钨合金的磨削加工去除机理

目的 解决钨合金磨削加工去除机理不明晰的问题。方法 基于单磨粒刻划有限元仿真、单磨粒刻划和磨削加工实验，探究钨合金的磨削加工去除机理。结果 在刻划过程中，划痕的不同位置材料的去除特性存在显著差异。在单颗粒刻划切入端，材料依次发生了塑性变形、隆起、微裂纹，再到钨相与黏结相的混杂交融。在划痕中段以材料去除为主，出现了材料微卷起和材料卷起现象，沿着刻划方向卷起现象越来越严重。在划痕切出端，划痕边缘和尾部均出现了“飞边”现象，且相较于切入端，切出端的形貌较差，实验与仿真吻合。此外，在不同相位处，材料的去除特性也存在一定不同。在钨相区域，同时存在脆性特征和塑性特征。在黏结相区域，刻划深度较浅时主要呈现塑性变形、塑性流动等特征，刻划中端深度较大时主要呈现与钨相的混杂和交融。在钨相与黏结相的相界处，相邻钨颗粒呈现不同的损伤或去除特征，且相界会阻断特征形貌的传递。最后，磨削后的钨合金表面存在单颗粒刻划痕上出现的所有去除特征，与单颗粒划痕的去除特征吻合。不同的是，磨削后划痕底部出现了区域性和放射状的裂纹。结论 钨合金的两相特性使得磨削表面的去除特征较复杂，存在塑性变形、微裂纹、微卷起、卷起、裂纹和两相交...     

Fundamental investigation on nano-precision surface finishing of electroless Ni–P-plated STAVAX steel using magnetic compound fluid slurry

Electroless nickel–phosphorus (Ni–P) plating used in a range of hot embossing metal molds/dies and injection metal molds/dies must be manufactured to nano-precision roughness for proper operation of the molds/dies. We therefore developed a novel polishing technique for mirror surface finishing of this kind of magnetic material using a magnetic compound fluid (MCF) slurry. The effects of the magnetic and gravitational forces acting on the carbonyl iron particles (CIPs) and abrasive particles (APs) within the MCF slurry were studied first, and the behaviors of the CIPs and APs in the presence of an external magnetic field were predicted. Then, experiments were performed to confirm the predictions by investigating the distribution of the CIPs and APs on the working surface of the MCF slurry. Finally, four MCF slurries containing CIPs and APs with different diameters were employed to finish the Ni–P-plated STAVAX steel specimen at different working gaps. The results revealed that for the magnetic workpiece, the resultant vertical force attracted CIPs towards the work surface, whereas APs were pushed away from the work surface. However, the CIPs and APs showed opposite behaviors with the non-magnetic workpiece. The percentage of APs distributed on the working surface increased and the distribution became more even as either the diameter of the CIPs or the working gap increased, whereas that of CIPs had the opposite tendency. The MCF slurry containing bigger CIPs and smaller APs should be employed and the working gap should be set at a smaller value in order to perform mirror surface finishing of a magnetic Ni–P-plated surface. Under the experimental conditions in this work, the Ni–P-plated surface quality improved significantly, and a mirror surface roughness (Ra) of 4 nm was successfully achieved without leaving scratches or particle adhesion when using an MCF slurry containing CIPs 7 μm in diameter and APs 1 μm in diameter, showing that MCF slurries containing commercial CIPs are applicable to the nano-precision finishing of magnetic materials.     

Nanomechanical characterization of RB-SiC ceramics based on nanoindentation and modelling of the ground surface roughness

Reaction bonded silicon carbide (RB-SiC) ceramics are the primary structure and mold materials for the optical industry and mostly are machined by means of ultra-precision grinding to achieve a satisfactory surface quality. However, it is not easy to attain the theoretical prediction of surface quality, particularly surface roughness, because of different mechanical characterization of Si/SiC phases inside the RB-SiC ceramics. In this work, the nanoindentation tests were performed to investigate the nanomechanical characterization of individual phase inside the RB-SiC ceramics. On the basis of the nanoindentation results of RB-SiC, a theoretical model was established to predict surface roughness in the ultra-precision grinding process, which considered the different removal mechanisms of Si matrix and SiC particles. The comparison of the prediction results of existing and novel models and single-factor experimental results shows that the novel model was well consistent with the experiment.     

Modeling and analysis of the material removal depth for stone polishing

In this paper, a model of predicting the material removal depth of the workpiece surface for the mould polishing by fixed abrasives is developed and an approach to achieve the material removal profile is presented. The effect of the grain size on material removal depth is considered. The distribution of the abrasive grain protrusion heights is taken to be Gaussian distribution. The relationship between the pressure and the depth of indentation is investigated by analyzing interaction of the abrasive grains and the workpiece. It is assumed that the pressure distribution is Hertzian at the contact between the tool and the workpiece surface. The theoretical model of linear removal intensity is presented by calculating the removal volumes of all abrasive grains participating in cutting. The depth of the material removal can be obtained by integrating the linear removal intensity along the polishing contact path formed by the polishing tool passing this position. The predicted results based on the current model are shown to be approximately consistent with the experimental results.     

