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Table of Content

    10 December 2019, Volume 30 Issue 23
    Experimental Study on Homogeneity Mutual Polishing of Monocrystalline Silicon
    LI Qingzhong;SUN Sulei;LI Qiangqiang
    2019, 30(23):  2773-2777. 
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    The material removal rate and surface roughness were used as evaluation indexes to design comparison experiments, which was used to verify the feasibility of the mutual polishing of hard and brittle materials, and the influence trends and degrees of the polishing pad speeds on the mutual polishing were obtained. The experimental results show that when the polishing pressure is as 48 265 Pa(7 psi), the polishing pad speed is as 70 r/min, the material removal rate of the mutual polishing with self-dispensing polishing slurry is as 672.1 nm/min, and the surface roughness is as 4.9 nm. It is similar to the polishing effectiveness of traditional CMP method, which proves that the method of homogeneity mutual polishing for hard and brittle materials is completely feasible. The polishing slurry may be made without abrasive, which improves the composition of traditional polishing slurry. When the polishing slurry is used for mutual polishing, the material removal rates firstly increase and then decrease with the increasing of the polishing pad speeds. The surface roughnesses of the silicon wafer firstly decrease and then increase as the polishing pad speeds increase.
    Lane-change Control for Intelligent Vehicles Based on Optimal Preview
    QIU Shaolin;QIAN Lijun;LU Jianhui
    2019, 30(23):  2778-2783. 
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    Considering the trajectory-tracking control problems during the processes of lane-change for intelligent vehicles, an optimal preview trajectory-tracking control model was proposed based on the “preview-tracking” control theory and the “vehicle-road” model. According to the linear quadratic regulator(LQR) theory, a trajectory-tracking controller was designed and the optimal steering angle inputs were obtained to realize the lane-change trajectory tracking of the intelligent vehicles. Under the co-simulation environment of MATLAB/Simulink and CarSim, the lane-change decision module, lane-change reference trajectory module and tracking control module for the intelligent vehicles were established, and the simulation analyses of the intelligent vehicles were carried out at the speeds of 30 km/h, 50 km/h and 70 km/h respectively. After the combination of vehicle test results, the accuracy and the stability of the proposed controller were verified.
    Comparable Application of Different Strength Criterions in Crankshaft Fatigue Researches
    SUN Songsong;WAN Maosong;XU Xiaomei;ZHANG Ying
    2019, 30(23):  2784-2789. 
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    The stress states of a crankshaft under bending moment loading were analyzed by using finite element method, and the stress distributions of a crankshaft were calculated by interpolation method. Then,the critical distance method and different strength criterions were chosen to predict the structural fatigue properties of crankshafts with the same material and different fillet radius. Corresponding experimental verifications were also conducted. The results show that the fatigue characteristics of the crankshafts with different fillet radius are predicted based on the first strength criterion and the critical distance method, both of the critical point method and line method will cause some relatively apparent errors. While the predictions are based on the third, fourth strength criterion and critical distance method, the critical line method has higher accuracy than that of the critical point method, which is caused by the damage types of the crankshafts.
    Subsurface Damage Mechanism of Nano Polycrystalline Coppers in Single Point Diamond Turning
    WANG Quanlong1;ZHANG Chaofeng1;WU Meiping1,2;CHEN Jiaxuan3
    2019, 30(23):  2790-2797,2808. 
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    Based on the Poisson-Voronoi and Monte Carlo methods, the nano polycrystalline copper molecular dynamics model of polycrystalline coppers was constructed. The material removal, change of cutting forces and the reciprocal transformation mechanism between grain boundary and dislocation were studied in nano-cutting. The research results show that the chip flow direction is changed under the hinder actions of grain boundary, and the burrs and cutting grooves are formed on the machined surface. There are several large fluctuations from maximum peak to minimum trough in the vibrational curves of cutting forces, which are caused by deformation energy accumulation and grain boundary fracture. The material removal process near grain boundary is undergone deformation accumulation, dislocation crossing the grain boundary, grain boundary transition into dislocation and grain boundary fracture. By analyzing the evolution processes between grain boundary and dislocation defect in detail, the mechanism of “grain-boundary-dislocation” reciprocal transformation in polycrystalline coppers is drawn out, which enriches the connotation of subsurface damage mechanism of polycrystalline coppers.
    Meshing Performance Analyses of Variable Tooth Thickness Involute Gear Enveloping Hourglass Worm Drives
    CHEN Yan1;YIN Guofu1;CHEN Yonghong2
    2019, 30(23):  2798-2808. 
