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Study on microstructural evolution of near-net shape forging process of AA6082 wheel – Dynamic recrystallization and processing map analysis AA6082 车轮近净成形锻造过程的微观结构演变研究 - 动态再结晶和加工图分析
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.006
Imang Eko Saputro , Chun-Nan Lin , Intan Mardiono , Hsuan-Fan Chen , Junwei Chen , Marlon Ho , Yiin-Kuen Fuh
The hot deformation behavior of AA6082 was investigated through isothermal compression tests performed within a temperature range of 350 °C to 560 °C and a strain rate range of 0.05 to 15 s−1 to replicate the actual process of a wheel near-net shape forging process using finite element (FE)-based numerical simulations. The near-net shape forging technology of an AA6082 commercial wheel consists of three stages: preforming, rough forging, and finish forging. The constitutive model of flow stress data was numerically integrated using a novel strategy that incorporates nonlinear regression methods on the mathematical models of up-to-peak, dynamic recovery (DRV), and dynamic recrystallization (DRX) behaviors of the material during isothermal compression tests. A processing map analysis was established based on the flow stress data, and the obtained parameters, such as power dissipation efficiency and instability, were integrated into the numerical model using trilinear interpolation with a clamping method. The primary contribution of this study is to evaluate the effectiveness of the numerically integrated processing map parameters in predicting microstructural grain evolutions during the wheel near-net shape forging process. Microstructures of the material in several areas of the workpiece after each forging stage were examined using an optical microscope. Subsequently, the Johnson-Mehl-Avrami-Kolmogorov (JMAK) numerical model of dynamic grain size was derived from a combination of experimental observations and numerical processing parameters to establish a prediction of average grain size in all areas of the workpieces during each stage. Overall results demonstrate that the new strategy employed in constitutive modeling is practical, efficient, and highly accurate in modeling the high-noise flow stress curves of AA6082 material, achieving an average absolute relative error of 1.88 %. The new numerical model for average grain size prediction closely aligns with experimental measurements, exhibiting errors below 6 % in most observation areas. However, one area was identified with a 12.88 % error, attributed to a grain growth defect. The new numerical simulation results of processing map parameters are promising in predicting recrystallization conditions and accurately identifying defect-prone areas. Ultimately, the near-net shape forging technology successfully refined the grain size on the wheel by 53.42 % to 61.66 %, and the uniformity of grain size increased to 92.43 % and 95.46 % after the rough and finish forging processes, respectively.
通过等温压缩试验研究了 AA6082 的热变形行为,试验温度范围为 350 °C 至 560 °C,应变速率范围为 0.05 至 15 s-1,利用基于有限元(FE)的数值模拟复制了车轮近净成形锻造工艺的实际过程。AA6082 商用轮毂的近净成形锻造技术包括三个阶段:预成形、粗锻造和精锻造。在等温压缩试验过程中,采用一种新颖的策略对流动应力数据的构成模型进行了数值整合,该策略将非线性回归方法纳入了材料的上峰、动态恢复(DRV)和动态再结晶(DRX)行为数学模型。根据流动应力数据建立了加工图分析,并利用箝位法三线插值将所获得的功率耗散效率和不稳定性等参数集成到数值模型中。本研究的主要贡献在于评估了数值集成加工图参数在预测车轮近净成形锻造过程中微结构晶粒演变的有效性。使用光学显微镜检查了每个锻造阶段后工件多个区域材料的微观结构。随后,结合实验观察结果和数值加工参数,推导出了约翰逊-梅尔-阿夫拉米-科尔莫戈罗夫(JMAK)动态晶粒尺寸数值模型,从而对每个阶段工件所有区域的平均晶粒尺寸进行了预测。总体结果表明,在对 AA6082 材料的高噪声流动应力曲线进行建模时,所采用的构成模型新策略是实用、高效和高精度的,其平均绝对相对误差仅为 1.88%。新的平均晶粒尺寸预测数值模型与实验测量结果密切吻合,在大多数观测区域的误差低于 6%。不过,有一个区域的误差达到了 12.88%,这是由于晶粒生长缺陷造成的。新的加工图参数数值模拟结果有望预测再结晶条件,并准确识别缺陷易发区域。最终,近净成形锻造技术成功地将轮毂上的晶粒细化了 53.42 % 至 61.66 %,粗锻和精锻工艺后的晶粒尺寸均匀性分别提高到 92.43 % 和 95.46 %。
