Identification of machine–tool–workpiece system dynamics

The aim of this paper is to present a method to identify the dynamics of a structure composed of a milling machine, a tool and a workpiece. The excitation is obtained as a result of the interrupted cutting of a narrow workpiece width and single tooth milling operations. This provides a pulse-like cutting force. The three components of the cutting force and the relative motion between the tool and the workpiece are measured simultaneously. A method was developed to determine the nine terms of the structural transfer matrix under a single cutting operation and without any assumption on the excitation direction. The proposed method is experimentally validated.     

Identification of Heat Transfer Coefficients by Use Conditions of Quenching Oil

Heat transfer coefficients of the quench medium are necessary for heat-treatment simulation. Cooling characteristics of quenching oil vary with kinds and usage greatly. Users are selecting oil solutions that come up to their desired hardness and quenching distortion requirements. In particular cooling performance rises by agitation and decompression. Therefore we identified a heat transfer coefficient by usage and kinds of quenching oil. Cooling characteristics are different greatly by a kind of quenching oil. A difference of a cooling characteristic by a kind of oil depends on a temperature range of a boiling stage and the maximum heat transfer coefficient mainly. On the other hand, in a convection stage, there are few changes in a boiling stage. Even if quenching oil temperature is changed, heat transfer coefficients do not change greatly. When quenching oil stirred, heat transfer coefficients of vapor blanket stage and a convection stage rise, but there are a few changes in a boiling stage. When quenching oil is decompressed a temperature range of a high heat transfer coefficient moves to the low temperature side. In addition, a heat transfer coefficient in a vapor blanket stage comes down. For precision improvement of heat-treatment simulation, it is important that the heat transfer coefficient is calculated in conformity to the on-site use reality.     

A scanning tunneling microscopy tip with a stable atomic structure

A single stable adatom on a {110}-type plane of a tungsten tip is created via field-evaporation in a field-ion microscope (FIM) operating at room temperature. This single adatom has sufficient surface mobility at room temperature and migrates, in one-dimension, along a <111>-type direction toward an edge of a {110}-type plane, due to the existence of an electric field gradient. The plane edge has a higher local electric field than its center, since it has a higher local geometric curvature. This result implies that the stable position of a single adatom during a scan of a scanning tunneling microscope (STM) tip on a surface is at the edge and not at the center of a {110}-type plane at room temperature. Therefore, the electron wave function of a tip is not symmetric and this fact should be taken into account in a careful analysis of STM images. Also a tip with a dislocation emerging at a {110}-type plane is suggested as an improved STM tip configuration, as the step at the surface, created by the intersection of the dislocation with it, is a perpetual source of single adatoms.     

捷联惯性制导系统的电路设计

通过对捷联惯性制导与平台惯性制导之间差异的分析，讨论了在进行捷联惯性制导系统的电路设计时所应注意的问题，在此基础上，用C32 DSP和可编程逻辑器件，设计了一个捷联惯性制导系统的电路。     

论大学教师修养

大学教师修养是大学教师主体自主自觉长期不断地进行理想人格自我建构的社会实践活动，大学教师理想人格范型为具有德高、学高、情智高、事功高特征的人文与科学大师，是科学（学术）大师，教学大师和思想大师三者的统一体。大学教师修养过程是大学教师主体内化与外化交互作用的过程，也是大学教师主体不断超越现实我、趋向理想我的终身实践过程。进行科学（学术）研究活动、教书育人活动和社会文化批判活动是大学教师修养的根本途径和方式方法。     

Stability analysis and motion planning strategies with fuzzy coordinator and learning for mobile base robotic part macro/micro-assembly tasks

