纳米银均匀喷射过程的数值计算与仿真

微滴喷射均匀液滴喷射过程受到多种因素的制约,包括压力波幅值、液滴物性(黏度、表面张力等)、喷嘴尺寸等。为深入理解微滴喷射过程机理,基于流体体积法建立了均匀液滴喷射数值模型,研究了压电驱动电压幅值对低粘度纳米银墨水稳定喷射行为的影响。通过数值仿真,给出了驱动电压幅值与液滴断裂长度、液滴飞行速度的数值关系,以及液滴飞行速度与卫星液滴的变化关系。采用27μm喷嘴直径的工业喷头构建微滴喷射系统,低粘度纳米银墨水为喷射材料,通过观测喷印到光面相纸的液滴尺寸及卫星液滴数量对数值模型进行实验验证。结果表明,液滴飞行速度取决于驱动电压幅值,液滴尺寸分布及卫星液滴数量取决于液滴飞行速度,与数值模型相吻合。通过数值模型仿真,针对纳米银墨水物性指标匹配合适的驱动电压幅值,生成均匀液滴流,对微液滴成型的工业化应用具有重要的理论指导意义。     

均匀钎料熔滴喷射装置设计

针对现有焊球生产设备结构复杂、成本高等缺点,设计了实验室用均匀钎料熔滴喷射装置。该装置分为压力控制器、液滴生成器、气体保护装置以及冷却凝固装置四个部分。其中液滴生成器采用喷嘴局部缩径,使熔滴在表面张力差及重力的作用下实现分离,有效地简化了装置的结构,降低了成本。利用所设计的装置对Sn3.0Ag0.5Cu焊球的制备工艺进行优化,并对优化工艺参数下制备的焊球从表面形貌与球形度、焊球尺寸分布以及钎料微观组织等方面进行质量评定。结果表明：喷射压力、喷嘴到冷却介质表面的距离以及喷嘴内径是影响焊球成形的主要因素。优化工艺参数下制备的焊球尺寸均匀、表面光亮、球形度好、内部组织细密无缺陷。所设计的装置能够满足实验室研究钎料喷射过程以及焊球制备的需要。     

直写快速成型机中背压系统的设计

介绍了直写快速成型技术的工作原理、特点和应用.喷嘴背压系统是用来控制喷嘴喷出液滴,选用合适的背压对喷嘴产生均匀的液滴有着重要的影响.为此,设计一套稳定、可靠的喷嘴背压系统是必要的.作者根据直写快速成型机液体喷射的要求,设计了液体喷射背压系统.     

均匀液滴喷射成形中微熔滴关键参数在线检测系统

为了在均匀液滴喷射成形中实现对微熔滴直径、喷射速度及偏转距离的在线检测,提出了基于机器视觉的微熔滴关键参数在线检测方法.利用双缓冲技术设计了图像采集处理流程,提出了微熔滴图像预处理及关键参数测量算法.将检测系统应用于均匀液滴喷射成形过程中,得到了微熔滴直径与激振频率、喷射速度与喷射压强、偏转距离与充电电压之间的关系.检测结果表明,测量值与理论计算值吻合较好,相对标准偏差(RSD)均不超过5.9%,为零构件的精确成形提供了必要保证.     

微细电化学加工双脉冲纳秒电源的研制

为了满足微细电化学加工的工艺需求与科研实验的要求,采用FPGA与STM32器件,设计了电化学微细加工双脉冲纳秒电源。测试实验表明,电源的脉宽、脉间、脉冲幅值电压、正/负脉冲个数调节方便,脉宽/脉间可以调至20ns以下,调节范围宽。通过RS232电源可以接收系统计算机的实时参数调整,能够有效满足微细电化学、微细电火花等多个领域与场合的生产与工艺实验需求。     

基于自适应脉宽的超声信号FRI采样方法及应用

脉冲超声信号求取包络后可视为具有有限新息率(FRI)的高斯脉冲串信号,对于FRI采样框架下的高斯脉冲串信号,时延和幅值的准确估计是以高斯脉冲宽度准确先验为前提的。针对此问题,研究了FRI采样框架下信号脉宽、时延和幅值的关系,并提出一种基于信号峰值先验信息的FRI采样方法,该方法可自适应调整脉冲宽度参数,无需准确先验脉宽参数,解决了传统FRI采样中脉宽准确先验的难题。通过仿真试验和在管道缺陷检测中的应用表明,即使在无法预知信号脉宽真实值的情况下,仍能准确从稀疏采样数据中估计得到信号的准确参数。     

