Evaluating application potentiality of unconventional fluids for grinding Ti-6Al-4V using alumina wheel

Conventional metalworking fluids carry an acute threat to the environment as these produce a hazardous ambiance. Furthermore, due to their excessive use and imprudent disposal, the risk of environmental pollution exaggerates. The present article is aimed at finding some alternative potential coolants to be applied in small quantity lubrication (SQL) mode for grinding of difficult-to-machine (DTM) material, titanium alloys, which could effectively replace the conventional metalworking fluids while ensuring minimal waste of the coolant. Three unconventional environmentally safe coolants viz. alkaline soap water, sodium nitrite, and propylene glycol are applied in SQL mode while grinding Ti-6Al-4V. Comparative performance analyses of these cutting fluids have been adjudicated, considering responses of force required for material removal, substrate roughness, grinding ratio, and SEM micrographs of chips and ground surface. The results reveal that the environment-friendly unconventional fluids perform better than the conventional Blasocut fluid and the most satisfactory operations are observed under propylene glycol environment on the basis of the relevant parameters and operating range considered herein.     

钢制车轮轮辐旋压成形数值模拟和工艺参数优化

为指导车轮轮辐旋压成形工艺参数的选择，利用Simufact Forming对某款轻型客车的轮辐旋压过程进行有限元仿真，改进旋轮轨迹的确定方法，对比厚度仿真结果和实际加工结果，验证该仿真方法的有效性。在数值模拟的基础上，设计四因素三水平正交试验表，对工艺参数进行正交试验优化设计，得到一组针对该钢制车轮轮辐旋压成形的最优工艺参数。利用优化后的工艺参数进行轮辐旋压成形仿真，结果表明轮辐最大厚度偏差和最大等效应力都有所减少。     

In-process estimation of fracture surface morphology during wheel scribing of a glass sheet by high-speed photoelastic observation

Defect-free glass separation techniques are in strong demand in glass processing industries. In this study, we intended to observe the internal stress field during/after wheel scribing of a glass sheet using the photoelastic method. First, we visualized the crack propagation behavior in a 0.7-mm-thick non-alkali glass sheet during mechanical scribing with a 2.0-mm-diameter serrated diamond wheel using high-speed imaging techniques. The observation results under various applied load conditions showed that the crack propagation behavior changed dramatically at a load of approximately 9–10 N; the generated crack hardly propagated in the thickness direction under lower load conditions, in contrast to the rapid propagation under higher load conditions. The fracture surface morphology that was observed after cleavage also changed, from damaged to defect-free surfaces with increments in the applied load around the transition point (9–10 N). This result indicated that the fracture surface morphology was determined by the crack propagation behavior. Second, the birefringence phase difference was measured from the upper side of the glass sheet to enable understanding of the stress fields induced by scribing wheel indentations. As a result, the phase differences that were distributed along the scribe line were shown to differ depending on the applied loads; the phase difference changed little under lower load conditions, but vanished immediately under higher load conditions. Therefore, these differences were dependent on whether or not rapid crack propagation occurred. The measured phase difference distribution thus included information about the crack propagation behavior, and this information could be used as a criterion for estimation of the fracture surface morphology. An in-process estimation method for the fracture surface morphology during mechanical wheel scribing was therefore developed based on high-speed polarization imaging techniques.     

Eight‐degrees‐of‐freedom kinematic model demonstrating after‐impact motorcycle's behavior

Abstract

Deriving a precise kinematic model to describe a motorcycle's behavior after impact is a prerequisite for developing a fact‐analytical tool for motorcycle accidents. Therefore, this paper successfully derives a high‐degrees‐of‐freedom model. Twenty‐four time‐response illustrations of simulation results demonstrate the dynamic behavior of the proposed model. A surface diagram is revealed while investigating the vehicle tracking. The twenty‐four illustrations include motion, velocity and acceleration with respect to longitudinal, lateral, vertical, pitching, yawing, vehicle rolling, rider rolling, and steering variations. The model proposed herein can be effectively used to preliminarily analyze the tendency toward stability or toward rolling of a motorcycle after a collision.     

