Cost estimation system of dies manufacturing based on the complex machining features

Part manufacturing estimation cost is a critical and important task for industrial firms. Price evaluation helps the enterprise occupy a successful competitiveness in the market. In fact there are three main approaches for the manufacturing cost evaluation the analytic approach, the analogic approach and the parametric approach. This paper presents a cost estimation system of manufacturing dies based on a semi-analytic approach. The developed system uses a semi-analytic approach based on the principle of the analogic approach and analytic approach. This principle has recourse to the analogic approach to search for analogies between the shapes to be machined before grouping them into complex machining features [1]. For each feature parameter the system generates a process to be used as a sample and consequently a model of machining time. In a second stage and by using the analytic approach, the cutting time is determined either by removal rates of metal units for rough operation (cm³/min) or from the finishing operation surface (cm²/min) or by both production ways [1]. The after cutting return time is calculated through the equations developed for each machining type [2].     

An evaluation of a modulated laser encoder

This paper introduces a new method of interpolation for sub-nanometer-resolution linear encoders. This method, called SPPE (scanning position probe encoder), uses high-order harmonics information obtained by a sinusoidal scanning pickup located on a periodic grating surface. The proposed encoder uses a current-modulated laser diode with diffractive grating optics. Since the electrical current changes the laser-diode wavelength, the interference light intensity is modulated as a sinusoidal scanning pickup on the scale grating. Phase-detection circuits can decode the position information in the pickup signal by using phase-locked loop techniques. The decoder achieves an interpolation rate of over 1/40,000 with interpolation errors of less than ±1 nm. A new interpolation-error measuring system was developed for the encoder. Finally, the evaluation results reveal that the presented encoder shows both high resolution and strong robustness.     

Objective comparison of scanning ion and scanning electron microscope images

Common and different aspects of scanning electron microscope (SEM) and scanning ion microscope (SIM) images are discussed from a viewpoint of interaction between ion or electron beams and specimens. The SIM images [mostly using 30 keV Ga focused ion beam (FIB)] are sensitive to the sample surface as well as to low-voltage SEM images. Reasons for the SIM images as follows: (1) no backscattered-electron excitation; (2) low yields of backscattered ions; and (3) short ion ranges of 20–40nm, being of the same order of escape depth of secondary electrons (SE) [=(3–5) times the SE mean free path]. Beam charging, channeling, contamination, and surface sputtering are also commented upon.     

Failure mechanism for metal cylinder under explosive loading

This paper presents the numerical study of dynamic fracture for metal cylinder under internal explosive loading. Also, the effects of fracture models and groove designs on fracture behavior are investigated. For the dynamic hardening behavior, the Lim-Huh model including the thermal softening effect is adopted [1, 2]. Also, the Lou-Huh fracture model considering the strain rate dependency is used for fracture prediction [3]. The tensile fracture occurs first at the outer surface, and the shear fracture is observed near the inner surface. In addition, finite element analyses are performed to study the effect of various groove designs on dynamic fracture; single U-groove and V-groove at the outer surface. The tensile and shear fracture lines are predicted near the groove tip and inner surface, respectively. It is concluded that the stress triaxiality parameter is one of the critical factors in the dynamic fracture prediction of the metal cylinder.

     

螺纹联接外螺纹牙底表面裂纹应力强度因子的实验研究

用Ｊａｍｅｓ－Ａｎｄｅｒｓｏｎ方法［１］，对螺纹联接外螺纹牙底表面裂纹在拉伸作用下的应力强度因子进行了实验研究。在大量疲劳裂纹扩展实验取得的ＳＩＦ正则系数值的基础上，用逐步回归分析得到了这种情况下表面裂纹最深点和表面点的应力强度因子近似式。并将所得结果与拉伸圆杆［２，３，４］和带螺纹拉伸圆杆表面裂纹应力强度因于进行了比较分析，结果表明，三者之间的规律性很好     

A New Circuit for Current Reversal Chronopotentiometry

Electrochemical techniques are being used today to measure the kinetics of homogeneous chemical reactions [1, 2]. The value of one of the techniques, current reversal chronopotentiometry (CRC), has been demonstrated with the study of several chemical systems [3, 4]. Recently, a circuit designed for cyclic chronopotentiometry (CC) utilizing tube-type operational amplifiers was published [5]. This circuit of course is also suitable for CRC and in fact has been used to elucidate the mechanism of the loss of water from p-hydroxyaminophenol [6]. The main disadvantage of this circuit is that the experiment is initiated by unshorting the electrochemical cell. Undesirable galvanic reactions are possible at the working electrode when it is shorted to the unpoised auxiliary electrode [7]. This has been circumvented by making the auxiliary electrode a large area reference electrode.

