An experimental technique to detect tool–workpiece contact in micromilling

There is a need for simple, accurate, and low-cost techniques to detect tool–workpiece contact (or tool touch-off) in micromilling operations. This paper presents a method that is based on monitoring changes in the power spectral characteristics of the spindle vibration signal. The accuracy of this contact detection method is evaluated under different conditions by measuring the overshoot of the tool into the workpiece surface. Specifically, the effects of tool geometry, workpiece surface roughness and hardness, tool wear, step size, and contact detection threshold on the overshoot are analyzed through experiments carried out on a 3-axis micromilling machine. The results show that the method is capable of sub-micron contact detection accuracy depending on the workpiece hardness, roughness, and contact detection threshold.     

Clamping Fault Detection in a Fixturing System

When a workpiece is located and clamped in a fixture, the dynamic response can be used to characterize its corresponding clamping condition. When the contact condition between the workpiece and the fixture is changed, the system response frequency will change accordingly. The identification of insufficient clamping forces is investigated in this study. This paper also presents the modeling and analysis of the contact condition between fixtures and components in a modular fixturing system. Analytical models were obtained using the finite element approach. Virtual spring elements are used to model the dynamic effect of surface contact in the model, and the estimation of the virtual spring constants is also presented. Experimental results are compared with the analytical predictions.     

Tool Path Planning for Avoiding Exit Burrs

Milling exit burrs usually form along the edges of a workpiece when the tool leaves the part while removing stock material. One of the most efficient methods for minimizing exit burrs is to prevent the tool from exiting the workpiece during material removal. This paper describes a systematic framework to generate tool paths that always enter a part, which is not a thin structure, in a planar milling operation. Three distinct tool exit conditions are analyzed for polygonal parts. A test criterion is then proposed to examine the occurrence of tool exits. For each condition, a tool path planning scheme is developed to avoid tool exits. These schemes are proved to be effective using the test criterion. This work is integrated into a networked manufacturing environment as a burr agent. Test parts are cut to demonstrate that this framework enhances edge quality by minimizing tool exits.     

生化池中不同粒径细微沙的悬浮特性

进入生化池的沙粒受粒径影响,或沉积或悬浮在生化池,粒径≤73 μm的细微沙容易悬浮在污泥混合液中,导致活性污泥ρ(MLVSS)/ρ(MLSS)(生物有机质所占的比例)下降. 以粒径≤73 μm的沙粒为对象,研究生化池中不同粒径细微沙对活性污泥ρ(MLVSS)/ρ(MLSS)的影响,探讨细微沙的可悬浮性和悬浮态势,揭示细微沙对污泥活性的影响,以期为污水厂的运行管理提供理论基础. 通过显微观察发现,粒径>33 μm的细微沙不易被活性污泥卷捕,呈自由悬浮态势;粒径≤33 μm的细微沙容易被活性污泥絮体卷捕,呈卷捕附着态势. 细微沙粒径越小,悬浮比(悬浮在污泥混合液中的细微沙占生化池进水中细微沙总量的比例)越大,活性污泥ρ(MLVSS)/ρ(MLSS)越低,悬浮比与细微沙粒径呈显著线性相关(y=0.996-0.010x),活性污泥ρ(MLVSS)/ρ(MLSS)与悬浮比相关性显著〔y=2.84/(12.27x+3.06)〕. 研究显示,细微沙不影响污泥中微生物的活性,污水厂可结合活性污泥ρ(MLVSS)/ρ(MLSS)调控ρ(MLSS),保证ρ(MLVSS)的稳定,有利于实现污水处理系统的稳定运行.      

生物絮凝剂与改性沸石复配处理猪场废水厌氧消化液的响应面优化

采用响应面分析法(RSM)对红平红球菌所产发酵液与聚合氯化铝(PAC)复配处理高岭土悬浊液及发酵液与改性沸石复配处理猪场废水厌氧消化液的过程进行了优化.设定的响应值分别为絮凝率和絮体粒径,COD和氨氮去除率.实验分别拟合了关于絮凝率,絮体粒径,COD去除率和氨氮去除率的二次模型,决定系数(R2)分别为0.8933,0.8353,0.7819和0.8343,表明拟合情况良好.根据响应值的分布情况,确定高岭土悬浊液的最佳絮凝条件为发酵液3.7mL/L,PAC 49mg/L,pH值8.7,CaCl224mg/L, 反应时间15min,相应絮凝率和絮体粒径分别为96.3%和0.67mm;猪场废水厌氧消化液的最佳絮凝条件为发酵液4.5mL/L,改性沸石12g/L,pH值8.3,CaCl216mg/L,反应时间55min,相应COD,氨氮去除率分别为87.9%和86.9%.     

