FEM simulation of welding quality in porthole die extrusion

The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.The numerical simulation results show that the welding quality of the hollow profiles has great sensitive to the die structure.With increasing the welding chamber height and decreasing the welding angle of the die leg can improve the welding quality.In addition,the welding quality index k of the new designed shape of the die leg is little down from 4.1 to 3.9 comparing the standard leg.     

Understanding of the influence of process parameters on the heat transfer behavior at the metal/die interface in high pressure die casting process

The current paper focuses on the influence of the process parameters on the peak values of the inter-facial heat transfer coefficient (IHTC) at metal/die interface during high pressure die casting (HPDC) process. A "step shape" casting and AM50 alloy were used during the experiment. The IHTC was de-termined by solving the inverse thermal problem based on the measured temperature inside the die. Results show that the initial die surface temperature (IDST, TDI) has a dominant influence while the casting pressure and fast shot velocity have a secondary influence on the IHTC peak values. By curve fitting, it was found that the IHTC peak value (hmax) changes as a function of the IDST in a manner of hmax =eαTγDI. Such relationship between the IHTC peak value and the IDST can also be found when the casting alloy is ADC12, indicating that this phenomenon is a common characteristic in the HPDC process.     

彩管荫罩模具的CAD/CAM

在彩管荫焊接模具数学模型分析计算的基础上，采用计算机辅助设计及辅助制造方法，对25‘彩色电视机荫罩焊接模进行了数控编程及数控加工。经实际使用验证，完全可以替代国外进口模具。     

人工智能在电力系统恢复中的应用综述

归纳总结专家系统、模糊数学、进化计算以及机器学习等人工智能方法应用于电力系统恢复的研究成果,指出现有研究仍以离线恢复方法为主,处于在线决策研究起步阶段,并展望人工智能技术在系统恢复中的应用潜力。     

Optimization strategy in end milling process for high speed machining of hardened die/mold steel

1. Introduction The introduction of advanced cutting tools like AlTiN-coated micro-grain carbide end mill since the 1990s has changed the trend in die/mold manufacturing towards hard machining both in roughing and finishing [1]. Nowadays, high speed machi…     

低压铸造充型过程的数值模拟技术

论述了低压铸造充型模拟的数学模型,由于低压铸造充填速度较慢、充型平稳,因此充型计算采用层流模型。采用SOLA-VOF算法对模型进行求解,其中SOLA法用于求解流体的速度场和压力场,VOF法用于处理自由表面。采用UG软件进行铸件三维造型,采用ProCAST软件进行网格划分,对叶轮的充型过程进行了模拟,并通过对叶轮的浇注试验,验证了低压铸造充型的数学模型及算法在保证模拟精度、提高计算效率上的有效性。     

半固态镁合金压铸充型过程的数值模拟研究

在考虑半固态AZ91D镁合金充型过程的压力和速度变化特征的基础上,建立了模拟计算所需要的表观黏度数学模型。采用ProCAST软件,对半固态镁合金压铸充型过程进行模拟,预测卷气、夹杂物产生的可能性,以便优化其工艺参数和工艺方案。结果表明,与全液态镁合金充型过程相比,半固态金属充型平稳,模具寿命长,铸件质量好;改变内浇道和溢流槽的设置位置和数量,还可有效地减少铸件本身内部杂质,提高铸件质量。     

基于ADAMS的热室压铸机机铰优化设计

基于多体动力学理论,介绍了热室压铸机机铰部分(即合模机构)从合模开始到合型保压过程的工作情况,应用ADAMS软件对该过程进行多体动力学仿真,获取了该过程中机铰部分输出锁模力、动型板行程及各个约束的约束反力等的变化规律,在此基础上对机铰部分进行优化设计.     

搅拌摩擦焊工艺对镁合金焊接接头机械性能的影响

采用不同搅拌摩擦焊工艺焊接镁合金，通过拉伸、三点弯曲试验分析了工艺参数对焊缝机械性能的影响。结果表明，采用合适的搅拌摩擦焊工艺可以成功地焊接镁合金并得到成型美观、质量好的焊接接头，焊缝中因产生充分的塑性流动，弯曲强度高，性能好，在一定参数范围内，随着搅拌头旋转速度R，R/V增加，抗拉强度极限值增加；随着焊接速度V增加，抗拉强度极限值下降，当采用最佳的工艺参数焊接，可得到最大抗拉强度极限值，接近母材的90％。     

FEM analysis of metal flowing behaviors in porthole die extrusion based on the mesh reconstruction technology of the welding process

A reconstruction technology of finite element meshes based on reversal engineering was applied to solve mesh penetration and separation in the finite element simulation for the divergent extrusion.The 3D numerical simulation of the divergent extrusion process including the welding stage for complicated hollow sections was conducted.Based on the analysis of flowing behaviors,the flowing velocities of the alloy in portholes and near the welding planes were properly controlled through optimizing the expansion angle as well as porthole areas and positions.After the die structure optinuzation,defects such as warp,wrist,and the wavelike are eliminated,which improves the section-forming quality.Meanwhile,the temperature distribution in the cross section is uniform.Especially,the temperature of the C-shape notch with alarger thickness is lower than that of other regions in the cross section,which is beneficial for balancing the alloy flowing velocity.     

