Anode Shape Prediction in Through-Mask-Ecmm using Fem

Recent technological developments require advanced manufacturing technologies for miniaturized and micro-scale components in various types of industrial products, e.g., fuel injection nozzle for automobiles, miniaturized medical tools, microprobes used to measure surface properties, integrated micro-channels used for drug delivery systems, micro-gears, and various aeronautical components. Through-mask electrochemical micromachining (TM-ECMM) is a feasible process for such products. In the present work, the finite elements method (FEM) is used for solving 2-D Laplace equation in the inter electrode gap to determine the potential and flux distribution for the anode shape prediction in TM-ECMM. Algorithm has been developed and implemented in MATLAB to estimate surface erosion of anode for finite time steps. Anode shape and undercut are predicted using FEM and compared with the experimental results. The shape evolution through finite element simulation is approximately complying with the experimental anode profile. This work would later help in tool (cathode) design for TM-ECMM.     

A comparative study of the tool–chip contact length in turning of two engineering alloys for a wide range of cutting speeds

Tool chip contact length is an important parameter in machining, as it provides an indication of the size of area of interaction between the hot chip and the tool surface and hence the interface heat transfer zone. Heat transfer and thermally activated wear modes usually dominate tool wear in the high speed machining of steels and machining of titanium alloys at most cutting speeds. In this study, existing models for the prediction of tool–chip contact length are reviewed and examined for their suitability in high speed machining of two widely used engineering alloys. Orthogonal turning tests for AISI 1045 steel and Ti6Al4V titanium alloy are conducted for a range of cutting speeds from conventional to high speeds. New contact length models are presented for both materials covering a wide range of cutting speeds. More significantly, these contact length models are appropriate for high speed machining where thermal loads significantly influence process performance. Additionally, the work discusses how the machinability of engineering materials influences the ability to predict contact length.     

基于ANFIS的地铁杂散电流腐蚀预警系统

地铁杂散电流腐蚀的影响因素很多,利用测量得到有限的数据进行杂散电流腐蚀分析是比较困难的,因此需要采取可行的方法来预测地铁杂散电流腐蚀。文中通过建立ANFIS模型,进行杂散电流腐蚀危险性等级的预测。通过对广州地铁杂散电流数据的分析预测,结果表明ANFIS预测模型具有很强的适用性,并在此基础上建立预警系统。     

Improvement of four anode rods ion source

In this work, an improved form of a saddle field ion source has been designed and constructed. It consists of four anode rods made from copper and two copper cathode discs. The two cathode discs are placed symmetrically on both sides of the four anode rods. The electrical discharge and output ion beam characteristics were measured at different pressures using argon gas. The optimum distance between each two anode rods was determined. Also the optimum distance between the four anode rods and any cathode disc was obtained. It was found that the optimum distance between each two anode rods equal to 6 mm, while the optimum distance between the four anode rods and any cathode disc equal to 16 mm, where a stable discharge current and maximum output ion beam current can be obtained. The effect of negative extraction voltage applied to both the extractor electrode and Faraday cup on the output ion beam current was studied. The sputter yield of copper and aluminum targets using argon ions of different energies was determined.     

Effects of shielding coatings on the anode shaping process during counter-rotating electrochemical machining

Electrochemical machining (ECM) has been widely used in the aerospace, automotive, defense and medical industries for its many advantages over traditional machining methods. However, the machining accuracy in ECM is to a great extent limited by the stray corrosion of the unwanted material removal. Many attempts have been made to improve the ECM accuracy, such as the use of a pulse power, passivating electrolytes and auxiliary electrodes. However, they are sometimes insufficient for the reduction of the stray removal and have their limitations in many cases. To solve the stray corrosion problem in CRECM, insulating and conductive coatings are respectively used. The different implement processes of the two kinds of coatings are introduced. The effects of the two kinds of shielding coatings on the anode shaping process are investigated. Numerical simulations and experiments are conducted for the comparison of the two coatings. The simulation and experimental results show that both the two kinds of coatings are valid for the reduction of stray corrosion on the top surface of the convex structure. However, for insulating coating, the convex sidewall becomes concave when the height of the convex structure is over 1.26 mm. In addition, it is easy to peel off by the high-speed electrolyte. In contrast, the conductive coating has a strong adhesion, and can be well reserved during the whole machining process. The convex structure fabricated by using a conductive iron coating layer presents a favorable sidewall profile. It is concluded that the conductive coating is more effective for the improvement of the machining quality in CRECM. The proposed shielding coatings can also be employed to reduce the stray corrosion in other schemes of ECM.     