Investigation of chipping and wear of silicon wafer dicing

Wafer dicing chipping and blade wear processes in transient and steady stages were investigated. Dicing blades with two different diamond grit sizes were used to cut wafers. In the cutting experiments, the dicing blades with two different diamond grit sizes were used to cut wafers and for a given type of wafer, the cooling water temperature, cutting feed speed, and rotational speed were fixed. The chipping size, blade surface wear area and surface roughness of the wafer were measured at cutting distances of 50, 150, 300, 975, 1350, and 1900 m, respectively. Cutting debris of cutting distances of 300 m and 1900 m was collected and analyzed. The correlation between blade surface properties and chipping size was investigated. Based on this experimental system, attention is to pay to examine the correlation between blade surface properties and chipping size for transient stage and steady stage. In transient stage, the roughness of dicing blade increases rapidly. This will rapidly increase the chipping size. In steady stage, the chipping size decreases slowly with the decreasing roughness of blade surface. This concludes that blade surface condition is an important factor that affects the chipping size. Moreover, in transient stage, diamond grits that are salient or less bonded to the blade detach leave caves on the blade surface which increases surface roughness of the blade and the chipping size. In steady stage, the heights of grits become even and the chipping size decreases accordingly.     

某污水处理厂旋流沉砂池结构改造及运行效果分析

沉砂池是污水处理厂预处理单元重要设备,近年来,旋流沉砂池在市政污水处理厂的应用越来越广泛,但实际运行中存在出砂效果不佳等问题。重点分析了某污水处理厂旋流沉砂池运行效果差、不出砂等问题,提出了换用螺旋曲面桨叶、降低旋桨转速、调整桨叶与底部距离等具体措施。改造后对该厂旋流沉砂池进行连续检测,发现其SS平均去除率由1.86%提升至21.38%,平均出砂量为51 kg/d,同时对COD的截留效果得到一定改善,有利于降低后续生物段的碳源投加量。改造前后沉砂池对TN的去除率基本保持在0.9%左右,而TP平均去除率从0.44%提升至0.99%。总体来说,旋流沉砂池经过改造后运行稳定,除砂效果良好,污水处理厂出水水质得到明显提升。     

钝锥表面脉动压力风洞试验研究

目的 获得钝锥在风洞实验连续变雷诺数过程中表面脉动压力的变化规律.方法 基于利用超声速风洞,研究Ma=6、α=0°工况下,单位长度雷诺数从4.5×107 m?1连续变化为1.0×107 m?1过程中钝锥表面脉动压力时域、频域的变化规律.结果 在雷诺数从高到低变化过程中,钝锥表面测点脉动压力时域信号幅值出现了瞬间下降现象...     

山地城市排水管网特细颗粒物特性及变化规律

对山地城市排水管网中特细颗粒物的粒径分布特征及变化规律、Zeta电位分布特征及变化规律和ρ(SS)的变化规律进行研究,同时对相关水化学参数(如电导率、pH)的变化规律进行了分析.结果表明:特细颗粒物的平均粒径、Zeta电位、ρ(SS)和电导率分别为21.04～73.53μm、-20.83～-11.15 mV、106～492 mg/L和973～2 445μS/cm,其统计平均值分别为(43.74±14.12)μm、(-17.95±1.88)mV、(233±90)mg/L和(1 343±331)μS/cm;pH为7.25～7.63.工业废水的排入对排水管网特细颗粒物的粒径分布特征、Zeta电位分布特征以及电导率有显著的影响并呈现出一定的规律性;传统沉砂池对进水中特细颗粒物的去除能力相当有限,特细颗粒物会直接进入生物处理系统.      