模具间隙对AZ31B板料成形性能的影响

凸凹模间隙是板料成形过程中的一个重要参数,其设计合理与否将直接影响成形产品的质量及模具寿命等,对镁合金板料而言也是如此。通过多次工艺实验,研究了模具单边间隙对AZ31B交叉轧制镁合金板料成形性能的影响,结果表明：针对0.8 mm厚的AZ31B板料,其最佳单边间隙为1.05-1.10t。     

Ni60-SiC coating prepared by plasma spraying,plasma re-melting and plasma spray welding on surface of hot forging die

In order to produce the hear-resistant inner layer of hot-forging die, plasma spraying and plasma re-melting and plasma spray welding were adopted. Substrate material was W6Mo5Cr4V2, including 10%, 20%, 30% SiC ceramic powder used as coating material to obtain different Ni-based SiC alloys coating. Micro-structure and micro-hardness analysis of the coating layer were followed, as well as thermophysical properties for the coating layer were measured. The experimental results show that the coating prepared with 70% Ni60, 30% SiC powder has best properties with plasma spray welding, in which the micro-hardness can achieve 1100 HV, meanwhile can improve the thermal property of hot-forging die dramatically.     

狭缝涂布理论建模与数值模拟

狭缝涂布是一种精密涂布技术,目前已经被广泛地应用在柔性电子、功能薄膜、平板显示器、微纳制造、印刷等众多领域.通过对狭缝涂布系统稳定流动后的涂布层进行纳维-斯托克斯方程理论分析,建立了上游和下游的流速、流量关系的理论模型,揭示了涂布层的流动机理,并通过对涂布过程的数值模拟,得到涂布开始后不同时刻流体的流动界面,阐述了基底运动速度对涂布层质量的影响规律.该研究为进一步提高狭缝涂布质量和效率,优化狭缝涂布的生产工艺奠定了理论基础.     

数值研究双螺杆挤出平行孔模具内聚合物流场

使用有限元方法数值计算双螺杆平行4孔模具内高黏度聚合物熔体的等温流场,分析模具压差对熔体流场的影响.研究结果表明,随着模具压差的增加,物料的平均速度、平均剪切速率增加,平均黏度降低,产量增大;在模具入口段,物料平均速度和平均剪切速率减小,平均黏度增大;在模具过渡段和平直段,熔体平均速度和平均剪切速率增大,平均黏度减小;模具内熔体各物理量梯度小,在模具过渡段,压力没有急剧增大;模具平行各孔道中熔体物理量分布基本相同,可以说明该模具能够均匀挤出制品,该平行4孔模具的设计合理.实际生产验证双螺杆挤出平行4孔模具可挤出成型多个质量合格制品.     

5083的激光传导焊接

研究了利用高能量的二氧化碳和YAG激光器作为于激光传导焊接2mm～3mm板厚的AA5083。结果表明,焊接2mm～3mm板厚的AA5083时产生的粗大的焊接区并充分渗透。通过观察,在这个过程中渗透深度最初开始增加并达到最大值,然后随着斑点大小的增加而逐渐减小。     

Research on a new forging technique—Short-hollow-rapid die forging

A new forging technique—short-hollow-rapid die forging, used in Ti-Al alloys was studied. Compared with conventional method, the new method can improve the crystalline structure properties of the forged piece, reduce the average forging pressure by 20% to 30%, lessen the thickness deviation by 5 mm, and prolong the service life of the dies by 2 to 4 times. Project supported by Commision of Science, Technology, and Industry for National Defence Synopsis of the author Zen Sumin, professor, born in 1932, specializing in forging technology.     

一种新型板材模头的设计及其计算方法

提出一种新型的能够保证熔体在口模出口处速度均布的片材模头，并推导流道系统的普适设计公式；运用流变学理论，根据模头中所有流道上压力损失相等及特征剪切速率相等的条件，推导不依存于材料特性和操作点的流道设计，即普适流道。     

抑制汽车纵梁弯曲回弹的弯曲模改进设计

汽车纵梁是一种形状和尺寸都比较大的冲压件,弯曲成形难度大且回弹不易控制。通过对U形件工艺和模具加工的分析,提出了解决回弹的工艺方法及可控制回弹的弯曲模改进设计,使汽车纵梁弯曲成形后的质量有了较大的提高,从而消除了由于产生回弹使零件侧壁的孔位与底部尺寸超差而影响纵梁装配等问题。     

FDTD analysis of the optical properties of vertical ZnO nanorod array

Based on the structure and dimensions of a vertical ZnO nanorod array(V-ZNA)sample,an ideal 2-D photonic crystal model was established.The optical properties of the V-ZNAs were analyzed with finite-difference time-domain(FDTD)method,and the influences of the geometry parameters,including the circumcircle diameters of the top and bottom surfaces(Dt and Db)and the height(H)of the nanorods,and the pitch between each column(L),were discussed.High transmittance and low reflectance in the waveband of 400–800 nm were proved,and the highest transmittance can be obtained with Dt50 nm,H=200 nm,and Db/L=0.85,which was verified by Effective Index Method(EIM).The result indicates that V-ZNAs can be used as excellent light coupling element and antireflection material for solar energy applications.     

一种新型板模头的设计及计算方法

提出一种能够保证熔体在口模出口处速度均布的板材模头，应用流变学原理，根据流道内任意流径上压力降相等及特征剪切速率相等的条件推导其设计公式；通过估计模头对工作条件的依赖性，证明该模头的设计程序是普适的；利用大型有限元软件ANSYS对设计进行模拟，证明该设计是可行的。