孔洞特征模型特征分割及自适应分层算法

目的 针对传统整体式3D打印分层算法对孔洞特征模型分层处理时层厚不够合理、难以较好平衡成形精度和成形效率等问题,通过改进分层算法,实现了孔洞特征模型3D打印成形精度和成形效率的提升。方法 首先确定模型上下水平面区域,剔除该区域的三角面片,使孔洞特征三角面片与其他部分处于非邻接状态,其次通过建立三角面片拓扑结构,将模型孔洞特征包含的三角面分离,最后以当前层相交三角面片法向量与z轴最小夹角为层厚判据,分别对模型孔洞特征及其他部分进行自适应分层,并将模型各部分分层路径整合,形成完整的模型3D打印机执行代码。结果 示例模型分层模拟及实际打印结果表明,对于实验所用的螺母模型和拇指轮模型,与三角面片法向量自适应分层算法相比,所提算法的模型成形精度分别提升了20.18%和62.68%,打印耗时分别缩短了34 min和11 min。结论 对于孔洞特征模型,采用分离模型孔洞特征与单独自适应分层的策略,能够较好地提升模型成形精度,并且缩短模型成形时间。     

Optimal part deposition orientation in FDM by using a multicriteria genetic algorithm

In rapid prototyping processes, the deposition orientation of the part is very important as it affects part surface quality, production time and the requirement for support structure and hence cost. Depositing the part with thinner slices results in a larger build time. At the same time, if a large slice thickness is chosen, the surface finish is very poor due to stair-stepping. These are two contradicting issues and are tackled by using adaptive slicing. In adaptive slicing, slice thickness is calculated based on local geometry of the computer-aided design model and rapid proto-typing machine specifications. Even though adaptive slicing controls part surface quality by compromising on build time for a deposition orientation, an optimum orientation can further reduce build time and enhance part surface quality. In the present work, an attempt has been made to determine the optimal part deposition orientations by considering two objective functions at a time, namely average part surface roughness (average part surface quality) and build time. The two objectives are minimized simultaneously using a multicriteria genetic algorithm.     

增材制造中基于零件特征的分段自适应分层算法

对一类不同部位有明显精度区别的零件进行增材制造时，相较于传统等厚分层算法，现有的分段等厚分层算法和自适应分层算法在弱化阶梯效应及减少分层和成型时间上各有所长，但它们在协调成型精度和成型效率方面并未达到最佳。为此，根据这类零件的立体光刻（stereo lithography，STL）模型，结合分段分层和自适应分层原理，提出了基于零件特征的分段自适应分层算法。沿成型方向按不同的精度要求对模型进行分段，并根据不同精度，利用以最大尖端高度调整分层厚度的方法对各段进行自适应分层。对斗齿类、链轨节类零件进行分层模拟试验，结果表明：基于零件特征的分段自适应分层算法在满足零件形状和精度等要求的前提下，较现有的分段等厚分层算法和自适应分层算法，其成型效率更高，稳定性及灵活性更好，且易于实现；在实际工程应用中可缩短零件的成型时间，促进增材制造向高效率方向发展。     

机械滚压对A473M钢疲劳性能的影响

采用机械滚压对A473M马氏体不锈钢轴套材料进行表面处理,研究滚压工艺对其力学性能的影响。采用SEM、白光干涉仪、X射线衍射仪、显微硬度计、EBSD、拉伸试验机和疲劳试验机分别对试样表面形貌、表面粗糙度、残余应力、显微硬度、拉伸性能和疲劳性能进行系统表征。结果表明:滚压加工试样表面的粗糙度明显降低,仅为车削加工的1/5;滚压加工在材料近表面引入残余压应力,其值最高可达946 MPa,沿深度方向逐渐减小,残余压应力层深度约为200μm,表面硬度提高30%左右,硬度影响层深度可达200μm;抗拉强度、屈服强度和伸长率分别提升了40%,22%和8%,疲劳寿命由基体材料的5.4×10^4周次提高到1×10^7周次。采用滚压加工后材料的力学性能明显提升,疲劳寿命显著增加。     

