Contact force modeling and analysis for robotic tilted-disc polishing of freeform workpieces

This paper investigates the tool-workpiece contact mechanism in the disc polishing process, where the soft polishing disc touches the rigid freeform workpiece with a small tilt angle. The developed contact force model can explain how the contact parameters, including the disc contact depth, the disc tilt angle, the radii of curvature of the disc and the workpiece, affect the normal contact force. Under some reasonable geometric and mechanical assumptions of the disc and the workpiece, an approximated contact force equation is derived in a simple power-law form similar to the Hertzian contact model. The contact force is found to be positively related to the disc contact depth and the disc radius, while negatively related to the disc tilt angle and the workpiece normal curvature that is orthogonal to the feed direction. Both finite element simulations and experiments verify the effectiveness of the proposed contact force model. Furthermore, the material removal process is analyzed and a model-based process parameter planning method is developed to achieve uniform material removal considering the variation of workpiece curvatures.     

多指抓取接触力求解及规划研究

分析了不同接触模型的力螺旋约束,首先通过建立力平衡方程求解了多指抓取的接触力,结合算例指出所求解接触力可能不满足接触的单向性约束;然后分析了多指抓取时的等式和不等式约束,给出了新型目标函数,通过优化方法规划出多指抓取的接触力,最后的算例验证了优化法的有效性和正确性.     

Contact force studies of a burnishing slider

In order to design the flying height of a burnishing slider accurately, the contact force between the burnishing slider and the disk needs to be well evaluated. This paper studies the contact force of a burnishing slider by both experiment and simulation. The experiment is conducted by measuring the acoustic emission signals of the contact force avalanche, and the simulation is based on the self-developed air bearing surface simulation code applying the probability model for the contact force calculation. The influence of contact force on the burnishing effect is discussed. It is observed that the simulation results are well correlated with the experimental measurements. It is believed that the simulation code is capable to design burnishing sliders with reasonable accuracy.     

Contact mechanics and friction of fractal surfaces probed by atomic force microscopy

We investigated the contact mechanics and friction forces between atomic force microscope (AFM) probes and self-affine fractal carbon films. We studied single-asperity contacts by means of conventional nanometric conical tips whilst custom-designed micrometric flat tips were adopted to form multiple junctions between the probe and the sample. By varying the externally applied load we found that the average frictional force follows a power-law behavior in the single-asperity regime and a linear behavior in the multi-asperity regime. The friction coefficient was the same for carbon specimens having different fractality. We also acquired quasi-static load-displacement curves on micrometric scale, revealing a strong dependence of the average indentation depth on the values of fractal parameters. A comparison of experimental data with contact theories for randomly rough surfaces is provided.     

Investigation on Contact Mechanics Between Soil and Metal

Soil-metal contact interaction is common with machinery operations in agricultural production. In this paper, a method has been proposed to determine the stress-strain relation of soil at soil-metal contact surface with a modified triaxial apparatus, and a constitutive model is developed for numerical analyses of such kind of contact problems.     

IC封装焊头机构接触力分析

针对IC封装焊头机构(bonder)高速运动、精密定位、微接触力的要求,运用虚拟样机技术,建立焊头机构虚拟样机模型.通过虚拟仿真,揭示了焊头部件的运动和动力学规律.为了保证取晶和固晶时的接触力要求,对弹簧参数和焊头与晶圆、引线框架的间隙进行优化.结果表明,焊头的位移控制精度则直接影响到接触力的大小,弹簧刚度则不仅影响接触力的大小,还影响它的稳定几性.     

An experimental rig for near-bit force measurement and drillstring acoustic transmission of BHA

An experimental rig for near-bit force measurement and drillstring acoustic transmission of bottom-hole assembly (BHA) is designed and implemented to investigate downhole dynamic behaviors of BHA. By using a developed dynamic force sensor device with a four-straight beam strain gauge, the rig can measure axial, lateral forces and torques exerted on simulated drillstring while rotating. For the upward transmission of downhole dynamic force data, drillstring acoustic telemetry method is further analyzed by transient numerical simulation. Considering acoustic signal attenuation and transmissibility, a narrow pulse on-off keyed modulated time-delay signal transmission method is developed. The near-bit force measurement experiments of BHA are performed under different weight on bit loads, deviation angles and drill pipe combinations. The obtained force data are transmitted via acoustic waves propagating along the simulated drillstring. The results show that acoustic transmission rate is approximated 77 bit/s along 6.4-m simulated drillstring under 1-W power excitation in the laboratory.     