航空电连接器腐蚀退化仿真研究

目的 探索当航空电连接器腐蚀退化时,其接触阻抗的变化规律,研究航空电连接器腐蚀退化对信号传输的影响规律。方法 首先对航空电连接器腐蚀退化的机理进行研究,建立其等效电路模型,然后分别对低频电连接器和射频电连接器进行仿真研究,提取阻抗参数,分析腐蚀退化对信号传输的影响规律。结果 接触电阻随着腐蚀程度的加深明显增大,接触电感随着腐蚀程度的加深变化不大,接触电容随着接触面腐蚀面积的增大而增大,随接触面间腐蚀厚度的增加而减小。接触电阻随频率的增加而增大,接触电感和接触电容随频率的增大基本保持不变。接触阻抗在低频时呈现感性特征,高频时呈现容性特征,阻抗幅值随频率的增加先增大、后减小,峰值出现在感性和容性转换频率处,腐蚀退化将使该转换频率减小。结论 对于低频信号,腐蚀退化将导致信号的衰减和延迟;对于高频信号,在转换频率处,信号的回波损耗、插入损耗和电压驻波比出现极值。     

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.     

Experimental investigation of the machining induced residual stress tensor under mechanical loading

Residual stress induced by machining is complex and difficult to predict, since it involves mechanical loads, temperature gradients or phase transformation in the generation mechanism. In this work, an experiment with a statistical design for the residual stress tensor was performed to investigate the residual stress profile on a machined surface. In order to understand the generation mechanism of residual stress in machining, three variables and workpiece materials were carefully selected to focus on the mechanical loads and avoid the temperature gradients and phase transformation on the machined surface. The mechanical loads considered here included the chip formation force at the primary shear zone and the plowing force at the tool tip–workpiece contact. Depths of cut and rake angles were selected to alter the chip formation force, and the tool tip radius was designed to emphasize the plowing effect. The workpiece material was aluminum 3003. The experimental results showed that the chip formation force provides basic shapes of the residual stress profile for a machined surface. It decides the depth of the peak residual stress below the surface. However, the plowing force was the dominating effect on the surface residual stress, causing high stresses on the surface. The plowing force can shift the surface stress from tensile to compressive. Additionally, the measured stress tensor proved that in-plane shear stress exists for the machined surface.     

Optimization of phenol degradation by Candida tropicalis Z-04 using Plackett-Burman design and response surface methodology

Statistical experimental designs were used to optimize the process of phenol degradation by Candida tropicalis Z-04,isolated from phenol-degrading aerobic granules.The most important factors influencing phenol degradation (p<0.05),as identified by a two-level Plackett-Burman design with 11 variables,were yeast extract,phenol,inoculum size,and temperature.Steepest ascent method was undertaken to determine the optimal regions of these four significant factors.Central composite design (CCD) and response surfac...     

车辆悬架螺旋弹簧断裂失效行为研究

目的 判定车辆悬架螺旋弹簧失效的原因,提出改进措施.方法 通过分析和测试其化学成分、氢含量、非金属夹杂物、力学性能、金相组织、断口形貌等,研究车辆悬架螺旋弹簧的失效行为.结果 试件弯曲变形内侧的剪切应力值最大,容易引起应力集中.材料最后断裂区为韧窝和沿晶的混合断裂,且断后伸长率偏低.喷丸并未完全去除脱碳层及表层的其他原始缺陷,表层形成疲劳缺陷的可能性增高.喷丸造成螺旋弹簧表层存在较深的凹坑,凹坑边缘形成明显凸起棱边,引起应力集中,且材料表层存在折叠缺陷.在循环应力作用下,凹坑处折叠缺陷端部首先成为裂纹萌生点,在循环应力作用下,裂纹持续扩展,最终疲劳断裂.结论 减小钢丸粒径,降低喷丸压力,以避免过深的凹坑及尖锐的凸起棱边,并适当增加喷丸过程的表层去除深度;调整热处理工艺,适度降低材料强度、提高韧性,使断后伸长率大于10％.改进轧制工艺,消除材料的折叠缺陷,加强材料缺陷检测.     

