Acoustic mirror effect increases prey detection distance in trawling bats

Many different and phylogenetically distant species of bats forage for insects above water bodies and take insects from and close to the surface; the so-called trawling behaviour. Detection of surface-based prey by echolocation is facilitated by acoustically smooth backgrounds such as water surfaces that reflect sound impinging at an acute angle away from the bat and thereby render a prey object acoustically conspicuous. Previous measurements had shown that the echo amplitude of a target on a smooth surface is higher than that of the same target in mid-air, due to an acoustic mirror effect. In behavioural experiments with three pond bats (Myotis dasycneme), we tested the hypothesis that the maximum distances at which bats can detect prey are larger for prey on smooth surfaces than for the same prey in an airborne situation. We determined the moment of prey detection from a change in echolocation behaviour and measured the detection distance in 3D space from IR-video recordings using stereo-photogrammetry. The bats showed the predicted increase in detection distance for prey on smooth surfaces. The acoustic mirror effect therefore increases search efficiency and contributes to the acoustic advantages encountered by echolocating bats when foraging at low heights above smooth water surfaces. These acoustic advantages may have favoured the repeated evolution of trawling behaviour.     

A case for 2-body material removal in prime LED sapphire substrate lapping and polishing

An alternative, and potentially better, means to process prime LED sapphire wafers is proposed. A brief history of material removal mechanisms suggests that brittle materials can be abraded in a ductile regime and that this can be a superior mode of removal. Advantages in material removal rate, surface finish and subsurface damage for a 2-body ductile removal of sapphire are shown relative to 3-body material removal. A major difficulty with this approach may be getting the LED manufacturing industry to understand that the appearance of the sapphire surface is quite different, unfamiliar yet predictable. Finally, some potential alternative process approaches are discussed that utilize 2-body material removal.     

Effects of spatial resolution of remotely sensed data on estimating urban impervious surfaces

Impervious surfaces are the result of urbanization that can be explicitly quantified, managed and controlled at each stage of land development. It is a very useful environmental indicator that can be used to measure the impacts of urbanization on surface runoff, water quality, air quality, biodiversity and microclimate. Therefore, accurate estimation of impervious surfaces is critical for urban environmental monitoring, land management, decision-making and urban planning. Many approaches have been developed to estimate surface imperviousness, using remotely sensed data with various spatial resolutions. However, few studies, have investigated the effects of spatial resolution on estimating surface imperviousness. We compare medium-resolution Landsat data with high-resolution SPOT images to quantify the imperviousness in Beijing, China. The results indicated that the overall 91% accuracy of estimates of imperviousness based on TM data was considerably higher than the 81% accuracy of the SPOT data. The higher resolution SPOT data did not always predict the imperviousness of the land better than the TM data. At the whole city level, the TM data better predicts the percentage cover of impervious surfaces. At the sub-city level, however, the ring belts from the central core to the urban-rural peripheral, the SPOT data may better predict the imperviousness. These results highlighted the need to combine multiple resolution data to quantify the percentage of imperviousness, as higher resolution data do not necessarily lead to more accurate estimates. The methodology and results in this study can be utilized to identify the most suitable remote sensing data to quickly and efficiently extract the pattern of the impervious land, which could provide the base for further study on many related urban environmental problems.     

Modelling feeding flow related shrinkage defects in aluminum castings

The process modelling of shape casting is geometrically complex and computationally very challenging. Besides the three-dimensional complex shapes with multiple domains, the defects of interest to industry arise as a consequence of the interaction amongst a range of phenomena. Conventionally, the key phenomena and defect prediction are modelled through empirical relations applied to the simulation results. Such approaches are neither comprehensive nor reliable. This paper presents a 3-D model that is capable of predicting the formation of shrinkage defects explicitly as a function of the interacting continuum phenomena, i.e. free surface flow, heat transfer, and solidification, in complex three-dimensional geometries which allows to identify the distinction between surface depression, surface connected cavities and internal cavities.The model solves the coupled macroscopic conservation equations for mass, momentum, and energy with a phase change during solidification. In the model, the volume deficit due to solidification can either be compensated by depression of the outside surface or by creating a cavity that initiates either on the surface or in the interior of the casting. The solidification morphology is taken into account by using a parameter, which depends on the fraction solid, in the momentum equation. By using an adapted free surface algorithm, it is suitable to predict surface connected defects: depressed surfaces and caved surfaces. A critical pressure serves as a criterion to open internal shrinkage cavities. The model does not need to search for connected zones to feed shrinkage, but the shrinkage distribution will automatically emerge from the continuity equation.This advanced shrinkage model has experimentally been validated successfully using two Al-Si alloys, a skin freezing eutectic alloy and a mushy freezing hypo-eutectic alloy.     

