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Study of materials effects on the single cutting in ultra-precision raster milling 超精密光栅铣削中材料对单次切削的影响研究
Q3 Engineering Pub Date : 2018-01-11 DOI: 10.1504/IJNM.2018.089181
Wang Sujuan, To Suet, Chen Xin
Ultra-precision raster milling (UPRM) rotates a single crystal diamond tool to discontinuously remove materials from the workpiece and can directly produce freeform surfaces with sub-micrometric form accuracy and nanometric surface finishing. This paper presents theoretical and experimental investigations on the workpiece material effect on single cutting profile in UPRM. Experiments are conducted to study the material effect on cutting profile by single cutting four materials including copper, aluminium alloy 6061, brass and aluminium bronze under the same cutting conditions in UPRM. A characterisation method is presented in the paper to study the effect of different workpiece material on the cutting profiles in UPRM. The experimental results show that copper alloy makes the smallest effect on the single cutting profile because of the lowest elastic recovery ratio while the material effect of aluminium bronze is the highest due to the highest elastic recovery ratio and the highest hardness.
超精密光栅铣削(UPRM)旋转单晶金刚石工具,以不连续地从工件上去除材料,并可以直接生产具有亚微米形状精度和纳米表面精加工的自由曲面。本文对UPRM中工件材料对单次切削轮廓的影响进行了理论和实验研究。在UPRM中,在相同的切削条件下,对铜、6061铝合金、黄铜和铝青铜四种材料进行了单次切削,研究了材料对切削轮廓的影响。本文提出了一种表征方法来研究UPRM中不同工件材料对切削轮廓的影响。实验结果表明,铜合金的弹性回复率最低,对单次切削轮廓的影响最小,而铝青铜的材料效应最高,弹性回复率最高,硬度最高。
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引用次数: 0
Performance of PVDF/TiO2 nano-composite film in the application of energy harvester PVDF/TiO2纳米复合膜在能量采集器中的应用性能
Q3 Engineering Pub Date : 2018-01-11 DOI: 10.1504/IJNM.2018.10009989
Ningli An, Jingjing Ye
The compression mode and shear mode for energy harvesting experimental platform was estabished. The energy collection efficiency of PVDF/TiO2 nano-composite film in the two mode and nonlinear piezoelectric effect were analysed. Experimental results show that the energy collection efficiency of the shear mode was higher than the compressed mode. The Piezoelectric constant and piezoelectric coupling coefficient have nonlinear changes under large stress. In this paper, the experimental data establish a relationship electromechanical coupling coefficients and parameters of composite thin film piezoelectric stress.
建立了能量收集实验平台的压缩模式和剪切模式。分析了PVDF/TiO2纳米复合膜在两种模式下的能量收集效率和非线性压电效应。实验结果表明,剪切模式的能量收集效率高于压缩模式。在大应力作用下,压电常数和压电耦合系数呈非线性变化。本文通过实验数据建立了复合薄膜压电应力参数与机电耦合系数的关系。
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引用次数: 0
Experimental study and prediction on impact scratching of single abrasive for K9 glass K9玻璃单磨料冲击划伤的实验研究与预测
Q3 Engineering Pub Date : 2018-01-11 DOI: 10.1504/IJNM.2018.10009999
Chen Li, Fei-hu Zhang, Xiaoshuang Rao, B. Leng
The orthogonal test L16 (43) was designed, and the impact scratching experiment for K9 glass was carried out by using Vickers diamond indenter on the DMG ULTRASONIC 70-5 linear. The three-dimensional morphology of the surface for glass was observed by scanning electron microscope (SEM), which was compared with that in the quasi static state. The strain rate of the grinding process was obtained by choosing the contact zone length as the impact contact length, which was the evaluation Index of impact. The relationships between strain rate and the depth of radial crack, strain rate and the depth of transverse crack, strain rate and normal scratching force were first analysed. The results showed that the depth of radial of crack, the depth of transversal crack and the normal scratching force decreased with the increase of strain rate. The two-layer BP neural network was established, which took the strain rate as input variables. The depth of radial crack, the depth of transversal crack and normal scratching force were predicted and the errors were within 10%, which indicated that the prediction results of BP neural network were reliable.