碳纳米管预涂覆低压膜去除水中腐殖酸的机理研究

以腐殖酸（Humic Acid,HA）为研究对象,通过压力辅助过滤技术将碳纳米管（Carbon Nanotubes,CNTs）预涂覆在聚醚砜（Polyethersulfone,PES）平板膜表面,制备了CNTs预涂覆低压膜,分别考察了该膜在恒压和恒流实验中对HA的去除情况及其对膜污染的缓解作用.研究表明,CNTs预涂覆膜可以有效缓解基膜的污染,保证CNTs的分散性,增加PES膜表面预涂覆CNTs的投加量,有助于缓解膜污染的发生;采用径向尺寸小的CNTs制备出的预涂覆低压膜,其抗污染能力更佳.研究进一步采用恒流膜滤装置对膜滤过程的3个阶段（新膜过滤阶段、膜污染加速阶段、堵塞膜截留阶段）进行了模拟,考察了CNTs预涂覆低压膜对HA的去除机理.结果表明,新膜过滤阶段,CNTs预涂覆低压膜运行初期,CNTs的吸附性能对HA的去除起主导作用,HA去除率随过滤时间的增加而不断减小,吸附阶段CNTs预涂覆膜的跨膜压差（Transmembrane Pressure,TMP）始终保持在较低水平（不高于15 kPa）,降低CNTs的径向尺寸和提高CNTs投加量,均有助于吸附去除HA;膜污染加速阶段,随着CNTs预涂覆膜进入膜污染加速阶段,HA的去除率由吸附阶段的不断降低开始出现上升拐点,TMP由于CNTs预涂覆膜的加快堵塞而不断升高;堵塞膜截留阶段,CNTs预涂覆低压膜在一定程度堵塞后,表现出截留去除HA的效能,且TMP仍保持在低压膜运行范围内,降低CNTs的径向尺寸,制备的预涂覆膜孔径小且分布均匀,有助于其提高截留去除HA的效能.整个恒流实验过程中,未负载CNTs的基膜对HA仅有微弱的吸附作用,且由于其较大的孔径,对HA的截留作用十分有限.本文通过对CNTs预涂覆低压膜吸附阶段和截留阶段的划分,明确了CNTs预涂覆低压膜在吸附饱和之后,能够有效截留水中HA,可作为水中腐殖质类污染物去除的一种有效手段.     

环形件摆动辗压过程中接触区域轮廓的数值计算方法

摆动辗压过程中锥形摆头与坯料接触面积是一个十分重要的参数,此文从辗压过程中坯料螺旋式送进的事实出发,首次给出了环形坯料,接触区域轮廓坐标的数值求解过程,为正确计算接触面积提供了精确的计算方法。     

Pulsed laser micro polishing: Surface prediction model

The objective of this work is to predict the final roughness of metal surfaces that have undergone pulsed laser micro polishing. The motivation for pulsed laser micro polishing is to reduce the surface roughness of parts whose surface texture can approach the feature size. Being able to predict the magnitude of the polishing and frequency (wavelength) content of the surface will assist in the design of optimal processing parameters with minimal experiments. Laser pulses are used to create shallow melt pools with a controlled size (e.g., depth) and duration in order to allow surface tension forces to “pull down” asperities with small radius of curvature. There is no ablation occurring in the process being modeled. The melt depth and duration are predicted with a transient, two-dimensional axisymmetric heat transfer model with temperature-dependent material properties. The surface of the melt pool is analytically modeled as oscillations of stationary capillary waves with damping resulting from the forces of surface tension and viscosity. Above a critical spatial frequency, f_cr, a significant reduction in the amplitude of the spatial Fourier components is expected. The work described in this paper extends the concept of critical frequency to a physics-based prediction methodology for predicting the spatial frequency content and surface roughness after polishing, given the features of the original surface, the material properties, and laser parameters. The proposed prediction methodology was validated using line polishing data for stainless steel 316L and area polishing results for pure nickel, Ti6Al4V, and Al-6061-T6. The predicted average surface roughnesses were within 12% of the values measured on the polished surfaces.     

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.     

等离子改性CNT/TiO2电极吸附去除水中苯酚的研究

利用电感耦合空气等离子体对涂覆法制备的CNT/TiO2复合电极进行射频放电改性处理.复合电极的表面形貌、润湿性及元素成分分别通过扫描电镜(SEM)、接触角测试仪、x射线光电子能谱(XPS)进行了表征.结果表明,改性后有利于苯酚吸附,电极比表面孔隙、亲水性、TiO2及含氧官能团均得以增加;循环伏安测试(CV)表明改性后电极比电容提高54%;改性后复合电极对苯酚的吸附量较改性前提高了45%.且等离子改性CNT/TiO2电极对苯酚的去除量随电压、苯酚初始浓度的增加而增加,吸附过程符合准二级动力学方程,吸附等温线符合Langmuir等温吸附模型.