Pub Date : 2023-08-09DOI: 10.1177/09544054231189104
Shashank Shukla, R. Jain, S. Gangopadhyay
Drill tip wandering during the entrance in the workpiece is a significant issue in micro-drilling because it directly affects hole quality, drill bit and dynamic stability. Although radial force and radial torque significantly influence drill tip wandering, measuring these characteristics has always been challenging, particularly due to their extremely low values. Therefore, the current research work aimed at measuring and analysing radial force and radial torque and correlating them with hole quality characteristics for the first time. Micro-holes are drilled on Al7075-T6 workpiece material using the pilot hole drilling technique under a wide range of spindle speeds and feeds. Radial force and radial torque exhibit increasing and decreasing behaviour with spindle speed, indicating the ‘size effect’. The oversize error shows an increasing trend with spindle speed and is closely related to radial force and radial torque. The deformation layer displays an increasing and decreasing pattern with spindle speed, clearly separating size effect regions. Furthermore, under a field-emission scanning electron microscope (FESEM), the deformation layer shows a higher possibility of cracks in the shearing region. However, due to the size effect, material accumulation with lesser or no cracks are obtained in the ploughing and transition regions. Hence, this research work clearly shows evidence of the ‘size effect’ and correlates it with radial force and radial torque for the first time. In addition, the impact of radial force and radial torque on hole oversize error and deformation layer in micro-drilling is being reported for the first time.
{"title":"Measurement and analysis of radial force, radial torque and surface integrity in micro-drilling of an Al7075-T6 alloy","authors":"Shashank Shukla, R. Jain, S. Gangopadhyay","doi":"10.1177/09544054231189104","DOIUrl":"https://doi.org/10.1177/09544054231189104","url":null,"abstract":"Drill tip wandering during the entrance in the workpiece is a significant issue in micro-drilling because it directly affects hole quality, drill bit and dynamic stability. Although radial force and radial torque significantly influence drill tip wandering, measuring these characteristics has always been challenging, particularly due to their extremely low values. Therefore, the current research work aimed at measuring and analysing radial force and radial torque and correlating them with hole quality characteristics for the first time. Micro-holes are drilled on Al7075-T6 workpiece material using the pilot hole drilling technique under a wide range of spindle speeds and feeds. Radial force and radial torque exhibit increasing and decreasing behaviour with spindle speed, indicating the ‘size effect’. The oversize error shows an increasing trend with spindle speed and is closely related to radial force and radial torque. The deformation layer displays an increasing and decreasing pattern with spindle speed, clearly separating size effect regions. Furthermore, under a field-emission scanning electron microscope (FESEM), the deformation layer shows a higher possibility of cracks in the shearing region. However, due to the size effect, material accumulation with lesser or no cracks are obtained in the ploughing and transition regions. Hence, this research work clearly shows evidence of the ‘size effect’ and correlates it with radial force and radial torque for the first time. In addition, the impact of radial force and radial torque on hole oversize error and deformation layer in micro-drilling is being reported for the first time.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"121 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-08-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"75710376","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Single crystal silicon wafers are often used as substrate material for integrated circuits. Often the wafer is cut by a wire with fixed abrasive diamond owning to a narrow kerf and a low cutting force. The cutting force changes during the process as the direction of wire movement continuously reverses (i.e., reciprocates), which may cause the wire saw to break, the wafer to collapse, and the wafer surface roughness to decrease even if the wire saw tension and the contact length between the wire and the wafer are fixed. In this work, a cutting force model including both normal and tangential forces was established to determine the relationship between the normal and tangential forces and the commanded wire speed. Separate controllers were developed to regulate both the normal force and the tangential force by adjusting the wire velocity. Experimental studies were conducted for wire saw processing of single crystal silicon wafers. Compared with a process using constant wire velocity, regulating the normal force can significantly reduce the processing time and the wafer surface roughness. The average improvements in processing time and wafer surface roughness are approximately 11% and 56%, respectively, when using normal force control, and approximately 29% and 30%, respectively, when using tangential force control. The results show that the normal and tangential forces can be well regulated during the machining process. In addition, the wafer surface roughness and machining time were lower in both experiments where the forces were regulated than in the experiment where a constant wire velocity was used. This paper demonstrates that the novel concept of regulating process forces in wire saw machining by adjusting the wire velocity can be used to optimize the cutting process of single crystal silicon, making the process more productive while decreasing the part roughness.