Analysis of machined surface quality in a single-pass of ball-end milling on Inconel 718

The ball-end milling process is widely used for generating three-dimensional sculptured surfaces with definite curvature. In such cases, variation of surface properties along the machined surface curvatures is not well understood. Therefore, this paper reports the effect of machining parameters on the quality of surface obtained in a single-pass of a ball-end milling cutter with varying chip cross-sectional area. This situation is analogous to generation of free form cavities, pockets, and round fillets on mould surfaces. The machined surfaces show formation of distinct bands as a function of instantaneous machining parameters along the periphery of cutting tool edge, chip compression and instantaneous shear angle. A distinct variation is also observed in the measured values of surface roughness and micro-hardness in these regions. The maximum surface roughness is observed near the tool tip region on the machined surface. The minimum surface roughness is obtained in the stable cutting zone and it increases towards the periphery of the cutter. Similar segmentation was observed on the deformed chips, which could be correlated with the width of bands on the machined surfaces. The sub-surface quality analysis in terms of micro-hardness helped define machining affected zone (MAZ). The parametric effects on the machining induced shear and residual stresses have also been evaluated.     

Model-Based Tampering for Improved Process Performance—An Application to Grinding of Shafts

This paper presents the model-based tampering (MBT) methodology to address performance degradation in complex nonlinear processes. MBT involves characterizing the dynamics of a process through experiments to derive nonlinear stochastic differential equation (n-SDE) models that can accurately and compactly represent a process, and using these models to dynamically compensate for the effects of process degradation on the performance. This research has yielded a new method to derive n-SDE models of complex processes through a signal-based reconstruction of Fokker-Planck equations.MBT was applied to control surface finish during cylindrical grinding of shafts of air bearings used in aircraft environmental control systems (ECS)—a core competency of Honeywell. It has been shown that n-SDE models help capture patterns in process outputs that cannot be captured using any simpler models, and that MBT reduces the surface finish variation by 62% over the current industry practice.     

An experimental investigation into micro ball end-milling of silicon

Silicon is a representative operational material for semiconductor and micro-electronics. In certain MEMS applications, it is required to fabricate three dimensional channels and complex pattern on silicon substrate. Such features are typically fabricated by photolithography and chemical etching. These processes have low productivity and have certain other limitations. Therefore, a viable switch-over from non-traditional fabrication processes to traditional machining is highly desired for improved productivity in high-mix low-volume production. However, machining of silicon by traditional process is extremely difficult due to its high brittleness. Even very small forces produced during machining can cause brittle fracture on silicon surface resulting in deteriorated surface quality. The fundamental principle in machining of a brittle material such as silicon is to achieve material removal through plastic deformation rather than crack propagation. This paper presents the experimental results of ductile-mode machining of silicon by micro ball end-milling. The workpiece surface was inclined to the rotational axes of the cutter to improve the surface finish. It was established experimentally that 15-μm deep, fracture-free slots can be machined on silicon wafer by micro ball end-milling if the feed rate is below a certain threshold. The influence of several machining parameters on the roughness of machined-surface was also investigated. Cubic boron nitride (CBN) is presented as much economical alternative tool-material to single-crystal diamond for machining silicon in ductile-mode.     

From large-scale to micromachining: A review of force prediction models

In this paper, a review of work performed in the area of force modelling in metal cutting processes is presented. Past and present trends are described and criticised to compare their relevance with current requirements. Several approaches are reviewed, such as empirical, mechanistic and analytical models. The models’ ability to predict forces, from rough machining to finish machining, is analysed.     

Parametric study along with selection of optimal solutions in dry wire cut machining of cemented tungsten carbide (WC-Co)

This work deals with parametric study of dry wire EDM (WEDM) process of cemented tungsten carbide. Experiments have been conducted using air as dielectric medium to investigate effects of pulse on time, pulse off time, gap set voltage, discharge current and wire tension on cutting velocity (CV) surface roughness (SR) and oversize (OS). Firstly, a series of exploratory experiments were carried out to identify appropriate gas and its pressure. Afterward, preliminary experiments were conducted to investigate effects of process parameters on dry WEDM characteristics and find appropriate ranges for each factor. Then a central composite rotatable method was employed to design experiments based on response surface methodology (RSM). Empirical models were developed to create relationships between process factors and responses by considering to analysis of variances (ANOVA). To increase the predictability of the process, intelligent models have been developed based on back-propagation neural network (BPNN) and accuracy of these models was compared with mathematical models based on root mean square error (RMSE) and prediction error percent (PEP). In order to select optimal solutions in the cases of single-objective and multi-objectives optimization problems, optimization includes two main approaches. First approach was based on mathematical model and desirability function. Also second approach was designed based on neural network and particle swarm optimization. These approaches were applied in both cases of single-objective and multi-objectives optimization problems and their results were compared with together. Results indicated that selection of air at inlet pressure of 1.5 bar is really appropriate for conducting experiments of next stages. Also, the BPNN creates more accurate prediction rather than mathematical model. Moreover, the BPNN-PSO approach was more efficient in optimization of process rather than mathematical model-desirability function in respect with validation tests.     

