Abrasive waterjet micro-machining of channels in metals: Comparison between machining in air and submerged in water

Abrasive water jet technology can be used for micro-milling using recently developed miniaturized nozzles. Abrasive water jet (AWJ) machining is often used with both the nozzle tip and workpiece submerged in water to reduce noise and contain debris. This paper compares the performance of submerged and unsubmerged abrasive water jet micro-milling of channels in 316L stainless steel and 6061-T6 aluminum at various nozzle angles and standoff distances. The effect of submergence on the diameter and effective footprint of AWJ erosion footprints was measured and compared. It was found that the centerline erosion rate decreased with channel depth due to the spreading of the jet as the effective standoff distance increased, and because of the growing effect of stagnation as the channel became deeper. The erosive jet spread over a larger effective footprint in air than in water, since particles on the jet periphery were slowed much more quickly in water due to increased drag. As a result, the width of a channel machined in air was wider than that in water. Moreover, it was observed that the instantaneous erosion rate decreased with channel depth, and that this decrease was a function only of the channel cross-sectional geometry, being independent of the type of metal, the jet angle, the standoff distance, and regardless of whether the jet was submerged or in air, in either the forward or backward directions. It is shown that submerged AWJM results in narrower features than those produced while machining in air, without a decrease in centerline etch rate.     

Electromagnetism-like algorithms for optimized tool path planning in 5-axis flank machining

Optimization of tool path planning using metaheuristic algorithms such as ant colony systems (ACS) and particle swarm optimization (PSO) provides a feasible approach to reduce geometrical machining errors in 5-axis flank machining of ruled surfaces. The optimal solutions of these algorithms exhibit an unsatisfactory quality in a high-dimensional search space. In this study, various algorithms derived from the electromagnetism-like mechanism (EM) were applied. The test results of representative surfaces showed that all EM-based methods yield more effective optimal solutions than does PSO, despite a longer search time. A new EM-MSS (electromagnetism-like mechanism with move solution screening) algorithm produces the most favorable results by ensuring the continuous improvement of new searches. Incorporating an SPSA (simultaneous perturbation stochastic approximation) technique further improves the search results with effective initial solutions. This work enhances the practical values of tool path planning by providing a satisfactory machining quality.     

A Linear Cross-Coupled Control System for High-Speed Machining

We present a linear cross-coupled controller to improve highspeed contouring accuracy independently of tracking accuracy in a biaxial machine tool feed drive servomechanism. Unlike conventional cross-coupled controllers, the cross-coupled controller presented here is a linear system, so it is very easy to perform the stability and steady-state error analysis, and to optimise the controller parameters. The proposed controller is evaluated experimentally on a CNC LOM machine and compared to an uncoupled controller and a conventional cross-coupled controller. Controller performance is evaluated for a circular contour at a feedrate of 30 m min _1 . The experimental results show that the proposed controller can greatly reduce the contour error at large feedrates. The linear cross-coupled controller is simple to implement and is practical.     

铣制三元流叶轮时产生误差的原因分析及解决方法

对在五坐标数控加工中心上铣制三元流叶轮时出现的叶轮附面尺寸误差问题，进行了详细分析，并提出了问题的解决方法，有效地避免了加工中产生的超差。     

钻杆接头螺纹退刀尺寸对接头寿命的影响

钻杆接头螺纹退刀尺寸是指外螺纹接头的台肩面到螺纹消失前第一个完整螺纹之间的距离。GB9253．1－88规定退刀尺寸应小于或等于12．7mm内螺纹，钻杆接头内螺纹的锤孔尺寸为16±2mm，以保证内、外螺纹啮合良好。经检测发现，从日本NKK公司进口的所有φ127mm钻杆接头外螺纹退刀尺寸都大于12．7mm，镗孔尺寸为16～18mm。而APISpec7K规定钻杆接头内螺纹最小镗孔尺寸为15．9mm。鉴于此，建议对我国的有关标准作相应修改，与API标准保持一致。     

数控加工的基本坐标系和对刀问题

数控加工中的对刀问题影响机械加工的各个方面。这里从介绍数控机床的基本坐标系出发，重点阐述了对刀的基本原理和方法以及常见数控机床对刀问题的处理。     

Ultrasonic measurement of the inter-electrode gap in electrochemical machining

During the process of electrochemical machining the dependency of the inter-electrode gap with time and process parameters can be used to determine process characteristics and to define the shape of the workpiece surface relative to the tool surface. Defining process variables to map out the required gap-time function requires the use of time-consuming iterative trials. In-line monitoring of the gap would enable process control and tool to workpiece transfer characteristics to be achieved (for ideal conditions) without the requirement to generate such parameter maps. This work explores the use of ultrasound applied as a passive, non-intrusive, in-line gap measurement system for ECM. The accuracy of this technique was confirmed through correspondence between the generated gap-time and current time data and theoretical models applicable to ideal conditions. Gap measurements are also used to demonstrate and quantify the degree of departure from ideal behaviour for an In718/chloride system as the electrolyte flow rate is reduced from 16 to 4 l min⁻¹. The monitoring of the gap size has also been shown to be effective when determining shape convergence under ideal conditions, for the example case of a 2D sinusoidal profile.     

回归分析法简化钻爆设计

以某工程钻爆参数为例,阐述了在地下工程掘进施工中,应用回归分析法建立钻爆参数的相关模型,并利用此模型帮助建立某断面钻爆方案.     

展望21世纪的制造业及相关技术

综述了制造业未来的发展前景，重点分析了与制造业相关的制造系统、机械加工技术、生产组织形式、人员素质的发展趋势。     

G104-5P42分支水平井钻井液工艺技术

G104-5P42井是在高尚堡G104-5区块构造较高部位部署的一口重点开发井，也是冀东油田第一口鱼骨型水平分支井，钻探目的是开发高浅北区Ng12油层，挖掘高浅北区井间剩余油潜力。该井主井眼斜深为2388m，水平位移为736．42m，水平段长243m，第一分支斜深为2342m，水平段长120．25m，水平位移为682．14m，第二分支斜深为2421m，水平段长117m，水平位移为761．73m。三开选用无固相甲酸盐聚合醇钻井液，在钻进油气层前加入GN-YBJ-I保护剂。应用结果表明，无固相甲酸盐聚合醇钻井液具有好的防塌能力和润滑减阻效果，性能稳定、黏度、切力较低，有利于减少环空压力损耗；在油气层段密度控制在1．08g／cm^3以内，为近年来同区块密度使用最低井，减小了有害固相及滤液对储层的伤害密度，经测试该井获高产油流；该井全井平均机械钻速为15．09m／h，钻井周期比原设计提前15d。该体系的配制及维护成本较高，适宜在目的层井段使用，但可回收再利用。