Search Results (663)

Carbon fiber (CF) and carbon fiber-reinforced polymers (CFRPs) are widely used in the aerospace, automotive, and energy sectors due to their high strength, stiffness, and low density. However, significant waste is generated during manufacturing and after the use of CFRPs. Traditional disposal methods like landfilling and incineration are unsustainable. CFRP machining processes, such as drilling and milling, produce fine chips and dust that are difficult to recycle due to their heterogeneity and contamination. This study investigates the oxidation behavior of CFRP drilling waste from two types of materials (tube and plate) under oxidative (non-inert) conditions. Thermogravimetric analysis (TGA) was performed from 200 °C to 800 °C to assess weight loss related to polymer degradation and carbon fiber integrity. Scanning electron microscopy (SEM) was used to analyze morphological changes and fiber damage. The optimal range for removing the polymer matrix without significant fiber degradation has been identified as 500–600 °C. At temperatures above 700 °C, notable surface and internal fiber damage occurred, along with nanostructure formation, which may pose health and environmental risks. The results show that partial fiber recovery is possible under ambient conditions, and this must be considered regarding the harmful risks to the human body if submicron particles are inhaled. This research supports sustainable CFRP recycling and fire hazard mitigation. Full article

Manufacturing in modern industrial sectors involves the machining of components where the undeformed chip thickness inevitably decreases to values comparable to the tool edge radius. Under such conditions, the ploughing effect between the workpiece and the tool becomes dominant, followed by the noticeable formation of a stagnation zone. This paper presents research focused on the analysis of the cutting process for small cross-sections of the removed layers, based on cutting force components. This study investigated the machining of two titanium alloy grades—Ti Grade 5 (Ti-6Al-4V) and Ti Grade 2—with the main focus on process stability. A material separation model was analyzed to demonstrate the mechanism of material flow within the cross-section of the machined layer. It was found that the material has a limited ability to flow sideways at the boundary of the chip thickness, thus determining the probable size of the stagnation zone in front of the cutting edge. Orthogonal cutting experiments enabled the determination of the minimum chip thickness coefficient for constant temperature conditions, independent of the tool edge radius, as $h_{min0}=$0.313. In oblique cutting tests, the sensitivity of thin-layer machining was demonstrated for the determined values of minimum undeformed chip thickness. By applying the 0–1 test for chaos, the measurement time (parameter $T·dt$) was determined for both titanium alloys to determine the range of observable chaotic behavior. The analyses confirmed that Ti Grade 2 enters chaotic dynamics much more rapidly than Ti Grade 5 and displays local cutting instabilities independent of the uncut chip thickness. Full article

Stainless steel is recognized for its excellent durability and anti-corrosion properties, which are essential qualities across various industrial applications. The machining of stainless steel, particularly under a dry environment to attain sustainability, poses several challenges. The poor heat conductivity and high ductility of stainless steel results in poor heat distribution, accelerating tool wear and problematic chip formation. To mitigate these challenges, the implementation of surface texturing has been identified as a beneficial strategy. This study investigates the impact of wave-type texturing patterns, developed on the flank surface of tungsten carbide ceramic tool inserts, on the machinability of AISI 316 stainless steel under dry cutting conditions. In this investigation, chip morphology and surface roughness were used as key indicators of machinability. Analysis of Variance (ANOVA) was conducted for chip thickness, chip thickness ratio, and surface roughness, while Taguchi mono-objective optimization was applied to chip thickness. The ANOVA results showed that linear models accounted for 71.92%, 83.13%, and 82.86% of the variability in chip thickness, chip thickness ratio, and surface roughness, respectively, indicating a strong fit to the experimental data. Microscopic analysis confirmed a substantial reduction in chip thickness, with a minimum observed value of 457.64 µm. The corresponding average surface roughness Ra value 1.645 µm represented the best finish across all experimental runs, highlighting the relationship between thinner chips and enhanced surface quality. In conclusion, wave textures on the cutting tool’s flank face have the potential to facilitate the dry machining of AISI 316 stainless steel to obtain favorable machinability. Full article

Assessing wood moisture and density is essential to understanding ecological processes such as tree growth and wood formation. This study compared basic density and moisture content estimates for three Catalpa species (Catalpa ovata G. Don, Catalpa bungei C. A. Mey, and Catalpa fargesii Bureau) using three sampling methods (incremental cores, wood chips, and standard wood blocks). While strong correlations (r² ≥ 0.99) were observed among all methods, the incremental core approach exhibited significant species-specific biases—overestimating density by 27.31–12.31% on average while underestimating moisture content by 5.61–30.51%. Despite its cost-effectiveness and minimal sample collection requirements, the method’s systematic deviations limit its applicability to multiple tree species. Consequently, we recommend developing species-specific linear calibration models that incorporate baseline data from standard wood block measurements to substantially improve estimation accuracy. This approach offers a practical, theory-supported solution for optimizing field sampling strategies in ecological research. Full article