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    In order to accurately grasp the macro-micro meshing performances of the variable tooth thickness involute gear enveloping hourglass worm drives and the influences of design parameters on meshing performances, a mathematical model of this hourglass worm drive was established. The meshing geometrical equations were deduced, and the influences of the main design parameters, such as helix angle, transmission ratio, normal modulus and pressure angle, on the meshing performance were studied. Afterwards, a sample of the transmission pairs was processed with corresponding optimal design parameters, and the distributions of contact spots were investigated by the contact tests. The results show that the suitable helix angle, larger gear ratio, larger normal modulus and larger pressure angle may achieve excellent contact line distribution and better local meshing quality under the conditions of satisfying the strength and stiffness of the hourglass worms throat diameters. Meanwhile, the local meshing quality on the right side is better than that on the left. The contact spots of the sample are consistent with the theoretical analysis results. And the distribution of the right tooth surface contact spots is better, which verifies the correctness of the analytical method.
    Overview on Formation Mechanism and Research Progresses of Burrs in Micro Cutting
    SHI Wentian;HOU Yanjun;LIU Yude;LI Qiangqiang
    2019, 30(23):  2809-2819,2828. 
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    The morphology, classification and mechanism of burrs in micro cutting were summarized. The research progresses of micro burr simulation analysis were demonstrated. In the experimental research progresses, the influences of processing parameters, geometry of the cutting tool, cutting method and auxiliary processes on micro burrs were discussed. The research status of burr processing for some common composite materials was introduced. According to the forming mechanism and processing technology of micro burrs, the deburring equipment and technology were summarized and the performance requirements of the deburring equipment were proposed. Finally, the deficiencies of the micro burr research were summaried, and the research directions in the future were pointed out.
    Technology of Cutting Ceramic Sheets with Microwave Based on Thermal Controlled Fracture Method
    WANG Xiangwei1;WANG Hailong2;WANG Yang2
    2019, 30(23):  2820-2828. 
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    Traditional ceramic cutting methods had the disadvantages of high pollution, high noise and low cutting quality. A method of cutting ceramic sheets with microwave was proposed based on thermal controlled fracture method, which might overcome the obstacles stated above. The cutting principles with microwave of thermal controlled fracture method were expounded, the experimental apparatus was developed to form circular microwave heating source, which was a circular microwave beam with diameter of 6 mm. And the mechanism of cutting four kinds of ceramics (glass, SiC plate, Al2O3 plate and ZrO2 plate) was studied by experiments. The research results show that bursting points are easy to occur at the internal micro-defects of absorbing ceramics, which are beneficial to reduce the cutting temperature(glass:85 ℃, SiC:230 ℃). The micro-discharge tracks are found in the coated graphite layer of non-absorbing ceramics, which may obtain a cutting path with smaller offsets. Compared with laser heat sources, the microwave heat source has advantages of wider applicability and lower cost.
    Parameter Optimization of High Speed Cylindrical Grinding for Bearing Steel GCr15 Based on Response Surface Method
    LIU Wei1,2;SHANG Yuanyuan1,2;DENG Zhaohui1,2;LIU Rentong1,2;XIAO Zhouqiang2
    2019, 30(23):  2829-2834. 
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    The optimization of HSCG parameters was studied for the full using of the superior material performance of bearing steel GCr15, as well as the processing quality and efficiency of bearing products. The response surface experiments of HSCG were carried out on GCr15 with a cubic boron nitride(CBN) grinding wheel. According to the experimental results, the regression models about the grinding results were established for grinding force, grinding temperature and deteriorative layer depth. Combined with the regression models and the maximum undeformed chip thickness model of grains, the influences of grinding parameters, such as grinding wheel speed, workpiece speed and grinding depth, on the grinding results were comprehensively analyzed. For the integrated minimum of grinding results, the multi-objective optimization were carried out on the grinding parameters. The correctness of the optimization models and results were verified by experiments.
    Theoretical Research and Practice of Machining Worm-face Gears by Flying Cutter Method
    LI Qing1,2;XU Weijun3;ZHANG Meng2;YANG Haijian2;LIU Yunjin2
    2019, 30(23):  2835-2843. 
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    In order to obtain the precise tooth surfaces of worm-face gears, a new method of machining face gears was presented where the flying cutter machining method was used. The theoretical model of worm-face gears was established, the machining coordinate system was built based on the four-axis CNC boring machine,the machining mechanism of the proposed method was analyzed and divided into two stages: the imitation stage and the rolling cutting stage. The flying cutter machining method was used to solve the cutter trajectories, the cutting contact lines of the trajectories on the face gear blanks were obtained, which verifies the correctness of the proposed method. According to the two processing stages above, the relationship among cutter spindle speeds, workpiece axis speeds and feed speeds were solved. The machining programs were compiled and the simulation machining of worm-face gears was carried out in VERICUT, which verified the feasibility of proposed method. Finally, the machining experimental verification was carried out.
