Thermal stresses during electro-chemical spark machining
The high temperature distribution generated during electro-chemical spark machining (ECSM) results in large localised thermal stresses in a very small heat affected zone. These thermal stresses can lead to micro-cracks and a decrease in strength and fatigue life of the components. A finite element model is developed to estimate the temperature distribution and thermal stresses due to a single spark (Gaussian distributed heat flux) and within the zone of influence of a single spark. Firstly, the finite element based (FEM) code is developed to estimate temperature distribution in the workpiece due to a single spark and, based on this temperature distribution, thermal stresses are calculated. Thermal stress analysis shows high temperature gradient zones and the regions of large stresses where, sometimes, they exceed the material yield strength.
Experimental Investigations into Electrochemical Spark Machining of Composites
Reports have indicated the poor performance of the conventional type of cutting tools during machining of composites. In this paper electrochemical spark machining (ECSM) for the cutting and drilling of holes in the composites is being proposed. The feasibility of using ECSM for composites was first ascertained. Then, kevlar-fiber-epoxy and glass-fiber-epoxy composites as work material, copper as tool material, and an aqueous solution of NaCl as electrolyte were used. It has been concluded that the ECSM is a viable solution for cutting of Fiber Reinforced Plastics (FRP). For achieving desired accuracy, surface finish, and economics of the process, the machining parameters should be optimized.
Mechanical behaviour and durability of high volume fly ash cementitious composites
The purpose of this research is to separate different morphological particles of ASTM class F fly ash, and study their effect on mechanical behaviour and durability of high volume cementitious mixtures. In this research wet separation of raw fly ash is carried out, which resulted in three layers of different morphological particles. The first layer of particles float, comprise of about 1-5% of fly ash, is identified as cenospheres or hollow spheres. The second layer of particles is measured to be 55-60% of raw fly ash and consisting of porous spherical and rounded particles rich in Si and Al. The third layer particles is measured to be about 35-40% of raw fly ash. High volume fly ash cementitious composites containing second or third layer particles are tested under compression and bending, highlighting a higher strength and ductility in comparison to cementitious ones containing raw fly ash particles. KEYWORDS. Cementitious matrix; Raw fly ash; Second layer particles; Third layer particles.