Creation of Ultra-precision Microstructures with High Aspect Ratios

In recent years, ultra-precision micromachining technology has been used in a variety of fields such as optical instruments, electronic devices, medical equipments, etc. At present, it is essential to meet the requirement of producing various shapes, one of which is a structure with a high aspect ratio. Such structures are applied, for example, to a shaft of micro robot, a long part of microactuator and micromachine, a microneedle for syringe, etc. However, due to its fragile nature, it is extremely difficult to fabricate the structure with a high aspect ratio since it is easily damaged during cutting. It is intended to produce micro towers with high aspect ratios by applying the ultra-precision milling technology using a single crystal diamond cutting tool. The method enables accurate creation of a variety of microstructures with high aspect ratios. In addition, the study also proposes a new machining method to create microneedle arrays, avoiding the contact of cutting edge with already machined parts again. As a result, it is concluded that the proposed method has the potential of producing a variety of microstructures with high aspect ratios.     

Transformations in machining. Part 1. enhancement of wavelet transformation neural network (WT-NN) combination with a preprocessor

Properly selected transformation methods obtain the most significant characteristics of metal cutting data efficiently and simplify the classification. Wavelet Transformation (WT) and Neural Networks (NN) combination was used to classify the experimental cutting force data of milling operations previously. Preprocessing (PreP) of the approximation coefficients of the WT is proposed just before the classification by using the Adaptive Resonance Theory (ART2) type NNs. Genetic Algorithm (GA) was used to estimate the weights of each coefficient of the PreP. The WT-PreP-NN (ART2) combination worked at lower vigilances by creating only a few meaningful categories without any errors. The WT-NN (ART2) combination could obtain the same error rate only if very high vigilances are used and many categories are allowed.     

An intelligent sensor for detection of milling chatter

In this paper, a new real-time sensor system has been developed to detect chatter in milling operations. In the developed sensor system, a pattern recognition technique based on an unsupervised neural network using the adaptive resonance theory (ART) is adopted for detection of milling chatter. The features on the cutting force spectrum are fed into the sensor system to classify the milling process with or without chatter. The experimental results indicate that the proposed sensor system can accurately detect milling chatter regardless of the variation in cutting conditions.     

在高速气流粉碎作用下PVC的力化学降解及形态变化的研究

通过ＧＰＴ、ＦＴ－ＩＲ、ＳＥＭ和力学性能测试，研究了在高速气流作用下聚氯乙烯（ＰＶＣ）的力化学降解反应、颗粒形态和微晶结构变化及其对ＰＶＣ物理、力学性能的影响。实验结果表明，经过高速气流处理ＰＶＣ，分子量将有所降低，晶体结构发生变化，颗粒尺寸和表观密度降低，比表面积增大，加工性能和力学性能得到明显改善。     

高能球磨AL─Cu合金固态合成反应研究

采用扫描电镜、能谱分析、Ｘ射线衍射和示差扫描量热分析研究了具有较大负混合焓的Ａｌ＿ｘＣｕ＿（１－ｘ）对称扩散系合金的高能球磨固态合成反应。高能球磨时组元晶粒细化达纳米级，造成纳米晶界亚互溶，为室温固态合成反应创造了条件，球磨强度对反应进程影响显著，在ｘ＝０．３～０．７范围内仅形成一种金属间化合物。     

数控机床主轴位置自动测量的实现

论述了数控机床主轴的结构以及数控机床主轴位王的测量电路的设计，实现了数控机床主轴位王参数的自动化测量过程。     

铣削刀片用纳米改性金属陶瓷的显微组织和力学性能

研究了铣削刀片用纳米改性金属陶瓷的显微组织与力学性能。SEM观察结果表明,铣削刀片用纳米改性金属陶瓷组织仍由陶瓷相和金属相组成,其中粗大的陶瓷相颗粒为芯/壳结构;Mo元素添加能有效细化金属陶瓷陶瓷基体组织。抗弯测试表明,随金属相含量增加,金属陶瓷的抗弯强度和断裂韧性增加,而硬度则降低;断口分析可知,沿晶断裂为其主要的断裂方式。     

纳米TiN改性金属陶瓷刀片的铣削性能

制备了两种纳米TiN改性金属陶瓷可转位铣刀片ToolA和ToolB。研究了这两种新型面铣刀在切削正火态45#钢时的铣削性能及其失效机理。试验结果表明,两种试验铣刀片在Vc=294m/min,fz=0.16mm/z,ap=0.5mm条件下铣削45#钢时,均未发现“崩刃”现象,并全都以“磨损”的形式失效,刀具寿命较长。此外,在同样切削条件下,ToolA具有良好的抗氧化磨损性能,而ToolB有更高的耐机械冲击能力;高温扩散和氧化磨损成为导致纳米TiN改性铣刀片磨损失效的主要原因。     

两坐标数控立式铣削欠切现象及其防止

在两坐标数控立铣削加工中,欠切是常见的异常加工现象,严重的影响了加工质量及加工效率。文中将欠切现象归纳为工艺系统引起的欠切、数控系统功能引起的欠切、工艺安排及编程引起的欠切三个大类,分析了十五种主要欠切形成的原因,并提出了控制欠切的措施。     

High-speed milling of titanium alloys using binderless CBN tools

The performance of conventional tools is poor when used to machine titanium alloys. In this paper, a new tool material, which is binderless cubic boron nitride (BCBN), is used for high-speed milling of a widely used titanium alloy Ti–6Al–4V. The performance and the wear mechanism of the BCBN tool have been investigated when slot milling the titanium alloy in terms of cutting forces, tool life and wear mechanism. This type of tool manifests longer tool life at high cutting speeds. Observations based on the SEM and EDX suggest that adhesion of workpiece and attrition are the main wear mechanisms of the BCBN tool when used in high-speed milling of Ti–6Al–4V.