However, this can be inconvenient and, moreover, is disastrous if appreciable reactions can proceed at zero volts vs. the particular reference electrode used.     

Numerical evaluation of the potential for fuel economy improvement due to boundary friction reduction within heavy-duty diesel engines

Advanced surface treatments have been developed by a number of research institutes as an approach to reduce friction at sliding interfaces. Laboratory tests have shown that some of these surface treatments can result in boundary friction reductions approaching an order of magnitude [1], [2] and [3]. While there are many potential applications for such surface treatments, friction reduction in internal combustion engines is of particular interest due to the apparent fuel savings potential. Ricardo, Inc. has performed simulations to estimate potential fuel economy improvements due to the application of such treatments at key interfaces within engines typical of those used in large trucks. The results show that fuel economy improvements in excess of 4% can be achieved from combined application of a surface treatment and reduction in lubricant viscosity, if the surfaces can be protected against wear.     

Precision of shaft basing in centers

Analytical formulas for the errors of shaft basing in centers are presented. Recommendations for more precise basing are outlined. The bases and theoretical basing systems currently employed for shafts in centers were analyzed in [1]. In addition, the main factors affecting the basing precision for the executable dimensions were identified. In the present work, we consider the basing error when the two most common systems for blanks with conical center holes are employed: 1) with a rigidly fixed front center and a mobile rear center (Fig. 1a); 2) with a recessed front center and a mobile rear center (Fig. 1b). First we determine the basing error for the executable dimensions due to each factor separately and then we consider their combined action. In the calculations, we use the approach outlined in [2, 4].     

后掠式压气机叶型的曲面原理

本文使用微分几何原理,直接推导了具有显明的后掠式压气机叶型几何形状的叶片翘曲角β与叶型型面方程与轮毂、轮盖回转面方程之间的关系式。因此,该式亦是叶型几何形状的数学表达式。在文献[1]中沿轮毂、轮盖的叶片翘曲角β的分布仅仅是预先给定的。所以,本文与文献[1]不同之处在于本文用曲面原理建立了叶片翘曲角β的关系式,并提供了一种方便而正确的方法。     

The substructure of immunoglobulin G resolved to 25 kDa using amplitude modulation AFM in air

Amplitude modulation (or tapping-mode) atomic force microscopy (AM AFM or TM AFM) in air can reveal sub-molecular details of isolated multi-subunit proteins, such as immunoglobulin G (IgG) antibodies, on atomically flat support surfaces such as mica [A. San Paulo, R. Garcia, Biophys. J. 78(3) (2000) 1599]. This is achieved by controlling the microscope imaging parameters (e.g. cantilever drive frequency and set-point amplitude) to keep the AFM tip predominantly in the attractive force regime. Under these conditions, the 50 kDa F(c) and F(ab) subunits can be resolved when the molecule has the appropriate orientation on the surface. The presence of a water layer on hydrophilic mica is an important factor affecting imaging contrast, a consequence of capillary neck formation between tip and surface [L. Zitzler, S. Herminghaus, F. Mugele, Phys. Rev. B 66(15) (2002) 155436]. Desiccation of samples to remove surface bound water layers can yield reproducible imaging of the IgG substructure [N.H. Thomson, J. Microsc. (Oxford) 217(3) (2004) 193]. This approach has also given higher resolution than previously achieved, down to about 25 kDa, and these data are detailed here. These subdomains are formed as two immunoglobulin folds from the light and heavy peptide chains of the IgG crossover. This result has been validated by comparing the AFM images with X-ray crystallography data from the protein data bank. These data show that the AFM can obtain 25 kDa resolution on isolated protein molecules with commercially available silicon tips, but, as expected for a local probe technique, resolution is highly dependent on the macromolecular orientation on the support surface.     