基于动态电磁力的主动式动平衡测量方法的研究

动平衡机在测量大质偏类工件时,由于不平衡量较大,振动信号往往会超出测量系统的线性范围而造成测量误差偏大。为了提高动平衡测量精度,提出了一种采用电磁力产生的同频振动抵消大部分初始振动,从而减小簧板振动量,保证系统线性度的动平衡测量方法。讨论了该方法的基本工作原理,建立了电磁力装置的磁路模型;采用有限元建模对电磁力的可控性进行了研究,并分析了气隙、温度等因素对电磁力的影响;最后介绍了测量控制系统和控制策略。动平衡测量实验表明,该测量方法能够有效地提高大不平衡量工件的动平衡测量精度。     

A Computational Study of Contact Mechanics between Magnetic Recording Heads and Thin-Film Disks

The tribological phenomena between magnetic head sliders and thin-film disks are studied during rest, during start-up and shutdown, and during regular operation using numerical simulations. A theoretical model of stiction is first derived based on the surface tension of liquid and capillary condensation. Next, a hybrid method of FEM and BEM is developed in order to carry out high-precision microscopic contact stress analysis of a disk covered by multilayer thin films. An impact simulator based on FEM is then presented which considers the air lubricant film to be an elastic spring system determined from the solution of a compressible Reynolds equation, ft is found, that these simulators can be used to effectively study the tribology of slider/disk interactions and that the results can be used to establish qualitative design criteria for slider/disk mechanisms.     

Identification of tool wear using acoustic emission signal and machine learning methods

The work concerns the monitoring of the edge condition based on acoustic emission (AE) signals. The tool edge condition was determined by the wear width on the flank face. The processed material was an aluminum-ceramic composite containing 10% SiC. A carbide milling cutter with a diamond coating was used as the tool. Based on the AE signals, appropriate measures were developed that were correlated with the edge condition. Machine learning methods were used to assess the milling cutter's degree of wear based on AE signals. The applied approach using a decision tree allowed the prediction error of the tool condition class with a value below 6%. The method was also compared with other machine learning methods such as neural networks and the k-nearest neighbor algorithm.     

Detection of buried reference structures by use of atomic force acoustic microscopy

The miniaturization of micro- and nanoelectronic components requires new methods for the inspection of buried inner structures at the nanoscale. We used the atomic force acoustic microscopy technique (AFAM) to image subsurface defects. This technique combines high lateral resolution with the capability to determine local elastic properties of materials near the surface. As the structures buried near the surface change the effective tip-sample contact stiffness it is possible to detect them. For the verification of the detection capabilities of AFAM we fabricated well-defined buried void structures with different geometries and dimensions. Large, thin, plate like structures of silicon nitride with a local filling were our first test samples. Then, sets of nine small, square, thin plates with thicknesses increasing stepwise from 30 to 270 nm were etched in a thinned silicon wafer. The last two samples contained wedge structures of widths varying between 1.6 and 10 μm. Our results showed that it was possible to detect buried void structures at depths between 180 and 900 nm. We also observed that the depths at which the buried defects can be detected by the use of the AFAM method depend on the defect dimensions and geometry, and on the mismatch in the elastic properties of the sample and the defects. The experimental results obtained for the groups of small, thin plates were verified by quantitative analysis via finite element method (FEM) simulations.     

Micro-scale hole profile measurement using rotating wire probe and acoustic emission contact detection

The development of a new probing method to inspect the inner diameter of micro-scale holes is presented in this paper. This was accomplished by contact detection using acoustic emission with a Ø170 μm rotating wire probe tip. Contact is detected when the rotating probe approaches and impacts the hole’s inner surface. The effective diameter of the rotating probe is calibrated by using a high precision grade 0 Mitutoyo gauge block. The wire rotating probe used was fabricated with micro stainless steel wire and micro tubes. The probe’s effective diameter was compensated for in the measurement of the hole. The probe was used to measure the diameter and the roundness of micro-scale holes. Probes used in previous publications have different geometry than the probe in this paper and are used almost exclusively for external dimensions. Micro-scale holes of less than 1.0 mm in diameter and 10 mm in depth are successfully measured and the 3D profile is created accordingly. Also, the out-of-roundness values of each level spacing, 50 μm apart in height, are calculated.     

激励力对发动机机体表面振动影响的仿真分析研究

发动机工作时内部主要激励力包括燃气爆发压力、活塞连杆等运动件惯性力、配气机构激励力和活塞敲击力等,机体表面振动是发动机内部各种激励力叠加的响应,构成成分复杂。通过AVL EXCITE软件,建立有限元与多体动力学联合仿真模型,计算获得不同激励力作用下的机体表面振动信号数据,再通过时域、频谱分析,研究激励力对机体表面振动的影响,从而解决真实发动机难以进行相关试验测试分析的问题,为发动机振动分析与优化设计提供可靠的依据。     

Vertical attractive force generated in a noncontact chuck using ultrasonic vibration

Squeeze-film chucks using ultrasonic vibration are attracting considerable attention because of their ability to vertically and horizontally support an object placed on their vibrating surface without any contact. In addition, it has been shown experimentally that an attractive force is exerted on an object set under the vibrating surface. Although the cause of the vertical and horizontal forces has been determined using computational fluid dynamics (CFD) calculations, the cause of the attractive force generated by the vibrating surface has not yet been clarified in detail. This paper investigates numerically and experimentally the cause of this attractive force generation. In the numerical calculations, CFD was used to obtain the pressure distribution both in the air gap between the object and the vibrating plate and in the space surrounding the object. The attractive force acting on the object was found to be generated by the inflow resistance at the outer edge of the object when the air flows into the narrow air gap from the outside, which lowers the pressure in the air gap around the outer edge of the object to below ambient.     

