闸下海漫柔性加糙体消能防冲机理试验

通过室内水工模型试验,量测了采用废旧轮胎加糙后三维流速的分布。结果表明:加糙后近底流速明显降低,但整个断面的平均流速近似相等;随着轮胎排数的增加,水流紊流强度平均值增大,附加切应力增大,流体质点间相互混掺的情况加剧,从而使消能效率得以提高。     

一种基于光散射原理在线测量晶圆表面质量的方法

在半导体工业中,晶圆表面质量的检测占据着重要的地位。选择粗糙度参数轮廓算术平均偏差R。作为衡量表面质量的参数,根据晶圆的一般粗糙度范围（Rα为0.01—0.8μm）,构建了一种基于光散射原理的视觉系统测量装置。通过分析光散射强度分布图像,提取出一些参数来表征Rα,达到检测晶圆表面质量的目的。给出了初步的实验结果,说明了此方案是可行的。     

Effect of interlayer on structure and performance of anode-supported SOFC single cells

To lower the operating temperatures in solid oxide fuel cell (SOFC) operations, anode-supported SOFC single cells with a single dip-coated interlayer were fabricated and the effect of the interlayer on the electrolyte structure and the electrical performance was investigated. For the preparation of SOFC single cells, yttria-stabilized zirconia (YSZ) electrolyte, NiO-YSZ anode, and 50% YSZ-50% strontium-doped lanthanum manganite (LSM) cathode were used. In order to characterize the cells, scanning electron microscopy (SEM) and atomic force microscopy (AFM) were utilized and the gas (air) permeability measurements were conducted for gas tightness estimation. When the interlayer was inserted onto NiO-YSZ anode, the surface roughness of anode was diminished by about 40% and dense crack-free electrolytes were obtained. The electrical performance was enhanced remarkably and the maximum power density was 0.57W/cm(2) at 800 degrees C and 0.44W/cm(2) at 700 degrees C. On the other hand, the effect of interlayer on the gas tightness was negligible. The characterization study revealed that the enhancement in the electrical performance was mainly attributed to the increase of ion transmission area of anode/electrolyte interface and the increase of ionic conductivity of dense crack-free electrolyte layer.     

Study of tool trajectory in blisk channel ECM with spiral feeding

Electrochemical machining (ECM) plays an important role in blisk manufacturing. There are two steps in blisk ECM: machining of channels and precise shaping of blade profiles. In channel machining, channels are machined in the workpiece with allowance left to the following process. Therefore, the main aim of channel machining with ECM is to improve the allowance distribution. With this aim, a new ECM method for blisk channels, spiral feeding ECM, is developed in which the cathode feeds from blade tip to hub along with rotation motion around its axis. Through this combined motion, twisted channels are produced in the workpiece. The relationship between feed position and rotation angle is presented in the form of a mathematical model. Experiments with a feed rate of 1 mm/min confirm that spiral feeding ECM is feasible and efficient. Compared with radial ECM, the allowance differences in blank back and blank basin decrease by 32.7% and 33.6%, respectively. The surface roughnesses Ra in blank back, blank basin, and hub are 0.358, 0.308, and 0.102 µm, respectively. Thus, the allowance distribution is improved to be more uniform considerably and the surface quality is relatively high.     

Formulation and performance evaluation of a novel coconut oil–based metalworking fluid

Metalworking fluid (MWF) supplies a film of lubricant to abate friction, acts as a cooling media to rebate induced heat, and prevents metal pick-ups by flushing away the chips. Hence a liquid used as a cutting fluid reduces wear on the tool, reduces the energy consumption, and produces a better surface quality on the work piece. This paper describes the formulation of a novel water-soluble MWF and its performance evaluation during straight turning and end milling experiments carried out with AISI 304 stainless steel, mild steel, and cast iron as work piece materials. The MWF was prepared by mixing water with white coconut oil as the base oil and food-grade additives as surfactants. Viscosity, pH value, and biodegradability were measured and compared with a commercially available non-vegetable oil–based MWF. The surface roughness and tool surface temperature were measured throughout the machining experiments, and better performances were observed with the coconut oil–based MWF. Tool tip geometry and flank wear for straight turning machining operation were identified by observing scanning electron microscope (SEM) images.     