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引用次数: 0
Regulation of drop-on-demand e-jet printing based on minimum pulse width and critical frequency 基于最小脉冲宽度和临界频率的按需滴落式电子喷射印刷调节器
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.014
Jinwei Li , Zongkun Lao , Lin Li, Shuoyi Xu, Yuanfen Chen, J. Li, Z. Lao, L. Li, S. Xu, Pro.Y. Chen
Drop-on-demand E-Jet printing enables the precision preparation of micro- and nanodots, which has great applications in micro/nanostructure fabrications. However, to accurately regulate the size of the printed dots is still a challenge. In this paper, we propose a method to control the diameter of the E-Jet printed dots by predicted pulse width and jetting number based on the minimum pulse width and critical frequency, achieving precise dot size regulation within one single pulse width. Firstly, relationship between process parameters and Taylor cone formation time Tf, liquid jetting time Tj, meniscus retraction time Tr, minimum pulse width Tpwm, as well as critical frequency fc are systematically studied. Then the relationship between pulse width and jetting number within on pulse cycle is established. Subsequently, the random forest regression (RFR) model is applied to predict the minimum pulse width and critical frequency. The predicted pulse widths for desired numbers of jets are applied to print microdot arrays of different sizes. This proposed real drop-on-demand E-Jet printing method could be applied to micro- and nanostructure fabrications for flexible electronics and printed electronics.
按需滴落式电子喷射打印技术可精确制备微点和纳米点,在微/纳米结构制造中具有巨大的应用价值。然而,如何精确调节打印点的尺寸仍然是一个挑战。本文根据最小脉冲宽度和临界频率,提出了一种通过预测脉冲宽度和喷射次数来控制电子喷射打印点直径的方法,实现了单脉冲宽度内点尺寸的精确调节。首先,系统研究了工艺参数与泰勒锥形成时间 Tf、液体喷射时间 Tj、半月板回缩时间 Tr、最小脉冲宽度 Tpwm 以及临界频率 fc 之间的关系。然后建立了脉冲宽度与脉冲周期内喷射次数之间的关系。随后,应用随机森林回归(RFR)模型预测最小脉冲宽度和临界频率。预测出的所需喷射次数的脉冲宽度可用于打印不同尺寸的微点阵列。这种按需真滴电子喷射打印方法可应用于柔性电子器件和印刷电子器件的微纳米结构制造。
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引用次数: 0
A globally smooth tool path reconstruction method for the ultra-precision diamond turning of microlens arrays 用于超精密金刚石车削微透镜阵列的全局平滑刀具路径重建方法
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-14 DOI: 10.1016/j.jmapro.2024.11.023
Yangqin Yu, Hao Wu, Zhiyue Wang, Junnan Chen, Xinquan Zhang, Mingjun Ren, Limin Zhu
Microlens arrays have been widely used in industry and extensively researched in academia over the years. Lens arrays machined by slow and fast tool servo technologies commonly suffer from vibration marks near lens edges, which undermine surface finish and from accuracy. The vibration marks are caused by the machine tool's nonlinear response to abnormally large local tool path accelerations at lens edges. In this study, a globally smooth tool path reconstruction method based on frame line guided cubic spline interpolation is proposed. The incorporation of globally continuous frame lines is demonstrated to significantly improve both tangential and radial tool path smoothness. Comparative theoretical analysis and experimental investigation are conducted together with direct strategy and tangentially smooth strategy. Experimental results show significant suppression in vibration marks, a 43.8 % decrease in surface roughness Sa, and a 63.0 % decrease in form error PV compared to the direct strategy. And equal results are acquired using the proposed method with twice the efficiency of the direct method. Moreover, the nonuniformity of surface topography in a single lens resulting from the periodic cutting-in motions is also observed, explained and effectively reduced in this study.
