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Die Design and Forging Analysis of Piston Connecting Rod of Aluminum Alloy 铝合金活塞连杆的模具设计与锻造分析
Q4 Physics and Astronomy Pub Date : 2024-01-09 DOI: 10.4028/p-ay8g5t
Tung Sheng Yang, Guan Yu Li, Zhe Yu Li, Jun Wei Li, Zhong Zhen Chen
The piston connecting rod is an indispensable in the internal structure of the automobile. As one of the important components in the internal combustion engine system, the piston connecting rod needs to meet the requirements of high fatigue and impact load resistance. Forged piston connecting rod can obtain high strength and fatigue resistance. In this study, the parting line, draft angle, forging tolerance, die fillet radius, shrinkage and scrap are considered in the design of forging die. The process parameters and die dimensions of the forging process of aluminum alloy piston rod are simulated by finite element analysis. The aluminum alloy piston rod with high dimensional accuracy is then forged according to the finite element simulation results.
活塞连杆是汽车内部结构中不可或缺的部件。作为内燃机系统中的重要部件之一,活塞连杆需要满足高抗疲劳和抗冲击载荷的要求。锻造活塞连杆可获得较高的强度和抗疲劳性能。本研究在设计锻造模具时考虑了分模线、牵伸角、锻造公差、模具圆角半径、收缩率和废料等因素。通过有限元分析模拟了铝合金活塞杆锻造过程的工艺参数和模具尺寸。然后根据有限元模拟结果锻造出尺寸精度较高的铝合金活塞杆。
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引用次数: 0
Engineering Tribology, Processing and Modeling 工程摩擦学、加工和建模
Q4 Physics and Astronomy Pub Date : 2024-01-09 DOI: 10.4028/b-jw3nji
Yunn Lin Hwang, Thangaprakash Sengodan
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引用次数: 0
Numerical Investigation of the Magnetohydrodynamic Mixed Convection inside an Extended Curved Duct in the Presence of a Nanofluid of Different Metallic Oxides Nanoparticles 存在不同金属氧化物纳米颗粒的纳米流体时延伸弯曲管道内磁流体动力混合对流的数值研究
Q4 Physics and Astronomy Pub Date : 2024-01-09 DOI: 10.4028/p-f3jucr
Djamila Derbal, M. Bouzit, Abderrahim Mokhefi, Fayçal Bouzit
The numerical work presented in this paper focuses on the influence of the magnetic field and the nanoparticles metallic nature on the hydrodynamic and thermal behavior of a nanofluid flowing in an extended curved duct. It deals with a semi-toroidal curved duct with an expanded circular section. The narrowed part of this duct from which the nanofluid enters with a cold temperature, is considered to be thermally insulated. However, the extended part is kept at a constant hot temperature. The nanoparticles used in the present study respectively are Alumina (Al2O3), copper oxide (CuO) and iron trioxide (Fe3O4). In this study, the effects of inertia, buoyancy and Lorentz forces as well as the metallic nature of the nanoparticles suspended in the pure water have been highlighted on the thermal, hydrodynamic and economic levels. The study is based on the resolution of the classical monophasic equations governing the non-isothermal flow of nanofluids by the use of finite element method, namely: the mass, momentum and energy equations. The obtained results have shown that the buoyancy and inertia forces strongly favor the global heat exchange rate. Moreover, the magnetic force acts negatively on these thermal exchanges. Furthermore, the CuO nanoparticles have demonstrated a better heat transfer rate, approximately 7% higher than that of pure water. Nevertheless, according to the economic needs, we suggest we suggest using alumina nanoparticles, as their transfer rate is comparable to that of CuO nanoparticles. It should be noted, that this study provides important insights for many industrial applications where the curved ducts are strongly presented.
