Effect of Different Cooling Strategies on Surface Quality and Power Consumption in Finishing End Milling of Stainless Steel 316.

In this paper, an experimental investigation into the machinability of AISI 316 alloy during finishing end milling operation under different cooling conditions and with varying process parameters is presented. Three environmental-friendly cooling strategies were utilized, namely, dry, minimal quantity lubrication (MQL) and MQL with nanoparticles (Al2O3), and the variable process parameters were cutting speed and feed rate. Power consumption and surface quality were utilized as the machining responses to characterize the process performance. Surface quality was examined by evaluating the final surface roughness and surface integrity of the machined surface. The results revealed a reduction in power consumption when MQL and MQL + Al2O3 strategies were applied compared to the dry case by averages of 4.7% and 8.6%, respectively. Besides, a considerable reduction in the surface roughness was noticed with average values of 40% and 44% for MQL and MQL + Al2O3 strategies, respectively, when compared to the dry condition. At the same time, the reduction in generated surface roughness obtained by using MQL + Al2O3 condition was marginal (5.9%) compared with using MQL condition. Moreover, the results showed that the improvement obtained in the surface quality when using MQL and MQL + Al2O3 coolants increased at higher cutting speed and feed rate, and thus, higher productivity can be achieved without deteriorating final surface quality, compared to dry conditions. From scanning electron microscope (SEM) analysis, debris, furrows, plastic deformation irregular friction marks, and bores were found in the surface texture when machining under dry conditions. A slight smoother surface with a nano-polishing effect was found in the case of MQL + Al2O3 compared to the MQL and dry cooling strategies. This proves the effectiveness of lubricant with nanoparticles in reducing the friction and thermal damages on the machined surface as the friction marks were still observed when machining with MQL comparable with the case of MQL + Al2O3.

Sonocogreen Decoration of Clinoptilolite by CaO Nanorods as Ecofriendly Catalysts in the Transesterification of Castor Oil into Biodiesel; Response Surface Studies.

A CaO/clinoptilolite green nanocomposite (CaO/Clino) was synthesized by a green modification technique using calcium nitrate and green tea extract. The CaO/Clino nanocomposite promises a total basicity of 4.82 mmol OH/g, surface area of 252.4 m2/g, and ion exchange capacity of 134.3 mequiv/100 g, which qualifies the product as an effective catalyst in the transesterification of castor oil. The transesterification performance of the CaO/Clino catalyst was addressed statistically based on the response surface methodology and central composite rotatable design, considering the essential experimental parameters. Based on the interaction effect between the studied variables, the CaO/Clino catalyst can achieve an experimental biodiesel yield of 93.8% after 2.5 h at 120 °C with 3.5 wt % catalyst loading and 15:1 ethanol/castor oil molar ratio. The optimization function of the design suggested enhancement in the performance of the CaO/Clino catalyst to achieve a yield of 95.4% if the test time interval increased to 2.65 h and the ethanol content increased to 16:1 as a molar ratio to castor oil. The produced biodiesel over CaO/ClinO has acceptable technical qualifications according to the international requirements (EN 14214 and ASTM D-6751). The synthetic green CaO/Clino nanocomposite has better recyclability as a heterogeneous catalyst and higher activity than some investigated catalysts in literature.

Insights into the green doping of clinoptilolite with Na+ ions (Na+/Clino) as a nanocatalyst in the conversion of palm oil into biodiesel; optimization and mechanism.

The critical demand for eco-friendly, renewable, and safe energy resources is an essential issue encountered in the contemporary world. The catalytic transesterification of plant oils into biodiesel was assessed as promising a technique for providing new forms of clean and safe fuel. Natural clinoptilolite was doped with Na+ ions by green chemical reactions between sodium nitrite and green tea extract, producing a novel modified structure (Na+/Clino). The Na+/Clino product had an enhanced total basicity (6.41 mmol OH/g), ion exchange capacity (387 meq/100 g), and surface area (312.7 m2 g-1), which qualified it to be used as a potential basic catalyst for the transesterification of palm oil. Transesterification tests were statistically assessed using a response surface methodology and a central composite design. Considering the effect of how the significant factors interact with each other, the synthetic Na+/Clino achieved a 96.4% experimental biodiesel yield after 70 min at 100 °C in the presence of 2.75 wt% catalyst loading and a 12.5:1 methanol-to-palm-oil ratio. Based on the optimization function of the statistical model, the performance of Na+/Clino can theoretically be enhanced to increase the yield to 98.2% by expanding the test time to 85 min and the loading value to 3 wt%. The product yielded by the Na+/ClinO process is of adequate technical properties, considering the international levels for standard biodiesel (EN 14214 and ASTM D-6751). Finally, the prepared green Na+ doped clinoptilolite had excellent recyclability as a heterogeneous basic catalyst and displayed higher efficiency than several species of previously studied heterogeneous and homogenous catalysts.

Insight into carbohydrate polymers (chitosan and 2- hydroxyethyl methacrylate/methyl methacrylate) intercalated bentonite-based nanocomposites as multifunctional and environmental adsorbents for methyl parathion pesticide.

