20MnCr5圆棒锯切困难原因分析

某厂在锯切20MnCr5圆棒过程中锯条容易断裂，采用光学显微镜(OM)和扫描电子显微镜(SEM)等观察分析手段，对锯条容易断裂的原因进行分析。分析结果表明：锯条断裂的原因为加工20MnCr5过程中粘刀崩齿。针对此类加工缺陷，提出了相应的改进措施。     

Recursive algorithm for modeling non-linear etching rates in reactive plasma jet based optical surface machining of borosilicate crown glass

Application-specific optical glass properties are achieved by utilizing complex material compositions. This can be problematic in reactive plasma-assisted deterministic surface processing since a non-volatile surface layer may form depending on the glass composition, which affects the etch rate and thereby the local etching depth. In this investigation, a model algorithm is proposed to tackle some restrictions in applying fluorine-based plasma jet as etching tool utilized for freeform surface machining of optics made of complex glass composition, like borosilicate crown glass (e.g., N-BK7®). In this regard, firstly an analytical model is proposed for estimating the depth-dependent etch rate function. Subsequently, a recursive simulation algorithm is introduced for convolving the derived depth-dependent etch rate function with the given dwell time matrix to simulate a deterministic freeform generation process. By the proposed simulation algorithm, the impeding influence of the residual layer on the reduction of etching depth is computed prior to a real experiment in order to scale the local dwell time to ensure the targeted local removal. Finally, the simulated freeform shape is compared with the corresponding result of an etching experiment to validate the feasibility of the proposed approach.     

Wire electrical discharge machinable SiC with GNPs and GO as the electrically conducting filler

SiC based composites filled with graphene nano-platelets (GNPs) or graphene oxide (GO) prepared by rapid hot-pressing exhibit sufficient electrical conductivity for their machinability by wire electro-discharge machining (WEDM). Composites microstructure anisotropy caused by graphene alignment as a consequence of rapid hot pressing was confirmed by measuring of electrical conductivity and thermal diffusivity. Electrical conductivity increased significantly with increased weight fraction of graphene in both measured directions. Highest value of 2031 S/m was obtained for composites with 15 wt. % of GNPs in parallel direction and only 1246 S/m in perpendicular direction to aligned GNPs. Thermal diffusivity is 63.3 mm²/s in parallel and only 23.3 mm²/s in perpendicular direction. The increase of the electrical conductivity has resulted in successful WEDM. The MRR was almost doubled when the filler concentration increased from 5 wt. % GNPs/GO to 15 wt. % GNPs. At the same time, the surface roughness decreased.     

接触器触头系统振动机理分析及算法优化

为了解决合闸过程中动、静触头接触引起的振动弹跳问题.本文建立了接触系统的二自由度运动微分方程,并利用遗传算法对交流接触器吸合过程进行优化,同时通过高速摄影实验对接触弹跳的全过程进行了观察和分析.结果表明:理论与实验结果高度一致,铁心在触头分离前发生碰撞,进一步加剧触头弹跳;铁芯弹跳再次碰撞时,触头的弹跳不受影响;在接触器运行过程中,动铁芯的运动会引起系统轻微振动;采用遗传算法优化的接触器触头弹跳时间和最大振幅均减小.研究结果为进一步控制和减小接触弹跳提供了理论依据.     

Pulse-burst laser-based 10kHz Thomson scattering measurements

Thomson scattering(TS),as a popular and reliable diagnostic technique,has successfully measured electron temperatures and electron number densities of plasmas for many years.However,conventional TS techniques using Nd:YAG lasers operate only at tens of hertz.Here,we present the development of a high-repetition-rate TS instrument based on a high-speed,pulse-burst laser system to greatly increase the temporal resolution of measurements.Successful instrument prototype testing was carried out by collecting TS light from laboratory helium and argon plasmas at 10 kHz.Calibration of the instrument detection sensitivity using nitrogen/oxygen rotational Raman scattering signal is also presented.Quantitative electron number densities and electron temperatures of the plasma were acquired at 10 kHz,for stable plasma discharges as,respectively,～0.9 eV and ～5.37×10~(21)m~(-3) for the argon plasma,and ～1eV and ～6.5×1021 m~(-3) for the helium plasma.     