Evolution of locomotory attachment pads of hexapods

This study shows that, in their evolution, hexapods have convergently developed two distinctly different mechanisms to attach themselves to a variety of substrates during locomotion. The first mechanism is provided by hairy surfaces and the second one by smooth flexible pads. The main similarity of both mechanisms is that the structured pad surface or particular properties of pad materials guarantee a maximum real contact with diverse substrata, regardless of their microsculpture. Ten characters of the two alternative designs were coded and analyzed together with a data matrix containing 105 additional morphological characters of different stages and body parts. The analysis demonstrates that similar structures (arolium, euplantulae, hairy tarsomeres) have evolved independently in several hexapod lineages. The evolution of flight and the associated necessity of being able to cling to vegetation or other substrates are suggested to be major triggers for the evolution of attachment structures.     

Selection of Optimal Superfinishing Parameters

This paper is concerned with the selection of optimal superfinishing conditions. During superfinishing of cylindrical surfaces, an axially oscillating abrasive stone is pressed against a rotating workpiece. Experimental results are presented that show the effect of contact pressure, process kinematics, and grit size on superfinishing behavior. An optimal contact pressure is found at which the removal rate is maximized. The ratio of axial oscillation frequency to workpiece rotational frequency should be selected so as to avoid integer values, which result in low stock removal, and half values, which can lead to lobe formation. Finer grit stones provide smoother surface finishes but less stock removal; therefore, the grit size selected should be only fine enough to generate the required surface roughness.     

Intensification of adsorption process by using the pyrolytic char from waste tires to remove chromium(Ⅵ) from wastewater

Pyrolysis has the potential of transforming waste into valuable recyclable products. Pyrolytic char(PC) is one of the most important products from the pyrolysis of used tires. One of the most significant applications for pyrolytic char recovered is used for the removal of Cr(Ⅵ) in the wastewater effluent to control waste by waste. The surface chemistry properties of surface element distribution / concentration and chemical structure were examined for the pyrolytic char and the commercial activated carbon(CAC) respectively. The results showed that surfaces of PC possesses a large amount of ester and hydrocarbon graft, whereas there are mainly carbon functional components of C-OH, C=O and COOH on the surface of CAC. Therefore the surface electronegativity of PC is lower than that of CAC in the water. The repulsive interactions between the surfaces of PC and the negatively charged Cr(Ⅵ) ion are weaker than that of CAC, which results in an intensification of the adsorption process by the utilization of PC. The adsorption isotherms of Cr(Ⅵ) ion on the two kinds of carbons were determined experimentally. The larger adsorption amount on the PC in the case of Cr(Ⅵ) may be attributed mainly to its special surface micro-chemical environment. The mechanism of the removal Cr(Ⅵ) from aqueous solution was assumed to be the integration of adsorption and redox reaction. The adsorption was the rate-controlled step for Cr(Ⅵ) removal. The adsorption of Cr(Ⅵ) has been identified as pseudo-second- order kinetics. The rate constants of adsorption have been evaluated.     

盒形件拉深模CAD系统研究

此文介绍了作者自行开发的盒形件拉深模CAD系统的组成、功能以及编程中的若干技术问题。该系统人机对话界面友好,整个设计过程程序化程度高。系统运行时只需输入工件特征数据就可根据人机对话和菜单选项完成整个设计过程,最后输出工件图、毛坯图、排样图、工序图、模具零件图及总装图。     

Laser tempering based turning process for efficient machining of hardened AISI 52100 steel

Cost-effective machining of hardened steel components such as a large wind turbine bearing has traditionally posed a significant challenge. This paper presents an approach to machine hardened steel parts efficiently at higher material removal rates and lower tooling cost. The approach involves a two-step process consisting of laser tempering of the hardened workpiece surface followed by conventional machining at higher material removal rates with lower cost ceramic tools to efficiently remove the tempered material. The laser scanning parameters that yield the highest depth of tempered layer are obtained from a kinetic phase change model. Machining experiments are performed to demonstrate the possibility of higher material removal rates and improved tool wear behavior compared to the conventional hard turning process. Tool wear performance, cutting forces, and surface finish of Cubic Boron Nitride (CBN) tools as well as low cost ceramic tools are compared in machining of hardened AISI 52100 steel (~63 HRC). In addition, cutting forces and surface finish are compared for the laser tempering based turning and conventional hard turning processes. Experimental results show the potential benefits of the laser tempering based turning process over the conventional hard turning process.     