本文所介绍的数值工作主要研究磁场和纳米粒子金属特性对在扩展弯曲管道中流动的纳米流体的流体动力学和热行为的影响。本文涉及一个具有扩展圆形截面的半环形弯曲管道。纳米流体以低温进入管道的狭窄部分被认为是隔热的。然而,扩展部分则保持恒定的热温度。本研究中使用的纳米粒子分别是氧化铝(Al2O3)、氧化铜(CuO)和三氧化二铁(Fe3O4)。本研究从热学、流体力学和经济学层面强调了悬浮在纯水中的纳米粒子的惯性力、浮力和洛伦兹力以及金属性质的影响。该研究基于使用有限元方法解决纳米流体非等温流动的经典单相方程,即质量、动量和能量方程。研究结果表明,浮力和惯性力对全局热交换率非常有利。此外,磁力对这些热交换起负面作用。此外,CuO 纳米粒子的热传导率更高,比纯水高出约 7%。不过,根据经济需要,我们建议使用氧化铝纳米粒子,因为其传热率与 CuO 纳米粒子相当。应该指出的是,这项研究为许多工业应用提供了重要的启示,因为在这些应用中,弯曲管道的作用非常明显。
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引用次数: 0
Physical Experiments and DEM Simulations for Erosion of Iron Target by Two Impingements of Al2O3 Particle with Impingement Angles of Double 90º 双 90º 角冲击 Al2O3 粒子对铁靶侵蚀的物理实验和 DEM 仿真
Q4 Physics and Astronomy Pub Date : 2024-01-09 DOI: 10.4028/p-4grgiz
Zi Qiang Fang, Song Lin Peng
In mechanical equipment interacting with impingement particles, worn surface morphology of parts and components is formed by an accumulative action of a large number of single-particle erosions. To exhibit the mechanism of multi-particle erosion of target, three physical experiments and Discrete Element Method (DEM) simulations of erosion of iron target by the two vertical impingements of Al2O3 particle are carried out under three different landing errors x of the two impingements. The experimental results showed that each of two overlapping worn morphologies by the two impingements has an spherical cap shape. When x is larger than radius R1 of worn morphology of target by the first erosion, two morphologies with an spherical cap shape are very close in size; while the size of worn morphology by the second erosion increases with the decrease of x, when x is smaller than R1. The predicting worn morphologies by DEM are almost consistent with the experimental results, where the maximum relative deviation in size of worn morphology is 2.98% in the direction along x, and is 3.93% in the direction perpendicular to x. All these proved the effectiveness of the DEM model in predicting erosion of target by two impingements of particle.
在与撞击颗粒相互作用的机械设备中,零部件的磨损表面形态是由大量单颗粒侵蚀的累积作用形成的。为了展示靶材的多粒子侵蚀机理,我们在两个 Al2O3 粒子的三个不同着陆误差 x 下,对铁靶材受到两个垂直撞击的侵蚀情况进行了三次物理实验和离散元法(DEM)模拟。实验结果表明,两次撞击产生的两种重叠磨损形态均为球形帽状。当 x 大于第一次侵蚀对靶件磨损形貌的半径 R1 时,两个球帽形貌的大小非常接近;而当 x 小于 R1 时,第二次侵蚀对靶件磨损形貌的大小随 x 的减小而增大。用 DEM 预测的磨损形态与实验结果基本一致,在沿 x 的方向上,磨损形态尺寸的最大相对偏差为 2.98%,而在垂直于 x 的方向上,磨损形态尺寸的最大相对偏差为 3.93%。
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引用次数: 0
Development of Manufacturing Process for High-Chromium Steel Large Welding Roll 高铬钢大型焊接辊制造工艺的开发
Q4 Physics and Astronomy Pub Date : 2024-01-09 DOI: 10.4028/p-s55ows
Volodymyr V. Kukhar, Oleg Vasylevskyi, Khrystyna Malii, Vadim Zurnadzhy, Bohdan Efremenko, Ivan Sili
Due to the operating conditions of weld and calibrating rolls used in the production processes of large electric-welded pipes, their material is subject to stringent wear and abrasion resistance requirements at high temperatures. The limited capabilities of conventional Cr-Mn-Ni tool steels and open die forging technologies with heat treatment processes do not provide the required performance properties for large welded rolls. Therefore, the material of the product was replaced with Cr12MoV high-chromium steel. This required identifying the formation patterns of the fine grain structure of high-chromium steel in order to adjust the production technology with adaptation to the unique conditions and equipment (12.5 MN hydraulic forging press, heating and thermal furnaces) of the forging shop. The technology was offered, which included the development of modes from heating to heat treatment with intermediate two-stage forging from Cr12MoV steel ingots in two sets of combined dies. At the first stage, deformation with a low reduction ratio ε = 5% and a relative feed rate of 0.4 per pass was provided to break and refine the carbide mesh, and at the second stage, intense deformation with a reduction ratio ε = 15% was performed. Further practical application has shown that the durability of weld rolls made from the new material increases by 20–30%.