紫铜板搅拌摩擦焊接温度场有限元分析

FSW传热过程直接决定工件所经历的热循环,进而影响焊接接头的微观组织和力学性能。同时温度场的分析对于预测接头残余应力和变形,以及焊缝区硬度都具有重要意义。本文在工艺研究基础上,分析了FSW的产热过程;根据搅拌头形状与尺寸,建立了FSW三维传热有限元模型。使用Ansys有限元分析软件,结合有限几个测量点温度变化的实验数据,对6 mm厚度紫铜板FSW焊接过程的温度场进行了有限元分析和计算,获得了该焊接过程的温度场分布与变化规律。计算过程中考虑了工件下表面与支撑板接触热传导对温度场的影响,以及温度对紫铜材料热传导系数的影响,有限元计算结果与实验测量结果接近。     

ANALYSIS OF SPARK PROFILES DURING EDM PROCESS

A fundamental study of electro discharge machining (EDM) based on the physics of an arc and heat transfer theory has been carried out. The field equations for electric potential and temperature in the spark region are simultaneously solved by employing the finite element method. Using the criterion of constant current at any cross section of a spark, the arc radii at different cross sections are corrected until convergence. The final spark shape obtained is noncylindrical, and has different radii at different cross sections. Also, the percent of heat input absorbed by cathode, anode, and dielectric has been calculated. The computed relative electrode wear has been compared with experimental results.     

微细电解加工的精度及定域性研究

在分析微细电解加工特点的基础上,探讨了底面间隙和侧面间隙之间的关系,并研究了它们对加工精度和定域性的影响。通过对定域性评价指标的比较,提出了以定域蚀除率评价杂散蚀除的新概念。运用定域蚀除率分析了在利用纳秒脉冲电流进行微小孔的电解加工时,脉冲宽度和工具电极直径对加工定域性的影响。结果表明,减小脉冲宽度和占空比可以增强定域蚀除能力,提高加工精度。     

八辊轧机板形预报模型及应用

在分析八辊轧机结构特点的基础上,结合八辊轧机的设备与工艺特点,对金属塑性变形模型和辊系弹性变形模型两个模型进行耦合,开发了一套适合于八辊冷轧机组的板形预报模型,给出了相应的板形计算流程图,并将模型应用到某冷轧厂1450八辊冷轧机组的生产实践中,开发出了相应的板形预报软件。现场使用效果表明：预报软件预报效果良好,能够较大幅度地降低板形封闭率,给企业带来较大的经济效益。     

ANALYSIS OF SPARK PROFILES DURING EDM PROCESS

Abstract

A fundamental study of electro discharge machining (EDM) based on the physics of an arc and heat transfer theory has been carried out. The field equations for electric potential and temperature in the spark region are simultaneously solved by employing the finite element method. Using the criterion of constant current at any cross section of a spark, the arc radii at different cross sections are corrected until convergence. The final spark shape obtained is noncylindrical, and has different radii at different cross sections. Also, the percent of heat input absorbed by cathode, anode, and dielectric has been calculated. The computed relative electrode wear has been compared with experimental results.     

A study on thermal fluid flow of magnetron cooling for microwave oven

A numerical study has been conducted on thermal dissipation fin shape of the magnetron of a microwave oven. The main focus of the study was on reducing the bypass away from cooling air around cooling fins and enhancing the heat transfer around cylindrical anode body with numerical investigation on louver, slit, dimple and bending shape. To optimize the location and the shape of the elliptical dimple, RSM(DOE) was adopted to enhance the thermal dissipation from the cylindrical anode of magnetron. The flow separation around the anode was delayed due to optimized dimple numerically and verified by experimental study. The enhancement of the fin cooling was utilized for cost reduction of the cooling fin by reducing the thickness of the fin from 0.6 mm to 0.5 mm, resulting in weight saving by 16.7 %.