3D打印燃气轮机天然气喷嘴的流场仿真分析

开展3D打印天然气喷嘴流场仿真研究,为小型化燃气轮机控制技术的提升奠定基础。利用Solidworks、ANSYS ICEM CFD软件进行3D打印天然气喷嘴模型建模和网格划分,基于FLUENT仿真完成不同压力工况下稳态天然气喷射流场的数值模拟计算。在天然气喷嘴外流场中形成的几何回流区会随着供气压强的增大而消失,中心回流区会随着工况压力的增大而逐渐向下游区域移动;天然气喷嘴的体积流量会先随着供气压强的增大而增大,供气压强大于0.15 MPa时体积流量逐渐饱和趋于平缓;质量流量随着压力工况的增大而呈线性增大;在距离喷嘴出口70mm处的不同压强工况下的不均匀度小于0.37。从仿真上研究天然气的分布以及气流的流动特性为3D打印喷嘴安全稳定运行及合理组织流场提供参考依据,为3D打印技术在燃气轮机制造中的应用提供了理论基础。     

气动式微滴喷射中液滴稳定生成的动力学特性研究

微滴喷射增材制造技术作为制造领域的新兴前沿技术有着广泛的应用前景,微滴生成特性对增材制造中微滴在基板铺展、搭接、凝固等过程影响较大,研究微滴生成特性对于提高液滴生成尺寸、频率和稳定性有重要意义。通过试验研究气动按需喷射作用下的微滴喷射行为,探究喷嘴尺寸、黏度和供给压力等因素对射流断裂过程及液滴生成稳定性的影响关系,并进一步研究形成角的变化对液桥断裂顺序及卫星液滴产生的影响关系。研究结果表明,随着喷嘴直径减少,韦伯数（We）显著减少,当喷嘴直径减少到100 μm时,We变为0.33,液滴尺寸与喷嘴直径的比值急剧增大;随着黏度的增加,射流颈缩段的液桥显著增长,液滴尺寸明显增大。在保证生成单个液滴的压力条件下,当供给压力较小时,液桥两端先后断裂形成卫星滴,并最终与半月面融合;随着压力的增大,液桥只发生一次断裂,剩余射流回缩到喷嘴内。在气动式喷射方式中由于上形成角始终大于下形成角,所以液桥总是在靠近液滴端首先断裂,该研究结果有助于提高气动式微滴喷射装置的液滴生成质量。     

无线无源的参数可控脉冲发生器

针对植入式刺激器内置电源容量有限、体积大、潜在安全隐患等问题,设计了一种无线无源的参数可控脉冲发生器.该发生器基于电磁耦合原理,由经皮变压器、储能电容、整流电路及双稳态触发器构成,与传统的脉冲发生器相比,在不加入微控制器和维持原有通信信道不变的情况下,实现了脉冲发生器输出信号的幅值、频率、脉宽、极性可调,克服了其他脉冲发生器信号极性不可控的弊端,且电路结构极为简单.通过pspice仿真、实际电路、样机实验的测试,实验结果与理论分析吻合.脉冲发生器输出信号的频率范围0 ～ 300 Hz,脉宽范围60 ～450μs,幅值范围0～10V,且极性可调.因此该脉冲发生器满足植入式刺激器的需求,同时还可用于某些密闭化学、生物装置.     

撞击型喷嘴雾化特性的试验研究

选用撞击型雾化喷嘴AM4进行雾化特性试验,研究了喷嘴背压对雾化液滴尺寸及分布的影响。研究发现,雾化液滴的直径随喷雾压力的增大而减小,但喷雾压力有其临界范围,该压力更有利于空气与液滴的热质交换。利用最小二乘法拟合出喷嘴雾化液滴的经验关联式,整理成韦伯数和雷诺数的函数关系,可用来预测喷嘴出口粒子的直径。     