This paper addresses problems of a mobile base robot’s part assembly. This process can be broken down into two phases. First, a macro-assembly, bringing a part to an assembly hole or a receptacle (target) for a purpose of a part mating. For the macro-manipulation task, a stability analysis of a mobile base robot subject to disturbances, such as an external impact force and torque as well as a tipping movement, is discussed. The mobile robotic system is stabilized by balancing the system moment through a fuzzy coordinator. Simulations are performed by applying external forces and torque to the system and adding disturbances to the mobile base’s tipping movement. Second, a micro-assembly, mating a part with a target. For the micro-manipulation task, two learning methodologies are presented. First, a learning strategy to minimize the entropy, uncertainty, and eliminate unneeded events in the plan related to avoiding jamming is described. An entropy function, which is a useful measure of the variability and the information in terms of uncertainty, is introduced to measure its overall performance of a task execution related to the part mating. Next, a fuzzy stochastic learning method, based on the probability of a fuzzy set and a modified distance metric, to update the probability of a plan composed of fuzzy events used for the part mating task is introduced. The degree of uncertainty associated with the fuzzy event of plan is used as an optimality criterion, or cost function, e.g. minimum Hamming distance, for a specific task execution. The above techniques are applicable to a wide range of mobile robotic tasks including pick and place operations, maneuvering around workspace, manufacturing, part mating, or complex assembly tasks.     

Soft physical vapour deposition coatings—a new coating family for high performance cutting tools

The joint effort of a cutting tool manufacturer and a coating specialist has led to the development of a cutting tool coating based on a soft solid lubricant (patents pending). It is applied by an advanced sputtering technique as a very thin uniform coating with a good adherence to the tools. It has a low coefficient of friction and a low affinity to alloy materials such as aluminium, titanium and precious metals. These factors and others allow machining at high spindle speeds and feed rates with an excellent workpiece surface finish. Values can be maintained which are far superior to even those permitted for cemented carbide tools. In some cases productivity and tool life can be increased by a factor of up to 20.     

Dynamics of boring processes: Part III-time domain modeling

This article presents a mathematical model and a computational algorithm for the time domain solution of boring process dynamics. The model is developed in a modular form; it includes a workpiece geometry and surface topography module, a kinamatics and tool position module, a dynamic chip load module, a dynamic cutting force prediction module and a structural dynamics module. The time domain model takes cutting process parameters, tool and workpiece geometries and modal parameters of the structure as inputs. It predicts instantanous cutting forces and vibrations along the machining time, and machined workpiece topography as outputs. Some of the simulated and experimental results for various cutting conditions are presented and compared for validation purposes.     

Superfinishing and grind-strengthening with elastic bonding system

This paper presents with a new grinding strategy for a surface superfinishing and a grind-strengthening of the surface layer of steels in a single grinding step. To grind-strengthen a surface layer both abrasive material removal and a plastic deformation are needed. This combination together with an appropriate grinding wheel design offers the possibility to ensure high precision surfaces with a consistent quality finish that meets the highest standards. This kind of grinding process could be applied to bearings, for example. During the run-in period, the initial contact surfaces change until they stabilize to a running-in condition and have a new surface topography. Grinding with the new process strategy leads to benefits because a grind-strengthened surface layer eliminates initial wear and abrasion within the system, reduces surface finish roughness, extends fatigue strength, and reduces risk of part failure during operation.     

通过吉田-上森模型进行回弹预测和利用Jstamp进行回弹补偿的研究

考虑到由塑性应变导致弹性模量发生变化,作者为商业软件LS-DYNA专门编制了一个子程序吉田-上森模型,然后分别使用实体单元和壳单元对两个冲压件进行回弹模拟。为制造与设计的形状和尺寸相一致的冲压件,提出了回弹研究的新功能和回弹补偿算法并集成到钣金成形仿真软件JSTAMP中。最后,研究了回弹的原因和介绍了使用JSTAMP对车身底座横梁板执行回弹补偿的过程。     

Residual stress analysis of an aircraft landing gear part using neutron diffraction

The residual stress of a landing gear part of a fighter jet that has a frequent practice of takeoff and landing was evaluated for the safety. The sample was a cylindrical steel bar with a 22.2 mm diameter and 55 mm length used to fix the main landing gear to the aircraft body. For a deep measurement up to 6 mm, we used a neutron beam. From the measurements, the tensile and compressive strain in the axial direction were observed around one side of the pin hole which was across the steel bar vertically with an 8 mm diameter. The strain distribution along the length of the bar presented a similar tendency through the thickness and a larger value on the surface. The maximum value of the residual stress around the pin hole was about 100 MPa. However, there was no strain on the opposite side of the pin hole. From the results, it may be surmised that the steel bar received a steady force in one direction around the pin hole, however the force was weak and affected a small limited area and thus not influence on the steel bar on the whole.     