设计了正交试验L16(43),利用维氏金刚石压头在DMG超声70-5直线上对K9玻璃进行了冲击刮擦试验。利用扫描电镜(SEM)观察了玻璃表面的三维形貌,并与准静态状态下的形貌进行了比较。选择接触区长度作为冲击接触长度作为冲击评价指标,得到磨削过程的应变速率。首先分析了应变率与径向裂纹深度、应变率与横向裂纹深度、应变率与法向划痕力之间的关系。结果表明:随着应变速率的增大,裂纹径向深度、横向裂纹深度和法向划痕力均减小;建立了以应变率为输入变量的双层BP神经网络。对径向裂纹深度、横向裂纹深度和法向划痕力进行了预测,误差在10%以内,表明BP神经网络预测结果可靠。
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引用次数: 3
Study on a non-contact polishing method using motion coupling confined etchant layer technique 运动耦合约束蚀刻层技术的非接触抛光方法研究
Q3 Engineering Pub Date : 2018-01-11 DOI: 10.1504/IJNM.2018.10009993
Y. Cao, Yuchao Jia, Yongda Yan, Han Lianhuan, Xuesen Zhao, Zhenjiang Hu, D. Zhan
The confined etchant layer technique (CELT) has been proved not only an effective electrochemical microstructures fabrication method, but also a potential polishing method due to its distance sensitiveness. To verify its polishing capability in motion mode and examine the influence of motion parameters on polishing efficiency and material removal rate, motion coupling confined etchant layer technique (MCCELT) polishing experiments were carried out on n-GaAs wafers by adopting central composite inscribe (CCI) design of response surface methodology. Furthermore, the interactions between motion, electrochemical reaction and substrate deformation were analysed using multi-physics coupling finite element simulations. Statistical model shows that sample surface roughness decreases with the decreases of working distance (between the electrode and the substrate) and feeding velocity, and indicates it still has potential to reach more smooth results.
受限蚀刻剂层技术(CELT)由于其距离敏感性,不仅被证明是一种有效的电化学微结构制造方法,而且是一种潜在的抛光方法。为了验证其在运动模式下的抛光能力,并考察运动参数对抛光效率和材料去除率的影响,采用响应面方法的中心复合刻字(CCI)设计,在n-GaAs晶片上进行了运动耦合约束蚀刻剂层技术(MCCELT)抛光实验。此外,通过多物理耦合有限元模拟,分析了运动、电化学反应和基底变形之间的相互作用。统计模型表明,样品表面粗糙度随着工作距离(电极和衬底之间)和进给速度的减小而减小,并表明其仍有可能达到更光滑的结果。
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引用次数: 0
Influence of clearance angle on micro/nano structure fabrication in elliptical vibration cutting of hardened steel 淬硬钢椭圆振动切削中间隙角对微纳结构加工的影响
Q3 Engineering Pub Date : 2017-10-20 DOI: 10.1504/IJNM.2017.10008414
Jianguo Zhang, N. Suzuki, Yilong Wang, E. Shamoto
Surfaces textured by sophisticated micro/nano structures can provide advanced and useful functions and features as compared with simply smooth surfaces. To promote widespread use of the structured surfaces, manufacturing technology of structured surfaces for ultra-precision dies and moulds made of hardened steel is absolutely essential. Conventional diamond cutting is not applicable to machining of steel due to rapid tool wear and surface deterioration. On the other hand, elliptical vibration cutting (EVC) equipped with the ultra-precision amplitude control sculpturing method is considered as a potential candidate for the functional surface fabrication on steel materials. In this method, tool geometry, especially the clearance angle, imposes a limit on the machinable part geometry due to the flank face contact to the target shape in the downhill machining. In order to clarify the influence of flank face contact on the machining accuracy and the tool wear, a series of theoretical and experimental investigations are conducted in this paper. A surface with micro sine-sweep profile is fabricated on hardened steel by applying the proposed amplitude control sculpturing method. It verified that the interference between flank face and fabricated structure causes not only the serious machining accuracy deterioration but also the serious tool damage due to the enhancing of ploughing process.
