楔横轧变形接触面的螺旋面方程及其应用

建立了楔横轧变形工件与模具接触面的旋转螺旋面方程。利用新方程求解工程问题,其结果比用传统的用圆锥曲面近似求解有明显改善。螺旋面方程的建立为楔横轧工程问题的精确求解创造了条件。对于研究楔横轧理论。提高工艺水平有一定的促进作用。     

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.     

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.     

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.     

TC11钛合金盘形件锻造过程的有限元模拟

在建立动态接触边界条件的通用处理方法的基础上,采用刚粘塑性有限元法模拟了TC11钛合金盘形件的锻造过程。     

Cryogenic Machining of Tantalum

A new approach for the machining of tantalum is presented. The new approach is a combination of traditional turning and cryogenically enhanced machining (CEM). In the tests, CEM was used to reduce the temperature at the cutting tool/workpiece interface, and thus reduce the temperature-dependent tool wear to prolong cutting tool life. The new method resulted in a reduction of surface roughness of the tantalum workpiece by 200% and a decrease of cutting forces by approximately 60% in experiments. Moreover, cutting tool life was extended up to 300% over that in the conventional machining.     

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.     

楔横轧轴肩的成形曲面的设计

此文分析在二辊楔横轧中轧制各类轴肩的过程。在假想工件轴端固定的图上确定楔侧面截面轮廓形状,再通过叠加轴向刚性移动量确定各截面实际位置,比较直观简便地设计出轧制轴肩的辊面上的成形曲面。最后归纳了设计步骤。     

利用落球探测资料分析临近空间大气重力波

目的探究利用落球探测数据分析临近空间大气重力波特征的优势。方法基于中国首次进行的火箭落球实验过程中,雷达跟踪获得的落球位置信息,计算得到大气水平风场廓线,并利用最大熵法提取重力波参数。与此同时,基于TIMED/SABER卫星在对应时间以及位置上探测得到的温度廓线,利用最大熵法和S变换方法同样获得相应的重力波参数。针对两种方法获得的重力波参数进行对比分析。结果利用最大熵法对火箭探测得到的水平风场扰动廓线和卫星探测得到的温度扰动廓线进行分析,发现纬向风场中的主导重力波的垂直波长约为4 km左右,而经向风场主导重力波的波长集中在6.5 km左右,由温度扰动廓线提取出的主导重力波垂直波长集中在12 km左右。利用S变换再次对卫星探测得到的温度扰动廓线进行分析,重力波垂直波长仍集中于10～12 km左右。这表明从风场廓线和温度廓线中提取出的重力波垂直波长的差异主要是由于卫星探测数据的分辨率不足产生的。结论相比较卫星探测的温度廓线,火箭探测得到的风场廓线数据对重力波的分辨率更高,能够分辨出垂直波长更小的精细结构,具有重要的精度优势。     

HN-AD菌强化3D-RBC处理养猪废水及微生物特性研究

针对现有养猪废水处理工艺中普遍存在的高氨氮（NH₄⁺-N）生物毒性大、工艺流程长、运行成本高和脱氮效果差等问题,采用耐受性强的异养硝化-好氧反硝化（HN-AD）菌挂膜启动三维结构生物转盘（3D-RBC）预处理养猪废水,仅需15d就完成了3D-RBC反应器的快速挂膜.采用调节盘片线速度和C/N的方式,仅65d实现了HN-AD菌在反应器中的富集及养猪废水预处理工艺的启动.采用该工艺对实际养猪废水进行处理,结果表明,HN-AD菌剂挂膜的3D-RBC工艺耐受高氨氮性能强,原水中COD、NH₄⁺-N、TN的去除率高达69.8%、87.9%和79.5%,污染物削减效果明显优于传统工艺.采用高通量测序技术研究了功能菌优势化构建过程中微生物群落结构的变化规律,结果表明,生物膜内具有HN-AD功能的优势菌由盐单胞菌属（Halomonas）、不动杆菌属（Acinetobacter）逐渐变为丛毛单胞菌属（Comamonas）、嗜氢菌属（Hydrogenophaga）等,且后者的相对丰度逐渐上升.扫描电子显微镜结果显示,生物膜以丝状菌为骨架,紧密附着在盘片上的生物膜层表面聚集了以杆状和球状为主的微生物,这与生物多样性分析得出的结论较一致.     

Prediction of polycrystalline materials texture evolution in machining via Viscoplastic Self-Consistent modeling

The crystallographic orientation or anisotropy is one of the main microstructural attributes strongly affecting the mechanical properties of materials. It is also an influential parameter to be considered during the manufacturing process especially for ultra-precision machining since it affects part quality, tool performance, and process productivity through material properties. In this study, a prediction toolset constituted of a Viscoplastic Self-Consistent model and machining process mechanics model is used to predict the texture evolution on the machined surface. The VPSC (Viscoplastic Self-Consistent) methodology which uses the mechanisms of slip and twinning that are active in single crystals of arbitrary symmetry was used. For this, an analytical model for the process mechanics is derived to understand the forces and stresses generated by the cutting tool at each workpiece point, then the strain and strain rate to capture the rate at which the material is deforming and finally the crystallographic orientations under various machining conditions. Experiments were performed on the orthogonal cutting of aluminum alloy AA-7075-T651 and the texture results were compared to model predictions.     

