板料变薄拉深过程中的润滑与模具设计

分析了常见的2种变薄拉深方法,指出要克服板料与模具接触面间由于强烈的摩擦造成磨损、烧粘、卡咬使模具失效,必须要进行有效的润滑。较详细的论述了变薄拉深时的润滑的机理和模具设计要点。     

某型波段开关瞬动动作特性及失效机理

目的 研究某型波段开关瞬动动作特性及磨损失效机理。方法 通过建立瞬动机构物理模型,进行瞬动机构滑动件受力分析、转动力矩随旋转角度变化分析,研究瞬动开关瞬动动作特性,分析并探讨瞬动机构的磨损失效机理。结果 在波段开关的瞬动角度范围内,瞬动力矩随着转动角度θ的增加呈先增大、后减小的趋势。在瞬动初始状态,旋转力矩为最小值1.2 kg·cm;当瞬动处于中间位置（瞬动角度为16°）时,转动力矩为最大值1.5 kg·cm;随着转动角度θ继续增大,转动力矩不断减小,最终恢复至初始值,与实物瞬动复位功能相符。瞬动机构滑动件受基座的正压力N随转动角度θ的增加而增大。基座塑料受过大压力产生磨损,使转动（复位）力矩降低,滑动件无法复位,导致瞬动功能失效。结论 某型波段开关瞬动功能由滑动件钢球、基座长弧形斜坡、接触压力保证,弧面磨损致使钢球所受接触压力分量不足,导致瞬动功能失效,该失效机制为疲劳磨损失效。可通过改变基座材料、滑动件结构或材料以及改善瞬动机构工作条件来提高瞬动寿命和可靠性。     

滨海发射场低温管路法兰连接螺栓环境腐蚀断裂失效机理

针对滨海发射场用于低温管路法兰连接的高强度螺栓的环境腐蚀断裂问题进行失效机理分析.结合螺栓所处"高温、高湿、高盐雾"环境及低温高压工况,讨论分析了盐雾腐蚀、应力作用、微观形貌、化学成分及硬度等影响因素.结果表明,螺栓显微硬度均值(108HRB)超标,材质中C、S、Cr含量异常,螺栓实际受力达到许用应力的60％以上,微观组织裂纹均为典型的应力腐蚀裂纹.在海南"三高"海洋腐蚀环境影响下,耐腐蚀性能较差的螺栓在热应力作用下萌生裂纹,产生应力腐蚀,在热应力和拉应力的作用下进行扩展,发生应力腐蚀开裂,螺栓延迟脆性断裂导致失效.最后,针对螺栓应力腐蚀机理,提出了相应的改进措施.     

表面纳米化对锆合金微动腐蚀行为的影响

目的 研究N36锆合金表面纳米化层的形貌和微观结构,分析表面纳米化层的微动腐蚀机理。方法 采用超声表面滚压技术(USRP)对锆合金进行表面纳米化处理,研究不同滚压速度对表面纳米化层形貌、相组成、粗糙度、显微硬度、电化学腐蚀和微动腐蚀行为的影响。结果 USRP处理后,锆合金表面有明显的塑性变形痕迹,致使锆合金表面发生加工硬化,提高了表面的硬度。锆合金的腐蚀电流密度相较于基体更低,最大磨损深度和磨损率均低于基体。结论 USRP处理后的锆合金晶粒细化、晶界增多,提高了锆合金的表面活性,有利于钝化膜的形成。锆合金的磨损机理为氧化磨损和磨粒磨损的共同作用。     

钛金属材料干摩擦磨损特性研究

目的研究钛金属材料干摩擦磨损失效机制。方法选用TA2工业纯钛和TC4钛合金材料,采用CETR UMT-3多功能摩擦磨损测试仪进行往复摩擦磨损试验,采集摩擦系数曲线,计算摩擦系数均值,从动态和静态分析钛金属材料的摩擦特性。采用Micromet-6030型自动显微硬度计测量样品材料表面硬度值,通过表面硬度分析耐磨损性能。采用Nova Nano SEM 650场发射扫描电镜并配置能谱仪对磨损表面和磨屑进行微观形貌观察和元素成分计量分析,从微观角度分析钛金属材料的磨损机理。采用Olympus Lext OLS3000-R型激光共聚焦显微镜测量磨损体积和轮廓,并观察磨损表面的三维形貌。结果频率对钛金属材料的摩擦系数和耐磨损性能影响较大,随着频率的加快,摩擦系数增大,数据跃变幅度增大,磨损体积随之增大。载荷对摩擦系数影响相对较小,随着载荷增大,在摩擦初期,摩擦系数有下降交汇趋势;摩擦后期,摩擦系数才明显上升,载荷与磨损体积之间基本呈线性增长关系。钛金属材料的磨痕呈现为"擦后型,随着载荷的增大和频率的加快,磨损体积轮廓呈现出加深变宽的趋势。TC4的表面硬度约为359.2 HV,TA2的表面硬度约为247.8 HV,前者比后者高出约111.4 HV。在相同试验条件下进行干摩擦磨损试验,TA2的磨损体积约为TC4的2.5倍,TA2的耐磨损性能相对较差。TA2的磨屑为细小的颗粒状磨屑,磨损表面存在严重的剥层脱落特征;TC4的磨屑粒径大小不一,在低频低载状态下,磨损表面有犁沟痕迹,不存在明显的剥落坑。随着载荷和频率的增大,摩擦表面层出现裂纹和碎化剥落现象。结论 TA2的磨损机制主要是剥层磨损和磨粒磨损。在低频低载状态下,TC4的磨损机制主要为磨粒磨损和氧化磨损,随着载荷和频率的升高,在瞬时闪现温度和载荷的作用下,其磨损机制主要为粘着磨损和剥层磨损。     