Passivation layer effect on surface integrity induced by Cu-CMP

To achieve efficient Cu-Chemical-Mechanical Polishing planarization at miniaturized device dimensions, there is a need for a better understanding of the surface integrity induced by the process. Surface quality and stresses are the two selected indices in this article to evaluate the Cu-CMP process induced surface integrity. The thickness of the passivation layer and the penetration depth of abrasives are considered as the main effects for the generations of surface qualities and residual stress. Experimental validation on copper films on silicon wafer was performed by CMP with different pads and slurries to generate varied residual stresses and surface qualities. Depth of scratches and surface roughness were measured by the atomic force microscope. The stress measurements of the thin films were performed by a Grazing Incident X-ray diffraction instrument with its principles based upon modified sin²Ψ method. Accordingly, the surface roughness and stress were related to the thickness of the passivation layer and the CMP process conditions. When the penetration depth is larger than the passivation layer thickness, the roughness values are mainly decided by the selection of pads and the resultant penetration depth. In addition, the residual stress profiles are dependent on the CMP process conditions which include the slurries and pad parameters. The stress profile obtained for the slurry SDK with soft pad Politex composed smallest maximum tensile stress below the surface and a steady transition of stress profile compared to the stress profile obtained at the initial condition. At the condition for the same slurry SDK, but with a hard pad of IC1000, the CMP process induced larger maximum stress and sharper profile transition.     

超薄四面体非晶碳膜的结构和性能

使用磁过滤阴极真空电弧(FCVA)技术制备不同厚度的超薄四面体非晶碳膜(ta-C)，研究了表征和测量超薄ta-C碳膜微观结构和性能的方法以及膜厚的影响。使用X射线衍射仪验证椭圆偏振光谱仪联用分光光度计表征膜厚度的可靠性并测量了膜密度；用拉曼谱分析薄膜的内在结构，验证用椭偏联用分光光度计表征sp³ C含量的可靠性；用Stoney^，s公式计算了薄膜的残余应力。结果表明，薄膜的厚度由7.6 nm增大到33.0 nm其沉积速率变化不大，为1.7±0.1 nm/min；根据椭偏联用分光光度计的表征结果，薄膜中sp³ C的含量逐渐减少，拓扑无序度降低，与拉曼谱的表征结果一致；厚度为7.6 nm的超薄ta-C碳膜中p³ C的含量最高；随着厚度的增大薄膜中的残余压应力从14 GPa降低到5 GPa；厚度为11.0 nm的薄膜主体层密度最大，为3070 kg/m³，致密性较好；厚度对薄ta-C碳膜表面粗糙度的影响较小。用椭偏和分光光度计测量超薄ta-C碳膜的厚度和表征显微结构是可行的，X射线反射法可用于测量超薄ta-C碳膜密度和表面粗糙度，但是对薄膜的质量要求较高。     

Turning of aluminum metal matrix composites: influence of the reinforcement and the cutting condition on the surface layer of the workpiece

Aluminum metal matrix composites (Al-MMCs) are difficult to machine. The reinforcement of aluminum using ceramic particles accelerates tool wear. Moreover, demanded machining accuracies or properties of the surface layer are difficult to achieve. In the present study, the effect of silicon carbide reinforcement particles on the surface layer of the workpiece was investigated using multiple cutting conditions for dry turning. Three differently reinforced Al-MMCs regarding the volume percentage (17% and 30%) and the particle size (0.6 μm and 3 μm) and their non-reinforced matrix were considered as the workpiece materials. The reinforcement and the cutting condition affect the results of turning. A greater particle volume percent improves the surface roughness and decreases the tensile stress in the surface. The smaller particle size caused a lower tensile stress in the surface. A general effect of the particle size on the workpiece roughness can not be concluded. The most important cutting parameter for the surface layer of the workpiece is the feed. Greater feeds decrease the tensile stress in the surface, but deteriorate the surface quality.     

