微米和中间尺度机械制造

微米和中间尺度机械制造的概念源于对广泛材料范围内的精密三维微米和中间尺度零件日益增长的需求。微米和中间尺度零件是指尺寸在0.01～10mm范围的微小零件,因而处于基于微电子的MEMS技术与传统的机械加工技术之间的领域。然而,目前的设备性能和尺寸计量方法生产单个微米和中间尺度零件的能力已经显示出局限性。因此,许多研究者正在探索有关新的或传统的机械制造技术在该尺度的应用问题。基于美国国家科学基金会主办的微米和中间尺度机械制造专题讨论会,介绍了日渐显现的微米和中间尺度机械制造技术的背景和现状,讨论了其应用的科学、技术和商业化挑战,以及其有效开展和实现的主要使能技术,给出了需要广泛研究与发展的几个主要方面问题。最后,提出了开展和证明微米和中间尺度机械制造可行性研究比较有希望的方法和策略。以此希望能对我国微米和中间尺度机械制造技术领域的研究有所启迪。     

Wind over complex terrain – Microscale modelling with two types of mesoscale winds at Nygårdsfjell

Nygårdsfjell, a complex terrain near Norwegian-Swedish border, is characterized by its significant wind resources. The feasibility of using mesoscale winds as input to microscale model is studied in this work. The main objective is to take into account the actual terrain effects on wind flow over complex terrain. First set of mesoscale winds are modelled with Weather Research and Forecasting (WRF) numerical tool whereas second set of mesoscale winds are taken from the Modern-Era Retrospective Analysis for Research and Applications (MERRA) data system. WindSim, a computational fluid dynamics based numerical solver is used as microscale modelling tool. The results suggest that the performance of microscale model is largely dependent upon the quality of mesoscale winds as input. The proposed coupled models achieve improvements in wind speed modelling, especially during cold weather. WRF-WindSim coupling showed better results than MERRA-WindSim coupling in all three test cases, as root mean square error (RMSE) decreased by 70.9% for the February case, 61.5% for October and 14.4% for June case respectively. Raw mesoscale winds from the WRF model were also more correct than the mesoscale winds from MERRA data set when extracted directly at the wind turbine by decreasing the RMSE by 62.6% for the February case, 62.7% for October and 23.7% for June case respectively. The difference of RMSE values between the mesoscale winds directly at wind turbine versus the coupled meso-microscale model outputs are not conclusive enough to indicate any specific trend.     

Z-fiber influence on high speed penetration of 3D orthogonal woven fiber composites

In the current work we present a computational investigation of high speed penetration response of 3D orthogonal woven fiber composites (3D OWC) utilizing sub-unit cell, meso-level partitioned damage mechanics with the specific aim of understanding the role of Z-fibers in the mechanical response. In our model, two primary sources of nonlinearities have been addressed – one resulting from the strain rate dependence and large deformation of the composite constituents and the other from evolving failure. We reduce a number of arbitrary parameters typically present in high speed models by taking advantage of specific geometrical properties of 3D OWC which prevent extensive delamination. This property allows us to partition the structure into resin impregnated fibers assumed to be wholly responsible for the progressive damage behavior and bulk resin which is identified as the source of visco-plasticity and strain rate dependence. The fibers are modeled as anisotropic linear elastic with strain rate dependent progressive damage evolution. The resin is modeled using an advanced high strain rate large deformation Mulliken–Boyce polymer model (Mulliken and Boyce 2006) together with a terminal thermo-mechanical failure criterion. The projectile is assumed to be cylindrical, isothermal, rigid and impacting at right angles to the plate. The shape of the damaged area and the extent of penetrative damage compares favorably with experiments. We find that Z-fibers aid in improving penetration and impact resistance by both energy absorption and structural engagement. However, we also find that they are susceptible to localized de-bonding especially around the winding crowns. In addition, we found crucial differences in mechanical response in wave propagation brought about by the interplay of fiber architecture and damage with respect to simplified membrane models.Finally, the Z-fibers were found to influence the shape and nature of the damaged area in the fibers compared to layered composites where the matrix damage is spread more evenly while the fiber damage is restricted towards the fiber axes directions.     