    Experimental Investigation on ZNR2.4 Roots Superchargers
    LIU Hougen;ZHANG Pan
    2019, 30(23):  2843-2848. 
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    A performance test-bed of superchargers was created, the adiabatic efficiency, volume efficiency, shaft power consumption and noise of the independently developed ZNR2.4 Roots superchargers were studied. The variation rules of ZNR2.4 Roots superchargers with the speed and pressure ratio were obtained. The results show that the adiabatic efficiency is affected by the compression ratio and the adiabatic efficiency is the highest when the pressure ratio is near 1.3. The volume efficiency increases with the increase of speed, and it is higher than 70% when the speed is above 3 500 r/min. The shaft power increases with the increase of speed, and the maximum is 0.7 kW. The noise increases with the increase of speed, but the average sound pressure level is less than 85 dB(A), the maximum will not be more than 95 dB(A). The research results provide the experimental reference for the subsequent improvement and optimization of the Roots superchargers.
    Research on Broaching Performance of Castor Oil Based Cutting Fluid with Additives
    NI Jing;LIU Xiaofan;HE Lihua;MENG Zhen
    2019, 30(23):  2849-2856. 
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    In order to study the influences of green cutting fluid on broaching performance, pure water(W), castor oil(O), surfactant(S) and nano-graphite(G) were used to prepare three kinds of cutting fluid through ultrasonic stirring, namely water based oil cutting fluid (W-O), water based oil cutting fluid with surfactant (WO-S), water based oil cutting fluid with surfactant and nano-graphite (WOS-G). Then the broaching tests were carried out under spraying. The testing results show that the addition of castor oil and surfactant may reduce the broaching loads. But the addition of nano-graphite is not conductive to reducing the broaching loads, due to the agglomeration effect with castor oil and surfactant, and the friction factor of cutting fluid is increased. By contrast, WO-S cutting fluid with 88.5% pure water, 10% castor oil and 1.5% surfactant(all are mass fractions) has the best application performance. The broaching loads of high and low values are reduced by 17.0% and 18.5% respectively, and the amplitude of the fundamental frequency is decreased by 10.6%. The average amount of chip adhesion in first five cutters is reduced by 35.8%, and that in total cutters is reduced by 23.0%, when compared with that under dry broaching conditions.
    Rotary Magnet-coupled Generator with Frequency Adjustment Using Extensions of a Piezoelectric Simply-supported Beam
    KAN Junwu;HE Hengqian;WANG Shuyun;LIAO Weilin;ZHANG Zhonghua;CHEN Song;WU Yaqi
    2019, 30(23):  2857-2862. 
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    To improve the reliability and broaden the effective speed bandwiths of rotary piezoelectric generators, a rotary magnet-coupled generator with the frequency adjustment using the extensions of a piezoelectric simply-supported beam was presented. The structures and working principles of the proposed generator were demonstrated, the influences of the number of rotating magnets and the precompression amounts of the piezoelectric beam vibrator on the power-generation performance and natural frequency were studied. The testing results show that there are multiple optimal speeds enable the generated voltage to reach the peak.The values of all the optimal speeds are increased with the increasing of precompression amounts, and the numbers of optimal speeds are decreased with the increasing of the number of rotating magnets. The effective speed ranges may broaden through adjusting the precompression amounts. If the number of rotating magnets is as 8,when the precompression amount is as 0, the generator may meet the voltage requirements only at several resonance points. However, when the precompression amounts are as 1 mm,3 mm,5 mm, the effective speed ranges may be broaden to 321~768 r/min, 160~1 000 r/min, 123~1 000 r/min, respectively. The natural frequency of generator may be adjusted in the range of 37.33~89.60 Hz, and the corresponding speed range is as 280~2 632 r/min.
    Design and Numerical Simulation of Plasma Welding Fume Removal Devices
    WU Zhongwei1;XIA Jinbing1;SHI Xijin2
    2019, 30(23):  2862-2869. 
