Minimum quantity lubrication in grinding: effects of abrasive and coolant–lubricant types

This research has been conducted to study the influence of the abrasive and coolant–lubricant types on the minimum quantity lubrication (MQL) grinding performance. One type of CBN and three types of conventional wheels (corundum) have been tested. The tests have been performed in presence of fluid, air jet and eleven types of coolant–lubricants, as well as, in dry condition. The results indicate that the finest surface quality and lower grinding forces could be obtained while grinding with CBN wheel. In case of conventional wheels, the coarser and high porosity wheels induce much proper grinding results. Furthermore, grinding when utilizing MQL with oil results in higher grinding performance.     

Machining evaluation of a hybrid MQL-CO2 grinding technology

Although there are already successful industrial experiences in other machining industries with the elimination of coolants, this is not so in the grinding industry due to the large amounts of generated heat that must be evacuated from the contact zone. In this work, a new approach to the elimination of fluids in grinding is presented. The technology is based on the use of a hybrid Minimum Quantity of Lubricant (MQL)-low temperature CO₂ system that reduces lubrication consumption. Abrasive grits are protected by the layer of frozen oil, resulting in a significant improvement in grinding wheel life and surface quality of the machined component. Although the cooling action is reduced with respect to the conventional coolant, no thermal damage was observed on the workpiece.     

Effect of fluid concentration in titanium machining with an atomization-based cutting fluid (ACF) spray system

The aim of this work is to investigate the effect of metal-working fluid (MWF) concentration on the machining responses including tool life and wear, cutting force, friction coefficient, chip morphology, and surface roughness during the machining of titanium with the use of the ACF spray system. Five different concentrations from 5 to 15% of a water-soluble metalworking fluid (MWF) were applied during turning of a titanium alloy, Ti–6Al–4V. The thermo-physical properties such as viscosity, surface tension and thermal conductivity of these concentrations were also measured. The test results demonstrate that the tool life first extends with the increase in MWF concentration and then drops with further increase. At low concentration (e.g., 5%), a lack of the lubrication effect causes to increase in a higher friction at the tool–chip interface resulting in severe chipping and tool nose/flank wear within a short machining time. On the other hand, at high concentration, the cooling effect is less. This increases cutting temperature and a faster thermal softening/chipping/notching of the tool material and higher friction at the tool–chip–workpiece interaction zones resulting in early tool failure. A good balance between the cooling and the lubrication effects seems to be found at the 10% MWF concentration as it offers the best machining performance. However, machining with flood coolant is observed to perform the best in the range of 5–7%.     

Determining work-brush interface temperature in magnetic abrasive finishing process

Magnetic abrasive finishing (MAF) is a process in which the work surface is finished by removing the material in the form of micro chips by magnetic abrasive particles (MAPs) in the presence of magnetic field in the finishing zone. During the MAF process, the frictional heat is generated at the workpiece surface due to the rubbing action of magnetic abrasive particles with the work surface. The order of temperature rise is important to study, as finishing mechanism and surface integrity of work materials depend upon it. The measurement of temperature distribution during MAF operation at the interface of work piece and flexible magnetic abrasive brush (FMAB) interface is difficult. In the present analysis, finite element based ANSYS software has been used to model and simulate magnetic field distribution, magnetic pressure and temperature distribution at work-brush interface during the process. In this work the maximum magnetic flux density has been simulated of the order of 0.223 T at 0.91 A of current in electromagnet coil. Magnetic pressure on MAPs due to magnetic field of electromagnetic coil has been calculated to evaluate the frictional heat flux generated at the work-brush interface. Transient thermal analysis of workpiece domain has been performed to predict the temperature rise due to frictional heat flux. The predicted temperature on work-brush interface was found in the range of 34–51 °C. The developed simulation results based on FEA have been validated with experimental findings.     

Modulation-assisted high speed machining of compacted graphite iron (CGI)

The application of controlled, low-frequency modulation (～100 Hz) superimposed onto the cutting process in the feed-direction – modulation-assisted machining (MAM) – is shown to be quite effective in reducing the wear of cubic boron nitride (CBN) tools when machining compacted graphite iron (CGI) at high machining speeds (>500 m/min). The tool life is at least 20 times greater than in conventional machining. This significant reduction in wear is a consequence of the multiple effects realized by MAM, including periodic disruption of the tool–workpiece contact, formation of discrete chips, enhanced fluid action and lower cutting temperatures. The propensity for thermochemical wear of CBN, the principal wear mode at high speeds in CGI machining, is thus reduced. The tool wear in MAM is also found to be smaller at the higher cutting speeds (730 m/min) tested. The feed-direction MAM appears feasible for implementation in industrial machining applications involving high speeds.     