多年来,微透镜阵列已广泛应用于工业领域,并在学术界得到了广泛研究。采用慢速和快速刀具伺服技术加工的透镜阵列通常会在透镜边缘附近出现振痕,从而影响表面光洁度和精度。振痕是由于机床对透镜边缘异常大的局部刀具路径加速度的非线性响应造成的。本研究提出了一种基于帧线引导的三次样条插值的全局平滑刀具路径重建方法。事实证明,全局连续帧线的加入能显著改善切向和径向刀具路径的平滑度。理论分析和实验研究与直接策略和切向平滑策略进行了比较。实验结果表明,与直接策略相比,振动痕迹明显减少,表面粗糙度 Sa 下降了 43.8%,形状误差 PV 下降了 63.0%。使用建议的方法可以获得相同的结果,其效率是直接方法的两倍。此外,本研究还观察、解释并有效减少了周期性切入运动导致的单个透镜表面形貌不均匀性。
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引用次数: 0
High-efficiency free-damage electrochemical shear-thickening polishing of single-crystal silicon carbide 单晶碳化硅的高效自由损伤电化学剪切增厚抛光
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-13 DOI: 10.1016/j.jmapro.2024.10.053
Mengmeng Shen , Lingwei Wu , Min Wei , Hongyu Chen , Julong Yuan , Binghai Lyu , Hui Deng , Suet To , Tufa Habtamu Beri , Wei Hang
A novel electrochemical shear-thickening polishing (ESTP) technique was proposed and successfully applied to polish a 4H-SiC (000-1) workpiece. An in-depth investigation of the anodization mechanism was undertaken and nanoindentation experiments and X-ray photoelectron spectroscopy were conducted to analyze the physical and chemical properties of oxidation product, confirming that the oxidation product was SiO2 and that the hardness decreased significantly from 21.07 GPa to 0.96 GPa after oxidation. The surfaces of 4H-SiC (000-1) workpieces were processed by ESTP at different voltages to study the relationship between the growth and removal rates of the oxide using scanning electron microscopy and energy dispersive spectrometry. The ideal voltage balancing the growth and removal rates of the oxide was determined to be 6 V based on Faraday's electromagnetic law. After 30 min of ESTP at 6 V, the average surface roughness Sa decreased significantly from 20.5 nm to 1.4 nm and the calculated material removal rate (MRR) was as high as 255.5 nm/min. Finally, the superiority of ESTP was subsequently demonstrated through a comparison with conventional shear-thickening polishing (STP) showing that ESTP exhibited an excellent polishing effect and effectively overcame the limited MRR of STP. In addition, the removal of subsurface damage was observed during the polishing process and confirmed by transmission electron microscopy. The observed phenomena demonstrate the efficient and nondestructive nature of the proposed ESTP technique, which represents an ideal polishing technology for hardy and brittle materials such as SiC.
提出了一种新型电化学剪切增厚抛光(ESTP)技术,并成功应用于 4H-SiC (000-1) 工件的抛光。对阳极氧化机理进行了深入研究,并通过纳米压痕实验和 X 射线光电子能谱分析了氧化产物的物理和化学性质,证实氧化产物为 SiO2,氧化后硬度从 21.07 GPa 显著下降到 0.96 GPa。在不同电压下对 4H-SiC (000-1) 工件表面进行 ESTP 处理,利用扫描电子显微镜和能量色散光谱仪研究氧化物生长率和去除率之间的关系。根据法拉第电磁定律,确定平衡氧化物生长率和去除率的理想电压为 6 V。在 6 V 电压下进行 30 分钟ESTP 后,平均表面粗糙度 Sa 从 20.5 nm 显著下降到 1.4 nm,计算得出的材料去除率 (MRR) 高达 255.5 nm/min。最后,通过与传统的剪切增厚抛光(STP)进行比较,证明了 ESTP 的优越性。此外,在抛光过程中还观察到了表面下损伤的消除,并通过透射电子显微镜得到了证实。所观察到的现象证明了所提出的 ESTP 技术的高效性和无损性,它是一种适用于碳化硅等硬脆材料的理想抛光技术。
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引用次数: 0
An efficient surrogate model for prediction of stress released distortion in large blade machining 用于预测大型叶片加工中应力释放变形的高效替代模型
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-13 DOI: 10.1016/j.jmapro.2024.10.066
Zhengtong Cao , Weihao Xu , Tao Huang, Yu Lv, Xiao-Ming Zhang, Han Ding
Deformation during the machining of large turbine blades based on a forged blank is always inevitable and unpredictable because of the individual difference in residual stress of the blanks. Compensation and control of the machining deformation is of great challenge since non-destructive measurement and accurate modeling of the distributed residual stress of complex surfaces are unavailable. To this end, this paper constructs a novel data-driven model based on the U-Koopman neural operator, which is an improvement of the Koopman neural operator to describe the relationship between the deformation after the current cutting stage and that of the next cutting stage. To avoid expensive experiments and tests, the finite element method is utilized to simulate the continuous multi-processes machining of large blades, which contains residual stress generation during forging process and deformation generation during cutting process, and then construct the dataset for model training. Cross-validation is implemented to verify the superior generalization ability of the proposed model over the benchmark models and the effectiveness of the related improvements of the model based U-Koopman neural operator. The results of case study show that the proposed model can predict and compensate for the deformation in-process and improve the machining accuracy and efficiency of large blades.