可溯源至质量的静电力复现与测量技术

为实现10-5 N以下微小力值的测量及溯源,提出了一种高精度、可溯源至质量的微小力值测量系统,采用受控静电力发生装置复现微小力值,其基本工作原理是基于一种精密设计的圆柱形电容器,电容器内外电极同轴,外电极固定不动作为参考电极,内电极由弹性机构支撑和导向,通过改变内外电极间的电压产生静电力,从而将力学量追溯至电容及电压等电学量,利用砝码质量与静电力平衡的原理,可以实现微小力值的溯源.实验结果表明:电容变化梯度为0.82 pF/mm,完全可以复现10-6～10-9 N范围内的静电力.     

机器人柔性抛光机床的力控制系统的建模与辨识

机器人柔性抛光系统中,力控制系统是重要的组成部分.力控制系统对抛光加工性能有重要的影响,直接关系着抛光质量.该力控制系统实际上是一个闭环的交流伺服系统,对力控制系统的建模为抛光系统的动态和静态性能分析提供了理论基础.     

Contact mechanics and tip shape in AFM-based nanomechanical measurements

Stiffness-load curves obtained in quantitative atomic force acoustic microscopy (AFAM) measurements depend on both the elastic properties of the sample and the geometry of the atomic force microscope (AFM) tip. The geometry of silicon AFM tips changes when used in contact mode, affecting measurement accuracy. To study the influence of tip geometry, we subjected ten AFM tips to the same series of AFAM measurements. Changes in tip shape were observed in the scanning electron microscope (SEM) between individual AFAM tests. Because all of the AFAM measurements were performed on the same sample, variations in AFAM stiffness-load curves were attributed to differences in tip geometry. Contact-mechanics models that assumed simple tip geometries were used to analyze the AFAM data, but the calculated values for tip dimensions did not agree with those provided by SEM images. Therefore, we used a power-law approach that allows for a nonspherical tip geometry. We found that after several AFAM measurements, the geometry of the tips at the very end is intermediate between those of a flat punch and a hemisphere. These results indicate that the nanoscale tip-sample contact cannot easily be described in terms of simple, ideal geometries.     

Developing and testing a laboratory system for recording and analysis of acoustic emission

A laboratory system for recording and analyzing acoustic emission was designed and experimentally investigated (tested). A block diagram and the operation algorithm of the system are presented. The relationship between the results of low-frequency, high-frequency, and statistical processing of recorded data and the physical features of input signals is shown using as an example simulated acoustic signals in the various units of the designed system. The system was tested on real test objects in the case of three-point bending of nitrided steel specimens with various thicknesses of the hardened surface layer. It is shown that crack formation leads to emission of signals with an amplitudes of up to 4 V, whereas during deformation in the absence of pronounced cracking, the amplitude of the amplified signal does not exceed 0.5 V.     

Effect of downward depth and inflation pressure on contact force of gasbag polishing

Gasbag polishing is a kind of ultra-precision machining technology by means of flexible contact, while how to control the polishing contact force online is one of the key issues. In this paper, by analyzing the effect of downward depth and inflation pressure on the contact force experimentally, and then the coupling contact force model is developed. Thus, the predictions of polishing contact force and inflation pressure in terms of the nonlinear composite material of rubber gasbag can be obtained, which can be used to get the optional combination and controllable range of polishing contact force, and to construct the control system of coupling contact force as well. Experimental study shows that applying coupling contact force model to the control system of gasbag polishing contact force with BP neural network PID control strategy is a proper method, which realizes the polishing contact force controllable online and uniform surface quality of mold.     

RETRACTED ARTICLE: Development and application of intensified envelope analysis for the condition monitoring system using acoustic emission signal

The application of the high-frequency acoustic-emission (AE) technique in the condition monitoring of rotating machinery has been increasing of late. It has a major drawback, though, the attenuation of the signal, and as such, the AE sensor has to be close to its source. Two signal-processing methods, envelope analysis and wavelet transform, were found to be useful for detecting faults in the rolling element bearing and gearboxes. These methods have a disadvantage, though: their application is focused only on a component of the assembled machine. For example, envelope analysis is a powerful method for detecting faults in the bearing system, but it is not proper for use in the gear system. Thus, these methods could not be used to detect combined faults in the common assembled machines. Therefore, we propose a signal-processing method consisting of envelope analysis and DWT (discrete wavelet transform). In addition, a novel mother function optimized for the AE signal for DWT was extracted through a fatigue crack growth test, and is also proposed herein. Then the proposed method, called intensified envelope analysis (IEA), was used to detect the faults in the rolling element bearing and rotating shaft. According to the results, IEA can be a better signal processing method for the condition monitoring system using AE technique.