Effect of Silicon Powder Mixed EDM on Machining Rate of AISI D2 Die Steel

In this paper, the effect of silicon powder mixing into the dielectric fluid of EDM on machining characteristics of AISI D2 (a variant of high carbon high chrome) die steel has been studied. Six process parameters, namely peak current, pulse-on time, pulse-off time, concentration of powder, gain, and nozzle flushing have been considered. The process performance is measured in terms of machining rate (MR). The research outcome will identify the important parameters and their effect on MR of AISI D2 in the presence of suspended silicon powder in a kerosene dielectric of EDM. The study indicated that all the selected parameters except nozzle flushing have a significant effect on the mean and variation in MR (S/N ratio). Optimization to maximize MR has also been undertaken using the Taguchi method. The ANOVA analysis indicates that the percentage contribution of peak current and powder concentration toward MR is maximum among all the parameters. The confirmation runs showed that the setting of peak current at a high level (16 A), pulse-on time at a medium level (100 μs), pulse-off time at a low level (15 μs), powder concentration at a high level (4 g/l), and gain at a low level (0.83 mm/s) produced optimum MR from AISI D2 surfaces when machined by silicon powder mixed EDM.     

Investigating surface roughness,material removal rate and corrosion resistance in PMEDM of γ-TiAl intermetallic

Titanium aluminide intermetallics offer an attractive combination of low density and good oxidation, corrosion and ignition resistance with unique mechanical properties. In this study two series of machining tests are designed. Firstly the powder mixed electrical discharge machining (PMEDM) of γ-TiAl by means of different powders such as aluminum, chrome, silicon carbide, graphite and iron is performed to investigate the output characteristics of surface roughness and topography, material removal rate (MRR), electrochemical corrosion resistance of machined samples and also the machined surfaces are investigated by means of EDS and XRD analyses. Secondly after selection the aluminum powder as the most appropriate kind of powder, the current, pulse on time, powder size and powder concentration are changed in different levels for overall comparison between EDM and PMEDM output characteristics. In the first setting of input machining parameters, aluminum powder improves the surface roughness of TiAl sample about 32% comparing with EDM case and also aluminum particles with the size of 2 μm, in the second setting of input parameters lead to 54% enhancement of MRR comparing with EDM case. The electrochemical corrosion results show that, corrosion resistance of the samples which are machined by graphite and chrome powders respectively are about three and two times more than the sample which is machined without powder.     

Water jet guided laser as an alternative to EDM for micro-drilling of fuel injector nozzles: A comparison of machined surfaces

To characterize the inner surface of the fuel injector nozzle holes drilled by EDM and water jet guided laser drilling (Laser Micro-Jet) a specifically conceived scanning probe microscopy technique with true non-contact operating mode was used. A difference in morphology of the drilled surfaces is evident from the acquired surface topography along the hole axis for the two compared drilling techniques. Results showed that the surface texture can be characterized by (i) maximum peak-to-valley distance and (ii) periodicity. Acquired maps confirm that electro-eroded surfaces are an envelope of craters randomly distributed with total excursion up to 1.7 μm with a crater size of 15 μm. While, the efficient melt expulsion and immediate cooling of water jet guided laser generates a peak to valley distance of 800 nm with a periodicity of 18 μm. Average R_q derived from the measured cylindrical surfaces was 450 nm and 150 nm for EDM and Laser Micro-Jet, respectively. Water jet guided laser drilling has proved to be a reliable alternative to EDM from the point of view of repeatability of the results and surface quality to facilitate the atomization of the fuel jet.     

Thermo-physical modeling of die-sinking EDM process

This paper reports the development of a thermo-physical model for die-sinking electric discharge machining (EDM) process using finite element method (FEM). Numerical analysis of the single spark operation of EDM process has been carried out considering the two-dimensional axi-symmetric process continuum. The analysis is based on more realistic assumptions such as Gaussian distribution of heat flux, spark radius equation based on discharge current and discharge duration, latent heat of melting, etc., to predict the shape of crater cavity and the material removal rate (MRR). Using the developed model, parametric studies were carried out to study the effect of EDM process parameters such as discharge current, discharge duration, discharge voltage and duty cycle on the process performance. Experimental studies were carried out to study the MRR and crater shapes produced during actual machining. When compared with the reported analytical models, our model was found to predict results closer to the experimental results. The thermo-physical model developed can further be used to carry out exhaustive studies on the EDM process to obtain optimal process conditions.     