     

短路过渡CO2焊接熔滴形状数值模拟与控制

为了进一步提高短路过渡CO2气体保护电弧焊的工艺性能和焊接质量,根据高速CCD摄像获得的熔滴及其短路过渡图像,分析了熔滴与熔池短路前的形状对熔滴与熔池的短路、熔滴在熔池中的铺展及液桥缩颈形成的影响.采用熔滴静力平衡模型研究了电磁力(燃弧电流)、表面张力、重力与熔滴形状的关系,并通过对燃弧电流的精确控制实现了对熔滴形状的有效控制.当熔滴与熔池短路前为细长形状时,短路过渡过程稳定柔顺,而当熔滴为扁平形状时,则不利于熔滴的短路过渡,甚至产生瞬时短路.燃弧阶段的熔滴形状体现了各种力对熔滴的作用,而电磁力(燃弧电流)是决定熔滴形状的主要因素.根据燃弧电流对熔滴形状的影响规律,提出了采用前期大、后期小的燃弧电流控制原则,以在燃弧的不同阶段获得不同的熔滴形状.试验结果表明该控制方法获得了良好的适合于熔滴短路过渡的短路前熔滴形状,短路过渡过程柔顺稳定,消除了瞬时短路以及由此导致的飞溅,改善了熔滴的短路过渡行为,短路过渡结束后焊丝端部的残余液态金属具有良好的一致性.     

Experimental study and numerical modeling of arc and weld pool in stationary GTA welding of pure aluminum

In this study, a 2D mathematical model was developed for both arc and weld pool in stationary GTA welding. In arc model, current continuity equation has been solved in both arc and cathode regions without any assumption of fixed current density on the cathode surface which was essential in most previous works. The results of arc model were presented for both copper and aluminum anodes to investigate the effect of anode material on arc properties. It was seen that aluminum anode has lower maximum anode current density and heat flux but the distributions are wider than copper anode. Furthermore, shear stress on anode surface is higher in the case of aluminum anode. Also, calculated results of this study were compared with other available theoretical and experimental results. It has been shown that the agreement between calculated and experimental results was fairly good. The necessary information to simulate the weld pool, including the anode current density and heat flux to the workpiece were taken from the arc model. In this model, due to high thermal conductivity of pure aluminum, fluid flow into the weld pool was ignored. Effects of arc variables, i.e., arc length, applied current and welding time on the shape and size of the weld pool were investigated as well. In order to check the validity of the weld pool model, a comparison between calculated results and the results of our experimental tests was conducted. Generally, these comparisons reveal an acceptable agreement between calculated results and experimental data.     

Quantitative measurements of magnetic stray field dynamics of Permalloy particles in a photoemission electron microscopy

By example of a Permalloy particle (40 × 40 μm(2) size, 30 nm thickness) we demonstrate a procedure to quantitatively investigate the dynamics of magnetic stray fields during ultrafast magnetization reversal. The measurements have been performed in a time-resolving photoemission electron microscope using the X-ray magnetic circular dichroism. In the particle under investigation, we have observed a flux-closure-dominated magnetic ground structure, minimizing the magnetic stray field outside the sample. A fast magnetic field pulse introduced changes in the micromagnetic structure accompanied with an incomplete flux closure. As a result, stray fields arise along the edges of domains, which cause a change of contrast and an image deformation of the particles geometry (curvature of its edge). The magnetic stray fields are calculated from a deformation of the X-ray magnetic circular dichroism (XMCD) images taken after the magnetic field pulse in a 1 ns interval. These measurements reveal a decrease of magnetic stray fields with time. An estimate of the lower limit of the domain wall velocity yields about 2 × 10(3) m s(-1).     

局部浪形对冷轧钢卷起筋的影响

针对带材卷取过程中在钢卷表面形成的容易使开卷后带材产生附加浪形、造成产品降级的起筋问题,在大量的现场试验与理论研究的基础上,结合小局部浪形与大局部浪形的相关特点,提出一套大小局部浪形的理论判断标准,并对大局部浪形引起起筋过程中轴向力的由来、起筋区域临界失稳应力与轴向力的计算等问题进行系统的分析。然后,分小局部浪形与大局部浪形两种情况,分别建立相应的起筋量计算数学模型,定量模拟出了不同情况下起筋量的大小,并将模型计算结果与现场实测值进行了跟踪对比,统计表明模型平均偏差保持在10%的范围内,单次最大偏差小于(等于)15%,达到相当高的精度,满足了工程上对起筋量预报的精度要求,并为厂方起筋缺陷的治理提供了有力的理论依据,创造了良好的经济效益。     