物理和摇蚊幼虫组合扰动对内源磷再生和形态转化的协同作用

为探讨物理和摇蚊幼虫组合扰动对内源磷再生和形态转化的协同作用,选取了苏州某富营养化河道为研究对象.利用室内静态培养试验和Rhizon间隙水采样技术,着重对比了单纯的摇蚊幼虫扰动和组合扰动下,上覆水、间隙水、沉积物中磷形态数量分布的变化规律.结果表明,组合扰动下,上覆水中不同形态磷含量(TP、PP、DTP、DIP)均处于较高水平,明显高于摇蚊幼虫扰动.这可归因于微生物活性的显著增加.与摇蚊幼虫扰动相比,组合扰动下,间隙水中DIP和Fe2+浓度的降低幅度和降低范围明显更大.这主要是由于物理扰动和底栖生物扰动产生的叠加效应,导致溶解氧渗透深度增加.另外,0~2 cm沉积物中,NH4Cl-P含量明显降低,Fe/Al-P明显增加,并且,NH4Cl-P和Fe/Al-P的变化幅度均在组合扰动下最大.这暗示了物理扰动和底栖生物扰动对磷再生和迁移产生的叠加效应.     

不同扰动下外源磷在形态磷间的分布规律

研究了3种扰动方式对外源磷在上覆水、间隙水、底泥中的数量分布的影响,并分析了内源磷形态间的转化过程.结果表明,与对照实验相比,物理扰动能促进上覆水中磷向底泥迁移,并高于生物扰动和组合扰动的促进作用,并且,三者均高于对照实验.这可归因于溶解氧的渗入.物理扰动能降低间隙水中DIP的平均含量,相比对照实验降低了12.13%(第6 d和第10 d平均值),但降低程度不如生物扰动(38.63%)和组合扰动(50.79%).3种扰动均能促进Fe/Al-P和Ca-P的形成,其中,物理扰动下Fe/Al-P和Ca-P平均形成量最大,物理扰动下AAP含量一直在减小,暗示物理扰动明显促进了AAP向闭蓄态的Fe/Al-P或者Ca-P转化.     

多重扰动对湖泊内源磷迁移转化的影响

为了阐明多重扰动因素对内源磷迁移转化的影响,以太湖梅梁湾沉积物为研究对象,借助Rhizon间隙水采样技术、Unisense微电极系统等技术,研究了扰动下泥水两相间溶解氧、不同形态磷、铁离子等变化规律.结果表明,与对照实验相比,河蚬的出现致使沉积物内部溶解氧含量降低.扰动致使间隙水中DIP的峰值区域由3~4 cm迁移至4~5 cm,暗示了摇蚊幼虫和河蚬的引入使得DIP再生的"活跃区域"更深入泥层.并且,河蚬和藻类的出现进一步降低了间隙水中DIP的含量,其主要来源于NH_4Cl-P的释放,去向为上覆水和形成Fe/Al-P.随着扰动因素的增加,NH_4Cl-P转化为Fe/Al-P的比重也逐渐增加(由44%增至59%).     

增压风机入口烟道磨损优化分析

冲刷磨损是目前工业系统运行的主要问题之一。本文通过对电厂增压风机前的一段双入口烟道进行了CFD分析,通过增加导流板来减小系统的压力不平衡性,改善颗粒对烟道的磨损,考察了不同粒径的灰分颗粒对烟道和导流板磨损趋势,为实际工程中的防磨措施制定提供参考。     

气相法聚丙烯装置卧式反应釜浮动端轴承失效分析及对策

对导致装置停工的卧式搅拌床气相反应釜浮动端轴承失效进行分析,采用轴承迷宫密封和冲洗吹扫方式,改善高粉尘运行工况下轴承的工作环境,通过增加轴承换油系统,实现了高压密闭环境下的轴承润滑脂的添加和排放,确保轴承润滑良好,提高了轴承的运行周期,大大降低了装置停工检修和开工停工带来的安全风险,提高了装置运行水平。     