基于Flow-3D的高速水流无压溢洪洞内消能工数值模拟

针对目前高速水流消能形式存在的缺点,基于Flow-3D软件,采用RNGκ-ε模型、Tru-VOF法模拟了无压洞式溢洪道内消能墩附近的水流运动特性,结合洞塞式消能工的消能机理和水工模型试验,对比分析了内消能墩附近的水流流态、流速分布、压强分布、水面线和消能率等。结果表明,在控制断面束窄度的条件下,消能墩附近流态不会影响洞内安全,消能效果较好,消能墩对墩后水流影响距离较短,为在洞内设置多组消能墩提供了依据。研究成果可为类似工程提供参考。     

基于修正等速运动规律的自由曲面多轴加工刀轴序列优化方法

针对自由曲面多轴加工中起始位置处刀具相对工件速度、加速度不为零导致的一定程度刚性冲击现象,提出了一种基于修正等速运动规律的刀轴序列优化方法,通过控制工件坐标系中决定刀具姿态的两个约束角,使之变化遵循修正等速运动规律,获得了切削行上平稳变化的刀轴序列,避免了由于起始位置处刀具相对工件速度、加速度不为零导致刀具不能精准到达后续加工位置的现象。算例分析表明,该方法能产生平稳且光滑的刀轴序列,可一定程度改善机床运动性能,提高加工表面质量。     

Enhancing nugget size and weldable current range of ultra-high-strength steel using multi-pulse resistance spot welding

ABSTRACT

This paper presents an innovative approach that uses a pulse-profile to improve the welding quality of CP1180 steel in resistance spot welding process. Three pulses with two cooling times were used in the developed multi-pulse welding (MPW) schedule. The experimental results show that the first pulse increases the contact area between the sheets to improve the current flow pattern. The second pulse was designed to extend the sheet-to-sheet contact area and corona bond for preventing rapid nugget growth. Using these designs, the nugget size was maximised through the third pulse. The maximum nugget size using the designed MPW schedule was 18.5% greater than that of the single-pulse welding schedule and the weldable current range was extended by 130%.     

铣削加工每齿进给量的决定因素研究及验证

研究了面铣刀的主偏角对切屑厚度和每齿进给量的影响,铣削中每齿进给量的决定因素,切削宽度与刀具直径的比值对切屑厚度的影响等问题进行理论分析,同时结合变速箱壳体铣削加工过程进行验证,解决了合理选择铣刀及切削参数以提升加工效率的问题。     

Processing capabilities of micro ultrasonic machining for hard and brittle materials: SPH analysis and experimental verification

Micro ultrasonic machining (micro-USM) is an unconventional micromachining technology that has capability to fabricate high aspect ratio micro-holes, intricate shapes and features on various hard and brittle materials. The material removal in USM is based on brittle fracture of work materials. The mechanical properties and fracture behaviour are different for varied hard and brittle materials, which would make a big difference in the processing capability of micro-USM. To study the processing capability of USM and exploit its potential, the material removal of work materials, wear of abrasive particles and wear of machining tools in USM of three typical hard and brittle materials including float glass, alumina, and silicon carbide were investigated in this work. Both smoothed particle hydrodynamics (SPH) simulations and verification experiments were conducted. The material removal rate is found to decrease in the order of glass, alumina, and silicon carbide, which can be well explained by the simulation results that cracking of glass is faster and larger compared to the other materials. Correspondingly, the tool wear rate also dropped significantly thanks to the faster material removal, and a formation of concavity on the tool tip center due to intensive wear was prevented. The SPH model is proved useful for studying USM of different hard and brittle materials, and capable of predicting the machining performance.