小通道内的冷凝换热模型分析

目前国内外对于大通道内的冷凝换热研究较多,而对小通道内的冷凝换热研究较少,小通道内重力、切应力、表面张力的相互作用与大通道不同,导致小通道内的冷凝换热机理不同于大通道,因此大通道内的冷凝换热模型不能很好地预测小通道内的冷凝换热,而小通道内冷凝换热的研究对设计和优化紧凑型换热器具有重要意义。总结9种小通道内的冷凝换热预测模型,并根据11个独立研究机构的测试结果,收集6种工质(R134a,R32,R22,R123,R410A,R1234yf)的1 183个小通道内的冷凝换热试验数据点。比较各模型的预测结果和数据点发现,各预测模型并不是适用于小通道内所有工质和工况的预测,应根据工质和工况选择合适的模型。GARIMELLA的预测模型对R134a、R32、R22、R1234yf的数据点的预测误差很小,而KOYAMA的预测模型适用范围比较广,大部分工况下误差也是可接受的。     

Hybrid analytical–numerical solution for the shear angle in orthogonal metal cutting — Part I: theoretical foundation

In metal cutting, the shear angle is considered as a fundamental parameter that defines the plastic deformation and the geometry of the process. The present paper presents a further development of the energy method for prediction of the shear angle in case of orthogonal metal cutting. Parallel-sided shear zone model is utilized to describe the geometry of chip formation. The material velocity in the primary shear zone is allowed to change gradually from the bulk material velocity to the chip velocity. The interaction between chip and tool in the secondary shear zone is modeled as sticking to sliding transition. The work material is characterized by an empirical equation, which allows for the influence of temperature, strain, and strain rate as well as their histories. To take into consideration the influence of the temperature on the work material properties, a finite element model (FEM) of heat transfer is employed. The FEM is developed as an adaptive model to reflect the change in the domain geometry. As the work material properties strongly depend on the temperature, an overall iterative calculation procedure including FEM is essential. In Part I, the theoretical basis of the model is described. In Part II the predicted values of the shear angle are compared with data from machining 0.18% C carbon steel over a range of cutting conditions and tool geometry.     

微量润滑平面磨削接触区换热机理的研究

磨削接触区材料去除厚度是不一致的,同时,在微量润滑过程中,雾滴之间的运动特征存在差异且易受其他因素的影响,致使整个接触区的磨削温度分布呈现出非线性,换热机理也异常复杂。从雾化机理出发,对影响换热效果的两个关键因素--雾滴直径和雾滴速度进行了分析。依据雾滴在不同壁温处表现出的不同换热特性,将磨削区划分为无沸腾换热、核态沸腾换热、过渡沸腾换热和稳定膜态沸腾换热四个不同的换热区域,建立了微量润滑磨削区的换热系数数学模型。在此基础上,运用有限元技术对微量润滑磨削表面的温度场进行了仿真分析,采用单级热电偶技术测量了磨削温度,发现磨削区仿真温度值与实验测量值吻合较好,表明通过该理论获得的微量润滑磨削表面换热系数是可信的。     

R-C系统消杂散光设计与效果评估

研究R-C系统的消杂散光以提高其成像质量。从杂散光的能量传输方程出发,分析总结了杂散光消除的基本途径。按照R-C系统杂散光消除的具体要求,结合作图法,推导出初始中心遮光比确定时的内遮光罩顶点坐标公式;为了减小初始中心遮光比,将次镜锥状遮光罩改进为百叶窗式结构。设计了杂散光源抑制角已知时的外遮光罩。最后,给出在Tracepro中利用仿真模拟测定杂光系数的方法及R-C系统遮光罩的应用实例。     

基矛COMSOLMultiphysics的杂散电流腐蚀仿真分析

对于埋在地下的钢制输气管道,若不采取适当的防腐措施,或者防腐涂层出现破损,在运行一段时间后,短则几个月,长则几年,都会因为腐蚀穿孔而泄漏。天然气管道泄漏所带来的后果是无可估量的。散流于大地中的电流对管道所产生的腐蚀（称杂散电流腐蚀）是一种由外界因素引起的强度较高的电化学腐蚀,杂散电流时可导致地下金属设施严重腐蚀破坏,其所引起的腐蚀比一般的电化学腐蚀要强烈得多。本文通过COMSOLMultiphysics仿真软件,实现对油气管道杂散电流腐蚀动态的仿真,分析计算出杂散电流在埋地钢制管道防腐涂层破损处的分布规律和强度变化,为检测和防范杂散电流提供理论支撑。