气垫船减速齿轮箱腐蚀与防护工艺研究进展

叙述了气垫船减速齿轮箱在海洋大气和海水溅射环境下腐蚀与防护工艺的研究进展。介绍了气垫船减速齿轮箱长期处于高温、高湿、高盐雾以及海水溅射环境下的腐蚀特征和主要腐蚀类型,总结了减速齿轮箱中铝合金、合金钢、不锈钢等不同材质零件腐蚀防护技术的研究进展。最后,提出了海洋环境下气垫船减速齿轮箱的腐蚀防护需从结构设计、材料选型、加工制造、运输贮存、维护保养等方面着手,在充分利用现有表面处理技术的基础上,加强阳极氧化、微弧氧化、电镀、涂料涂层等技术的组合;强化腐蚀监测技术,有效预警防护层失效,同时大力研发海洋环境下长期有效、绿色环保的表面处理和涂层技术。另外,采用系统工程来提高海洋环境下金属材料的环境适应性,进而提高减速齿轮箱等部件的可靠性和安全性。     

宁波市区道路机动车综合排放因子

机动车综合排放因子是计算城市机动车污染物排放总量和排放分担率的基础,是降低城市机动车排放的重要依据,是控制城市道路交通污染的源头.根据宁波市区道路机动车运行工况的研究成果,利用加速模拟工况(ASM)排放测试系统,检测主要污染物HC,CO和NO_x的排放浓度;依据试验车变速器和主减速器的结构参数,以及试验车在宁波市区道路运行时的档位分布计算排污值,并依据机动车的年代和车型分布对该值进行修正,计算宁波市区道路机动车综合排放因子.结果表明,宁波市区道路机动车主要污染物HC,CO和NO_x的综合排放因子分别为5.89,21.22和18.91 g/(km·辆).      

Study of specific energy and friction coefficient in minimum quantity lubrication grinding using oil-based nanolubricants

An investigation on minimum quantity lubrication (MQL) grinding was carried out with the scope of documenting the process efficiency of oil-based nanolubricants. The nanolubricants were composed of MoS₂ nanoparticles (<100 nm) over coated with organic agents, dispersed in two different base oils—mineral oil (paraffin) and vegetable oil (soybean). Surface grinding tests were carried out on cast iron and EN 24 steel under different lubrication conditions—MQL using nanolubricants (varying compositional chemistry and concentration of nanoparticles), pure base oils (without nanoparticles) and base oils containing MoS₂ microparticles (3–5 μm), and flood grinding using water-based coolant. Specific energy, friction coefficient in grinding and G-ratio were used as measurands for determining the process efficiency. Results show that MQL grinding with nanolubricants increases the process efficiency by reducing energy consumption, frictional losses at the wheel–workpiece interface and tool wear. The process efficiency is also found to increase with increasing nanoparticle concentration. Soybean and paraffin based-nanolubricant performed best for steel and cast iron, respectively, showing a possible functional relationship between the compositional chemistry of nanolubricant and the workpiece material, which will be the goal of future work.     

Improvement of fuel injection system of locomotive diesel engine

The traditional locomotive diesels are usually designed for the performance of rated condition and much fuel will be consumed. A new plunger piston matching parts of fuel injection pump and injector nozzle matching parts were designed. The experimental results of fuel injection pump test and diesel engine show that the fuel consumption rate can be decreased a lot in the most of the working conditions. The forced lubrication is adopted for the new injector nozzle matching parts, which can reduce failure rate and increase service life. The design has been patented by Chinese State Patent Office.     

Evaluation of near-dry machining effects on gear milling process efficiency

One of the main environmental pollution sources related to machine building industry is the huge amount of cutting fluids which are supplied during the machining processes. In order to avoid the problems induced by cutting fluids' usage, considerable progress has been recently made in the field of near-dry machining (NDM). Converting conventional processes to minimal quantity lubrication (MQL) methods imposes new tasks' classification within the tribiological system in order to guarantee the process safety and product quality. This paper gives an overview on some requirements to be considered for a successful MQL application into industrial practice. Its last part is focused on the evaluation of NDM effects on the gear milling process efficiency, with respect to hob wear, surface quality, cooling effect, and environment protection.     

