Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Helical milling is a hole-making process which has been applied in hardened materials. Due to the difficulties on achieving high-quality boreholes in these materials, the influence of noise factors, and multi-quality performance outcomes, this work aims the multi-objective robust design of hole quality on AISI H13 hardened steel. Experiments were carried out through a central composite design considering process and noise factors. The process factors were the axial and tangential feed per tooth of the helix, and the cutting velocity. The noise factors considered were the tool overhang length, the material hardness and the borehole height of measurement. Response models were obtained through response surface methodology for roughness and roundness outcomes. The models presented good explanation of data variability and good prediction capability. Mean and variance models were derived through robust parameter design for all responses. Similarity analysis through cluster analysis was performed, and average surface roughness and total roundness were selected to multi-objective optimization. Mean square error optimization was performed to achieve bias and variance minimization. Multi-objective optimization through normalized normal constraint was performed to achieve a robust Pareto set for the hole quality outcomes. The normalized normal constraint optimization results outperformed the results of other methods in terms of evenness of the Pareto solutions and number of Pareto optimal solutions. The most compromise solution was selected considering the lowest Euclidian distance to the utopia point in the normalized space. Individual and moving range control charts were used to confirm the robustness achievement with regard to noise factors in the most compromise Pareto optimal solution. The methodology applied for robust modelling and optimization of helical milling of AISI H13 hardened steel was confirmed and may be applied to other manufacturing processes.     

肼对硅片的各向异性腐蚀技术研究

采用肼水溶液在各种条件下对硅片进行腐蚀 ,通过分析与腐蚀速率有关的因素 ,即改变腐蚀溶液温度和肼的质量分数 ,来提高腐蚀速率。整个实验过程实质就是寻求最佳腐蚀工艺条件 ,从而提高硅片的表面质量。     

Optimize tool paths of flank milling with generic cutters based on approximation using the tool envelope surface

This paper presents a global optimization method to generate a tool path for flank milling free-form surfaces with a generic cutter based on approximation using the tool envelope surface. It is an extension of our previous work [Gong Hu, Cao Li-Xin, Liu Jian. Improved positioning of cylindrical cutter for flank milling ruled surfaces. Computer Aided Design 2005; 37:1205–13]. First, given initial tool path or tool axis trajectory surface, the grazing points of the tool envelope surface can be calculated. Second, the errors between the tool envelope surface and the designed surface along the normal direction of the tool envelope surface are calculated. Based on this new definition of error, an optimization model is established to get the global optimized tool axis trajectory surface. In order to simplify the calculation, two variants of this method based on the least square criterion are proposed to solve this model. Since this method is really based on the tool envelope surface, it can reduce the initial machining errors effectively. The proposed method can be used not only for cylindrical cutters and conical cutters, but also for generic cutters with a surface of revolution. In addition to ruled surfaces, it also can be used for machining non-ruled surfaces. Finally, several examples are given to prove its effectiveness and accuracy. The generated tool paths and calculated grazing points for test are available in supplementary files for the readers’ convenience in verifying this work in different CAD/CAM systems.     

基于间断性腐蚀法的铂热敏传感器的研制

针对铂湿法刻蚀工艺,提出了间断性腐蚀法,并与边腐蚀边搅拌法和静止法进行了对比,结果显示该方法腐蚀铂曲线光滑、效果好。之后,以普通硅片作为衬底材料,二氧化硅作为隔热层,采用上述微机电(MEMS)工艺加工制作了铂热敏传感器。经热敏性能测试,其电阻温度系数在20℃～80℃时为1571.2×10-6/℃;同一批次电阻阻值均匀性为0.35%;非线性度为0.57%;热时间常数为1.1μs;在0.5 h的稳定性测试中其变化幅值为0.005Ω,即精度为0.01%。该热敏传感器制作工艺简单,性能优异,可用于温度敏感、气体传感等热敏传感。     

改进的硅各向异性腐蚀GPU并行模拟

硅各向异性腐蚀过程复杂,采用元胞自动机模拟硅各向异性腐蚀非常耗时。为了加速腐蚀模拟过程,研究了基于图形处理器(GPU)进行硅的各向异性腐蚀模拟。针对串行算法直接并行化方法存在加速效率低等问题,提出了一个改进的并行模拟方法。该方法增加了并行部分的负载,减少了内存管理的开销,从而提高了加速性能。实验证明该方法能够获得较理想的加速比。     

基于粗糙集理论的煤磨故障诊断模型

针对水泥煤磨系统的常见故障,将基于粗糙集理论的数据挖掘技术应用于水泥煤磨故障诊断。结合具体的数据,采用粗糙集的方式,建立了故障诊断系统,通过该系统对识别数据进行故障诊断实验,表明该系统能有效地对煤磨堵仓和钢球小故障进行诊断。诊断结果的精度可以满足现场应用的要求。     