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.     

Characteristics of abrasive waterjet cut-edges and the affect on formability and fatigue performance of high strength steels

The characteristic surface properties and internal workpiece transformations formed during the Abrasive Waterjet (AWJ) cutting process influences the formability and fatigue performance of steel cut-edges. This relatively established cutting technology is used in industry to generate specialist low production components, which may undergo continual loading cycles under operational service conditions. The fatigue performance of AWJ cut-edges can be critical since individual notch defects produced by the cutting process can act as initiation sites from where fatigue cracks can propagate. Due to the increased sensitivity of high strength structural steels to cut-edge fatigue, AWJ cut-edge defects have an ever more significant influence on fatigue performance. The relationship between the traverse cutting speed and the influence on the resulting properties of the cut-edge has been the critical area of investigation. The affects of traverse cutting speed on the surface roughness properties and cut-edge hardening through a process of plastic deformation of grains in the near edge region were observed to be influenced by the traverse cutting speed. It is these characteristic factors that were determined to influence the cut-edge ductility and fatigue performance of steel components. It is a combination of the AWJ properties that produces cut-edges, which are positive for the Hole Expansion Capacity (HEC) but negative for stress life and cyclic stress strain life fatigue performance of AWJ cut high strength steels.     

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.     

Surface functionalized amorphous nanosilica and microsilica with nanopores as promising tools in biomedicine

Cellular interactions with engineered nanoparticles (NPs) are dependent on many properties, inherent to the nanoparticle (viz. size, shape, surface characteristics, degradation, agglomeration/dispersal, and charge, etc.). Modification of the surface reactivity via surface functionalization of the nanoparticles to be targeted seems to be important. Utilization of different surface functionalization methods of nanoparticles is an emerging field of basic and applied nanotechnology. It is well known that many disease-causing organisms induce host lipids and if deprived, their growth is inhibited in vivo. Amorphous nanosilica (ANS) and amorphous microsilica with nanopores (AMS) were prepared by a combination of wet chemistry and high-energy ball milling. Lipophilic moieties were attached to both ANS and AMS via chemical surface functionalization method. Lipophilic ANS and AMS were found to inhibit the growth of Bombyx mori nuclear polyhedrosis virus (BmNPV) and chicken malarial parasites via absorption of silkworm hemolymph and chicken serum lipids/lipoproteins, respectively, in vivo. Therefore, intelligent surface functionalization of NP is an important concept, and its application in curing chicken malaria and BmNPV is presented here. Surface functionalization method reported in this paper might serve as a valuable technology for treating many diseases where pathogens induce host lipid.     

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.     

基于统计能量分析的热效应对高频声振响应影响研究

目的研究热效应对统计能量分析中三个重要参数的影响规律。方法利用有限元法和波法对耦合损耗因子进行分析计算,采用上述两种计算方法分别在三种工况下(仅考虑材料参数变化的工况;仅考虑热应力影响的工况;综合考虑材料参数变化和热应力影响的工况)进行高频声振响应分析,研究热效应对L型板耦合损耗因子的影响规律。结果两者计算结果基本一致。温度变化会对耦合损耗因子造成一定影响,但是影响有限,相对而言在低频段造成的影响较大,在高频段影响较小。结论在400~5000 Hz频带范围内,利用FEM计算耦合损耗因子,其计算结果与波法计算结果基本一致,证明了它的有效性。     

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.     

活性污泥胞外聚合物提取动力学模型

为研究活性污泥胞外聚合物(EPS)提取过程中各参数间的基本关系及优化EPS提取过程,建立了EPS提取过程中浓度随时间变化的动力学模型,并通过前人研究数据和本次试验数据对模型进行验证.结果表明,模型对一些经典文献中的数据拟合效果较好,拟合系数(R2)均大于0.94.对MLSS为(1064.47±298.70)mg/L,MLVSS为(822±147)mg/L的活性污泥进行EPS提取, TOC和蛋白质的拟合效果较好,但多糖和DNA的拟合效果不理想.该模型可以大致估算试验中EPS的最大提取量及任一时间的EPS产量.     

基于限定motif关联规则的海洋热浪事件模式发现研究

海表温度作为近岸海洋热浪事件的重要孕灾环境要素,揭示其变化规律有助于预测未来热浪事件的发生。本文将用于表达热浪事件发生前和发生时海表温度变化规律的关联规则定义为事件模式,提出了基于限定motif关联规则挖掘的模式发现方法。方法通过STAMP算法挖掘出motif,运用MDL评分策略分割motif形成候选关联规则,结合热浪事件发生的约束条件,实现对海洋热浪事件模式的提取。本文利用中国近海3个站点的海表温度数据进行海洋热浪事件模式发现实验,研究结果表明,中国近海的海洋热浪呈季节特征,主要发生于夏季,且持续时间达20天以上,海洋热浪事件模式呈现有规则的升温和下降趋势,升温速率和降温速率呈对称特性,且在热浪发生前,海表温度有一个短暂的升温间歇期。