On the Accuracy of Precision Involute Hobs: An Analytical Approach

This paper investigates the impact of the major design parameters of an involute hob on deviations of the hob tooth profile. Desired and actual hob tooth profiles are considered. The desired hob tooth profile is given as the line of intersection of the generating surface of the involute hob by the rake face. The actual hob tooth profile is a certain linear approximation of the desired profile. To evaluate deviation of the actual hob tooth profile with respect to the desired profile, the maximal deviation of the profiles from each other is used. This deviation is measured along the pitch line of the involute hob. An analytical method for computation of the deviation is developed. Using the commercial software MathCAD/Scientific, numerous computer codes are developed. Analysis results reveal a significant impact of the major design parameters of involute hobs on hob accuracy. Optimal configuration of the hob rake face is determined in order to minimize the deviations of the actual hob tooth profile from the desired profile. Based on the research results, reliable ways are proposed for increasing the accuracy of involute hobs in actual practice.     

中新天津生态城青坨子雨水泵站泵池及雨水管网臭味源分析

雨水泵站外排水体的恶臭对收纳水体水质具有重大影响。以中新天津生态城青坨子雨水泵站为研究区,通过对其泵池水样、雨水管网水样和底泥以及区域地下水的采样监测,分析了导致其外排水体黑臭的主要原因及潜在污染源。结果发现:雨水泵站泵池、雨水管网以及地下水中主要检出污染指标或污染物为电导率、溶解性总固体、总硬度、总碱度、化学需氧量、氯化物、SO₄2-、HCO₃-、钠、钾、钙和镁,其中雨水管网水样水质要略优于雨水泵站泵池水样和区域地下水水样。雨水管网底泥中主要检出污染物为氨氮和硫。雨水泵站泵池和雨水管网水体中的碳、氮和硫等在低氧环境中被还原生成CH₄、NH₃及H₂S,是导致泵池以及雨水管网水体恶臭的主要原因,而泵池及雨水管网水体和底泥中的硫化物在扰动条件下形成硫化铁、硫化锰是导致泵池以及雨水管网水体发黑的主要原因。另外,初期雨水及降雨径流污染是中新天津生态城青坨子雨水泵站污染物的主要来源。结合以上结论,中新天津生态城青坨子雨水泵站及雨水管网臭味处置拟采用曝气为主,防渗、清淤等技术相结合的方案。     

Modeling of X-Ray Fabrication of Macromechanical Structures

This paper evaluates the application of Lithographie, Galvanoformung, Abformung (LIGA) as a technique for fabricating millimeter to centimeter-scale mechanical components. The main focus of the work is an investigation of modeling approaches to estimate dimensional accuracy of complex profile features. Numerical models for X-ray exposure and an empirical model for polymethyl-methacrylate (PMMA) development are presented. Optical coordinate measurements are performed on two case studies associated with fabricating a planetary gear assembly: (1) a spider frame and (2) involute gear tooth profiles.     

清洁检修机泵的改造方法

解体维修蜡油重油机泵时的放空浪费及拆卸现场的污染问题一直无法解决。南常减压装置2001年防腐扩能改造时，增设了热柴油冲洗机泵系统。旨在改善作业环境、减少浪费、杜绝污染。通过1年多的实施，取得了良好的使用效果。     

Analytical model of metalworking fluid penetration into the flank contact zone in orthogonal cutting

Metalworking fluids (MWFs) are used widely in machining process to dissipate heat, lubricate moving surfaces, and clear chips. They have also been linked to a number of environmental and worker health problems. To reduce these impacts, minimum quantity lubrication (MQL) sprays of MWF delivered in air or CO₂ have been proposed. MQL sprays can achieve performance comparable with conventional water-based or straight oil MWFs while only delivering a small fraction of the fluid. This performance advantage could be explained by the enhanced penetration into the cutting zone that results from delivering MWF in high pressure and precise sprays. To explore this hypothesis, an analytical model of MWF penetration into the flank face of the cutting zone is developed and validated using experimental data. The model is based on a derivation of the Navier–Stokes equation and the Reynolds equation for lubrication and applied to an orthogonal cutting geometry under steady-state conditions. A solution to the model is obtained using a numerical strategy of discretizing the analytical scheme with two-dimensional centered finite difference method. Penetration into the cutting zone is estimated for MQL sprays delivered in air, CO₂ and N₂ as well as two conventional MWFs, straight oil and semi-synthetic emulsion. The model suggests that conventional MWFs, do not penetrate the cutting zone fully and fail to provide direct cooling to the flank zone where wear is most likely to occur. MQL sprays do penetrate the cutting zone completely. Using convective heat transfer coefficients from a previous study, a finite element heat balance is carried out on the tool to understand how each fluid impacts temperature near the flank tip of the tool. The results of the modeling effort are consistent with experimental measurements of tool temperature during turning of titanium (6AL4V) using a K313 carbide tool. The prediction of temperature near the flank indicates that MQL sprays do suppress temperatures near the flank effectively. These results help explain the low levels of tool wear observed for some MQL sprays, particularly those based on high pressure CO₂. This modeling framework provides valuable insight into how lubricant delivery characteristics such as speed, viscosity, and cutting zone geometry can impact lubricant penetration.