Mechanical integrity analysis of multilayer insulator coatings on flexible steel substrates

The cohesive and adhesive properties, and related critical radius of curvature of thin multilayer insulator coatings on a 152 μm thick flexible steel substrate were investigated using tensile experiments carried out in-situ in an optical microscope. This method was found to be well adapted for the two types of coatings studied: SiO₂ single layers with different thickness and SiO₂/SiN_x/polyimide stacks. Special attention was paid to the influence of surface roughness and yielding of the steel substrate. Coating delamination and spallation was observed at low strain in case of SiO₂ coatings on unpolished steel, resulting from roughness-induced stress concentrations and slippage of grain boundaries. Polishing the steel substrate, or using a polyimide interlayer, was found to be useful to avoid premature delamination of the layers. In all investigated cases, a critical radius of curvature for layer damage of approximately 5 mm was found.     

Spacing of edge fractures in layered materials

Opening-mode fractures developed from a free surface in a layered material often terminate at the interface that divides the fractured layer and the underlying layer. They also display regular spacing that is of the same order of magnitude as the thickness of the fractured layer. We have investigated the stress distribution between two adjacent edge fractures as a function of the ratio of fracture spacing to thickness of the fractured layer using a two-layer elastic model with a fractured top layer. The results show that when the ratio of fracture spacing to the layer thickness changes from greater than to less than a critical value the normal stress acting perpendicular to the fractures near the free surface changes from tensile to compressive. This stress state transition precludes further infilling of fractures unless they are driven by mechanisms other than a pure extension, or there are flaws that significantly perturb the local stress field between the fractures. Hence, the critical fracture spacing to layer thickness ratio defines a lower limit for fractures driven by extension, which also defines the condition of fracture saturation. The critical value of the fracture spacing to layer thickness ratio is independent of the average strain of the fractured layer, and it increases with increasing ratio of Young's modulus of the fractured layer to that of the underlying layer. The critical value increases with increasing Poisson's ratio of the fractured layer, but it decreases with increasing Poisson's ratio of the underlying layer. For the case with the same elastic constants for the fractured layer and the underlying layer, the critical spacing to layer thickness ratio is about 3.1. Delamination between the fractured layer and the underlying layer makes the critical spacing to layer thickness ratio much greater. Infilling fractures grow more easily from flaws located near the bottom of the fractured layer than from those located near the free surface when the spacing to layer thickness ratio is less than the critical value. The propagation of an edge flaw between adjacent edge fractures is unstable, but for the flaw to propagate to the interface, its height has to be greater than a critical size, that decreases with increasing fracture spacing to layer thickness ratio. The propagation behavior of an internal flaw with its lower tip at the interface depends on the edge fracture spacing to layer thickness ratio. The propagation is unstable, when the fracture spacing to layer thickness ratio is greater than a critical value; stable, when the fracture spacing to layer thickness ratio is less than another critical value; and first unstable, then stable, and/or unstable again, when the fracture spacing to layer thickness ratio is between these two critical values.     

微注塑成型充模流动中的对流换热实验

微注塑成型中,聚合物熔体与微型腔壁面间的对流换热行为与常规注塑成型不同,对流换热系数也发生了变化。通过采用微模具和温度传感器,对聚丙烯(PP)、ABS和两种聚甲醛(POM)熔体,以不同注射速度填充厚度为0.510 mm和0.420 mm,表面粗糙度为0.062μm、0.393μm和0.695μm的不同微型腔时的模具温度分布进行测量,从而求得对流换热系数。结果表明,微注塑成型中对流换热系数,与聚合物材料热物理性质紧密相关,热物性参数值高的材料,对流换热系数也大;且随注射速度和型腔表面粗糙度的增加以及型腔厚度的减小而增大。     

Effect of chemical treatment on tensile strength and surface roughness of 3D-printed ABS using the FDM process