纤维干燥尾气余热利用中的积灰研究

在纤维干燥尾气的余热回收利用中,飞灰沉积会直接影响设备的安全高效运行,不利于木材工业的节能减排。阐述了飞灰沉积机理和数值模拟等研究现状。对于弹性球形颗粒的沉积,已获得了一些科学可靠的机理模型和论证结果,为灰污防治提供了合理的技术支持;关于柔性细长颗粒的沉积,仅取得少量的成果,需要进一步全面深入展开相关研究。     

Integrated assessment of urban environment in China

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Micro fabrication on cylinder surface for control of wettability

A micro fabrication is presented to control wettability on cylinder surfaces. A machine tool is developed to form the micro-scale structure on the cylinder in incremental stamping. The stamping tool is manufactured with fabricating the micro-scale structure on the top of the tool in FIB sputtering. The micro incremental stamping is repeated with linear motion of the tool and rotation of the workpiece. The rotation is controlled by the friction drive on the machine table because of the stable stamping with reducing bending of the workpiece. The critical stamping depth, the minimum depth in which the structure is formed, is determined in the forming tests using the structured tool. Then, a stripe type structure is formed to control wettability on the cylinder surface. Anisotropic wettability appears on the structured surface.     

Revealing photon transmission in an ultraviolet reactor: Advanced approaches for measuring fluence rate distribution in water for model validation

Fluence rate (FR) distribution (optical field) is of great significance in the optimal design of ultraviolet (UV) reactors for disinfection or oxidation processes in water treatment. Since the 1970s, various simulation models have been developed, which can be combined with computational fluidic dynamic software to calculate the fluence delivered in a UV reactor. These models strive for experimental validation and further improvement, which is a major challenge for UV technology in water treatment. Herein, a review of the simulation models of the FR distribution in a UV reactor and the applications of the current main experimental measurement approaches including conventional flat-type UV detector, spherical actinometer, and micro-fluorescent silica detector (MFSD), is presented. Moreover, FR distributions in a UV reactor are compared between various simulation models and MFSD measurements. In addition, the main influential factors on the FR distribution, including inner-wall reflection, refraction and shadowing effects of adjacent lamps, and turbidity effect are discussed, which is helpful for improving the accuracy of the simulation models and avoiding dark regions in the reactor design. This paper provides an overview on the simulation models and measurement approaches for the FR distribution, which is helpful for the model selection in fluence calculations and gives high confidence on the optimal design of UV reactors in regard to present methods.     

Production of separation-nozzle systems for uranium enrichment by a combination of X-ray lithography and galvanoplastics

X-ray lithography using synchrotron radiation has been applied in a multi-step process for the production of plastic moulds to be used in the fabrication of separation nozzles by electrodeposition. For characteristic dimensions of a few microns a total height of the nozzle structure of about 400 μm has been achieved. Structural details of about 0.1 μm are being reproduced across the total thickness of the polymer layer. The surface finish of metallic separation nozzles produced by electrodeposition was equivalent to the high quality of the polymer surface. The separation-nozzle systems fabricated by the described method allow an increase by a factor three of the gas pressure in separationnozzle plants as compared to the present standard. This results in considerable savings in the enrichment of ²³⁵U for nuclear power production.     

Experimental investigation of turning AISI 1045 steel using cryogenic carbon dioxide as the cutting fluid

The intensive temperatures in high speed machining not only limit the tool life but also impair the machined surface by inducing tensile residual stresses, microcracks and thermal damage. This problem can be handled largely by reducing the cutting temperature. When the conventional coolant is applied to the cutting zone, it fails to remove the extent of the heat effectively. Hence, a cryogenic coolant is highly recommended for this purpose. In this paper, an attempt has been made to use cryogenic carbon dioxide (CO₂) as the cutting fluid. Experimental investigations are carried out by turning AISI 1045 steel in which the efficiency of cryogenic CO₂ is compared to that of dry and wet machining with respect to cutting temperature, cutting forces, chip disposal and surface roughness. The experimental results show that the application of cryogenic CO₂ as the cutting fluid is an efficient coolant for the turning operation as it reduced the cutting temperature by 5%–22% when compared with conventional machining.It is also observed that the surface finish is improved to an appreciable amount in the finished work piece on the application of cryogenic CO₂. The surface finish is improved by 5%–25% in the cryogenic condition compared with wet machining.