Determination of Electric and Mechanical Characteristics of Piezoceramic Elements

Piezoceramic elements (PCE) have been widely used in manufacture of various emitters and receivers of acoustic waves, filters, delay lines, and in other devices, such as piezoelectric transformers and drivers, etc. In order to improve their performance and widen the domain of PCE applications, methods and instruments are required for rapid and accurate determination of their parameters. The paper describes a technique for automated measurements and calculations of electric and mechanical characteristics of piezoceramic materials based on dynamic methods [1, 2] and American IEEE standards [3, 4]. The technique can be used in measuring rated parameters of PCE. In addition, we attempted to refine formulas prescribed by the State Standard GOST 12370-80 [2] using the theory of piezoelectric effects [5–8].     

新型粉末涂层刀具材料的研制

用异丙醇铝和正硅酸乙酯作前驱物,制得用于涂层的复合溶胶。利用溶胶-凝胶法在TiC粉末表面成功地涂覆了一层纳米级A l2O3/S iO2陶瓷薄膜,通过热压烧结成功制得了粉末涂层材料。材料的平均维氏硬度为19.5GPa,平均抗弯强度为860 MPa,平均断裂韧性为7.8 MPa.m1/2。     

Integrated approach between pulsed thermography,near-infrared reflectography and sandwich holography for wooden panel paintings advanced monitoring

The durability of an exterior finish is affected by the characteristics of the wood. Satisfactory finish life is usually more difficult to achieve on woods of higher density. All wood shrinks as it loses moisture and swells as it absorbs moisture, but some species are more stable than others. Species that shrink and swell the most cause more stress on paint films than woods that are more stable [1]. To this end, let us recall that a painting on wood can be considered as a layered structure: The wood support is coated with a number of superposed priming layers made from mixtures of gesso and glue. A frequent fault resulting from such a system is the formation of detached regions inside the layered structure caused by the shrinkage process of the wood support [2]. Obviously, wood deteriorates more rapidly in warm, humid regions with respect to cool or dry places [3]. The influence of wood conditions on surface coatings is a critical point that should be monitored and that depends on environmental parameters such as microclimate. To prevent and control the effects, keeping costs down, a non-destructive monitoring of wood support behavior under thermal stress is needed. In this work, an integrated approach based on traditional and innovative (HI, PT and NIR) techniques was conducted on a primed support of poplar wood with a complex-shape surface containing areas of artificial defects at several depths due to the influence of the support on the various layers. The obtained results could be arranged, if integrated into a multidisciplinary approach, in order to define and design the conservation of the wooden artifacts.     

The instantaneous motion of a line in a t-position

This paper deals with matter belonging to plane instantaneous kinematics. It describes geometric properties of the motion of a line at an instant in which the pole of the motion is at infinity. This work has been stimulated by a recent paper of Kimbrell and Hunt on line-envelopes of 4-bar linkages in asymptotic configurations [1]. The first part (Sections 1 and 2) of the present paper concerns the behaviour and the mutual situation of the centrodes in the vicinity of the (infinite) pole. The Sections 3 and 4 are dealing with the nature of the point of contact of the line with its envelope. The remainder of the paper contains an application to 4-bar motion. It cannot be denied that in some respects the results of the present study contradict and unsettle various of the statements made in[1].     

Tribological Performance of Halogen-Free Ionic Liquids as Lubricants of Hard Coatings and Ceramics

Ionic liquids are expected to be used as new high-performance lubricants because of their low volatility, high thermal stability, and high oxidation stability. It is well known that halogen-containing ionic liquids exhibit excellent lubricity for metals. However, there is a concern about the corrosiveness of ionic liquids caused by the formation of halides. The lubricity of halogen-free ionic liquids for metals is inferior to that of halogen-containing ionic liquids; however, they do not cause any remarkable corrosion effects. In this study, the lubricity of halogen-free ionic liquids—1-butyl-3-methylimidazolium tricyanomethanide ([BMIM] [TCC]) and 1-ethyl-3-methylimidazolium dicyanamide ([EMIM] [DCN])—for hard coatings and ceramics was evaluated using an SRV oscillating sliding tester. Ionic liquids exhibited excellent lubricity for sintered ceramics. It is supposed that the lubricity of ceramics depends on the chemical interaction between the surface and the ionic liquids. Ionic liquids exhibited different lubricating properties with each nitride coating. [EMIM] [DCN] exhibited a better wear reduction than [BMIM] [TCC] on CrN, and its friction coefficient was higher than that of [BMIM] [TCC]. DLC coatings with [EMIM] [DCN] exhibited better lubricity than with [BMIM] [TCC], and the combination of H-free DLC and [EMIM] [DCN] particularly showed excellent lubricity. XPS analysis showed that two kinds of nitrogen compounds were on the sliding surface of H-free DLC lubricated with [EMIM] [DCN].     