Fused deposition modelling (FDM) is one of the most commonly used additive manufacturing processes because of its environment-friendly nature and cost-effectiveness. However, it suffers badly from low surface quality due to a larger layer resolution. The surface finish of FDM parts can be enhanced by post chemical treatment using various solvents. The chemical treatment reduces the surface roughness by dissolving the external surfaces of 3D-printed samples. Chemical treatment is an easy, fast and economical technique. In the present investigation, the effect of chemical treatment on surface roughness and tensile strength of acrylonitrile butadiene styrene (ABS) parts made using the FDM process is investigated using two chemicals, namely acetone and 1, 2 dichloroethane. The post chemical treatment dramatically improves the surface finish and dimensional accuracy of ABS specimens. But chemical treatment results in the reduction of the tensile strength. Better tensile strength is obtained while using acetone solvent and a better surface finish is obtained using dichloroethane.     

直线运动滚动导轨副混合润滑研究

综合考虑了直线运动导轨副接触几何、预紧力、真实表面粗糙度、曲率系数等因素,建立了直线运动导轨副混合润滑数值模型,研究了滑块移动速度、曲率半径系数、工作载荷、表面粗糙度对导轨接触副润滑特性的影响,得到结论:导轨副法向工作载荷、最大赫兹接触压力和赫兹接触半径随着外加总载荷的增大而增大,平均膜厚随着载荷的增大而减小;混合润滑模型可预测导轨副在大范围工况条件下完整的润滑状态;直线运动导轨大多工作在混合润滑状态下,随着滑块移动速度的增加,接触界面由边界润滑状态向混合润滑状态转变,润滑性能逐渐提高;适当增加曲率半径系数,有利于润滑油膜的形成与稳定。     

Influence of graphite powder mixed EDM on the surface integrity characteristics of Inconel 625

Surface integrity in electric discharge machining (EDM) has always been a major concern in the manufacturing industry. Although, EDM with a powder suspended dielectric has shown good potential in enhancing the material removal rate and improving surface finish, influence of the same on the overall surface integrity is not very clear. The current work utilized the graphite powder and evaluated its role in combination with concentration and machining parameters, on surface roughness (Ra), surface crack density (SCD), white layer thickness, microhardness depth profile, possible phase changes, and residual stress during powder-mixed EDM (PMEDM) of Inconel 625 (a nickel-based super alloy), that is now-a-days regularly used in aerospace, chemical and marine industries. The results showed that significant reduction in surface roughness, crack density, and white layer thickness is possible with the PMEDM process. It also promoted formation of carbides and other alloy compounds which is responsible for augmentation of hardness in surface and subsurface region. The added particles also caused a decline in tensile residual stress of the machined samples.     

X射线反射法分析ZnO基薄膜的厚度、密度和表面粗糙度

采用X射线反射法(XRR)测试了在SiO_2玻璃衬底上磁控溅射沉积的单层ZnO基薄膜的反射强度,得到了反射强度随掠入射角变化的曲线;讨论了薄膜厚度、密度和表面粗糙度与反射曲线的关系,最后通过拟合XRR曲线获得了所制备薄膜的厚度、密度和表面粗糙度分别为55.8 nm,5.5 g·cm~(-3)和1.7 nm,与利用XRR数据直接计算出的薄膜厚度56.2 nm仅相差0.4 nm,表面粗糙度也与AFM测试的结果基本相符。可见XRR能无损伤、精确且快速地测试薄膜试样的厚度、密度和表面粗糙度等参数。     