由于锻造坯料的残余应力存在个体差异,因此在加工基于锻造坯料的大型涡轮叶片时,变形总是不可避免且不可预测的。由于无法对复杂表面的分布式残余应力进行无损测量和精确建模,因此补偿和控制加工变形是一项巨大挑战。为此,本文构建了一个基于 U-Koopman 神经算子的新型数据驱动模型,该模型是对 Koopman 神经算子的改进,用于描述当前切削阶段后的变形与下一切削阶段的变形之间的关系。为了避免昂贵的实验和测试,利用有限元法模拟大型叶片的连续多工序加工,其中包括锻造过程中产生的残余应力和切削过程中产生的变形,然后构建用于模型训练的数据集。通过交叉验证验证了所建模型优于基准模型的泛化能力,以及基于 U-Koopman 神经算子对模型进行相关改进的有效性。案例研究结果表明,所提出的模型可以预测和补偿加工过程中的变形,提高大型叶片的加工精度和效率。
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引用次数: 0
The generation mechanism of cutting heat and the theoretical prediction model for temperature on the rake face of the cutting tool in Zirconia ceramics 氧化锆陶瓷切削热的产生机理及刀具斜面温度的理论预测模型
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-13 DOI: 10.1016/j.jmapro.2024.11.013
Yang Sun , Lianjie Ma , Jing Jia , Yanqing Tan , Shuyu Qi , Benjia Tang , Hongshuang Li , Yunguang Zhou
Cutting temperature and its distribution are crucial factors influencing tool strength and wear rate, due to the hardness and brittleness of Zirconia (ZrO2) ceramics, significant challenges arise in both direct temperature measurement in the cutting zone and theoretical analysis of cutting heat. Thus, focusing on the turning characteristics of ZrO2 ceramics, this study analyzes the mechanism of cutting heat generation and proposes utilizing thermodynamic state equations to determine the cutting heat source on rake face of tool. Based on the heat source method, a theoretically prediction model for temperature distribution on rake face is established. This model considers primary cutting parameters, workpiece material properties, crack fracture characteristics of the machined surface, and thermal characterizations of the tool material. The relationship between tool wear and cutting temperature is experimentally analyzed to determine the characteristic temperature that indicates the initial stage of tool wear. The validity of the theoretical model is verified, as the predicted results show high consistency with experimental results within the range of experimental parameters, with a relative error within 15.2 %.The results reveal the highest temperature during brittle cutting occurs within the cutting layer area, with the highest temperature occurring approximately 50 μm from the tool tip, followed by a gradual decrease beyond 150-200 μm. This study also demonstrates that cutting heat in ceramic turning does not solely originate from friction heat between tool flank-workpiece but also includes impact heat from tool rake face-workpiece, which under certain cutting parameters exerts a more significant influence on cutting temperature. This model can facilitate the selection and optimization of cutting process parameters for brittle materials and provide a theoretical basis for analyzing the relationship between tool thermal damage, thermophysical properties, and tool wear.