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    Based on the principles of plasma discharge adsorption, a new technology of fume collection, fume filtration, charge and fume removal was proposed to purify welding fumes. A fume removal device was designed which might track welding fume source in real time, and parameters of length and spacing of two electrode plates were determined. By the charge calculation and three-dimensional electric field analysis of plasma electrostatic adsorption device, the motion trajectory and the change law of fume particles in electric field were studied, and COMSOL software was used to simulate and analyze the effects of particle sizes, inlet gas flow rates and inter-plate voltages on the adsorption efficiency of fume particles. The results show that when the inter-plate voltage is in the range of 0.6~2.4 kV, while movement time in the electric field is as t≥0.1 s, the fumes with 0.1~1 μm particle size may achieve rapid and efficient adsorption, and resulting in significant purification.
    Layered Mapping Method of Local Displacement Field for Panel Deformation Prediction
    XU Qinghe1;WANG Min1;CHEN Wenliang1;LIU Dengwei2
    2019, 30(23):  2870-2876,2883. 
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    Aiming at the problems of long calculation period of panel riveting deformation prediction simulation in aircraft assembly processes, according to the idea of local-global mapping method, a layered mapping method was proposed based on local displacement field,and a mapping model was established. And the finte element analysis results of proposed model and 3D dynamic model were compared. The research results show that the proposed method may effectively reduce the simulation time, and increase the reliability of the actual drilling riveting processes. The relatively errors of axial displacement are as 2.2% by using the proposed method. The calculation time of a single rivet is decreased from 45.56 min to 3.33 min, when the mapping area is in the range of 2.5R(R is the radius of the rivet hole). Besides the effectiveness of the proposed method was verified by three rivets model.
    Analysis and Experimental Research of Deep Sea Sediment Airtight Samplers
    LIU Guangping;WAN Buyan;PENG Youduo;JIN Yongping
    2019, 30(23):  2877-2883. 
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    In order to meet the requirements of high-quality deep seabed sediment pressure-maintaining sample during the scientific researches of deep seabed under full sea depth, a mechanical hand-held device with pressure-maintaining function was designed in accordance with the maneuverability of the manned submarine operations. The key components such as pressure-maintaining container and pressure compensation device of sediment airtight sampler under full sea depth were analyzed and calculated. Finite element simulation analysis was performed under full sea-deep pressure environments. The results show that the stress and strain of the airtight sampler increase with the increase of the applied pressure, the maximum stress and strain appear at the sealing positions of the end cap and the cylinder seal, and stress and strain are small in the contact positions of the square stopper and the pressure-maintaining cylinder end caps with good sealing performance. Finally, the internal pressure tests and the manipulator cooperative adaptability tests of the full sea-deep sediment airtight samplers were carried out. The results of tests verify the feasibility of the pressure-maintaining performance and the adaptability of the manipulator for the full sea-deep sediment airtight samplers.

    Research on Dissolution Mechanism of Multi-component Ceramic Phases in Laser Cladding Coatings
    FU Yuming, ZHAO Huayang, ZHENG Lijuan, QI Tong
    2019, 30(23):  2884-2889,2897. 
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    The laser cladding coating materials were based on iron-based powders, with the additions of TiC, WC and SiC multi-component ceramic reinforced phases. The chemical reaction direction and reaction degree in laser cladding processes were analyzed by thermodynamics according to the free energy change theory, and the dissolution mechanism of the ceramic reinforced phases was studied. The research results show that under the given processing parameters and lasers, the coating surface may produce the high temperature of about 2 000~3 000 K. Through the microstructure analysis, it is found that the ceramic materials partially or completely dissolve in the temperature ranges mentioned above, and the free Fe, Cr, Ni plasma or particles in the molten pool react with the decomposed Ti, W, Si and C elements one after another. The materials possess certain metallicity as well as strength and hardness of ceramic phases, such as FeNi2Ti, Fe-Cr-Ni-Si and other new alloy phases or solid solutions, and achieve the effectiveness of strengthening coating properties, which is the same as the results of theoretical analysis model.
    STL Model Based Interference Check and Correction in Double Sided CNC Incremental Forming
    ZHU Hu1;XIAO Dongxuan1;KANG Jaeguan2
    2019, 30(23):  2890-2897. 
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    For the problems of the interferences were easy to occur between the tool head and sheet metal in the double sided CNC incremental forming, a interference check and correction method was proposed based on the STL model. For the main tool head, the non-interference forming toolpath were generated to avoid the interference by using the equidistant surfaces. For the vice tool head, the interference types were divided into the interferences between the tool head and the areas of the forming characteristics and the interferences between the tool head and the areas of the non-forming characteristics. And the position relationship between the cutter location points of the vice tool head and the support surfaces was used to judge whether the interference occured. The case studies and the forming experimental results show that the interferences may be avoided and the interference free toolpaths of the tool head may be generated by using the proposed algorithm.