由于大型电焊管生产过程中使用的焊接辊和校准辊的工作条件,其材料在高温下需要满足严格的磨损和耐磨要求。传统的铬锰镍工具钢和热处理工艺的开放式模锻技术能力有限,无法提供大型焊接辊所需的性能特性。因此,该产品的材料被替换为 Cr12MoV 高铬钢。这就需要确定高铬钢细晶粒结构的形成模式,以调整生产技术,适应锻造车间的独特条件和设备(12.5 MN 液压锻造压力机、加热炉和热处理炉)。提供的技术包括开发从加热到热处理的模式,以及在两套组合模具中对 Cr12MoV 钢锭进行中间两阶段锻造。在第一阶段,以低缩减率 ε = 5%和每道 0.4 的相对进给率进行变形,以破碎和细化碳化物网;在第二阶段,以缩减率 ε = 15%进行强烈变形。进一步的实际应用表明,由新材料制成的焊接辊的耐用性提高了 20-30%。
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引用次数: 0
Elastohydrodynamic Rotational Lubrication Analysis on the Multi-Body Dynamic Properties of Journal-Bearing Systems 对关节轴承系统多体动态特性的弹性流体力学旋转润滑分析
Q4 Physics and Astronomy Pub Date : 2024-01-09 DOI: 10.4028/p-ptk9sd
Yunn Lin Hwang, Adhitya Adhitya
This research aims to investigate the properties of elastohydrodynamic rotational lubrication analysis on journal-bearing systems. To simulate elastohydrodynamic lubrication on journal-bearing systems, the Elasto-Hydro-Dynamic (EHD) solver is combined with the Multi-Body Dynamic (MBD) solver to create MBD virtual environment with lubricant. The hydrodynamic lubricant is governed by using the Reynolds equation, whereas the elastic contact is governed using Greenwood and Tripp theories. The simulation is performed by changing the operating conditions such as the speed, load, and clearance between two surfaces. One can find these parameters’ effects such as film thickness, hydrodynamic pressure, and friction. The result shows that the friction induced by shaft speed is similar to the Stribeck curve on mixed lubrication regime. Consequently, the clearance, speed, and load will not only affect the friction but also affect the hydrodynamic pressure and film thickness.
本研究旨在探讨轴颈轴承系统弹性流体动力旋转润滑分析的特性。为了模拟轴颈轴承系统的弹性流体动力润滑,将弹性流体动力(EHD)求解器与多体动力学(MBD)求解器相结合,创建了带有润滑剂的 MBD 虚拟环境。流体动力润滑剂由雷诺方程控制,而弹性接触则由格林伍德和特里普理论控制。模拟是通过改变两个表面之间的速度、载荷和间隙等运行条件来进行的。可以发现这些参数对薄膜厚度、流体压力和摩擦力的影响。结果表明,轴速引起的摩擦与混合润滑条件下的 Stribeck 曲线相似。因此,间隙、速度和载荷不仅会影响摩擦力,还会影响流体动力压力和油膜厚度。
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引用次数: 0
Fatigue Crack Propagation in 5754 Aluminum Alloy under Four-Point Bending 5754 铝合金在四点弯曲下的疲劳裂纹扩展
Q4 Physics and Astronomy Pub Date : 2024-01-09 DOI: 10.4028/p-bzqd89
M. Makhatha, Pawan Kumar, D.A. Baruwa
The aluminum 5754 alloy is one of the widely used engineering materials in shipping, rivet making, tread plates and automotive industries. These engineering structures envisage variable loading conditions during their service. In addition to it, it is also experiencing seismic vibrations. Hence, the engineering components made from such aluminum alloy are susceptible to fatigue fracture. In the current study, the prediction of fatigue crack growth (FCG) in 5754 aluminum alloy was made using the exponential function. The beam specimen comes up with a cross-section of 25X25 mm2, a span length of 300 mm with a mechanical notch length of 2.70 mm at the centre was subjected to four-point bending (FPB) employing hydraulic INSTRON 8800 tensile testing apparatus. The periodic loading condition deformed the material up to large plastic deformation. The applied load was further down the elasticity of the material. The experimental data provided the relation between crack length (a) to the number of cycles (N) to failure. The response surface methodology (RSM) and modified exponential equation were used to predict the FCG. In RSM, when “stress intensity factor (K)” and “number of the cycle (N)" were considered independent variables, the response (a) was optimum (maximum) as compared to when “stress intensity factor range (del K)” and “fatigue crack growth rate (da/dN)” were considered independent variables. Hence, for designing the aluminum 5754 alloys as engineering structures, it was the number of cycles which provides a safe design as compared to da/dN. The modified exponential equation using an exponential function predicted the FCG for aluminum 5754 alloy in the form of a beam specimen. The anticipated results agreed with experimental data as the prediction ratio was 1.20 and the % deviation was 3.7.