Two-hybrid products of bentonite intercalated carbohydrate polymers (chitosan (BE.P.CH) and 2- hydroxyethyl methacrylate/methyl methacrylate copolymer (BE/P.HEMA/MMA)) were synthesized as enhanced adsorbents for methyl parathion pesticide (MPP). The intercalation processes induced the affinity and the capacity of bentonite achieving the best value at pH 8. The maximum MPP adsorption capacities of BE (287.3 mg/g), BE/P.CH (634.5 mg/g), and BE/P.HEMA-MMA (868.5 mg/g) obtained after 300 min, 240 min, and 360 min, respectively. The kinetic properties of BE follow the Pseudo-second order behavior (R2 = 0.93) while BE/P.CH and BE/P.HEMA-MMA are of Pseudo-First order behavior (R2 > 0.92). Based on the equilibrium studies, the three products are of Freundlich isotherm behavior (R2 > 0.9) and the uptake is of multilayer forms on heterogeneous surfaces. The Gaussian energies (>8 KJ/mol), Gibbs free energies (>20 to <40 KJ/mol), and enthalpies (>40 to <80 KJ/mol) give an indication about adsorption mechanism involved chemical and physical reactions. The thermodynamics of MPP uptake reactions by the three products are of endothermic and spontaneous behaviors. The MPP uptake in the presence of NH+4, PO4-3, Mn+2, and Pb+2 competitive ions reflects enhancement in the affinity of BE after the integration between it and the selected polymers.

Enhancing the removal of organic and inorganic selenium ions using an exfoliated kaolinite/cellulose fibres nanocomposite.

Exfoliated kaolinite sheets/cellulose fibres nanocomposite (EXK/CF) was synthesised as a novel hybrid of materials of enhanced surface area and adsorption capacities for inorganic-selenate [Se(VI)] and selenite [Se(IV)]-and organic selenium pollutants-selenomethionine (SeMt). The adsorption reactions of the addressed selenium forms followed pseudo-first-order as a kinetic model and Langmuir as an isotherm model. The fitting results and the calculated Gaussian energies-Se (VI) at 2.0 KJ/mol, Se (IV) at 2.2 KJ/mol, and SeMt at 1.7 KJ/mol-suggested physisorption uptake in a monolayer and homogeneous form. The theoretical maximum selenium uptake capacity (qmax) for Se (VI), Se (IV), and SeMt was 137.5 mg/g, 161.4 mg/g, and 95.4 mg/g, respectively. The thermodynamic investigation verified spontaneous and exothermic properties of the selenium uptake reactions by the EXK/CF composite.

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts.

This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel.

Multi-Response Optimization in High-Speed Machining of Ti-6Al-4V Using TOPSIS-Fuzzy Integrated Approach.

Titanium alloys are widely used in various applications including biomedicine, aerospace, marine, energy, and chemical industries because of their superior characteristics such as high hot strength and hardness, low density, and superior fracture toughness and corrosion resistance. However, there are different challenges when machining titanium alloys because of the high heat generated during cutting processes which adversely affects the product quality and process performance in general. Thus, optimization of the machining conditions while machining such alloys is necessary. In this work, an experimental investigation into the influence of different cutting parameters (i.e., depth of cut, cutting length, feed rate, and cutting speed) on surface roughness (Rz), flank wear (VB), power consumption as well as the material removal rate (MRR) during high-speed turning of Ti-6Al-4V alloy is presented and discussed. In addition, a backpropagation neural network (BPNN) along with the technique for order of preference by similarity to ideal solution (TOPSIS)-fuzzy integrated approach was employed to model and optimize the overall cutting performance. It should be stated that the predicted values for all machining outputs demonstrated excellent agreement with the experimental values at the selected optimal solution. In addition, the selected optimal solution did not provide the best performance for each measured output, but it achieved a balance among all studied responses.

WS2: A New Window Layer Material for Solar Cell Application.

Radio frequency (RF) magnetron sputtering was used to deposit tungsten disulfide (WS2) thin films on top of soda lime glass substrates. The deposition power of RF magnetron sputtering varied at 50, 100, 150, 200, and 250 W to investigate the impact on film characteristics and determine the optimized conditions for suitable application in thin-film solar cells. Morphological, structural, and opto-electronic properties of as-grown films were investigated and analyzed for different deposition powers. All the WS2 films exhibited granular morphology and consisted of a rhombohedral phase with a strong preferential orientation toward the (101) crystal plane. Polycrystalline ultra-thin WS2 films with bandgap of 2.2 eV, carrier concentration of 1.01 × 1019 cm-3, and resistivity of 0.135 Ω-cm were successfully achieved at RF deposition power of 200 W. The optimized WS2 thin film was successfully incorporated as a window layer for the first time in CdTe/WS2 solar cell. Initial investigations revealed that the newly incorporated WS2 window layer in CdTe solar cell demonstrated photovoltaic conversion efficiency of 1.2% with Voc of 379 mV, Jsc of 11.5 mA/cm2, and FF of 27.1%. This study paves the way for WS2 thin film as a potential window layer to be used in thin-film solar cells.