电磁成形中板料厚度与变形深度的关系

通过纯铝板的电磁胀形试验,发现在工艺条件相同的情况下,不同厚度的板料有不同的变形深度,而且在试验条件下,对于性能相同的材料,厚板的变形深度比薄板的要大。对这一现象进行了分析,认为这是由于不同的板料厚度可以导致不同的设备能量利用率,而其最根本的原因则是趋肤效应。在设备能量相同的情况下,若板料厚度小于趋肤深度,则板料的厚度越大,变形深度越大;板料厚度大于趋肤深度时,板料厚度越大,变形深度越小。并且分析了如何能获得一个最高的设备能量利用率,得出了设备电容与放电回路电感之间的关系。研究成果对指导电磁成形的工艺设计有着重要的意义。     

电磁力作用下平板变形的实验研究

通过平板件的电磁无底凹模成形、有底凹模成形的实验研究，发现不同形式的压边圈可以导致不同的工件变形高度。有底凹模成形时，在设备能量足以使工件变形达到凹模底部的情况下，工件的最大变形高度小于凹模深度，并且电压越大，工件的变形高度越小，而且在较大电压的情况下，工件底部还会出现反向变形。对实验现象进行了分析，认为不同形式的压边圈，板料所受径向拉深力不同，导致不同的工件变形高度；板料受撞击产生的反向运动是导致工件最大变形高度小于凹模深度的主要原因。     

平板件电磁成形时线圈最小尺寸的计算

成形线圈是平板件电磁成形的一个关键部件。从平板加工线圈的磁感应强度分布入手，分析了平板件上的电磁力分布，确定在成形特定尺寸的工件时，存在一个线圈的最小尺寸，并通过二分法和复合形法分别对圆形线圈和椭圆形线圈的最小尺寸进行了计算。     

电磁成形铝板时变形高度与成形电压的关系

通过纯铝板的电磁自由成形实验，得出了工件最大变形高度与成形电压呈线性关系的结论，列出了线性方程。通过对变形曲线的分析，提出用二次多项式曲线来近似工件的变形曲线。这样，在变形高度与成形电压的线性方程已知的情况下，成形电压确定，工件的近似变形曲线就可以确定。     

并列线圈在平板电磁成形中的磁场力分布与受力分析

建立平板电磁成形3D有限元模型,分析线圈与板料间隙磁感应强度的分布,并与试验数据对比,验证了模拟方法的准确性。设计并列圆形与并列方形线圈结构,对于线圈加载不同方向电流,采用有限元模拟方法研究了线圈在被成形平板件上产生的磁场力分布规律。分析了并列圆形与并列方形线圈结构的受力状况和失效模式,提出了线圈结构设计改进方案与失效预防措施。根据并列圆形与并列方形线圈结构的特点,为并列线圈成形不规则工件的工程应用提供了指导。     

钛合金板料激光冲击变形的数值模拟和实验

实验研究了激光能量和不同的冲击路径、冲击次数对TA2钛合金板料变形的影响，并用ABAQUS软件进行了有限元模拟。结果表明：随着激光能量的增加，板料的变形量增大；板料几何尺寸和厚度越大，板料越难变形；冲击次序不同，板的变形量也不同，板的变形以沿板的长度方向且对称冲击为最大。通过数值模拟可优化激光冲击的相关参数，预测板料变形。     

线圈形状及几何参数对电涡流传感器性能的影响

针对电涡流传感器探头线圈形状及其参数对传感器灵敏度和线性范围的影响问题，本文以Biol-Savart定律为基础，推导了具有梯形截面的矩形柱线圈和圆形柱线圈对称轴上任一点的磁场分布，确定了在以位移为检测量的电涡流传感器中采用圆柱线圈更合理，并通过有限元法研究和分析了在线圈匝数密度不变和变化2种情况下圆柱线圈内径、外径、厚度、截面形状（矩形、梯形和倒梯形）对传感器灵敏度和线性范围的影响，为合理选择线圈参数和优化传感器性能提供参考。     