圆管进口段层流一湍流边界层发展区的流动阻力

本文提供了一种计算模型,可以根据前文[1][13]所提供的圆管进口段边界层单纯层流和单纯湍流时的近似分析解作为基础,计算3×10{sup}3≤ReD≤1×10{sup}5时进口平滑的圆管进口段内边界层先层流、然后过渡为湍流的任何区段不可压缩流体的流动阻力和壁面摩擦阻力。计算的流动阻力为文献[6]所报导的实验原始资料所验证。     

鲨鱼软骨粉中无机成分与形态分析

本文用等离子发射光谱法测定了鲨鱼软骨粉中的无机元素,并用红外光谱仪和X射线衍射仪进行了结构分析。结果表明,鲨鱼软骨粉中的主要无机成分为1/2[Ca(OH)_2·3Ca_3(PO_4)_2]。还讨论了锶的营养作用。     

Case study: A comparison of error sources in high-speed milling

This paper describes a case study devised to quantify the relative contributions of geometric, thermal, contouring, and cutting force errors to machined part dimensional errors. Measurements were performed to independently evaluate the: (1) quasi-static geometric errors using the laser ball bar; (2) variations in geometric errors due to thermal effects; (3) spindle thermal growth errors using a capacitance gage nest; (4) two-dimensional contouring errors using a grid plate encoder; and (5) surface location error due to (stable) forced vibrations during cutting. The effects of the first three error components were related to part dimensions using a homogeneous transformation matrix approach integrated into a Monte Carlo simulation. A comparison of the individual influences of these error sources showed that the cutting force error was dominant for the high-speed machining center/tool-holder combination selected for this study.     

Ionic Liquids as Lubricants of Titanium–Steel Contact. Part 3. Ti6Al4V Lubricated with Imidazolium Ionic Liquids with Different Alkyl Chain Lengths

The tribological behaviour and surface interactions of Ti6Al4V sliding against AISI 52100 steel have been studied in the presence of three commercial methylimidazolium (mim) room-temperature ionic liquids (ILs) containing the same anion, bis(trifluoromethylsulfonyl)amide, [(CF₃SO₂)₂N] (Tf₂N), and cations with increasing alkyl chain length, 1-ethyl-3-methylimidazolium [C₂mim], 1-butyl-3-methylimidazolium [C₄mim] and 1-octyl-3-methylimidazolium [C₈mim]. Increasing alkyl chain length increases viscosity whilst reducing the onset temperature for thermal degradation in air, the surface tension and the molecular polarity of the ILs. At room temperature, the tribological performance of the three ILs has been compared with that of a mineral oil (MO). The results show the reduction of the running-in period for the ILs with respect to the MO. In contrast with previously described results for IL lubrication, wear rates for Ti6Al4V at room temperature increase as the alkyl chain length of the ILs increases. The maximum wear reduction, of a 39%, with respect to MO is obtained for the [C₂mim] cation, with only two carbon atoms on the lateral chain. This was the IL selected for the tests at 100 °C. At this temperature, the reduction of the mean friction coefficient with respect to the MO is higher than 50%, whilst the wear rate of Ti6Al4V is reduced by 78%. The friction-sliding distance records for the IL at 100 °C show sharp transitions, related to formation of wear debris and surface interactions between the Tf₂N anion and the aluminium present in the Ti6Al4V alloy. Surface tribolayers and wear debris have been studied by SEM–EDX observations and XPS analysis.     

High resolution SEM of bacterial virus T7.

High resolution "low-loss" scanning electron microscopy is a relatively new technique which permits an investigator to examine structures that were formerly visualized exclusively by transmission electron microscopy [1]. This paper presents some images of intact bacterial virus T7, viewed at the ultrastructural level. Due to the high resolution capibility of this technique, and the demanding physical prerequisites for visualization of the specimen, current specimen preparation techniques were modified in order to permit 1--2 nm resolution in surface mode. Using this method of microscopy, it is possible to view clearly this small bacteriophage (the smallest of the T-coliphages), adsorbed to its host bacterium, in a scanning mode at magnification (and resolution) comparable to TEM without resorting to the use of replicas, or reconstruction of a two-dimensional image.