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.     

气候变暖对中国夏热冬冷地区居住建筑采暖降温年耗电量的影响

20世纪80年代中期以来的气候变暖,尤其是90年代中期以来的气候显著变暖带给社会经济发展的利与弊,一直以来受到广泛关注。气候变暖对于建筑耗能,尤其是对采暖和降温总耗能的影响很值得研究。论文以主要使用电能进行空间调节的中国夏热冬冷地区为对象,以《夏热冬冷地区居住建筑节能设计标准JCJ134-2001》中所规定的采暖、降温耗电量限值为依据,研究了气候变暖对该区居住建筑单位面积采暖年耗电量、降温年耗电量及采暖降温年耗电总量的影响。结果表明,1986年以来的气候变暖,尤其是1996年以来的气候显著变暖,理论上使夏热冬冷地区居住建筑单位面积采暖年耗电量降低;同时增加了相当一部分地区居住建筑单位面积降温年耗电量;除个别地区外,气候变暖理论上使中国夏热冬冷地区居住建筑单位面积采暖降温耗电总量普遍下降。     

烟塔合一排放参数试验及特征

在电厂典型工况条件下,测试烟塔排放口及塔体内部混合烟气的流速、温度、气压和相对湿度等参数的分布. 结果表明:在烟塔排放口和塔体内部,混合烟气各参数的分布均是非均匀的. 烟塔排放口处各参数水平分布均为中心处高、边缘处低;2月17,21和22日烟塔排放口处混合烟气的平均流速分别为2.8,3.1和2.9 m/s,总平均流速为2.9 m/s;3 d平均温度分别为13.1,13.4和13.2 ℃,总平均温度为13.2 ℃;3 d平均相对湿度分别为94.1%,87.8%和90.3%,总平均相对湿度为90.7%. 塔体内部混合烟气各参数垂直分布规律为:温度、气压和相对湿度均为烟塔中心处高、边缘处低,但流速分布不同,在塔体上部流速分布呈中心处高、边缘处低,而下部则相反.      

Novel Composite CBN-TiN Coating: Synthesis and Performance Analysis

Cubic boron nitride (CBN) coating, due to its promising properties, is under development worldwide for machining and other related applications. To synthesize a continuous CBN coating by conventional vapor deposition methods (CVD/PVD), however, poses many challenges, such as metastable CBN phase stabilization, as well as the high levels of intrinsic stress developed during the growth. A novel combinatorial approach, which is under development in an effort to develop a CBN composite coating for cutting tools, is reported in this paper. The approach involves a two-step process consisting of electrostatic spray coating (ESC) of CBN particles, followed by chemical vapor infiltration (CVI) of TiN. The process is optimized to deposit a CBN-TiN composite coating with a thickness in excess of 10 μm on tungsten carbide inserts. Such coated tools have been successfully evaluated and tested for machining applications. For production on a commercial scale, the laboratory systems have been upgraded to industrial size. The outcome of scaling up from an experimental to an industrial-sized unit is reported in this paper. The industrial electrostatic spray coating unit, which can coat a batch of about 50 inserts in a couple of minutes, is currently being field tested.     

车用锂离子电池组冷却系统传热仿真分析

目的 解决电动汽车锂离子电池组在高温下的安全性和热失控问题.方法 建立锂离子电池组冷却系统的三维分析模型,应用计算流体动力学(Computational Fluid Dynamics,CFD)方法 ,结合热传导和热对流理论,对电池组进行仿真分析.结果 锂离子电池组的温度场分布基本相同,呈现出中间低、两侧高的分布特点,且...     

A comparative review of entrainment survival studies at power plants in estuarine environments

Steam-electric power plants drawing cooling water from surface waters entrain a variety of plankton and weak-swimming nekton. These small organisms pass through the intake screens and are carried along with the cooling water through the plant and are subjected to thermal, physical, and chemical (biocide) stresses. In once-through cooling systems, entrained organisms are returned to the source water body, where they are subjected to rapidly decreasing temperatures as cooling waters are mixed into receiving waters. With 4316(b) of the Clean Water Act as the impetus, studies were conducted at many power plants to quantify the number of entrained organisms. Early studies focused on simple abundance, and assumed total mortality. By the late 1970s and early 1980s, advances in sampling technology demonstrated that many entrained organisms survived. Continuing refinement of sampling techniques revealed impressive survival statistics for many species (>90% in some cases), with concomitant reductions in perceived impacts. This paper reviews state-of-the-art sampling methods and results of field entrainment studies at seven power plants. This review demonstrates that high entrainment survival of a variety of aquatic organisms does, in fact, occur and specifies the plant-operating and environmental conditions under which high survival occurs.     