切削温度及其分布是影响刀具强度和磨损率的关键因素,由于氧化锆(ZrO2)陶瓷的硬度和脆性,直接测量切削区温度和切削热理论分析都面临巨大挑战。因此,针对 ZrO2 陶瓷的车削特性,本研究分析了切削热产生的机理,并提出利用热力学状态方程来确定刀具前刀面的切削热源。基于热源法,建立了切削面温度分布的理论预测模型。该模型考虑了主要切削参数、工件材料特性、加工表面的裂纹断裂特性以及刀具材料的热特性。通过实验分析刀具磨损与切削温度之间的关系,确定了表示刀具磨损初始阶段的特征温度。结果表明,脆性切削过程中的最高温度出现在切削层区域内,最高温度出现在距刀尖约 50 μm 处,随后在 150-200 μm 处逐渐降低。这项研究还表明,陶瓷车削中的切削热不仅来自刀具侧面与工件之间的摩擦热,还包括刀具前刀面与工件之间的冲击热,在某些切削参数下,冲击热对切削温度的影响更为显著。该模型有助于选择和优化脆性材料的切削工艺参数,并为分析刀具热损伤、热物理性能和刀具磨损之间的关系提供理论依据。
{"title":"The generation mechanism of cutting heat and the theoretical prediction model for temperature on the rake face of the cutting tool in Zirconia ceramics","authors":"Yang Sun ,&nbsp;Lianjie Ma ,&nbsp;Jing Jia ,&nbsp;Yanqing Tan ,&nbsp;Shuyu Qi ,&nbsp;Benjia Tang ,&nbsp;Hongshuang Li ,&nbsp;Yunguang Zhou","doi":"10.1016/j.jmapro.2024.11.013","DOIUrl":"10.1016/j.jmapro.2024.11.013","url":null,"abstract":"<div><div>Cutting temperature and its distribution are crucial factors influencing tool strength and wear rate, due to the hardness and brittleness of Zirconia (Z<sub>r</sub>O<sub>2</sub>) ceramics, significant challenges arise in both direct temperature measurement in the cutting zone and theoretical analysis of cutting heat. Thus, focusing on the turning characteristics of Z<sub>r</sub>O<sub>2</sub> ceramics, this study analyzes the mechanism of cutting heat generation and proposes utilizing thermodynamic state equations to determine the cutting heat source on rake face of tool. Based on the heat source method, a theoretically prediction model for temperature distribution on rake face is established. This model considers primary cutting parameters, workpiece material properties, crack fracture characteristics of the machined surface, and thermal characterizations of the tool material. The relationship between tool wear and cutting temperature is experimentally analyzed to determine the characteristic temperature that indicates the initial stage of tool wear. The validity of the theoretical model is verified, as the predicted results show high consistency with experimental results within the range of experimental parameters, with a relative error within 15.2 %.The results reveal the highest temperature during brittle cutting occurs within the cutting layer area, with the highest temperature occurring approximately 50 μm from the tool tip, followed by a gradual decrease beyond 150-200 μm. This study also demonstrates that cutting heat in ceramic turning does not solely originate from friction heat between tool flank-workpiece but also includes impact heat from tool rake face-workpiece, which under certain cutting parameters exerts a more significant influence on cutting temperature. This model can facilitate the selection and optimization of cutting process parameters for brittle materials and provide a theoretical basis for analyzing the relationship between tool thermal damage, thermophysical properties, and tool wear.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 584-597"},"PeriodicalIF":6.1,"publicationDate":"2024-11-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657378","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Feasibility analysis and parameter optimization of ultrasonic assisted electrolytic plasma polishing of small modulus gears 小模数齿轮超声波辅助电解等离子抛光的可行性分析和参数优化
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-13 DOI: 10.1016/j.jmapro.2024.11.022
Yangjian Chen , Jun Yi , Huixu Song , Wei Zhou , Hui Deng
Precision polishing of small modulus gears is a difficult task due to the complexity of their geometry. Electrolytic plasma polishing technology as a green and efficient processing method, it can effectively decrease the friction between parts and improve the service life. However, considering the uneven distribution of gas layers on the surface of workpieces in electrolytic plasma polishing, which affects the precision of workpiece shapes after polishing, this study proposed the use of ultrasonic vibrations to generate pressure waves to improve the fluid characteristics. Comparative experiments on small modulus gear electrolytic plasma polishing with and without ultrasonic vibration were conducted. A high-speed camera was utilized to monitor the distribution of gas layers around the workpiece during the polishing process in real-time. The optical measurement methods were used to evaluate the gear precision. The results indicate that ultrasonic assistance is beneficial in improving the uniformity of the gas layers surrounding the workpiece, achieving higher gear precision, and obtaining a lower surface roughness after polishing. Through orthogonal experiments, this study analyzed the effects of various process parameters on the surface roughness of gear profiles and the uniformity of material removal after polishing. These parameters included power voltage, polishing time, workpiece immersion depth, ultrasonic frequency, and workpiece posture angle. An optimal combination of process parameters was identified. The results show that the best surface roughness and gear precision were achieved with a power voltage of 300 V, a polishing time of 4 min, a workpiece immersion depth of about 10 mm, an ultrasonic frequency of 40 kHz, and a workpiece tilt angle of 45°.