铝 5754 合金是船运、铆钉制造、花纹板和汽车行业广泛使用的工程材料之一。这些工程结构在使用过程中承受着不同的负载条件。此外,它还会经历地震振动。因此,由此类铝合金制成的工程部件很容易发生疲劳断裂。在当前的研究中,使用指数函数对 5754 铝合金的疲劳裂纹增长(FCG)进行了预测。横梁试样的横截面为 25X25 mm2,跨度为 300 mm,中心的机械缺口长度为 2.70 mm,采用液压 INSTRON 8800 拉伸试验设备对其进行四点弯曲(FPB)试验。周期性加载条件使材料产生了较大的塑性变形。施加的载荷进一步降低了材料的弹性。实验数据提供了裂纹长度(a)与失效循环次数(N)之间的关系。采用响应面方法(RSM)和修正的指数方程来预测 FCG。在 RSM 中,当 "应力强度因子 (K)" 和 "循环次数 (N)" 被视为自变量时,与 "应力强度因子范围 (del K) "和 "疲劳裂纹生长率 (da/dN)" 被视为自变量时相比,响应 (a) 最佳(最大)。因此,在设计作为工程结构的铝 5754 合金时,与 da/dN 相比,循环次数更能提供安全的设计。修正的指数方程使用指数函数预测了铝 5754 合金梁试样形式的 FCG。预期结果与实验数据一致,预测比为 1.20,偏差为 3.7%。
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引用次数: 0
Investigation of Structural, Morphological and Luminescent Features of Eu3+ Activated Molybdate Based Phosphor for W-LED Applications 研究用于 W-LED 应用的 Eu3+ 活化钼酸盐基荧光粉的结构、形态和发光特性
Q4 Physics and Astronomy Pub Date : 2024-01-09 DOI: 10.4028/p-bpqeg3
Pranjali Sharma, Muskan Kaushik, M. Jayasimhadri
In the present work, NaBi(MoO4)2 (NBM) phosphor has been successfully synthesized by doping 1.0 mol% of Eu3+ via the conventional solid state reaction technique. The undoped synthesized NBM sample and 1.0 mol% Eu3+ doped phosphor were characterized to explore crystal structure, morphology, photoluminescence (PL) and colorimetric properties using various characterization techniques. The structural properties were analysed via x-ray diffraction and diffraction peaks were compared with the standard JCPDS (card no. 79-2240) pattern. The morphological studies of the sample have been done through FE-SEM micrograph. From the photoluminescence emission spectra, it has been observed that an intense peak was obtained in the at 615 nm under blue excitation. Colorimetric property of 1.0 mol% of Eu3+ doped NBM phosphor has been investigated and traced in the red region with high color purity of 92.79%. The aforementioned characteristics demonstrate that the NaBi(MoO4)2: 1.0Eu3+ phosphor has great potential in the field of w-LED applications.