纳米压痕和划痕法测定 TiO2 纳米薄膜的力学性能

目的研究相同工艺条件下阳极氧化法在不同钛合金基底(TA1,TC4,TC4F136)上生成的TiO2薄膜的力学性能差异。方法采用扫描电镜结合原子力显微镜观察3种薄膜的形貌和结构,用UNHT型纳米压痕仪测试TiO2纳米薄膜的力学性能,利用纳米划痕法测试3种钛合金表面生成的TiO2薄膜与基底的结合强度及摩擦性能,用纳米压痕技术测试TiO2的显微硬度和弹性模量。结果电解液及其它电化学条件相同时,不同钛合金基底上形成的TiO2薄膜结构(管直径、管壁厚及管长度)不同。结论阳极氧化法在钛合金基底上生成的TiO2纳米薄膜的力学性能,由TiO2微观结构及其与基底的结合强度决定,微观结构和结合强度归根到底由合金中元素决定。     

Pose and trajectory control of shield tunneling machine in complicated stratum

The present study is focused on developing a method for controlling the pose and trajectory of a shield tunneling machine (STM) applied in complicated stratum. Lacking method to determine target motions of thrust cylinders and suitable electro-hydraulic control system are major restrictions for the STM to realize automatic pose control. To overcome these bottlenecks, a mathematical method for determining the target motions of thrust cylinders is proposed based on kinematic analysis of the thrust mechanism. With this method, target motions of thrust cylinders when the STM excavates along any specific curves can be obtained and used as the input signal of the pose control system. A multi-cylinder control system is proposed based on master/slave control strategy to control the length of each kinematic chain in order to adjust the pose of the thrust mechanism. Experiments are carried out to evaluate the performances of this control system. The experimental results verify that the proposed pose control system is effective in controlling the pose and trajectory of the shield machine no matter it advances along a straight or a curved tunnel axis. Considering the complex loads during the experiments, the proposed system has great potential for applying in practical tunnel construction.     

Mismatch between classroom furniture and anthropometric measures of university students

The appropriate design of tools, equipment and accessories for human body sizes, while meeting the social, cultural, economic and psychological needs of people, provides maximum benefit. This is crucial for students who spend most of their time using school furniture. The aim of the study is to investigate the mismatch between school furniture dimensions and students’ anthropometric measures. Nine anthropometric measures were taken of 225 students (68 female and 157 male) from nine departments of an engineering faculty using a specially designed measurement tool. The mismatch percentages between the existing classroom furniture dimensions and the anthropometric measures were determined using some well-known criterion equations. The results indicated a considerable mismatch: 44.45% for seat height, 100% for seat depth, and 21.28% for desk height. Two types of proposed classroom furniture achieved much higher percentage matches. The match percentages were above 70% for four dimensions for type A and above 95%, except for seat height and width of backrest, for all of the dimensions for both types.Relevance to industryThis study helps in establishing and motivating necessary further studies in classroom ergonomics in university settings.     

Modelling of carbon utilisation efficiency and its application in milling parameters optimisation

At present, the evaluation index for low carbon manufacturing was mainly focused on the relationship between carbon emission and economic benefits or removal volume. But there was rarely comprehensive evaluation index to evaluate the carbon utilisation level of processing. Based on this, this paper presented the carbon utilisation efficiency as the comprehensive evaluation index in low carbon manufacturing. The carbon utilisation efficiency was defined as the ratio of the carbon emission of materials removal to the whole carbon emission in manufacturing process. A carbon utilisation efficiency model was established in milling process, based on flow characteristics and removal mechanism of carbon emission during milling. Then a multi-objective optimisation model was established based on Particle Swarm Optimisation, and the minimum processing time and high carbon utilisation efficiency were set as the optimisation objectives. And the experiment was performed to confirm the undetermined constant in the optimisation model and verify the effectiveness of the optimisation model. The optimised milling parameters were verified to reduce the processing time and improve the carbon utilisation efficiency.     

碳纤维增强树脂复合材料齿槽加工中分层缺陷的形成机制

针对碳纤维增强树脂复合材料(Carbon fiber-reinforced plastic,CFRP)齿槽加工中易产生分层缺陷的问题,尤其以切出侧最严重。根据齿槽加工中分层缺陷的形成过程,重点构建CFRP齿槽加工切出侧最表层材料分层形成的临界切削力模型,并以平纹编织CFRP为研究对象,采用T型铣刀进行试验,从力学角度揭示齿槽加工中分层缺陷的形成机制。结果表明:齿槽上下两侧的经向纤维分层缺陷较小;A情形(有支撑)、B情形(无支撑)下纬向纤维分层缺陷产生的临界切削力均较小,因此,齿槽加工中分层缺陷均易产生,尤其是B情形;A、B两种情形下单束纤维临界力均在边缘附近呈较大值,中间部位临界力变化较小及纤维的变形均以中间部分较大,边缘部位变形小,由此导致A、B两种情形下的分层缺陷均以单束纤维为边界形成半月弧形“波峰”;随着每齿进给量f_z和切削速度V_c的增大,两种情形下的分层缺陷均呈增大趋势。试验结果与临界力理论推导结果基本一致。      

New Grinding Methods for Aspheric Mirrors with Large Curvature Radii

In this paper some new methods for grinding toroidal mirrors, elliptic and circular cylinder mirrors with large curvature radii are investigated. By using the grinding methods proposed here, we successfully obtain aspheric mirrors made of SiC, with higher precision in shape accuracy and low surface roughness, as R_max = 20-40 nm, R_a = 2 ~ 5 nm. The data measured show that the roughness is independent of the direction of measurement. Also, the time consumed in the processes is very short.