舵面结构热模态试验方法研究

目的 探究高温对舵面结构模态试验结果的影响.方法 以导弹舵面为研究对象,开展高温环境下结构模态试验方法研究.基于石英灯热辐射高温加热系统和模态测试系统搭建热模态试验测试平台,采用带水冷装置的耐高温加长激振杆实现激励的施加,设计耐高温陶瓷引伸杆进行振动信号的测试,通过有限元仿真分析与试验数据对比,验证所提热模态试验方案的可行性.结果 当激振杆的正弦扫频试验在20～1000 Hz范围内,其传递函数值接近于1,说明激振杆传递性能良好.陶瓷引伸杆对试验件前四阶模态频率及振型影响较小,验证了陶瓷引伸杆设计的有效性.试验数据表明,试验件材料的刚度随着环境温度的升高逐渐降低,导致各阶模态的频率呈逐渐降低的趋势.结论 高温会使舵面结构的模态参数降低,该研究为后续型号产品的热模态试验提供了的试验手段和技术支持.     

冷凝水冷却玻璃幕墙构建及其对室内环境的影响分析

为利用空调冷凝水的冷量同时解决单层玻璃幕墙夏季高温的问题,将冷凝水用于冷却单层玻璃幕墙,并对其进行了水量、造价及能耗分析.通过Ecotect、CFD模拟、对比了冷凝水冷却玻璃幕墙与普通玻璃幕墙在夏季的光环境和热环境.结果表明：冷凝水冷凝水冷却玻璃幕墙应用规模与建筑冷凝水产量有关,其应用会减少夏季日照辐射,减少幅度在30.1%~41.8%.加装了冷凝水冷却玻璃幕墙的房间温度较普通房间降温幅度为6.64%,白天降温幅度在6.64%~12.73%.综合分析,冷凝水冷却单层幕墙能够较为有效地调节室内环境,同时也是一种新的建筑幕墙改良途径和冷凝水利用方式.     

Micro end mill tool temperature measurement and prediction

The objective of this work is to characterize the heat transfer in micro end mill tools during machining operations. This analysis will aid in the design of heat dissipation strategies that could potentially increase tool life and machining precision. Tool temperatures, above the unmachined workpiece surface, have been measured using an infrared camera during slot milling of aluminum (6061-T6) and steel (1018) with 300 μm-diameter two-flute tungsten carbide end mills. The measured temperatures compare favorably with temperature distributions predicted by a two-dimensional, transient, heat transfer model of the tool. The heat input is estimated by applying Loewen and Shaw’s heat partitioning analysis. Analysis of heat transfer in the tool found that 46 s into a cut conduction through the length of the tool, storage in the tool, and convection from the surface account for 41.5%, 45%, and 13.5% of the heat generated during machining. Thermal expansion and cooling strategies are discussed.     

Climate change and temperature-dependent biogeography: oxygen limitation of thermal tolerance in animals

Recent years have shown a rise in mean global temperatures and a shift in the geographical distribution of ectothermic animals. For a cause and effect analysis the present paper discusses those physiological processes limiting thermal tolerance. The lower heat tolerance in metazoa compared with unicellular eukaryotes and bacteria suggests that a complex systemic rather than molecular process is limiting in metazoa. Whole-animal aerobic scope appears as the first process limited at low and high temperatures, linked to the progressively insufficient capacity of circulation and ventilation. Oxygen levels in body fluids may decrease, reflecting excessive oxygen demand at high temperatures or insufficient aerobic capacity of mitochondria at low temperatures. Aerobic scope falls at temperatures beyond the thermal optimum and vanishes at low or high critical temperatures when transition to an anaerobic mitochondrial metabolism occurs. The adjustment of mitochondrial densities on top of parallel molecular or membrane adjustments appears crucial for maintaining aerobic scope and for shifting thermal tolerance. In conclusion, the capacity of oxygen delivery matches full aerobic scope only within the thermal optimum. At temperatures outside this range, only time-limited survival is supported by residual aerobic scope, then anaerobic metabolism and finally molecular protection by heat shock proteins and antioxidative defence. In a cause and effect hierarchy, the progressive increase in oxygen limitation at extreme temperatures may even enhance oxidative and denaturation stress. As a corollary, capacity limitations at a complex level of organisation, the oxygen delivery system, define thermal tolerance limits before molecular functions become disturbed.     