与简单的光滑表面相比,复杂的微纳米结构纹理表面可以提供先进和有用的功能和特征。为了促进结构化表面的广泛应用,超精密淬火钢模具的结构化表面制造技术是必不可少的。由于刀具磨损快、表面劣化,传统的金刚石切削不适合加工钢。另一方面,椭圆振动切割(EVC)配合超精密幅度控制雕刻方法被认为是钢材料功能表面加工的潜在候选。在这种方法中,刀具的几何形状,特别是间隙角,由于在下坡加工中刀面与目标形状的接触,对可加工零件的几何形状施加了限制。为了明确刀面接触对加工精度和刀具磨损的影响,本文进行了一系列的理论和实验研究。采用所提出的幅度控制雕刻方法,在淬硬钢上加工出具有微正弦扫描轮廓的表面。验证了后端面与加工结构之间的干涉不仅会导致加工精度的严重下降,而且由于犁耕过程的加强,还会造成严重的刀具损坏。
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引用次数: 3
Comprehensive error modelling and error compensation for complex optical free-form surface polishing platform 复杂光学自由曲面抛光平台综合误差建模与误差补偿
Q3 Engineering Pub Date : 2017-10-20 DOI: 10.1504/IJNM.2017.10008421
Zhang Zhong, Zhao Ji, Ji Shi Jun, Li Gang
Four-axis polishing platform plays an important role in machining a complex optical free-form surface and the kinematic error generally determine the accuracy of the optical free-form surface fabricated by this platform. This paper analyses kinematics of the polishing platform based on the homogeneous coordinate transformation theory and the error of kinematics synthesis model is established. Based on minimum error assumption, transition matrix is obtained from machine tool coordinate system to the cutting tool coordinate system and changing rule of comprehensive error in different position and direction is gained in two-axis motion worktable. Laser interferometer is used to measure the geometric error of polishing platform, it is found that different feed rate and measured spacing had no significant effect on the positioning error of moving axis and positioning error rather than the straightness and angle error has more significant influence on the accuracy of machine tool. Compensation experiment was conducted based on integrated error model, the x-axis and z-axis positioning error was reduced by 87.37% and 90.32% after compensation and the compensation result is remarkable.
四轴抛光平台在加工复杂的光学自由曲面中起着重要作用,其运动误差通常决定着该平台所加工光学自由曲面的精度。基于齐次坐标变换理论,对抛光平台的运动学进行了分析,建立了运动学综合模型的误差。基于最小误差假设,得到了机床坐标系到刀具坐标系的转换矩阵,得到了双轴运动工作台在不同位置和方向上综合误差的变化规律。利用激光干涉仪测量抛光平台的几何误差,发现不同的进给速度和测量间距对移动轴的定位误差没有显著影响,定位误差对机床精度的影响比直线度和角度误差更大。基于集成误差模型进行了补偿实验,补偿后的x轴和z轴定位误差分别降低了87.37%和90.32%,补偿效果显著。
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引用次数: 1
Study on algorithm of automatic alignment compensation of electron gun in a scanning electron microscope 扫描电子显微镜电子枪自动对准补偿算法研究
Q3 Engineering Pub Date : 2017-10-20 DOI: 10.1504/IJNM.2017.10008419
Seung Jae Kim, D. Jang
Primary electrons are emitted from the cathode in a scanning electron microscope (SEM). The electron gun's cathode diameter is ~60 µm and the anode's internal diameter is ~3 mm. When the cathode and anode centres do not match, the SEM image is distorted. We developed an automatic alignment method for the electron gun. The primary electrons are scanned under the anode hole for secondary electron image acquisition. However, when the primary electrons are scanned from the upper anode hole, secondary electrons on the specimen as big as the size of the anode hole are generated. The alignment of the cathode and anode centres is determined from the image's brightness and position on the screen; if the image is very bright, the alignment is normal. We employ pattern recognition to analyse images to achieve automatic alignment of the electron gun. We designed a scanning device and performed image scale calibration.
在扫描电子显微镜(SEM)中从阴极发射初级电子。电子枪的阴极直径约为60µm,阳极内径约为3 mm。当阴极和阳极中心不匹配时,SEM图像会失真。我们开发了一种电子枪的自动对准方法。初级电子在阳极孔下被扫描,用于次级电子图像采集。然而,当从上部阳极孔扫描初级电子时,在样品上产生与阳极孔大小一样大的次级电子。阴极和阳极中心的对准由图像在屏幕上的亮度和位置确定;如果图像非常明亮,则对齐是正常的。我们采用模式识别来分析图像,以实现电子枪的自动对准。我们设计了一个扫描设备并进行了图像比例校准。
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引用次数: 0
Study on the analysis of the mechanism of EDM based on Su-Field 基于Su场的电火花加工机理分析研究
Q3 Engineering Pub Date : 2017-10-20 DOI: 10.1504/IJNM.2017.10008407
S. Ma, Zhanhui Wang, Lingyu Lin
EDM is an important means of processing in mould processing industry. In this paper, the Su-Field analysis method is applied to study the mechanism of EDM, the application process of Su-Field analysis method to solve the problem of EDM discharge system was established, the microscopic process of EDM dielectric breakdown was described, the Su-Field model of the single pulse discharge four phases, discharge channel formation, breakdown discharge, galvanic corrosion throwing and the deionisation between the medium, was established, and finally the complete Su-Field model of single pulse discharge process of EDM was achieved. In the single-pulse discharge established Su-Field model basis, the factors affecting the processing speed, surface roughness and electrode wear were analysed, further integration of 76 standard solutions, the plan to solve the problem of instability in the discharge process was achieved, at the same time, a new way for the research of EDM process was provided.