Evaluation of the effectiveness of low frequency workpiece vibration in deep-hole micro-EDM drilling of tungsten carbide

The application of micro-electrical discharge machining (micro-EDM) in deep-hole drilling is still limited due to the difficulty in flushing of debris and unstable machining. Present study introduces a simplistic analytical model to evaluate the effectiveness of low frequency workpiece vibration during the micro-EDM drilling of deep micro-holes. In addition, experimental investigation has been conducted to validate the model by studying the effects of workpiece vibration on machining performance, surface quality and dimensional accuracy of the micro-holes. The effect of vibration frequency and amplitude for three different settings of aspect ratios has been studied experimentally. Moreover, the vibration experiments have been conducted at different levels of gap voltages and capacitances in order to understand the effect of electrical parameters and effectiveness of low-frequency workpiece-vibration at different levels of discharge energies. It has been shown analytically that the effectiveness of low frequency workpiece vibration during micro-EDM drilling can be evaluated by a parameter ‘K_v’ (ratio of maximum acceleration of the vibrating plate in gravitational direction to gravitational acceleration ‘g’), which can be determined from the vibration frequency, amplitude and phase angle of the vibrating workpiece. The theoretical model reveals that for K_v > 1, the position of debris particles will be above the workpiece; thus can be flushed away from machined zone effectively. The experimental reasons for improved micro-EDM drilling performance at the setting of K_v > 1 are found to be the increased effective discharge ratio, reduced short-circuits and improved dielectric flushing. The experimental results also reveal that the low frequency vibration is more effective at the low discharge energy level, thus making it more suitable for micro-EDM. Considering the effect on both the machining characteristics and micro-hole accuracy parameters, vibration frequency of 750 Hz and amplitude of 1.5 μm was found to provide improved performance for the developed vibration device.     

Effect of process parameters on the performance of EDM process with ultrasonic assisted cryogenically cooled electrode

In this work the parametric study on EDM process using ultrasonic assisted cryogenically cooled copper electrode (UACEDM) during machining of M2 grade high speed steel has been performed. Electrode wear ratio (EWR), material removal rate (MRR) and surface roughness (SR) was the three parameters observed. Discharge current, pulse on time, duty cycle and gap voltage were the controllable process variables. The effect of process variables on EWR, MRR and SR has been analyzed. The MRR, EWR and SR obtained in EDM process with normal electrode, cryogenically cooled electrode and ultrasonic assisted cryogenically cooled electrode have been compared. EWR and SR were found to be lower in UACEDM process as compared to conventional EDM for the same set of process parameters, while MRR was at par with conventional EDM process. The surface integrity of work piece machined by UACEDM process has been found to be better as compared to conventional EDM process. The shape of the electrode has also been measured and it was found that the shape retention was better in UACEDM process as compared to conventional EDM process. Thus in the present work UACEDM process has been established to be better than conventional EDM process due to better tool life, tool shape retention ability and better surface integrity.     

自适应模糊PID在SNCR烟气脱硝系统中的仿真与应用

针对当前在选择性非催化还原反应(SNCR)烟气脱硝工艺应用中喷氨量的控制问题,通常采用传统PID控制方式。控制系统的时效滞后或负荷的波动等,使得SNCR脱硝系统存在惯性滞后,因此提出一种喷氨量自适应模糊PID控制策略,通过对输出误差在线实时检测,再根据模糊推理对PID控制器的3个参数进行在线纠正,得到最佳控制参数。将自适应模糊PID控制与常规PID控制进行仿真比较,结果表明前者控制效果优于后者。该策略既具有传统PID控制策略的特点,而且还有模糊策略超调量小、调节迅速的优点,从而实现喷氨量的实时准确控制。     

低压脉冲袋式除尘器清灰控制策略研究

从理论上分析清灰过程及影响因素,针对传统控制方式的缺陷和变频调速后带来的新问题,提出了除尘器清灰模糊控制策略。即先根据风量变化对除尘器阻力目标值进行模糊修正,再根据阻力偏差和风量大小模糊推理脉冲间隔时间。在此对模糊控制器设计过程作了详细介绍。该策略应用效果良好。     

SBR法反硝化过程模糊控制器的设计和碳源投加方式的选择

在大量试验的基础上构建了SBR法反硝化过程的模糊控制器，并进行了3种碳源投加方式的实时控制试验。结果表明，按较小的速率连续投加碳源是最佳投加方式，它不仅可以满足反硝化速率上的要求，还可以尽量地减少再曝气时间，以pH和ORP作为SBR法反硝化时间和碳源投加的在线模糊控制参数是可行的和可靠的。     

模糊控制在湿法脱硫烟气系统中的应用

介绍了石灰石-石膏湿法脱硫装置烟气系统的设计情况,重点讲述了增压风机动叶的控制,针对增压风机动叶系统时滞、非线性等特点,常规PID控制效果并不理想,设计出模糊控制器,仿真后证明了理论的正确性。     