基于修复效果的污染土壤修复工程环境足迹分析

为定量评估污染土壤修复工程的环境影响，基于北方某焦化厂有机污染场地原位热脱附和阻隔通风技术的实际修复效果，计算了该工程各阶段的环境足迹及相对贡献，阐明了其主要来源，并对这两种技术修复单位方量土壤的环境足迹和基于污染物含量变化与风险削减的环境足迹强度进行了分析. 结果表明:在达到修复目标的情况下，工程施工准备阶段环境足迹占比仅在1%左右，高风险区原位热脱附施工运行阶段温室气体排放量、能源消耗量、耗水量、空气污染物排放量占比分别为63.39%、93.02%、72.82%和71.08%，低风险区阻隔通风施工运行阶段温室气体排放量、能源消耗量、耗水量、空气污染物排放量占比分别为35.40%、6.77%、26.26%和27.74%；原位热脱附技术修复单位方量土壤的环境足迹高于阻隔通风技术，原位热脱附技术的能源消耗量约为阻隔通风技术的49.70倍，温室气体排放量、耗水量、空气污染物排放量为阻隔通风技术的6.32~10.30倍. 研究显示:天然气使用、电能消耗和现场机械设备使用是该工程环境足迹的主要来源，在高风险区原位热脱附修复工程中苯的环境足迹强度高于苯并[a]芘，原位热脱附技术的能源强度高于阻隔通风技术，基于污染物含量降低情况的环境足迹强度对量化原位热脱附技术的环境足迹适用性较好，而基于风险削减的环境足迹强度适用于阻隔通风技术.      

高超声速飞行器异型气膜孔无喷流热增量研究

目的获取高超声速飞行器气膜孔不喷流时的热负荷增量。方法通过计算流体力学(CFD)方法针对典型高超声速飞行器50km、飞行马赫数为15条件下的无开孔、有开孔气膜冷、有开孔无喷流3种工况开展壁面热流分布研究。结果无开孔的最大热流分布在头部滞止点附近,约为2.2 MW/m~2,有气膜冷却的工况热流最高值在侧面气膜孔没有覆盖到的部位,约为1.4 MW/m~2,有异型孔但是不喷流的工况,热流密度最大值主要分布在开孔附近,最大值大于3.3 MW/m~2。结论对于在高超声速飞行器表面开孔采用气膜冷却方式冷却时,如果由于某种原因气膜孔不喷流,那么在孔的附近乃至整个滞止区域附近的热流负荷将会大幅度升高。     

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.     

SiO2气凝胶隔热性能的影响因素研究

目的 在不同热流条件下,通过调整SiO2气凝胶的孔隙率、涂层厚度等,以满足合适的隔热要求。方法 针对中短程飞行器飞行时外壁面承受短时高热流的特点,在分析孔隙率对SiO2气凝胶热导率影响规律的基础上,通过数值仿真研究不同气凝胶孔隙率、气凝胶厚度及热流作用下的温度响应。结果 得到了不同条件下满足隔热要求的气凝胶最小厚度,以及气凝胶表面的最高温度。高温情况下,气凝胶孔隙率为96%时,有效热导率最低,孔隙率超过96%时,隔热性能变差。结论 当飞行器内壁面温度满足要求时,增大气凝胶的孔隙率,则需要减小气凝胶的厚度,相应的气凝胶表面温度会升高,但升幅很小。当飞行器外壁面承受长时间大热流时,仅调整气凝胶的厚度和孔隙率不能达到结构的隔热要求。     

Experimentally-derived upper thermal tolerances for redhorse suckers: revised 316(A) variance conditions at two generating facilities in Ohio

American Electric Power’s Conseville Station and Muskingum River Plant, located on the Muskingum River in southeastern Ohio, utilize once-through cooling for seven (combined) generating units. Both facilities had approved 316(a) variances that required maintenance of a baseline fully-mixed downstream temperature of 31.6°C (88.9°F). Fish sampling conducted during critical conditions in Summer 1993 indicated the presence of thermally-sensitive redhorse suckers (Moxostoma sp.) at river temperatures >32.2°C (90.0°F). Because the assumed upper tolerance limit for redhorse suckers (31.6°C) was extrapolated from field observations, we determined the actual thermal tolerance of suckers using fish collected locally. During September 1996 golden and shorthead redhorses were collected from the nearby Walhonding River. The short-term upper thermal tolerances were determined by the ultimate upper incipient lethal temperature (UUILT) and the critical thermal maximum (CTM) endpoints. For shorthead redhorse the calculated UUILT was 33.3°C (91.9°F), and the CTM was 35.1°C (95.2°F). For golden redhorse a similar CTM was obtained; however, a reliable UUILT could not be extrapolated due to procedural problems. The results of these tests played a role in Ohio EPA approving a higher fully-mixed downstream limit. This study demonstrates the value of obtaining thermal tolerances experimentally when assumed tolerance values are considered suspect.