基于FPGA的等精度频率计IP Core设计

介绍了等精度频率测量方法的原理及误差分析,利用基于FPGA的SoPC技术在QuartusⅡ5.0环境下用VHDL语言实现了等精度频率计的软核IPCore设计,并在相应的开发平台上作了验证。     

On the machining induced residual stresses in IN718 nickel-based alloy: Experiments and predictions with finite element simulation

Residual stresses after machining processes on nickel-based super alloys is of great interest to industry in controlling surface integrity of the manufactured critical structural components. Therefore, this work is concerned with machining induced residual stresses and predictions with 3-D Finite Element (FE) based simulations for nickel-based alloy IN718. The main methods of measuring residual stresses including diffraction techniques have been reviewed. The prediction of machining induced stresses using 3-D FE simulations and comparison of experimentally measured residual stresses for machining of IN718 have been investigated. The influence of material flow stress and friction parameters employed in FE simulations on the machining induced stress predictions have been also explored. The results indicate that the stress predictions have significant variations with respect to the FE simulation model and these variations can be captured and the resultant surface integrity can be better represented in an interval. Therefore, predicted residual stresses at each depth location are given in an interval with an average and standard deviation.     

ICP工艺参数对刻蚀Pyrex玻璃影响的实验研究

影响ICP刻蚀的工艺参数包括反应室压力,偏置射频功率,氩气流量比率。通过正交试验的方法,以CHF3和Ar的混合物作为反应气体,利用电感耦合等离子体技术刻蚀Pyrex玻璃。并采用回归分析方法建立了二次回归方程模型描述腐蚀速率和三个因素之间的关系。实验结果表明,氩气的流量比率（总气体流量（CHF3+Ar）是恒定的）对刻蚀速率的影响最大,影响程度的主次顺序为氩气的流量比率,反应室压力,偏置射频功率。腐蚀速率和三个因素之间的数学表达式为：腐蚀速率=532.6800+2.0556×Ar+0.0127×（偏置射频功率）-0.9641×压力-0.0655×Ar2-0.0067×Ar×（偏置射频功率）+0.0217×（偏置射频功率）×压力-0.0504×（压力）2,实验结果证明数学拟合结果良好。     

基于VPRS的信息系统风险分析

提出了基于可变精度粗糙集（VPRS）的风险分析方法。利用VPRS模型中的β约简有效地克服了传统粗糙集处理噪声数据的不足;同时提出了通过定性和定量相结合的方法过滤风险规则,不但约简了风险规则的数量,而且提高了风险规则的有效性。最后,运用VPRS模型对文献[4]中的风险评估数据进行分析,有效地挖掘出了隐含在其中的风险规则。     

Shape optimization of stiffeners in stiffened composite plates with thermal residual stresses

The finite element analysis method is used to examine the influence of manufacturing-induced thermal residual stresses on the optimal shape of stiffeners in stiffened, symmetrically laminated plates. Three stiffener arrangements are studied via an optimization process in which the objective is to maximize the first natural frequency of the stiffened plate. The optimization problem is solved using the method of moving asymptotes (MMA). The numerical simulations indicate that thermal residual stresses can either cause a dispersion of stiffeners along the perimeter or a concentration around the centre. Further, the optimum fundamental frequency tends to increase with increasing temperature difference.     

Laser-induced etching parameters impact on optical properties of the silicon nanostructures

Porous silicon (PS) was fabricated by laser-induced etching (LIE) process. The objective of this study is to investigate the selected LIE parameters to control size and shape of nanostructures,which are considered important factors in semiconductor device applications. Photoluminescence output intensity becomes stronger due to the increase in the number of emitted photons on the porous surface. There is a dramatic increase in photoluminescence intensity due to the increase of porosity as a function of laser...     

Influence of tool path strategy on the cycle time of high-speed milling

This work at first look discusses the influence of the tool path strategy on the cycle time of high-speed milling operations. Experiments and predictions were focused on pocketing operations with a zig-zag tool path, quantifying the significant discrepancy between the programmed feed rate and the actual average feed rate. A mechanistic approach for cycle time evaluation is proposed. The mechanistic model construction is based on the experimental measurement of the machine tool acceleration and specific geometric assumptions regarding tool motion. For high feed rates, the proposed approach is capable of capturing the influence of the zig-zag tool path orientation on the machining cycle time.     

The effect of isopropyl alcohol concentration on the etching process of Si-substrates in KOH solutions

In this paper the process of silicon anisotropic etching in KOH solutions containing isopropyl alcohol in a wide concentration range is extensively studied. Though the alcohol does not take part in the etching process itself, it strongly affects the etching results. Both etch rates and the roughness of etched surfaces depend on the alcohol concentration in the etching solution, which is connected with the adsorption phenomena on the etched surface. The surface coverage with alcohol depends on the level of saturation of the etching solution and crystallographic orientation of an etched surface. It was observed that the best morphology of (1 1 0) surface was achieved just below saturation level with IPA whereas the (1 0 0) surfaces were improving above the saturation. A model, which explains these phenomena, was proposed. Based on this model, a simple way of selection of the composition of KOH solutions with alcohol additives, assuring optimization of etching results was suggested. The method is restricted to surface tension measurements and allows one to avoid elaborated etching experiments.     