浅谈极坐标在数控编程中的应用

在数控加工前，必须根据工件的形状、尺寸精度等将工件各关键点坐标的位置准确无误地确定在平面上，通过分析这些点的坐标尺寸及相互关系，并用机床所能接受的指令编制出程序，作为信息输入机床，使其加工工件。但有大量工件，其尺寸精度要求高，形状复杂，APT编程时，在XOY平面上难以确定出关键点的位置，需借助大量的辅助点进行辅助运算，这样计算出的关键点坐标就会产生取舍误差，不仅编程时间长，也影响工件的加工精度，甚至会造成工件报废。在这种情况下，若采用极坐标法，则只需确定关键点的一个极半径ρ和极角θ两参数，而且在编…     

微型细长轴类零件车削技术研究

细长轴类零件在车削过程中产生振动及变形是影响其加工质量的主要原因。通过对微型细长轴车削过程中零件变形、切削力的影响因素进行分析可以看出,在工件材料及毛坯尺寸一定的情况下,工件的悬伸长度对零件的变形影响最大,切削力次之。通过在加工过程中选择合适的切削参数,并在切削力选定的情况下采用分段切削的加工方式控制工件的悬伸长度,保证工件的变形在可接受的范围内,解决了微型细长轴车削变形的问题,并通过切削验证,证明了理论计算的分段长度的合理性,为类似零件的加工提供了参考依据。     

胶囊内窥镜能量接收稳定性研究

提出了用三维接收线圈组成接收电路,解决由于无线胶囊内窥镜在人体消化道内姿态不确定所带来的接收能量不稳定问题.分析了由三维接收线圈组成的不同接收电路的接收效果,得出了对每一维线圈单独全桥整流后再并联输出的电路结构是最适合于为胶囊内窥镜供能的电路.计算了该接收电路的输出范围,并通过试验对其进行了验证.结果表明:当发射功率为 25 W时,胶囊内窥镜可在姿态任意变化的情况下获得320 mW以上可用能量,满足其高清晰度、高帧率功能对能量的需求.     

Dynamic analysis of electromagnetic sheet metal forming process using finite element method

This paper presents a simple and efficient method for the analysis of dynamic behavior of the workpiece in the electromagnetic forming process. A two-dimensional (2D) axisymmetric finite element model with the equations of electrical equivalent circuit, electromagnetic field, and mechanical field has been developed for calculating the discharge currents through the forming coil, the magnetic forces acting on the workpiece, and the plastic deformation of the workpiece. By considering the effects of the sheet geometry and velocity on the above parameters, the method realizes the full coupling between the electromagnetic fields and the workpiece deformation, which should be more accurate than the existing loose coupling and sequential coupling simulation methods.     

Study on the driver plate for electromagnetic forming of titanium alloy Ti-6Al-4V

In order to improve energy efficiency, a driver plate made from high-conductivity material is normally used in the electromagnetic forming process of high-strength but low-conductivity sheet metal. The choice of driver plate significantly influences final deformation of the workpiece. In this paper, the electromagnetic free bulging process of Ti-6Al-4V titanium alloy sheet, widely used in aerospace, was studied by both experimental means and numerical simulation. The forming efficiency and quality of the workpiece under different types of driver plates were investigated in detail. The results show that by using high-conductivity and easily deformed materials such as aluminum alloy, with a skin depth in thickness, high efficiency and uniform deformation can be achieved. The results of this study can provide guidance on the choice of process parameters such as the material and thickness of a driver plate.     

激光冲击金属板料变形的 最小激光能量估算及其实验研究

介绍了激光冲击板料变形的机理和冲击波产生的原因,提出了激光冲击板料变形中激光－能量转换体－靶材系统的爆轰波压力估算式。根据此压力估算式和材料的动态屈服强度,对激光冲击板料变形中所需的最小激光能量进行了估算,板料厚度为0.5 mm,约束凹模孔径Φ20 mm,在光斑直径6 mm,脉宽25 ns条件下的不锈钢靶材变形所需的最低脉冲能量大约为11 J。实验结果表明估算的最小激光能量与板料变形所需的能量阈值基本一致,且板料变形量随激光能量的增加呈非线性增大。最小激光能量的估算以及能量与板料变形的实验研究为板料变形的精确控制和预测提供了理论依据。     