{"title":"Cutting force modeling and control of single crystal silicon using wire saw velocity reciprocation","authors":"Jiabin Wang, Shujuan Li, Lie Liang, Zheng Hao, Feilong Liu, R. Landers","doi":"10.1177/09544054231190023","DOIUrl":"https://doi.org/10.1177/09544054231190023","url":null,"abstract":"Single crystal silicon wafers are often used as substrate material for integrated circuits. Often the wafer is cut by a wire with fixed abrasive diamond owning to a narrow kerf and a low cutting force. The cutting force changes during the process as the direction of wire movement continuously reverses (i.e., reciprocates), which may cause the wire saw to break, the wafer to collapse, and the wafer surface roughness to decrease even if the wire saw tension and the contact length between the wire and the wafer are fixed. In this work, a cutting force model including both normal and tangential forces was established to determine the relationship between the normal and tangential forces and the commanded wire speed. Separate controllers were developed to regulate both the normal force and the tangential force by adjusting the wire velocity. Experimental studies were conducted for wire saw processing of single crystal silicon wafers. Compared with a process using constant wire velocity, regulating the normal force can significantly reduce the processing time and the wafer surface roughness. The average improvements in processing time and wafer surface roughness are approximately 11% and 56%, respectively, when using normal force control, and approximately 29% and 30%, respectively, when using tangential force control. The results show that the normal and tangential forces can be well regulated during the machining process. In addition, the wafer surface roughness and machining time were lower in both experiments where the forces were regulated than in the experiment where a constant wire velocity was used. This paper demonstrates that the novel concept of regulating process forces in wire saw machining by adjusting the wire velocity can be used to optimize the cutting process of single crystal silicon, making the process more productive while decreasing the part roughness.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"20 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"80940890","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-08-01DOI: 10.1177/09544054221136524
M. Tlija, A. Al-Tamimi
Smart manufacturing involves the use of emergent technologies and requires dynamic feedback of customer’s demands. These concerns need a rapid Decision Support System (DSS) considering emergent manufacturing processes such as Additive (AM) and Hybrid (HM) Manufacturing and tracking the product changes. This paper proposes a DSS for process selection based on manufacturing complexity and cost. The complexity parameters, deduced from design for manufacturing (DFM), design for additive manufacturing (DFAM) and design for hybrid manufacturing (DFHM) rules, are automatically extracted from computer aided design (CAD) model to follow the product changes. Cost models are defined for each manufacturing process type. In design phase, the manufacturing cost estimation allows considering the cost as a selection factor. The combined complexity based on manufacturing difficulty and cost represents a new paradigm for process selection. The case studies show the reliability of the proposed DSS and its ability to respect the company resources and strategy.
{"title":"Combined manufacturing and cost complexity scores-based process selection for hybrid manufacturing","authors":"M. Tlija, A. Al-Tamimi","doi":"10.1177/09544054221136524","DOIUrl":"https://doi.org/10.1177/09544054221136524","url":null,"abstract":"Smart manufacturing involves the use of emergent technologies and requires dynamic feedback of customer’s demands. These concerns need a rapid Decision Support System (DSS) considering emergent manufacturing processes such as Additive (AM) and Hybrid (HM) Manufacturing and tracking the product changes. This paper proposes a DSS for process selection based on manufacturing complexity and cost. The complexity parameters, deduced from design for manufacturing (DFM), design for additive manufacturing (DFAM) and design for hybrid manufacturing (DFHM) rules, are automatically extracted from computer aided design (CAD) model to follow the product changes. Cost models are defined for each manufacturing process type. In design phase, the manufacturing cost estimation allows considering the cost as a selection factor. The combined complexity based on manufacturing difficulty and cost represents a new paradigm for process selection. The case studies show the reliability of the proposed DSS and its ability to respect the company resources and strategy.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"78 1","pages":"1473 - 1484"},"PeriodicalIF":2.6,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"72905860","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-08-01DOI: 10.1177/09544054231189300
Ahmed Seifallah Frih, Ezzeddine Ftoutou, Ated Ben Khalifa, M. Trigui
Fe-Ni alloys present excellent heat resistance properties while preserving their rigidity, strength, toughness, and dimensional stability at high temperatures. As a result, they are widely used in manufacturing aerospace or aeronautic parts where the operating temperature is very close to their melting temperature. Supra50 (named in the Unified Numbering System UNS as K94800) is a Fe-Ni alloy currently used in space and aviation industries, which confirmed its efficiency. However, improving the surface roughness of this high-precision part is challenging to overcome in manufacturing. The main objective of this study is to carry out an experiment based on a factorial plan and aims to predict the surface roughness of Supra50 parts as a function of cutting parameters in a milling process. Results show that the best combination of cutting parameters, giving the best surface roughness, is obtained at the lowest value of feed per tooth. Results also show that cutting speed and radial depth have little effect on roughness quality.
