model feed system saline water at 0.8, and 3.5% wt. NaCl was used. The efficiency and selectivity of membranes used in PV and RO were examined, and power of the devices was measured. The desalination processes were found to have a high retention factor (over 99%) for both PV and RO. For PV, the permeate fluxes were small but they increased with increasing feed flow rate, process temperature and salt content in the feed. The calculated SEC values for both laboratory processes ranged from 2 to 70 MWh/m 3. Lowering the process temperature, which consumes 30 to 60% of the total energy used in the PV process, can be an important factor in reducing energy consumption.
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Authors and Affiliations

Izabela Gortat
1
ORCID: ORCID
Joanna Marszałek
1
ORCID: ORCID
Paweł Wawrzyniak
1
  1. Lodz University of Technology, Faculty of Process and Environmental Engineering, Wólczańska 213, 93-005 Łódź, Poland

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