Design and Test of a Reconfigurable Forming Die

Reconfigurable tooling is an attractive prospect for aerospace sheet metal forming because many different part shapes must be produced in small numbers. This paper describes the design and test of a particular type of “discrete-die” reconfigurable tool. The discrete-die concept involves using the ends of densely packed rod-shaped elements as the working surface of the die. The rod-shaped elements are reconfigured manually or automatically to change the shape of the die. Numerous mechanical schemes can be employed to move the elements: this paper describes the use of a shaft-driven lead screw concept. The input shaft turns continuously, and each pin's position is controlled by the engagement of an individual clutch. The required design parameters were developed using a combination of theory and experiment, and a laboratory-scale working prototype device was built and tested. The design parameters included an evaluation of the suitability of open-loop pin-position control based only on time, an evaluation of the torque capacity, engagement time, and reliability of the clutches, and the development of design loads. Experience in construction of the prototype showed that the design concept was sound but that significant enhancements to the control system would be required in a full-scale device.     

Effects of magnetic field and rotary tool on EDM performance

In this work, the effects of tool rotation and various intensities of external magnetic field on electrical discharge machining (EDM) performance have been studied. Experimental trials divided into three regimes of low energy regime, middle energy regime and high energy regime. The influences of process parameters were investigated on main outputs of material removal rate (MRR) and surface roughness (SR). In order to correlate the input parameters and output values two mathematical models were developed to predict the MRR and SR according to variations of discharge energy, magnetic field intensity and tool rotational speed. Results indicated that the applying a rotational magnetic field around the machining gap improves the MRR and SR. Combination of rotational magnetic field and rotary electrode increases the machining performance, in comparison of previous conditions. This is due to better flushing debris from machining gap. This work introduces a new method for improving the machining performance, in cost and time points of view.     

Study of ultrasonic assisted cryogenically cooled EDM process using sintered (Cu–TiC) tooltip

In most EDM operations, the maximum contribution in the total operation cost is the tool cost. Electrode wear is a major problem in EDM process. Therefore, in this paper, the process performance of sintered copper (Cu)–titanium carbide (TiC) electrode tip in ultrasonic assisted cryogenically cooled electrical discharge machining (UACEDM) has been studied. The performance parameters studied in this paper are electrode wear ratio (EWR), material removal rate (MRR), surface roughness (SR), out of roundness and surface integrity. The process parameters considered in this study are discharge current, pulse on time, duty cycle and gap voltage. Cermet was fabricated, having copper content of 75% and titanium carbide content of 25%, by mixing, pressing, and sintering. The performance of the newly formed cermet electrode tip is compared with conventional copper electrode tip for UACEDM process and analyzed. It has been observed that EWR and out of roundness decreases when cermet electrode tip is used as compared to conventional tooltip. It has also been observed that MRR and SR increase when cermet tooltip is used. The surface cracks density and crack width on workpiece machined by cermet tooltip have been found to be lesser as compared to the specimen machined by conventional tooltip.     

Microspectrophotometric evidence for cone monochromacy in sharks

Sharks are apex predators, and their evolutionary success is in part due to an impressive array of sensory systems, including vision. The eyes of sharks are well developed and function over a wide range of light levels. However, whilst close relatives of the sharks—the rays and chimaeras—are known to have the potential for colour vision, an evolutionary trait thought to provide distinct survival advantages, evidence for colour vision in sharks remains equivocal. Using single-receptor microspectrophotometry, we measured the absorbance spectra of visual pigments located in the retinal photoreceptors of 17 species of shark. We show that, while the spectral tuning of the rod (wavelength of maximum absorbance, λ_max 484–518 nm) and cone (λ_max 532–561 nm) visual pigments varies between species, each shark has only a single long-wavelength-sensitive cone type. This suggests that sharks may be cone monochromats and, therefore, potentially colour blind. Whilst cone monochromacy on land is rare, it may be a common strategy in the marine environment: many aquatic mammals (whales, dolphins and seals) also possess only a single, green-sensitive cone type. It appears that both sharks and marine mammals may have arrived at the same visual design by convergent evolution. The spectral tuning of the rod and cone pigments of sharks is also discussed in relation to their visual ecology.     