Influence of discharge current on machined surfaces by thermo-analysis in finish cut of WEDM

In finish machining of wire electrical discharge machining (WEDM), the discharge current has distinct influences on the machined surface. In order to study the differences in surface morphology under various pulse durations, thermo-analysis was carried out to investigate the mechanism of erosion of the workpiece material using the finite element method. Additionally, related single discharge experiments under different pulse energies were performed. Under the same discharge energy, the comparison of analytical and experimental results shows that a discharge current with a short-duration pulse and a high peak value removes the workpiece material mainly by gasifying, while a discharge current with a long-duration pulse and low peak value removes the workpiece material mainly by melting. It was also found that surfaces machined by a discharge current with a short- and long-duration pulses would have similar roughness values when the pulse energies were almost the same and were high enough; however, the surface morphologies would be totally different. A discharge current with a long pulse duration and a low peak value could not produce craters on the workpiece surface when the pulse energy was reduced to a certain value. However, a discharge current with a short pulse duration and a high peak value could produce clear craters on the workpiece surface. This indicates that a discharge current with a short pulse duration and a high peak value can generate better surface roughness, which cannot be achieved with a current with a long pulse duration and a low peak value.     

Location of steel reinforcement in concrete using ground penetrating radar and neural networks

Ground-penetrating radar is becoming increasingly popular for use as a non-destructive assessment method for investigating reinforced concrete structures. The amount of data collected however can be very large and take a significant level of subjective experience to interpret. This study focuses upon the use of a neural network approach to automate and facilitate the post-processing of ground penetrating radar results. The radar data is reduced to a simplified data set by using an edge detection routine. Signal reflections from reinforcing bars displaying a hyperbolic image format are detected using a multi-layer perceptron (MLP) network with a single hidden layer containing 8 nodes to recognise a simplified hyperbolic shape. Training and testing of the network was carried out making use of an emulsion analogue tank, simulating the properties of concrete, and using real concrete specimens. The results showed that the use of a MLP neural network approach could be quite effective in automating the identification and location of embedded steel reinforcing bars from a radar investigation. Accurate estimation of depth, or cover, requires a reliable knowledge of the dielectric properties of the concrete, and recent work using a specially-developed wideband horn antenna for direct determination of in situ properties is also outlined.     

Electrochemical performance of tris(2-chloroethyl) phosphate as a flame-retarding additive for lithium-ion batteries

We studied tris(2-chloroethyl) phosphate (TCEP) as a potential flame-retarding additive and its effect on the electrochemical cell performance of lithium-ion battery electrolytes. The electrochemical cell performance of additive-containing electrolytes in combination with a cell comprised of a LiCoO₂ cathode and a mesocarbon microbeads anode was tested in coin cells. The cyclic voltammetry results show that the oxidation potential of TCEP-containing electrolyte is about 5.1 V (vs. Li/Li⁺). A cell with TCEP has a better electrochemical cell performance than a cell without TCEP in an initial charge and discharge test. In a cycling test, a cell containing a TCEP-containing electrolyte has a greater discharge capacity and better capacity retention than a TCEP-free electrolyte after cycling. The results confirm the promising potential of TCEP as a flame-retarding additive and as a means of improving the electrochemical cell performance of lithium-ion batteries.     

Biological interactions at metal surfaces

Adsorption of biomolecules, whether it is a consequence of a material being put into service in a biological medium such as a biomedical implant device or a heat exchanger tube, are governed by fundamental interactions and surface conditions that are well characterized (and in some cases not so well). This work reviews those fundamental interactions and also describes a study of the adsorption of a naturally occurring biological polymer onto a stainless steel alloy.     