Precision manufacturing of turbine wheel slots by trim-offset approach of WEDM

The present study aims to precisely manufacture the turbine wheel slot using a novel trim-offset approach of wire-electrical-discharge-machining (WEDM) in order to overcome the challenges of a conventional broaching process. Two dimensional model of turbine wheel slot is prepared in ‘ELCAM’ software to generate the computer-numerical-control (CNC) code of fir-tree-profile geometry. The experimental plan based on a trim-offset approach is executed to minimize the thermal damage and to improve the surface fatigue strength, which is most desirable for a long operating life of the jet engine. An average cutting speed of ~1.5 mm/min is observed for rough-cut and ~5 mm/min for trim-cut operation. Six categories of wires are used to manufacture the turbine wheel slots without any wire breakage and gap-short issue. The fabricated profile slots have demonstrated an average roughness (Ra) of 0.65 μm, profile accuracy within ±5 μm, minimum hardness alteration (34.87 Hv), and negligible recast layer (<5 μm) using B-150 wire and fulfilled the essential requirements of the gas turbine industries. Compared to wire-electrochemical-machining (WECM), WEDM trim-offset approach is quite advantageous and should be beneficial for the researchers working in ‘Precision machining of aerospace materials’.     

Mechatronic design of a self-balancing three-dimensional inertia wheel pendulum

In this paper a three-dimensional self-balancing cube is introduced. For stabilization and swing-up, reaction wheels are placed within the cube along with the actuation, electronics and sensors. This allows the cube to swing up from a rest position and to balance around the unstable steady-state positions. We conducted a design assessment to review different design approaches. For the most promising design, we formulated a parameter optimization to calculate the most suitable dimensions for the cube and the inertia elements. These results were used in the mechanical design stage to obtain the optimal design parameters for the cube in an iterative process. To show the effectiveness of the test bench we considered a proportional control law for swing-up and stabilization at the various steady state positions.     

新型立交分片机

传统分片机结构复杂,设备笨重,响应缓慢,安装和维修困难。新型立交分片机由输送结构和升降机构两部分组成,结构简单,升降灵活,响应快速,安装维修方便。其更换同步带的新结构,解决了同步带更换难题。同时,通过设置连体式曲柄连杆机构,使升降功能更加简单稳定。     

埋地管道泄漏内封堵装置设计与研究

针对流体输送埋地管道泄漏问题,设计了一种利用管道机器人携带封堵气囊进行快速应急封堵修复的埋地管道泄漏内封堵装置。采用矩阵变换方法建立了牵引系统驱动轮过弯方程,利用MATLAB软件对过弯方程进行了验证,同时利用ADAMS软件仿真分析过弯路径与驱动轮转角对牵引系统行走速度的影响。研究结果表明:由两个串联封堵器组成的应急封堵系统可满足复杂工况下的管道泄漏封堵要求;牵引系统驱动轮在弯管内部行走时,单轮速度呈周期性变化,但三个驱动轮整体周期运动特性一致;驱动轮转角在25°~40°时,牵引系统行走速度与驱动轮转角成正比,且转角为30°时驱动效果最好。该内封堵装置的结构设计可为管道泄漏应急封堵领域装备的研发提供重要参考。     

Adaptive back-stepping tracking control for rotor shaft tilting of active magnetically suspended momentum wheel

Two-dimensional gyroscopic torque can be produced by tilting the rotor shaft of the active magnetically suspended momentum wheel. The nonlinear magnetic torque is analyzed and then an adaptive back-stepping tracking method is proposed to deal with the nonlinearity and uncertainty. The nonlinearity of magnetic torque is represented as bounded unknown uncertainty stiffness, and an adaptive law is proposed to estimate the stiffness. Combined with back-stepping method, the proposed method can deal with the uncertainty. This method is designed by Lyapunov stability theory to ensure the stability, and its effectiveness is validated by simulations and experiments. These results indicate that this method can realize higher tracking precision and faster tracking velocity than the conventional cross feedback method to provide high precision and wide bandwidth outputting torque.     

新时期的冷却液净化需求

正2016年已悄然而至,在这辞旧迎新的时刻,我代表Turbo全体同仁向所有客户及社会各界朋友致以诚挚问候和衷心感谢。新时期的冷却液净化需求没有变化,变化的是我们的应用环境。冷却液的净化需要满足以下需求:排除有害颗粒物,不能破坏冷却液,净化效果满足工艺需求,加工设备不会被污染,无可视杂质,可以承受净化设备成本。简单来说,在过去的几年里我们的应用环境发生了变化。新的时期,所有的磨削工艺都需要在高压下运行。随着加工效率被更多地关注,人们开始重视过滤