GMAW焊接熔滴过渡模型的研究进展

对实芯焊丝GMAW焊接熔滴过渡数值模型的研究进展进行综述,认为主要熔滴过渡模拟理论为SFBT、PIT和VOF理论。通过对SFBT、PIT、VOF三种理论的比较,认为VOF理论在处理复杂的自由边界形态时比其他方法更适合和更有效,与实验结果更吻合。为提高理论计算与实验结果的一致性,指出VOF理论还需考虑金属蒸发产生的蒸气压力等因素的影响。     

Droplet interaction of adiabatic dense sprays

The effect of the droplet interactions which arise in the interior of dense sprays is examined by considering the vaporization of a single droplet in a confined region or “bubble”. In the present study the temporal variation of vaporization was determined at two levels of approximation, such as “film analysis” and “quasi-steady analysis”. Thermodynamic analysis was used to determine the final equilibrium conditions which must be satisfied by the unsteady solutions. The results of these two approximate approaches to the unsteady problem were found to be in good agreement providing support for the use of the relatively simple film theory and clearly indicated that the d²-vaporization law cannot be applied in dense sprays. It was shown that the transition between complete and incomplete evaporation is very sensitive to the initial air temperature and to the ratio of the mass of the liquid to the air. In order to gain a preliminary indication of the effect of spray size distribution on the vaporization process the film analysis was extended to sprays with a bimodal droplet size distribution, and it was found that then the kinetics of vaporization also depends on the ratio of the mass of the smaller to that of the larger droplets.     

Droplet transfer model for laser-enhanced GMAW

Laser-enhanced gas metal arc welding (GMAW) is a recent modification of conventional GMAW. It applies a low power laser to the droplet to obtain an auxiliary detaching force to help the detachment and achieve controlled metal transfer. As a primary parameter that affects the process and weld quality, the size of the droplet needs to be monitored and controlled. However, its direct measurement requires a high-speed camera and is not preferred in a manufacturing site because of its high cost and complicated system structure. Soft-sensing method was thus proposed as an alternative to obtain it in real time. Laser power intensity, wire feed speed and welding voltage were identified as the major parameters that determine the droplet size and were thus selected as the auxiliary variables to estimate the primary parameters: size and transfer rate of the droplet. Least squares (LS) regression equation, back-propagation neural network (BPNN), particle swarm optimization-based back-propagation neural network, and three swarm cooperative particle swarm optimization-based back-propagation neural network (TSCPSO-BPNN) models were established from the collected data. Simulation results were analyzed and compared among these models. It was found that the selected auxiliary variables were closely related to the primary variables. Droplet size and transfer rate estimates made based on the TSCPSO-BPNN model are similar to those based on LS regression equation. After dimension reduction, the LS equation can be simpler than TSCPSO-BPNN model while the accuracy is sufficient and meets the requirement for future control. The estimation by LS method could thus be utilized in the control of the laser-enhanced GMAW.     

气压驱动金属微熔滴可控喷射及沉积精度分析?

金属微滴按需喷射成形制造中,保证喷射系统按需产生均匀微滴和喷射沉积的位置精度是成形高质量金属零件的关键。采用试验研究的方法,分析喷嘴壁附着杂质对稳定喷射以及工艺参数对微滴均匀性的影响,并对喷射系统在可控喷射情况下按需产生的锡铅合金(Sn60%Pb40%)微滴尺寸分布进行分析;研究沉积高度变化对微滴沉积精度的影响。在上述研究基础上,通过选择合适的沉积高度,沉积制造一个6×6微滴阵列,并对微滴阵列的沉积精度进行分析。结果表明,所产生微滴的平均直径为321μm,尺寸标准偏差为2.897μm,约99%的颗粒分布在平均直径±2.8%附近区间内,分布较集中,均匀性较好;得到了发散距离随沉积高度增加而增大的变化趋势;成形的微滴阵列精度满足制造要求。为后续成形高质量微小金属零件提供必要的基础。     

气动系统中水滴的蒸发机理分析

气动系统往往会发生结露现象,即系统内部出现水滴。结露现象发生的本质为系统在运动过程中凝结的水滴经过沉积和蒸发后,仍有水滴滞留于系统中。本文利用传热传质理论,对气动系统中沉积的水滴的蒸发状态进行理论研究,并分析了系统中各参数对蒸发过程的影响。     