圆筒形件充液拉深成形精度

本文系统地研究了平底和球面圆筒形件充液拉深成形精度。充液拉深成形中，由于高压液体紧紧将毛坯贴向凸模表面，因而零件具有良好的贴模性并能获得很高的内径精度。同样，由于液压的施加在凸模圆角和压边圈之间产生与凸模运动方向相反的局部胀形，减小了凸模圆角处的弹复，提高了侧壁及球面件底部的形状冻结性。但是，平底零件的底面形状因液压的施加而使形状冻结性不好，平面度降低。     

Ultraviolet lithography on sloped surfaces utilizing diamond turned holograms

A lithography method by means of a diamond turned hologram (DTH) is presented, that allows patterning of sloped surfaces. The DTH is manufactured by a modified diamond turning process, using a piezoelectric actuator, the nano fast tool servo, which modulates the depth of cut within submicrometer range at a frequency up to 10 kHz. In order to machine a DTH to be applied as phase masks for ultraviolet lithography, workpiece materials have to feature a sufficient reflectivity and excellent machinability. Ultra-fine grained aluminium was identified as most suitable workpiece material, since its reflectivity measures around 80 % and a homogenous structure can be machined. The employed DTH is used in a lithography setup in conjunction with a helium cadmium laser emitting at a wavelength of λ = 325 nm. Patterns up to a linewidth of 30 μm were successfully and consistently transferred on a photoresist coated planar substrate with a tilt angle of 30° with respect to the optical axis.     

Korrelation zwischen der beschleunigten Bewitterung im Laboratorium und der Freibewitterung eines kohlenstoffarmen Stahls in Meeresatmosphäre

Correlation between laboratory and weathering tests with a low carbon steel in maritime atmosphere The work presented here shows a possible correlation of the corrosion behaviour of a low carbon steel in maritime atmosphere and in a salt spray chamber. The corrosion tests in maritime atmosphere have been conducted in the open air and in a covered cabin at the coast of the Black Sea over two years. The laboratory corrosion tests have been conducted in a salt spray chamber and had a duration of 70 days. The correlation between laboratory and weathering tests is represented graphically. The chemical composition of the corrosion products is given.     

Expedient modeling of ball screw feed drives

Ball screw feed drives are the most commonly used mechanism to provide linear motion in high speed machine tools. Position accuracy and the achievable closed loop bandwidth of such drive systems are usually limited by the structural vibration modes of the mechanical components. Higher order plant models allow for a better understanding of the system dynamics, improve the design process of feed drives and are essential for the development of sophisticated control strategies. The ball screw shaft, describing a complex flexible structure, is probably the most significant component concerning structural vibration modes of a feed drive. In this paper, the behavior of the shaft and its dominant influence at different operating and coupling conditions is particularly addressed. Using a hybrid modeling technique, the main characteristics of the shaft are derived and projected onto a clearly arranged and versatile lumped mass model. Simulative and experimental examinations are conducted and a parameter analysis is performed. The presented model proofs to be accurate for a great range of parameters and in addition allows for a physical interpretation of the dominant structural vibration modes of a feed drive.     

Experimental and numerical study on shaping of aluminum sheets with integrated piezoceramic fibers

Force-fit integration of piezoceramic fibers in micro-formed structures is a new approach for function integration in structural sheet metal parts. In a first step, a micro-structured surface is formed in a planar semi-finished sheet metal part by micro-impact extrusion. Piezoceramic fibers are then assembled into this micro-structured surface with a small assembly clearance. The fibers and the structured surface of the sheet metal are joined by a forming process. In the next step, the sheet metal with piezoceramic fibres within a locally micro-formed substructure is shaped by deep drawing into a 3D-geometry. In this paper, results of the micro-impact extrusion and the joining by forming experiments are presented. Furthermore, the design constraints for assembly and joining due to the dimensional and form deviations of the piezoceramic fibers are discussed. Results of a numerical study of micro-forming, joining by forming and the global loading during a deep drawing process step were in good agreement with the experimental investigations. The direct comparison between experiment and numerical simulation increases the process knowledge and shows further improvement potential.