电磁层析成像技术在刹车盘缺陷检测中的应用

针对列车刹车盘缺陷检测的实际需求,提出采用电磁层析成像技术(electromagnetic tomography,EMT)对刹车盘进行缺陷检测,检测得到的数据经过图像重建后对缺陷的位置、形状和大小等分布信息进行显示。根据列车刹车盘的结构特点,设计平板型传感器线圈阵列,通过电磁场仿真软件对不同缺陷的刹车盘模型进行仿真,并使用不同算法进行缺陷成像。通过评价指标对比了不同算法的图像重建质量,仿真结果验证了电磁层析成像技术用于列车刹车盘缺陷检测的可行性;搭建了刹车盘缺陷检测的EMT实验系统,对刹车盘缺陷进行数据采集与成像实验。实验结果表明,电磁层析成像技术在高速列车刹车盘缺陷检测中具有很好的应用前景。     

An experimental study of tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts

Inconel 718 is a difficult-to-cut nickel-based superalloy commonly used in aerospace industry. This paper presents an experimental study of the tool wear propagation and cutting force variations in the end milling of Inconel 718 with coated carbide inserts. The experimental results showed that significant flank wear was the predominant failure mode affecting the tool life. The tool flank wear propagation in the up milling operations was more rapid than that in the down milling operations. The cutting force variation along with the tool wear propagation was also analysed. While the thermal effects could be a significant cause for the peak force variation within a single cutting pass, the tool wear propagation was believed to be responsible for the gradual increase of the mean peak force in successive cutting passes.     

切削刀具PVD涂层技术的发展及应用

PVD涂层是利用蒸发、辉光放电等物理过程 ,在基材表面沉积出所需要的涂层的技术 ,通常采用的 PVD技术有蒸发镀膜、离子镀膜和溅射镀膜三大类 ,其中离子镀和溅射镀适合于对切削刀具进行超硬材料涂层。本文着重介绍了溅射镀技术及采用该技术生产的几种重要的涂层 ,结合实例介绍了它们的使用性能 ,并对 PVD涂层切削刀具技术的研究进展 ,工业化生产及应用现状进行了综述。     

铝合金涡轮叶片砂芯芯盒的设计与制作

涡轮叶片铸件的难点是叶片砂芯的制作。采用线切割的方法制作涡轮叶片砂芯芯盒，用该芯盒手工起模制作叶片砂芯。对于产品批量适中的铸件，本制芯方法可行而适用。     

粉末冶金涡轮盘寿命稳健性分析与设计

基于限界不确定性原理和方法，对粉末冶金涡轮盘寿命进行稳健性分析与设计。首先，系统给出了分析方法：结合区间有限元方法，给出了在给定参数限界不确定性时，FGH95材料粉末冶金盘寿命的限界(上下限)。其次，分析了在满足粉末冶金盘设计寿命(以4000周次为例)时，各随机变量所要求的限界(偏差)范围和组合取值范围。此方法克服了经典可靠性理论对随机变量分布要求的严格性，适于工程应用，为盘的质量控制提供明确的指导和依据。     

RANDOM-FUZZY SAFETY ANALYSIS FOR AN AERO ENGINE TURBINE DISK

A numerical simulation method is presented for the random-fuzzy safety analysis of an aero engine disk. Based on the equivalent transformation from a fuzzy variable to a random variable, the equivalent random Probability Density Functions(PDFs) are got from their corresponding Fuzzy Possibility Distributions(FPDs) for the fuzzy variables. In that case the perfect numerical simulation method for the random uncertainty is employed to solve the fuzzy uncertainty. For the complex structure such as the aero engine disk with implicit relationship between the input basic variable and the response variable, the equivalent PDFs of the input basic variables are delivered simultaneously to the response variable by an empirical PDF, which is simulated by Finite Element Method(FEM). Then, in view of the fuzzy application requirement occurring in engineering usually, the reliability definition and calculation are discussed for the aero engine disk with multiple fuzzy failure modes. On the other hand, through the inverse transformation of the fuzzy variable to the random variable, the FPDs of the response variables can be calculated from their empirical PDFs as well.     

不对称拉延零件成形工艺及模具设计

不对称拉延零件的加工，从工艺上考虑，应将其设计成能成对地进行拉延加工的对称结构，经过剖切保证产品最终尺寸要求。本文通过实例说明了确定不对称拉延零件合理工艺方案的重要性，同时介绍了模具结构特点及工作过程。     

Surface finish generated in hard turning of quenched alloy steel parts using conventional and wiper ceramic inserts

Significant progress has already been achieved in green manufacturing including dry and hard, often high-speed, machining technologies. For instance, the demand for higher productivity has resulted in the wider application of ceramic and PCBN tools with special multi-radii (wiper) geometry. This paper reports some important characteristics of the surface roughness produced in the turning of a hardened low-chromium alloy steel using mixed alumina–titanium carbon (TiC) ceramic cutting tools equipped with both conventional and wiper inserts. The characteristic geometrical features of surfaces obtained in both these turning operations have been assessed by means of representative two-dimensional (2D) surface roughness parameters, and some 3D visualizations, which allowed more complete characterization of the surface topography and prediction of its service properties. Results show that keeping equivalent feed rates, i.e. 0.1 mm/rev for conventional and 0.2 mm/rev for wiper tools, the surfaces obtained have similar 3D height roughness parameters, and comparable values of skew and kurtosis. At defined cutting parameters, surfaces produced by wiper tools contain blunt peaks with distinctly smaller slopes resulting in better bearing properties. Only marginal changes of Ra parameter were recorded during 15 min machining trials.     

高速铣削钛合金TC4切削力试验研究及切削参数优化

采用正交试验研究了高速铣削钛合金TC4粗加工阶段时切削参数对切削力的影响规律，并以Y向切削力最小和材料去除率最大为优化目标，利用MATLAB基于Pareto遗传算法优化高速铣削TC4的切削参数，结合Pareto最前沿给出了优化后的切削参数最优解集。     

Simplified and efficient calibration of a mechanistic cutting force model for ball-end milling

Accurate evaluation of the empirical coefficients of a mechanistic cutting force model is critical to the reliability of the predicted cutting forces. This paper presents a simplified and efficient method to determine the cutting force coefficients of a ball-end milling model. The unique feature of this new method is that only a single half-slot cut is to be performed to calibrate the empirical force coefficients that are valid over a wide range of cutting conditions. The instantaneous cutting forces are used with the established helical cutting edge profile on the ball-end mill. The half-slot calibration cut enables successive determination of the lumped discrete values of the varying cutting mechanics parameters along the cutter axis whereas the size effect parameters are determined from the known variation of undeformed chip thickness with cutter rotation. The effectiveness of the present method in determining the cutting force coefficients has been demonstrated experimentally with a series of verification test cuts.