基于PLC的金属工件毛刷清洗机控制系统设计

为了更高效地清洗圆柱形金属工件内表面,设计了此套毛刷清洗设备。毛刷清洗机主要执行元件有加热电阻、电磁阀、气缸和三相交流电动机。该电气控制系统以三菱FX2N系列PLC为核心控制器,通过对线圈和电磁阀的控制,能够方便地实现毛刷电机的转动、清洗篮的上下摆动、储液箱的循环加热以及清洗液的排放,从而完成对金属工件内表面的清洗。该设备投入使用后,表现出工作性能稳定、操作方便、经济适用等优点,能够很好地完成对金属工件的清洗工作。     

A simple model to simulate electromagnetic sheet free bulging process

Electromagnetic sheet forming is a high-velocity forming process driven by the coupled electromagnetic and mechanical phenomena. The deformation of the workpiece is governed by the body forces (Lorentz forces) that results from a pulsed magnetic field produced by a flat spiral coil. Formability can be increased using this high-velocity forming technique due to the inertial forces and high strain rates. In this study, we consider the electromagnetic and the mechanical aspect of the process as two independent problems. The finite difference method has been employed to solve the electromagnetic equations. The pressure acting on the sheet and due to the Lorentz forces is estimated neglecting the influence of the sheet velocity on the magnetic field. Then it has been treated as a load in the mechanical problem. Numerical simulations of the mechanical problem have been performed with the commercial finite element code ABAQUS/Explicit. The magnetic pressure has been introduced in ABAQUS/Explicit as an analytical pressure distribution. The general objective of this study is to better understand the complex phenomenon of deformation and the influence of viscoplastic material behaviour during the simulation of a free bulging electromagnetic sheet forming process.     

Numerical and experimental approach to reduce bouncing effect in electromagnetic forming process using cushion plate

Electromagnetic forming (EMF) is a high strain rate forming process that uses Lorentz force. In this study, electromagnetic forming with a rectangular block shape in the center of the forming die was examined to determine the possibility and applicability of EMF. However, the high speed of the process in the absence of a medium between the coil and the workpiece results in bouncing of the workpiece, which may result in poor forming. So, in this study, the use of a cushion plate is proposed as a means of reducing the degree of bounce in an EMF process. A 3D electromagnetic numerical model using a spiral forming coil was considered. An RLC circuit, coupled with the spiral coil, was numerically simulated to determine the deformation behavior and design parameters, such as the input current and the magnetic forces. A cushion plate was used between the forming coil and the sheet to be deformed to reduce the extent of bounce. In the numerical simulation, the sheet was found to be well fitted to the objective die with the cushion plate. The simulation results showed that the extent of bounce was drastically reduced because of the velocity direction of the workpiece and the cushion plate. The experiment was performed using 24 kJ to deform Al 1100 with a thickness of 1.27 mm, based on the simulation results. The deformed sheet was well formed, and closely fitted the objective die with a minimum of wrinkling, relative to the results obtained without a cushion plate. As a result, an EMF process with a middle-block die was successfully established both numerically and experimentally to reduce the bouncing.     

Selections of working conditions for creep feed grinding. Part(III): avoidance of the workpiece burning by using improved BP neural network

In this study, the grinding force of the creep feed grinding are modeled and forecasted by using the improved back propagation neural (BPN) network. The results show that the grinding energy can be accurately predicted by the application of the grinding force model. Due to the previous paper, the workpiece burning occurs as the grinding energy is greater than the critical grinding. Thus, a judgment for the occurrence of the workpiece burning can be achieved. Comparing with the experimental results, the applied algorithm of the improved BPN network is proved to be effective in forecasting the working conditions of the workpiece burning. Thus, a selection scheme of working conditions in view of the avoidance of the workpiece burning is further developed. Considering the working efficiency, the working conditions are selected to maximum metal removed rate, MRR_max. The results show that a larger size of wheel is available to have a better working efficiency.