Meso-scale numerical investigation on cracking of cover concrete induced by corrosion of reinforcing steel

Concrete cover cracking induced by corrosion of steel reinforcement is a major influencing factor for durability and serviceability of reinforced concrete structures. Here in this study, the influence of concrete meso-structure on the failure pattern of concrete cover is accounted for. The concrete is assumed to be a three-phase composite composed of aggregate, mortar matrix and the interfacial transition zone (ITZ). And a concrete random aggregate structure is established for the study on the mechanical behavior of radial corrosion expansion. In the present simulations, the plasticity damaged model is used to describe the mechanical behavior of the mortar matrix and the ITZ, and it is assumed that the corrosion of steel reinforcement is uniform. The cracking of concrete cover due to steel reinforcement corrosion is numerically simulated. The simulation results have a good agreement with the available test data and they are between the two analytical results. The failure patterns obtained from the macro-scale homogeneous model and the meso-scale heterogeneous model are compared. Furthermore, the influences of ratio of cover thickness and reinforcement diameter (i.e. c/d), the location of the steel reinforcement (i.e., placed at the middle and corner zones) and the concrete tensile strength on the steel corrosion rate when the concrete cover cracks are investigated. Finally, some useful conclusions are drawn.     

Optimizing thermal performances and NOx emission in a premixed ammonia-hydrogen blended meso-scale combustor for thermophotovoltaic applications

As a carbon-free energy carrier, ammonia has attracted significant interest in the combustion field as a potential substitute for fossil fuels. However, the focus has been given to the application at meso-scale conditions, particularly with regard to thermal performance and NO_x emissions. Therefore, the present study numerically investigates a 3-dimensional time-domain premixed ammonia/oxygen meso-scale combustor to optimize its' thermal performance and NO_x emission for power generation applications. The numerical model is firstly validated by using experimental data available in the literature. Then, the effects of 1) the inlet pressure (P_in), 2) the equivalence ratio, and 3) the hydrogen blended ratio on the temperature uniformity, the combustor outer wall mean temperature (OWMT), NO emission, and exergy efficiency are examined. The results indicate that increasing P_in intensifies the mixing process of the mixture gases, thus reducing the residence time for the high-temperature flame in the combustion chamber. The optimized OWMT and NO emissions are up to 26% and 40.3% respectively, with only 9% compensation of the standard deviation achieved, when the inlet velocity is set to 0.5 m/s and P_in is 3.0 bar. Furthermore, varying the equivalence ratio in the range of 0.95–1.1 has a minor influence on improving thermal performances, but a significant impact on mitigating the NO_x emission performance. Additionally, blending less than 15% hydrogen has a significant reduction in the maximum NO_x emission (up to 53%); however, the influence on the OWMT can be neglected. Further exergy analysis reveals that elevating P_in results in a decrease in the exergy efficiency due to the increased inlet exergy. In general, this work provides a preliminary method for improving the thermal performance and NO_x emission of an ammonia/hydrogen-oxygen-fueled meso-scale combustor for power generation purpose.     

A numerical study on the combustion limits of mesoscale methane jet flames with hydrogen addition

A meso-scale jet flame model was established for the flame ports of domestic gas stoves. The influences of hydrogen addition ratio (β = 0%–25%) on the combustion limits were explored. The results show that with the increase of hydrogen addition ratio, the blow-off limit increases obviously, while the extinction limit decreases slightly, namely, the combustible range expands significantly. Quantitative analysis was carried out in terms of chemical effect and thermal effect. It was found that hydrogen addition will reduce O₂ fraction in the pre-mixture for a constant equivalence ratio. Under near-extinction limit condition, since the flame is located at the nozzle exit, the external O₂ cannot be entrained into or diffuse into the upstream of the flame, which leads to the decrease of reaction rate. However, for the near-blow-off cases, the external O₂ can be entrained and diffuse into the flame, which compensates the difference of O₂ content in the pre-mixture. Therefore, the combustion reaction is enhanced by hydrogen addition because more H radicals can be produced. In addition, as the flame is located closer to the tube with the increase of hydrogen addition ratio, heat transfer between flame and tube wall is augmented and the preheating of fresh mixture is strengthened by the inner tube wall. This heat recirculation effect becomes especially notable in low velocity cases. In conclusion, the extension of extinction limit by hydrogen addition is attributed to the thermal effect, while the increase of blow-off limit is mainly due to the intensification of chemical effect.     