聚合物熔体微滴喷射装置设计

针对现有3D打印制造技术对材料种类与形状的限制,结合现有微滴喷射制造技术,设计出了一种由螺杆挤出建压系统,电磁铁驱动的机械冲击系统,加热系统,温控系统和三维移动平台组成的聚合物熔体微滴喷射装置,并介绍了其工作原理。采用PP(聚丙烯)粉料作为熔体微滴喷射装置试验用料,通过调节加热温度,螺杆转速,机械冲击脉冲频率,喷嘴和基台距离等工艺参数和机械参数,实现了均匀可控的熔体输送和熔滴喷射,极大的拓展了传统聚合物3D打印所需材料种类与形状限制。     

均匀液滴喷射过程中温度的测量及计算

针对喷射过程中飞行液滴的温度难以准确测量的问题,本文设计了微小液滴温度检测系统.采用该系统测量并得到了液滴初始温度,沉积板预热温度,液滴的冷却速率及其飞行轨迹的环境气体温度.利用快速响应热电偶测量液滴在飞行时的温度,直径为400 μm和600 μm液滴的冷却速率分别为-3.76 ℃/mm和-1.82 ℃/mm.根据液滴的初始温度和冷却速率即可求得其在飞行时的瞬时温度值.依据飞行液滴降温模型,将液滴初始温度和环境气体温度分布函数代入模型的传热控制方程,计算出液滴的冷却速率分别为-4.01 ℃/mm和-1.99 ℃/mm.该计算值与实验测量值吻合良好,证明了本文液滴温度测量方法的可行性.     

Droplet deviation modeling and compensation scheme of inkjet printing

The depositing quality accomplished by inkjet printing process is significantly affected by droplet positioning accuracy which plays an essential role in formation performance and printing efficiency. However, the droplet deviation induced by various factors is rarely studied specifically because most researchers mainly concentrate on the dynamics and mechanics of droplet and ink-substrate interaction to enhance the printing precision. In fact, among all the contributing factors to droplet deviation, the relative motion between nozzle and substrate tends to cause the ejected droplet to deflect from its desired position and the deviation is inevitable as long as the existence of horizontal velocity. The error brought about by this phenomenon is commonly negligible in the majority of current studies with the assumption of slow relative horizontal speed between nozzle and substrate. But it is not always acceptable to keep a quite low horizontal translation speed which would result in inefficiency of printing. In order to satisfy the demanding requirements in efficiency and accuracy of inkjet printing, some strategies are proposed to mitigate the droplet deviation out of the above phenomenon in this paper. An adaptive approach to nozzle feedrate control with a look-ahead algorithm is presented in this paper to compensate the errors by means of reconstructing the tool paths with deviation prediction in advance based on the feedrate profile and the geometrical characteristics of tool paths. The error model is established with full consideration of different circumstances influenced by droplet deviation and is subsequently integrated into the control process of the nozzle feedrate. The practical implementation demonstrates the effectiveness and feasibility of the proposed method.     

超疏水表面液滴的冷凝成长特性研究

利用聚二甲基硅氧烷(PDMS)为基底采用光刻技术制备了微方柱状超疏水表面,分析了冷凝条件下超疏水表面液滴的冷凝生长特征,发现液滴的生长过程可分为微液滴成核冷凝独立生长、冷凝微液滴合并生长以及大液滴生长3个阶段。超疏水表面初始合并的液滴呈Wenzel-Cassie状态和Wenzel状态,随着冷凝液滴的成长,液滴的液-固接触面积与粗糙结构表面的表观面积之比f随着冷凝液滴尺寸的增大而增大,Wenzel-Cassie状态向完全Wenzel状态转变。最后分析了超疏水性破坏的原因。     

声表面波微流控液滴生成技术研究进展

微液滴是一种十分优秀的微反应器,在化学合成、生物检测及细胞研究等领域应用广泛。近年来,声表面波微流控技术发展迅速,在微液滴制备中具有重要应用前景。首先简单回顾了微液滴和声表面波微流控的研究发展历程,然后重点介绍了声表面波微流控液滴生成的工作原理、器件结构、液滴生成过程及工艺参数等;同时介绍了声表面波微流控核壳微液滴的可控生成机理及其制造过程。最后总结并展望了该技术在生化检测、生物3D打印等领域的应用前景。