由于小模数齿轮的几何形状复杂,对其进行精密抛光是一项艰巨的任务。电解等离子抛光技术作为一种绿色高效的加工方法,可以有效降低零件之间的摩擦,提高使用寿命。但考虑到电解等离子抛光中工件表面气层分布不均匀,影响抛光后工件形状精度,本研究提出利用超声波振动产生压力波来改善流体特性。研究人员对有超声波振动和无超声波振动的小模数齿轮电解等离子抛光进行了对比实验。在抛光过程中,利用高速摄像机实时监测工件周围的气层分布。采用光学测量方法对齿轮精度进行了评估。结果表明,超声波辅助有利于改善工件周围气体层的均匀性,实现更高的齿轮精度,并在抛光后获得更低的表面粗糙度。通过正交实验,本研究分析了各种工艺参数对齿轮轮廓表面粗糙度和抛光后材料去除均匀性的影响。这些参数包括电源电压、抛光时间、工件浸入深度、超声波频率和工件姿态角。最终确定了工艺参数的最佳组合。结果表明,功率电压为 300 V、抛光时间为 4 分钟、工件浸入深度约为 10 mm、超声波频率为 40 kHz、工件倾斜角度为 45°时,表面粗糙度和齿轮精度最佳。
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引用次数: 0
Direct ink writing of 17–4PH stainless steel using green binder: Rheological sensitivity and performance assessment 使用绿色粘合剂对 17-4PH 不锈钢进行直接油墨书写:流变敏感性和性能评估
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-12 DOI: 10.1016/j.jmapro.2024.10.077
Sean Wei Zen Fong , Jing Yuen Tey , Wei Hong Yeo , Shiau Foon Tee
Direct ink writing has emerged as a promising and cost-effective 3D stainless steel printing technique due to its capability in room temperature printing without a heat source. In this study, a novel solvent-based cellulose-derivative binder was incorporated to form a yield-pseudoplastic colloidal ink suspension up to 54.9 vol% (or 91.5 wt%) solid loading, improving shrinkage predictability. Rheological sensitivity analysis is used to construct a printability boundary for stainless steel printing with the cellulose-derivative binder. The method proposed in this paper offers attractiveness over conventional powder bed fusion, particularly in avoiding the challenges associated with loosely packed powder handling and environment safety. Moreover, it addresses environmental concerns by making use of non-toxic and eco-friendly binder. A comprehensive analysis of rheological study was conducted to identify parameters affecting printability and shape retention by varying the binder concentration and metal content. Through the sensitivity rheology analysis, the outcome yields exceptional printing quality and demonstrates its capability in producing complex parts. The sintered performance: achieving 93.6 % density at a sintering temperature of 1360 °C, minimal carbon content (0.033 wt%), with a hardness of 35.8 HRC and xyz-shrinkage of 10.81 %, 10.78 %, and 11.85 %, respectively which has high performance competitive value to technologies currently dominating the market like atomic diffusion additive manufacturing and bound metal deposition.
直接墨水写入技术无需热源即可进行室温打印,因此已成为一种前景广阔且经济高效的三维不锈钢打印技术。在本研究中,加入了一种新型溶剂型纤维素衍生物粘合剂,以形成一种固体含量高达 54.9 vol%(或 91.5 wt%)的良率-假塑性胶体油墨悬浮液,从而提高了收缩率的可预测性。流变敏感性分析用于构建使用纤维素衍生物粘合剂进行不锈钢印刷的可印刷性边界。本文提出的方法比传统的粉末床融合方法更具吸引力,尤其是避免了与松散包装粉末处理和环境安全相关的挑战。此外,它还通过使用无毒环保的粘合剂解决了环境问题。通过改变粘合剂浓度和金属含量,对流变研究进行了全面分析,以确定影响印刷适性和形状保持的参数。通过灵敏度流变分析,结果获得了卓越的打印质量,并证明了其生产复杂零件的能力。烧结性能:在烧结温度为 1360 °C 时密度达到 93.6%,碳含量最低(0.033 wt%),硬度为 35.8 HRC,xyz-收缩率分别为 10.81 %、10.78 % 和 11.85 %,与目前市场上占主导地位的原子扩散增材制造和结合金属沉积等技术相比,具有很高的性能竞争价值。
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引用次数: 0
Investigation of MoSe2 filled MAO Coating on TC6 alloy- tribological and corrosion characterization of multiple interface structure 研究 TC6 合金上的 MoSe2 填充 MAO 涂层--多界面结构的摩擦学和腐蚀表征
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-12 DOI: 10.1016/j.jmapro.2024.10.017
An Liu , Song Gao , Hailin Lu
To enhance the tribological properties and corrosion resistance of titanium alloys, this study proposes a novel tribological interface structure combining micro-arc oxidation ceramic coatings with MoSe2. Comprehensive analysis using X-ray diffractometry, profilometry, energy-dispersive spectroscopy, and scanning electron microscopy was conducted to evaluate the tribological characteristics of this structure under dry friction and liquid lubrication conditions. Electrochemical experiments assessed the corrosion resistance of the structure. The results indicated that under 3 N-2.5 cm/s, oil lubrication, the structure exhibited the best friction-reducing and lubricating performance, with the friction coefficient reduced by 75 %. The synergistic interaction between the low shear force MoSe2 particles and the TiO2-rich ceramic coating formed a lubricating layer on the surface, thereby achieving reduced friction and enhanced wear resistance. Additionally, this structure demonstrated excellent corrosion resistance. This study provides valuable insights for integrating micro-arc oxidation with new materials in engineering applications.