精密微小型制造理论、技术及其应用

以中间尺度的微小型构件为目标,以传统制造技术为基础,提出精密微小型制造技术概念和主要内涵.提出并实现了高转速数控精密微小型车铣复合加工技术,研究在微小型车铣复合加工中心上进行微小型零件完整性加工的工艺技术及特性.针对超薄、异型微小型金属构件的制造,提出大功率高频群脉冲电化学微小型制造方法和工艺.提出并初步研究基于制造特征仿真的相关理论和建模方法,介绍应用实例.提出基于工艺匹配原则的计算机显微检测技术,介绍关键技术研究进展.     

基于颗粒流离散元模型的弹丸侵彻细观混凝土数值模拟方法研究

利用颗粒离散单元法,研究弹丸侵彻细观混凝土模型中弹丸受到介质的阻应力与侵彻速度的关系。采用蒙特卡罗法随机生成并投放混凝土骨料且骨料的粒径分布满足级配曲线。通过对混凝土颗粒离散元细观力学模型进行单轴压缩实验、巴西劈裂实验和双轴压缩实验的参数反演,确定细观模型参数,能使细观混凝土模型具有和一般混凝土等效的力学性能。分析了骨料、过渡层和砂浆三相材料各细观参数对混凝土单轴压缩应力应变关系影响以及锥形弹和平头弹弹丸直径对侵彻阻应力的影响。将颗粒离散元细观力学模型方法计算的弹丸阻应力与空腔膨胀理论计算模型相比较,表明计算离散元方法具有良好的精度和实用性。     

Meso-scale numerical simulation and experimental verification of single grain grinding TiC–Fe composites

Grinding process of particle reinforced metal matrix composites (PRMMCs) is extremely challenging due to the addition of hard particles. To reveal the material removal mechanism, a meso-scale numerical model for single grain grinding of TiC–Fe composites was established, considering the random particle distribution model and cohesive zone model. The simulated grinding forces and machined surface topography based on the proposed model show a similar trend and were consistent with the experimental results. The transition stage of ductile-brittle removal of TiC–Fe composites was explored. Results indicated that the grinding forces increase abruptly due to the obstruction of high-strength TiC particles and fluctuate periodically in the Fe matrix. The grinding forces decrease with the elevated grinding speed. Additionally, the material removal processes at different stages were studied and the removal modes mainly include: matrix plastic removal, particles wear, particles debonding, particles fracture, particles pull out. This paper provides significant guidance for the digitization and information construction of PRMMCs machining in enterprises and increases the economic benefits for the manufacturing industry.     

介观尺度心轴的表面粗糙度预测模型建立及参数优化

为控制惯性约束聚变靶制备中介观尺度心轴的表面粗糙度,提出一种应用旋转设计技术安排试验的方法,通过非线性回归分析,建立基于进给量、背吃刀量、主轴转速和刀尖角四个主要切削参数的介观尺度心轴的表面粗糙度二次预测模型。分析结果表明,该模型的拟合值能较好地反映心轴车削表面粗糙度,并且具有比理论表面粗糙度计算值更高的精度。在主要切削参数中,进给量和刀尖角比背吃刀量和主轴转速对心轴表面粗糙度的影响更显著。利用优化得到的最佳表面粗糙度为目标切削条件,选用直线切削刃超细晶粒硬质合金刀具,在φ0.6 mm的心轴上得到Ra16.53 nm的表面粗糙度。