The extensive utilization of the Snappy compression algorithm in digital devices such as smartphones, IoT, and digital cameras has played a crucial role in alleviating demands on network bandwidth and storage space. This paper presents an improved Snappy compression algorithm optimized for implementation on field programmable gate arrays (FPGAs). The proposed algorithm enhances the compression ratio by refining the encoding format of Snappy and introduces an innovative approach utilizing fingerprints within the dictionary to minimize storage space requirements. Additionally, the algorithm incorporates a pipeline structure to optimize performance. Experimental results demonstrate that the proposed algorithm achieves a throughput of 1.6 GB/s for eight hardware kernels. The average compression ratio is 2.27, representing a 6.1% improvement over the state-of-the-art Snappy FPGA implementation. Notably, the proposed algorithm architecture consumes fewer on-chip storage resources compared to other advanced algorithms, striking a balance between logic and storage resource utilization. This optimization leads to higher FPGA resource utilization efficiency. Our design addresses the growing demand for efficient lossless data compression solutions in consumer electronics, ultimately contributing to advancements in modern digital ecosystems. Full article

The use of aluminum honeycomb structures is fast expanding in advanced sectors such as the aeronautics, aerospace, marine, and automotive industries. However, processing these structures represents a major challenge for producing parts that meet the strict standards. To address this issue, an innovative manufacturing method using longitudinal ultrasonic vibration-assisted cutting, combined with a CDZ10 hybrid cutting tool, was developed to optimize the efficiency of traditional machining processes. To this end, a 3D numerical model was developed using the finite element method and Abaqus/Explicit 2017 software to simulate the complex interactions among the cutting tool and the thin walls of the structures. This model was validated by experimental tests, allowing the study of the influence of milling conditions such as feed rate, cutting angle, and vibration amplitude. The numerical results revealed that the hybrid technology significantly reduces the cutting force components, with a decrease ranging from 10% to 42%. In addition, it improves cutting quality by reducing plastic deformation and cell wall tearing, which prevents the formation of chips clumps on the tool edges, thus avoiding early wear of the tool. These outcomes offer new insights into optimizing industrial processes, particularly in fields with stringent precision and performance demands, like the aerospace sector. Full article

Blood is a widely used sample for diagnosing diseases such as malaria and diabetes. While diagnostic techniques have advanced, sample preparation remains labor-intensive, requiring steps like mixing and centrifugation. Microfluidic technologies have automated parts of this process, including cell lysis, yet challenges persist. Electrical lysis offers a chemical-free, continuous approach, but lysing small cells like red blood cells requires high electric fields, which can damage electrodes and cause system failures. Here, we present a microfluidic device utilizing ion concentration polarization (ICP) for rapid blood cell lysis at 75 V. Fluorescence imaging confirmed the formation of an ion depletion region near the Nafion^® nanochannel membrane, where the electric field was concentrated across the entire microchannel width. This phenomenon enabled the efficient trapping and lysis of blood cells under these conditions. Continuous blood injection achieved a lysis time of 0.3 s with an efficiency exceeding 99.4%. Moreover, lysed cell contents accumulated near the Nafion membrane, forming a concentrated lysate. This approach eliminates the need for high-voltage circuits or chemical reagents, offering a simple yet effective method for blood cell lysis. The proposed device is expected to advance lab-on-a-chip and point-of-care diagnostics by enabling rapid and continuous sample processing. Full article

Ball-end milling cutters are normally used for complex surface machining. During the milling process, the tool posture and cutting parameters of the ball-end milling cutters have a significant impact on chip formations and morphological changes. Based on the Cutter Workpiece Engagement (CWE) model, this study establishes a chip flow model for ball-end milling cutters with consideration of the tool posture variation. The machining experiments of Ti-6Al-4V with a 15° inclined plane and different feed directions were carried out. The influence mechanism of time-varying tool posture on chip formation was systematically investigated. The results reveal an interaction between the chip flow direction and the cutting velocity direction. The included angle between the chip flow directions at the maximum and minimum contact points in the CWE area affects the degree of chip curling, with a smaller angle leading to weaker curling. This research provides a theoretical foundation for the optimization of posture parameters of ball-end milling cutters and expounds on the influence of the chip flow angle on chip deformation. Full article