为了提高钛合金的摩擦学性能和耐腐蚀性,本研究提出了一种结合了微弧氧化陶瓷涂层和 MoSe2 的新型摩擦学界面结构。利用 X 射线衍射仪、轮廓仪、能量色散光谱仪和扫描电子显微镜进行了综合分析,以评估该结构在干摩擦和液体润滑条件下的摩擦学特性。电化学实验评估了该结构的耐腐蚀性。结果表明,在 3 N-2.5 cm/s 的油润滑条件下,该结构的减摩和润滑性能最佳,摩擦系数降低了 75%。低剪切力的 MoSe2 颗粒与富含 TiO2 的陶瓷涂层之间的协同作用在表面形成了润滑层,从而实现了降低摩擦和增强耐磨性的目的。此外,这种结构还具有出色的耐腐蚀性。这项研究为微弧氧化与新材料在工程应用中的结合提供了宝贵的见解。
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引用次数: 0
Microstructural evolution of polycrystalline α-Fe/Fe3C ultra-precision grinded under water lubrication 水润滑条件下多晶α-Fe/Fe3C 超精密磨削的微观结构演变
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-12 DOI: 10.1016/j.jmapro.2024.11.007
Changjiang Zhou , Fa Zhang , Haifeng Chen , Ningwei Xia
Ultra-precision grinding has gained substantial attention for its ability to significantly improve surface integrity. However, existing studies rarely investigate the effects of lubrication conditions at the microscopic level, which limits the understanding of microstructure evolution during ultra-precision grinding. In this work, a large-scale molecular dynamic (MD) method is proposed for simulating microstructural evolution of polycrystalline α-Fe/Fe3C ultra-precision grinded under water lubrication. The water molecule and polycrystalline α-Fe/Fe3C models are established using the measured and calculated interatomic potential functions. The effects of grinding parameters (infeed depth and lubrication status) on the ultra-precision grinding of internal stresses, temperature fields, workpiece topography and plastic deformation are investigated. Results show that the water film has a beneficial impact on workpiece quality, but has a negative effect on grinding efficiency. The plastic deformation mechanism of ultra-precision grinded polycrystalline α-Fe/Fe3C primarily involves dislocation modulation, with the water film serving to reduce dislocations and promote cluster formation. This work offers valuable insights into the production of high-quality components.
超精密磨削能够显著改善表面完整性,因而受到广泛关注。然而,现有研究很少从微观层面研究润滑条件的影响,这限制了对超精密磨削过程中微观结构演变的理解。本研究提出了一种大规模分子动力学(MD)方法,用于模拟水润滑条件下多晶α-Fe/Fe3C超精密磨削的微观结构演变。利用测量和计算的原子间势函数建立了水分子和多晶 α-Fe/Fe3C 模型。研究了磨削参数(进给深度和润滑状态)对超精密磨削内应力、温度场、工件形貌和塑性变形的影响。结果表明,水膜对工件质量有利,但对磨削效率有负面影响。超精密磨削多晶α-Fe/Fe3C 的塑性变形机制主要涉及位错调制,水膜的作用是减少位错并促进簇的形成。这项工作为生产高质量元件提供了宝贵的见解。
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Journal of Manufacturing Processes
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