A new approach for predicting and collaborative evaluating the cutting force in face milling based on gene expression programming

Cutting force is one of the fundamental elements that can provide valuable insight in the investigation of cutter breakage, tool wear, machine tool chatter, and surface finish in face milling. Analyzing the relationship between process factors and cutting force is helpful to set the process parameters of the future cutting operation and further improve production quality and efficiency. Since cutting force is impacted by the inherent uncertainties in the machining process, how to predict the cutting force presents a significant challenge. In the meantime, face milling is a complex process involving multiple experts with different domain knowledge, collaborative evaluation of the cutting force model should be conducted to effectively evaluate the constructed predictive model. Gene Expression Programming (GEP) combines the advantages of the Genetic Algorithm (GA) and Genetic Programming (GP), and has been successfully applied in function mining and formula finding. In this paper, a new approach to predict the face milling cutting force based on GEP is proposed. At the basis of defining a GEP environment for the cutting force prediction, an explicit predictive model has been constructed. To verify the effectiveness of the proposed approach, a case study has been conducted. The comparisons between the proposed approach and some previous works show that the constructed model fits very well with the experimental data and can predict the cutting force with a high accuracy. Moreover, in order to better apply the constructed predictive models in actual face milling process, a collaborative model evaluation method is proposed to provide a distributed environment for geographical distributed experts to evaluate the constructed predictive model collaboratively, and four kinds of collaboration mode are discussed.     

Choosing the geometry of a halogenide antireflection grating profile based on etching technique capabilities

This work studies the propagation of middle IR laser radiation through an antireflection relief fabricated on the optical surface (made of silver halohenide). A new technology of microrelief fabrication that allows its antireflection properties to be enhanced is proposed.     

基于VPRS的决策树算法中处理噪音数据的新方法

噪音数据是影响决策树训练效率和结果集质量的重要因素。目前的树剪枝方法不能消除噪音数据对选择决策树测试节点属性的影响。为改变这种状况,基于变精度Rough集(VPRS)模型,提出了一个在决策树算法中处理噪音数据的新方法---预剪枝法,该方法在进行选择属性的计算之前基于变精度正区域求取属性修正的分类模式,来消除噪音数据的对选择属性以及生成叶节点的影响。利用该方法对基本ID3决策树算法进行了改进。分析和实验表明,与先剪枝方法相比,该方法能进一步减小决策树的规模和训练时间。     

Numerical simulation on the effect of welding parameters on welding residual stresses in T92/S30432 dissimilar welded pipe

Dissimilar welded joints are commonly used in fossil power plants to connect martensitic steel components and austenitic stainless steel piping systems. The integrity for such welded structures is depended on residual stresses induced by manufacturing process. In this paper, the characteristics of residual stresses on the dissimilar welded pipe between T92 steel and S30432 steel were investigated using finite element method. Moreover, the effects of heat input, groove shape and layer number on the residual stress distribution were studied to find the approach to reduce the residual stress. The numerical results revealed that the hoop and axial stress in heat affected zone (HAZ) of T92 steel side of the dissimilar welded joint had sharp gradients. By decreasing the groove angle, the peak values of the hoop and axial stress on T92 steel side were reduced greatly while the peak values in welded metal and HAZ of S30432 steel side differed little. Furthermore, more layer number and less heat input decreased the peak value of the tensile residual stress on welded metal and S30432 steel side, but had little effect on the residual stress in T92 steel side.     

The effect of the crystallization of indium tin oxide on indium tin oxide wet etching based on gate line with the structure of copper/indium tin oxide

In thin film transistor-liquid crystal display (TFT-LCD), the copper/indium tin oxide (Cu/ITO) layer was often used to be gate line. In this event, the patterning of ITO is necessary and important. However, the high temperature generated during Cu deposition will cause ITO to crystallize, which is not conducive to ITO etching. In this paper, the ITO films prepared by radio frequency (RF) magnetron sputtering were annealed according to the monitoring results of production line to simulate and study the effect of crystallization on the etching properties of ITO film. When the annealing temperature was less than 200°C, no large size grains were detected in ITO films, and the ITO films could be easily etched by etchant. However, the ITO films transformed from amorphous structure to polycrystalline structure after being annealed more than 200°C. After wet etching experiments, the polycrystalline ITO films could be hardly removed by etchant. The X-ray photoelectron spectroscopy (XPS) results showed that high temperature annealing induced a large amount of Sn⁴⁺ on ITO films surface. The Sn⁴⁺ was difficult to be dissolved by acid under normal conditions, which might be the most important factors that led to the greatly decreased etching rate for polycrystalline ITO films.