Optically pumped semiconductor disk lasers—known as vertical-external-cavity surface-emitting lasers (VECSELs)—are promising devices for ultrashort pulse formation. For it, a “SESAM-free” approach labeled “self-mode-locking” received considerable attention in the past decade, relying solely on a chip-related nonlinear optical property which can establish adequate pulsing conditions—thereby suggesting a reduced reliance on a semiconductor saturable-absorber mirror (the SESAM) in the cavity. Self-mode-locked (SML) VECSELs with sub-ps pulse durations were reported repeatedly. This motivated investigations on a Kerr-lensing type effect acting as an artificial saturable absorber. So-called Z-scan and ultrafast beam-deflection experiments were conducted to emphasize the role of nonlinear lensing in the chip for pulse formation. Recently, in addition to allowing stable ultrashort pulsed operation, self-starting mode-locked operation gave rise to another emission regime related to frequency comb formation. While amplitude-modulated combs relate to signal peaks in time, providing a so-called pulse train, a frequency-modulated comb is understood to cause quasi continuous-wave output with its sweep of instantaneous frequency over the range of phase-locked modes. With gain-bandwidth-enhanced chips, as well as with an improved understanding of the impacts of dispersion and nonlinear lensing properties and cavity configurations on the device output, an enhanced employment of SML VECSELs is to be expected. Full article

During the machining of unidirectional carbon fiber-reinforced polymers (UD-CFRPs), their anisotropic characteristics and the complex cutting conditions often lead to defects such as delamination, burrs, and surface/subsurface damage. This study systematically investigates the effects of different fiber orientation angles (0°, 45°, 90°, and 135°) on cutting force, chip formation, stress distribution, and damage characteristics using a coupled macro–micro finite element model. The model successfully captures key microscopic failure mechanisms, such as fiber breakage, resin cracking, and fiber–matrix interface debonding, by integrating the anisotropic mechanical properties and heterogeneous microstructure of UD-CFRPs, thereby more realistically replicating the actual machining process. The cutting speed is kept constant at 480 mm/s. Experimental validation using T700S/J-133 laminates (with a 70% fiber volume fraction) shows that, on a macro scale, the cutting force varies non-monotonically with the fiber orientation angle, following the order of 0° < 45° < 135° < 90°. The experimental values are 24.8 N/mm < 35.8 N/mm < 36.4 N/mm < 44.1 N/mm, and the simulation values are 22.9 N/mm < 33.2 N/mm < 32.7 N/mm < 42.6 N/mm. The maximum values occur at 90° (44.1 N/mm, 42.6 N/mm), while the minimum values occur at 0° (24.8 N/mm, 22.9 N/mm). The chip morphology significantly changes with fiber orientation: 0° produces strip-shaped chips, 45° forms block-shaped chips, 90° results in particle-shaped chips, and 135° produces fragmented chips. On a micro scale, the microscopic morphology of the chips and the surface damage characteristics also exhibit gradient variations consistent with the experimental results. The developed model demonstrates high accuracy in predicting damage mechanisms and material removal behavior, providing a theoretical basis for optimizing CFRP machining parameters. Full article

During the dry machining of 6061 aluminum alloy, cemented carbide tools often suffer from severe wear and built-up edge (BUE) formation, which significantly shortens tool life. Inspired by the non-smooth surface structure of dung beetles, this study proposes an elliptical dimple–groove composite bionic micro-texture, applied to the rake face of cemented carbide tools to enhance their cutting performance. Four types of tools with different surface textures were designed: non-textured (NT), single-groove texture (PT), circular dimple–groove composite texture (AKGC), and elliptical dimple–groove composite texture (TYGC). The cutting performance of these tools was analyzed through three-dimensional finite element simulations using the Deform-3D (version 11.0, Scientific Forming Technologies Corporation, Columbus, OH, USA) software program. The results showed that, compared to the NT tool, the TYGC tool exhibited the best performance, with a reduction in the main cutting force of approximately 30%, decreased tool wear, and significantly improved chip-breaking behavior. Based on the simulation results, a response surface model was constructed to optimize key texture parameters, and the optimal texture configuration was obtained. In addition, a theoretical model was developed to reveal the mechanism by which the micro-texture reduces interfacial friction and temperature rises by shortening the effective contact length. To verify the accuracy of the simulation and theoretical analysis, cutting experiments were further conducted. The experimental results were consistent with the simulation trends, and the TYGC tool demonstrated superior performance in terms of cutting force reduction, smaller adhesion area, and more stable cutting behavior, validating both the simulation model and the proposed texture design. This study provides a theoretical foundation for the structural optimization of bionic micro-textured cutting tools and offers an in-depth exploration of their friction-reducing and wear-resistant mechanisms, showing promising potential for practical engineering applications. Full article