Investigation on the cutting quality characteristics of abrasive water jet machining of AA6061-B4C-hBN hybrid metal matrix composites

Aluminum metal matrix composites (AMMCs) explicitly show better physical and mechanical properties as compared to aluminum alloys and results in a more preferred material for a wide range of applications. The addition of reinforcements embargo AMMCs employment to industry requirements by increasing order of machining complexity. However, it can be machined with a high order of surface integrity by nonconventional approaches like abrasive water jet machining. Hybrid aluminum alloy composites were reinforced by B₄C (5–15?vol%) and solid lubricant hBN (15?vol%) particles and fabricated using a liquid metallurgy route. This research article deals with the experimental investigation on the effect of process parameters such as mesh size, abrasive flow rate, water pressure and work traverse speed of abrasive water jet machining on hybrid AA6061-B₄C-hBN composites. Water jet pressure and traverse speed have been proved to be the most significant parameters which influenced the responses like kerf taper angle and surface roughness. Increase in reinforcement particles affects both the kerf taper angle and surface roughness. SEM images of the machined surface show that cutting wear mechanism was largely operating in material removal.     

Investigation of TiAlN coated roller burnishing on Al-(B4C)p MMC workpiece material

Burnishing avoids the need for super finishing operations after the conventional turning process, to enhance the surface quality. This paper deals with the surface modifications of Al(B₄C)_p Metal Matrix Composites (MMC) workpiece material after burnishing with a TiAlN coated WC roller. The burnishing speed, lubrication type, burnishing passes, and coating were the input parameters. Surface hardness and roughness after the burnishing were studied. It was found that the coating on the WC roller had enhanced the hardness in the workpiece after burnishing in the case of Al-5?wt.% (B₄C)_p, under all conditions. The effect of the coating on the work piece surface hardness was not significant with Al-10?wt.% (B₄C)_p. While burnishing Al-5?wt.% (B₄C)_p, the minimum surface roughness combined with maximum surface hardness was obtained, during the third pass under dry condition using uncoated rollers. The number of passes to achieve the desired surface conditions reduced, on using coated rollers with kerosene as the lubricant.     

Optimization of interior roller burnishing process for improving surface quality

Improving the surface characteristics of roller burnishing processes is one of effective approaches to decrease the machining costs and time. This paper systematically investigates the nonlinear relationships between machining parameters and surface characteristics, including surface roughness (R_a), surface hardness (H), and hardness depth (HD) of the interior roller burnishing using response surface method (RSM) model. Three process parameters considered include spindle speed S, feed rate F, and burnishing depth D. A set of physical experiments was carried out with AISI 1045 steel on a computer numerical control (CNC) milling machine using the roller burnishing tool. The target of the current complex optimization is to enhance the surface hardness and hardness depth, while the surface roughness is considered as the constraint. Finally, an evolutionary algorithm entitled archive-based micro genetic algorithm (AMGA) was used to generate a set of feasible optimal solutions and determine the best machining conditions. The results show that an appropriate trade-off solution can be drawn with regard to the low surface roughness and high the surface hardness as well as hardness depth. Furthermore, the integration of RSM model and AMGA can be considered as a powerful approach for modeling and optimizing interior roller burnishing processes.     

Experimental investigation on carbon steel micro-rod machining by LS-WEDT

This article proposed for the first time the method of the low-speed wire electrical discharge turning (LS-WEDT) combined with the multiple cutting strategy to fabricate carbon steel micro-rods. First, the rotating apparatus submerged in working fluid is designed and manufactured to enable the low-speed wire electrical discharge machine to generate cylindrical geometries. Besides, material removal rate, surface roughness, and machining precision of the micro-rod manufactured by the LS-WEDT are, respectively, investigated. Moreover, the surface microstructure and surface chemical reaction of micro-rods are characterized using scanning electron microscopy and energy-dispersive spectroscopy analysis. Experimental results display that the micro-rod of 70?µm diameter and 1000?µm length can be successfully fabricated. More importantly, the mean absolute diameter deviation of the micro-rod fabricated by LS-WEDT is 0.65?µm and the surface roughness is 0.53?µm, which identified the high machining precision and good surface quality of the micro-rod.     

A study on the effect of polishing fluid volume in ball end magnetorheological finishing process

Ball end magnetorheological finishing is a unique process that utilizes a magnetically controlled ball of polishing fluid at the tip of the rotating tool to finish workpiece of different materials and shapes. The aim of this research is to study the effect of polishing fluid volume on finishing spot size and the surface finish associated with it. A magnetostatic simulation is done to find the variation of flux density in the working gap and on the workpiece surface. The maximum limit of the polishing fluid volume is selected on the basis of area of threshold magnetic flux density (minimum value required for finishing) region on the workpiece surface. The surface characteristics and the diameter of the finished spot are analyzed by varying the fluid volume. The surface obtained with high fluid volume is poorly finished and has scratch marks as the excess fluid flows out from the working gap and forms a thick ring at the periphery of the tool tip. Contrary to this, if the fluid volume is too less, then it merely rotates over the workpiece surface without causing any finishing action. An optimum range of fluid volume produces a good quality surface finish with constant finished spot size.