电火花加工是模具加工行业的一种重要加工手段。本文应用苏场分析方法研究了电火花加工的机理,建立了苏场分析法解决电火花加工放电系统问题的应用过程,描述了电火花介质击穿的微观过程,建立了单脉冲放电四相、放电通道形成、击穿放电的苏场模型,建立了电腐蚀和介质间的去离子过程,最终建立了完整的电火花单脉冲放电过程的Su场模型。在建立Su-Field单脉冲放电模型的基础上,分析了影响加工速度、表面粗糙度和电极磨损的因素,进一步整合了76个标准溶液,实现了解决放电过程中不稳定问题的方案,同时为电火花加工工艺的研究提供了新的途径。
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引用次数: 0
A study on the displacement analysis in the injection moulding for the camera-phone 照相手机注塑过程中的位移分析研究
Q3 Engineering Pub Date : 2017-10-20 DOI: 10.1504/IJNM.2017.10008410
Joo-Sang Lee
Smartphones are currently the most popular electronic devices with high volume production activities driven by high demand and requirements for rapid turnaround time. The changes of displacement were analysed according to a variable of the gate size and runner system. The radial type and gate with large size were shown that better results in displacement. While the design and production of lenses, the key component of a camera, still need to be improved, the current technology has run into its limit with regard to trends in size and weight reduction. In this study, an injection moulding analysis was performed on plastic lenses that are widely employed for smartphone cameras. Specifically, the displacement of lenses at the time of injection moulding was studied by varying the gate size and runner system.
智能手机是目前最受欢迎的电子设备,其大量生产活动受到高需求和快速周转时间要求的驱动。根据闸门尺寸和转轮系统的变化,分析了位移的变化。径向型和大尺寸闸门的位移效果较好。虽然作为相机关键部件的镜头的设计和生产仍需改进,但就尺寸和重量减轻的趋势而言,目前的技术已经达到了极限。在这项研究中,对广泛用于智能手机摄像头的塑料镜头进行了注塑分析。具体而言,通过改变浇口尺寸和流道系统来研究注射成型时透镜的位移。
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引用次数: 0
A multiscale simulation investigation of dislocation behaviour of PCD failure process PCD破坏过程位错行为的多尺度模拟研究
Q3 Engineering Pub Date : 2017-10-20 DOI: 10.1504/IJNM.2017.10008422
Jinxuan Bai, Q. Bai
Although polycrystalline diamond (PCD) is ever viewed as brittle materials, it can present strong dislocation activity in certain condition. In this paper, the two dimensional discrete dislocation plastic (DDP) simulation under fully periodic boundary conditions was employed to study PCD dislocation behaviour. Crystal dissipation and entropy theory were introduced into the computational study to reveal dislocation density evolution and disordered sequence during PCD failure process. Our result showed that the developed model can capture the essential features of PCD dislocation evolution behaviour and realises accurate description of PCD failure process. Investigations of plastic dissipation and dislocation structure evolution reveal that the dislocation structure evolution plays a key role in the fracture process.
聚晶金刚石(PCD)一直被认为是一种脆性材料,但在一定条件下,它会表现出很强的位错活性。本文采用全周期边界条件下二维离散位错塑性(DDP)模拟方法研究了PCD的位错行为。将晶体耗散和熵理论引入计算研究,揭示了PCD失效过程中位错密度的演化和无序顺序。结果表明,所建立的模型能够捕捉到PCD位错演化行为的基本特征,实现了对PCD破坏过程的准确描述。塑性耗散和位错结构演化研究表明,位错结构演化在断裂过程中起着关键作用。
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引用次数: 0
期刊
International Journal of Nanomanufacturing
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