Rock-breaking cutters are critical components in tunneling, mining, and drilling operations, where efficiency, durability, and energy consumption are paramount. Traditional cutter designs and empirical process optimization methods often fail to address the dynamic interaction between heterogeneous rock masses and tool structures, leading to premature wear, high specific energy, and suboptimal performance. Topology optimization, as an advanced computational design method, offers transformative potential for lightweight, high-strength cutter structures and adaptive cutting process control. This review systematically examines recent advancements in topology-optimized cutter design and its integration with rock-cutting mechanics. The structural innovations in cutter geometry and materials are analyzed, emphasizing solutions for stress distribution, wear/fatigue resistance, and dynamic load adaptation. The numerical methods for modeling rock–tool interactions are introduced, including discrete element method (DEM) simulations, smoothed particle hydrodynamics (SPH) methods, and machine learning (ML)-enhanced predictive models. The cutting process optimization strategies that leverage topology optimization to balance objectives such as energy efficiency, chip formation control, and tool lifespan are evaluated. Full article

This work presents a novel microfabrication process that addresses the interference of thiol groups on off-stoichiometry thiolene (OSTE) surfaces with the curing of polydimethylsiloxane (PDMS) by integrating the high-performance polymer Parylene-C. The process utilizes a Parylene-C coating to encapsulate the active thiol groups on the OSTE surface, enabling precise replication of PDMS microstructures. Based on this method, PDMS micropillar arrays and microwell arrays were successfully fabricated and applied in passive plasma separation and polymorphic crystal formation, respectively. The experimental results demonstrate that the plasma-separation chip efficiently isolates plasma from whole-blood samples with varying hematocrit (HCT) levels, achieving a separation efficiency of up to 57.5%. Additionally, the microwell array chip exhibits excellent stability and controllability in the growth of salt and protein crystals. This study not only provides a new approach for microfabricating microfluidic chips, but also highlights its potential applications in biomedical diagnostics and materials science. Full article

Rapid mixing is widely prevalent in the field of microfluidics, encompassing applications such as biomedical diagnostics, drug delivery, chemical synthesis, and enzyme reactions. Mixing efficiency profoundly impacts the overall performance of these devices. However, at the micro-scale, the flow typically presents as laminar flow due to low Reynolds numbers, rendering rapid mixing challenging. Leveraging the vortices within a droplet of the Taylor flow and inducing chaotic convection within the droplet through serpentine channels can significantly enhance mixing efficiency. Based on this premise, we have developed a droplet micromixer that integrates the T-shaped channels required for generating Taylor flow and the serpentine channels required for inducing chaotic convection within the droplet. We determined the range of inlet liquid flow rate and gas pressure required to generate Taylor flow and conducted experimental investigations to examine the influence of the inlet conditions on droplet length, total flow rate, and mixing efficiency. Under conditions where channel dimensions and liquid flow rates are identical, Taylor flow achieves a nine-fold improvement in mixing efficiency compared to single-phase flow. At low Reynolds number (0.57 ≤ Re ≤ 1.05), the chip can achieve a 95% mixing efficiency within a 2 cm distance in just 0.5–0.8 s. The mixer proposed in this study offers the advantages of simplicity in manufacturing and ease of integration. It can be readily integrated into Lab-on-a-Chip devices to perform critical functions, including microfluidic switches, formation of nanocomposites, synthesis of oxides and adducts, velocity measurement, and supercritical fluid fractionation. Full article

Compared to the traditional flip-chip bonded focal plane array, in high-density vertically integrated photodiode (HDVIP) focal plane technology, the thickness of the mercury cadmium telluride (MCT or Hg_1−xCd_xTe) layer serves as a more critical parameter. This parameter not only influences the efficiency of photon energy absorption but also defines the pn junction area, thereby affecting the magnitude of the dark current. Furthermore, it significantly impacts the manufacturability of via-hole etching and formation processes. This paper investigated the photonic crystal resonances and coherent perfect absorption (CPA) effect of a thin MCT layer in HDVIP by using COMSOL Multiphysics^® 4.3b and optimized the structure of the loop-hole photodiode device. The CPA, which is formed by this structure, achieves high absorption of illumination in a very thin MCT film. It is demonstrated that an absorption rate of infrared radiation of more than 95% with a wavelength during the 8 µm–10 µm range can be achieved in Hg_1−xCd_xTe (x = 0.225) with a thickness of only 1.5 µm–3 µm. The benefit of thinner MCT film is that it decreases the dark current of pn junction and reduces the technical difficulty of etching and metallization of the loop-hole photodiode. Full article