SANDWICH STRUCTURE DELAMINATION OF RESIN TRANSFER MOLDING

One of the apparent advantages of sandwich structures is that after the core is made, the sandwich is produced in one process by resin transfer molding (RTM) and no adhesive is used between the core and skins. The bond between the core and skins is therefore likely to depend upon the core material, the type of matrix and the core surface roughness. This is of great importance, because the stiffness of the sandwich structure is likely to be reduced by even partial delamination of the core and skins. The objective of this study was to ascertain the effects of manufacturing parameters such as injection pressure, mold temperature, core thickness and core surface roughness on skin/core adhesion using the direct tensile adhesion and peel test methods. Polyurethane foam was used as the core material throughout the work. The major objective was to examine different surface treatment methods by which the strength of the skin-core bond could be improved. The influence of the core surface roughness on the adhesive fracture energy and the delamination between core and skin were also measured. The fracture energy release rate equation was used as the basis for comparison and for measurements of the adhesion. For this purpose a double-cantilever beam was used to characterize the delamination. Critical energy release rate (G_IC) and fracture toughness (K_IC) were calculated using several alternative methods based on linear elastic fracture mechanics.     

电源频率对铸铝合金微弧氧化陶瓷层的影响

研究了微弧氧化处理中电源频率对铸铝合金微弧氧化陶瓷层的影响.发现频率也是影响微弧氧化陶瓷层厚度及表面粗糙度的因素之一.试验结果表明:陶瓷层厚度及表面粗糙度均是先随频率的升高而增加,而后又随频率升高而减小.在微弧氧化后期在增加电源频率的同时,适当降低占空比,可以获得表面质量好并具有一定厚度的陶瓷层.     

基于刨切策略的纸基彩色3D打印提速方法

为了改善纸基类彩色3D打印技术产业化所面临的打印周期长问题,利用现有的STL文件几何信息,提出了一种新的基于刨切策略的快速稳定着色算法。利用分层后的3D数据模型中切层斜率D值的正负来判定着色面,并采用改进型着色油墨进行选择性单面着色替换双面着色来实现打印提速。结果表明,在给定的3D彩色模型中,从上至下刨切法、从下至上刨切法、正公差刨切法、负公差刨切法4种常用刨切策略提速效率指数Es都高于0.5,其中负公差刨切法的提速效果最明显。由此可知,在现有耗材和设备的基础上,纸张着色判定的正面优先简化模型,能够低成本地提高纸基彩色3D打印速度。     

Substrate- and oxidation-induced roughness of individual terraces of pentacene thin films

The roughness at the surface of individual pentacene terraces on naturally oxidized silicon wafers was investigated with scanning force microscopy as function of film thickness (one to five layers) and sample exposure to ambient air. For pristine samples, the root-mean-square roughness on individual (001) pentacene terraces was 0.18 nm and varied by less than 0.02 nm between monolayer terraces and terraces in the fifth layer. Storing samples in air and ambient light led to a substantial increase of the roughness, which for terraces up to the third layer became 0.24 nm after four weeks. For fourth layer terraces, the roughness increased less, and terraces in the fifth layer exhibited no significant roughness increase. We explain the roughness increase by photo-oxidation of pentacene, particularly strong within the first layer, which is supported by the appearance of grain boundary widening with storage time. The observation that layers beyond the third one from the substrate are less affected by photo-oxidation (smaller terrace roughness) is likely due to better structural perfection in layers farther from the substrate, which reduces the effective cross-section of molecules for oxidation. These results indicate that native silicon oxide does not allow for the immediate formation of structurally perfect pentacene films in the range of one to three layers, which will reduce charge carrier mobility in pentacene thin film transistors. Thicker pentacene layers can protect underlying layers against oxidation.     

Effect of crack curvature on stress intensity factors for ASTM standard compact tension specimens

The stress intensity factors (SIF) are calculated using the method of lines for the compact tension specimen in tensile and shear loading for curved crack fronts. For the purely elastic case, it was found that as the crack front curvature increases, the SIF value at the center of the specimen decreases while increasing at the surface. For higher values of crack front curvatures, the maximum value of the SIF occurs at an interior point located adjacent to the surface. A thickness average SIF was computed for parabolically applied shear loading. It is assumed that it reflects the average stress environment near the crack edge. These results were used to assess the requirements of ASTM standards E399-71 and E399-81 on the shape of crack fronts.