重大环境自然灾害下的电网应急模型设计研究

在重大环境自然灾害下构建电网应急调度模型,确保电网畅通,提出一种基于区域网格分割和功率相关性调制的重大环境自然灾害下的电网应急模型,利用多个独立的网格分布模式进行电网和电力资源调度,采用Small-World模型构建电网应急调度网络结构,结合电网传输电力资源的相关性特征构建电力数据权重分配机制,采用自适应分配方法进行电网输出的网格模块化分区,通过区域网格分割进行电网应急调度的最优化分块设计,根据功率相关性调制方法提高电网的输出增益,避免重大环境自然灾害的影响。仿真结果表明,采用该方法进行重大环境自然灾害下的电网应急调度,能提高电网的连通性,电网的输出增益较好,组网能力较强。     

Informational uncertainties of risk assessment about accidents of chemicals

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Machining efficiency of powder mixed near dry electrical discharge machining based on different material combinations of tool electrode and workpiece electrode

Powder mixed near dry electrical discharge machining (PMND-EDM) is a novel electrical discharge machining (EDM) process. It is proposed to further improve the machining efficiency of dry EDM. The principle of material removal in PMND-EDM is illustrated and its deionization principle is proposed. The influence of residual heat on MRR is analyzed. The concept of superfluous residual heat is proposed. The material removal rate (MRR), the main index of machining efficiency for PMND-EDM process, is researched. Single factor experiments are performed to get effect of peak current, pulse on time, pulse off time, flow rate, tool rotational speed, air pressure and powder concentration on MRR under different material combinations of tool electrode and workpiece electrode. Thermal phenomena in PMND-EDM are illustrated. Effect of each process parameter on MRR of PMND-EDM is gotten and analyzed based on the deionization principle of PMND-EDM. Differences in MRR under different material combinations are found out. Brass tool electrode and W18Cr4V workpiece gain higher MRR under most of discharge conditions, while the superiority of copper tool electrode and 45 carbon steel workpiece in MRR arise when there is improper heat dissipation. The difference is analyzed based on the deionization principle of PMND-EDM.     

基于模糊神经网络的A2/O工艺出水氨氮在线预测模型

采用厌氧/缺氧/好氧污水处理系统(A2/O)对人工合成污水进行处理,并利用人工神经网络(ANN)模型和自适应模糊人工神经网络(ANFIS)模型对A2/O处理污水的过程进行仿真模拟.在MATLAB环境下,选取可在线监测的水力停留时间(HRT)、进水pH值(pH)、好氧池溶解氧(DO)和混合液回流比(r)作为输入参量,系统出水氨氮浓度(NH4+eff)为输出量,建立在线预测模型.结合自适应模糊C均值聚类算法,确定ANFIS模型的模糊规则数及最优运行参数,对实验数据进行仿真预测.结果表明,与ANN模型相比,ANFIS模型的仿真输出值与实际值的拟合程度更高,相对误差在6.45%之内,平均绝对百分比误差(MAPE)为2.8%,均方根误差(RMSE)为0.1209,相关系数(R)达0.9956.模型训练过程中所得到的三维曲面图,可直观的反映各因素与出水氨氮浓度之间的非线性函数关系,为A2/O系统的高效稳定运行提供指导.     

Surface modification of die steel materials by EDM method using tungsten powder-mixed dielectric

Surface modification by material transfer during electrical discharge machining (EDM) has emerged as a key research area in the last decade. Material may be provided to the machined surface of the workpiece by the eroding tool electrode or by using powder-mixed dielectric. Breakdown of the hydrocarbon dielectric contributes carbon to the plasma channel which may also cause surface modification. The present work has investigated the response of three die steel materials to surface modification by EDM method with tungsten powder mixed in the dielectric medium. Taguchi experimental design technique was used to conduct the experiments on each work material independently. Peak current, pulse on-time and pulse off-time were taken as variable factors and micro-hardness of the machined surface was taken as the response parameter. X-ray diffraction (XRD) and spectrometric analysis show substantial transfer of tungsten and carbon to the workpiece surface and an improvement of more than 100% in micro-hardness for all the three die steels. Presence of tungsten carbide (WC and W₂C) indicates that its formation is taking place in the plasma channel. Machining parameters for the best value of micro-hardness for each work material were found to be the same.     

模糊控制技术在污水处理中的应用

针对污水处理过程中采用传统的流量程序控制和时间程序控制的不足,提出了一种基于单片机的模糊控制方法。该方法以污水流量、溶解氧(DO)浓度和污泥回流比为主要被控对象,以DO浓度为主要控制参数,通过离散计算和在线查表的模糊推理方法可得到最佳的风机转速,使污水处理生化池内DO浓度保持在最佳状态,同时还通过控制曲线展示了当输入污水流量发生扰动时对DO浓度的控制精度,使污水处理质量保持稳定。通过实际应用表明,该控制方法不但能确保出口净化水水质达标,还可以节约15%的电能。