在本研究中,通过传统的固态反应技术,成功合成了掺杂 1.0 mol% Eu3+ 的 NaBi(MoO4)2 (NBM) 荧光粉。利用各种表征技术对未掺杂合成的 NBM 样品和掺杂 1.0 mol% Eu3+ 的荧光粉进行了表征,以探索其晶体结构、形貌、光致发光 (PL) 和比色特性。通过 X 射线衍射分析了结构特性,并将衍射峰与标准 JCPDS(卡号 79-2240)图案进行了比较。样品的形态研究是通过 FE-SEM 显微照片完成的。从光致发光发射光谱中可以观察到,在蓝色激发下,在 615 纳米波长处出现了一个强烈的峰值。对掺杂了 1.0 mol% Eu3+ 的 NBM 荧光粉的色度特性进行了研究,结果显示其红色区域的色度纯度高达 92.79%。上述特性表明,NaBi(MoO4)2: 1.0Eu3+ 荧光粉在 w-LED 应用领域具有巨大的潜力。
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引用次数: 0
Effects of the Lubricants on the Tribology Properties under the Extreme Pressure for the Induction-Treated Linear Guides 润滑剂对感应处理直线导轨极压下摩擦学特性的影响
Q4 Physics and Astronomy Pub Date : 2024-01-09 DOI: 10.4028/p-euwym0
Yuh-Ping Chang, H. Wang, Li-Ming Chu, C. Liu, Cheng Chieh Yang
In view of the fact that the load on the transmission element under extreme pressure conditions is much greater than that used in traditional machine tools, the contact surface between the ball and the track must bear great stress. Furthermore, it will heat up due to friction after starting and running. These effects are prone to material deformation and fatigue damage, and may even lead to the disappearance of the lubricating oil film. They are prone to surface damage due to metal fatigue, and then a serious situation of large pieces of peeling occurs for the linear guides. In order to prolong the fatigue life of the machine tools, this study investigates the effects of the lubricants on the tribology properties under the extreme pressure for the induction-treated linear guides.
鉴于在极压条件下传动元件所承受的负荷远大于传统机床,滚珠与轨道之间的接触面必须承受很大的应力。此外,在启动和运行后,由于摩擦会产生热量。这些影响容易导致材料变形和疲劳损坏,甚至可能导致润滑油膜消失。它们容易因金属疲劳而造成表面损坏,进而导致直线导轨出现大块剥落的严重情况。为了延长机床的疲劳寿命,本研究探讨了润滑剂对感应处理直线导轨在极压下摩擦学特性的影响。
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引用次数: 0
Cooling Effect on Nano Eutectoid Phase Formation of Hypereutectic Zn-Al Alloy 冷却对超共晶锌铝合金纳米共晶相形成的影响
Q4 Physics and Astronomy Pub Date : 2023-12-12 DOI: 10.4028/p-Nse4Xi
A. Hu, Henry Hu, Xingyuan Wei, X. Nie
To understand the nano phase formation, cooling experiments of a hypereutectic Zn-Al alloy containing 6 wt% of Al are carried out under two different cooling rates of 0.04 and 10.00 °C/s. The applied cooling rates significantly influence the phase change behavior of the investigated alloy. The liquidus temperature (TN) for the nucleation of the primary phase decreases from 390.3 to 382.9 °C, and the undercooling increases from 0.7 to 8.1 °C, as the cooling rate rises from 0.04 to 10 °C/s. The eutectic and eutectoid temperatures decrease from 381.5, 277.7 to 375.6 and 267.6 °C, respectively, when the cooling rate increases from 0.04 to 10.00 °C/s. The SEM and EDS analyses reveal that the solidified alloy contains the primary γ-ZnAl phase, the eutectic β-Zn phase, and the eutectoid α-Al and eutectoid β-Zn phases. The fast phase change and transformation caused by rapid cooling results in the formation of nano eutectoid phases and fine microstructure.
为了解纳米相的形成,在 0.04 和 10.00 °C/s 两种不同的冷却速率下对含 6 wt% Al 的过共晶锌铝合金进行了冷却实验。所采用的冷却速率对所研究合金的相变行为有很大影响。随着冷却速率从 0.04 ℃/s 上升到 10 ℃/s,初级相成核的液相温度 (TN) 从 390.3 ℃ 下降到 382.9 ℃,过冷度从 0.7 ℃ 上升到 8.1 ℃。当冷却速度从 0.04°C/s 增加到 10.00°C/s 时,共晶和共晶体温度分别从 381.5、277.7 °C 下降到 375.6 和 267.6 °C。扫描电镜和 EDS 分析表明,凝固的合金含有原生的 γ-ZnAl 相、共晶的 β-Zn 相、共晶的 α-Al 相和共晶的 β-Zn 相。快速冷却导致的快速相变和转变形成了纳米共晶相和精细的微观结构。
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引用次数: 0
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