{"title":"Experimental optimization of cutting conditions to improve surface roughness of aeronautic parts made of Fe-Ni alloys","authors":"Ahmed Seifallah Frih, Ezzeddine Ftoutou, Ated Ben Khalifa, M. Trigui","doi":"10.1177/09544054231189300","DOIUrl":"https://doi.org/10.1177/09544054231189300","url":null,"abstract":"Fe-Ni alloys present excellent heat resistance properties while preserving their rigidity, strength, toughness, and dimensional stability at high temperatures. As a result, they are widely used in manufacturing aerospace or aeronautic parts where the operating temperature is very close to their melting temperature. Supra50 (named in the Unified Numbering System UNS as K94800) is a Fe-Ni alloy currently used in space and aviation industries, which confirmed its efficiency. However, improving the surface roughness of this high-precision part is challenging to overcome in manufacturing. The main objective of this study is to carry out an experiment based on a factorial plan and aims to predict the surface roughness of Supra50 parts as a function of cutting parameters in a milling process. Results show that the best combination of cutting parameters, giving the best surface roughness, is obtained at the lowest value of feed per tooth. Results also show that cutting speed and radial depth have little effect on roughness quality.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"214 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"73979735","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-31DOI: 10.1177/09544054231189313
Shihao Wu, Y. Li, Weiguang Li, Xuezhi Zhao, Jiawei Zheng, Ru Chen, Song Yan, Shoujin Lin
Accurate prediction of the remaining useful life for the cutting tool is a key part of the predictive maintenance of computer numerical control machines. However, the wide variety of tools makes the process of modeling different tool wear regularities redundant and cumbersome. In addition, it is difficult to deal with the input characteristics of multi-sensor monitoring signals in a targeted manner. To solve the above problems, a hybrid predictive model with squeeze-and-excitation (SE) module is proposed. Combined with adaptive feature extraction based on convolutional neural network and observation based on bidirectional gated recurrent unit, accurate multivariate regression prediction is achieved. The SE module enhances the focus on crucial features. Finally, through the design of the tool wear experiment and the combination of the public dataset, the accuracy and generalization ability of the proposed model are verified under different tool types and different working conditions.
{"title":"Tool remaining useful life prediction considering wear state based on hybrid attention network","authors":"Shihao Wu, Y. Li, Weiguang Li, Xuezhi Zhao, Jiawei Zheng, Ru Chen, Song Yan, Shoujin Lin","doi":"10.1177/09544054231189313","DOIUrl":"https://doi.org/10.1177/09544054231189313","url":null,"abstract":"Accurate prediction of the remaining useful life for the cutting tool is a key part of the predictive maintenance of computer numerical control machines. However, the wide variety of tools makes the process of modeling different tool wear regularities redundant and cumbersome. In addition, it is difficult to deal with the input characteristics of multi-sensor monitoring signals in a targeted manner. To solve the above problems, a hybrid predictive model with squeeze-and-excitation (SE) module is proposed. Combined with adaptive feature extraction based on convolutional neural network and observation based on bidirectional gated recurrent unit, accurate multivariate regression prediction is achieved. The SE module enhances the focus on crucial features. Finally, through the design of the tool wear experiment and the combination of the public dataset, the accuracy and generalization ability of the proposed model are verified under different tool types and different working conditions.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"15 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-07-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"86009010","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-31DOI: 10.1177/09544054231189763
Lianjie Li, Haibo Xie, Tao Zhang, Di Pan, Tianwu Liu, Xingsheng Li, Xu Liu, Enrui Wang, Hongqiang Liu, Li Sun, Zhengyi Jiang
Thermal crown and wear crown of work roll (TWW) are the main interfering factors of loaded roll gap profile in tandem cold rolling (TCR). However, the effect of TWW on the strip shape is not well understood. This paper presents a quantitative study about the effect of TWW on the strip crown and strip flatness based on a novel 3D multi-pass elastic-plastic finite element (EPFE) model that has been validated by industrial trials in the TCR. The results show that the thermal crown introduces the centre wave and quarter wave, while the wear crown brings in the edge wave and edge-centre coupled wave; the thermal crown has a larger influence efficiency on the quadratic strip shape than the wear crown does, while the wear crown exerts a larger influence efficiency on the quartic strip shape than the thermal crown does. In addition, the influence efficiency of TWW on the strip crown decreases nonlinearly with an increase in strip plastic rigidity from Pass 1 (P1) to Pass 5 (P5). This is the first scientific report on the link between the strip plastic rigidity and the effect of TWW on the strip crown, affording the mathematical models for predicting the influence efficiency of TWW based on the strip plastic rigidity at each pass.
{"title":"Influences of thermal crown and wear crown of work roll on strip shape in tandem cold rolling using a novel 3D multi-pass FE model","authors":"Lianjie Li, Haibo Xie, Tao Zhang, Di Pan, Tianwu Liu, Xingsheng Li, Xu Liu, Enrui Wang, Hongqiang Liu, Li Sun, Zhengyi Jiang","doi":"10.1177/09544054231189763","DOIUrl":"https://doi.org/10.1177/09544054231189763","url":null,"abstract":"Thermal crown and wear crown of work roll (TWW) are the main interfering factors of loaded roll gap profile in tandem cold rolling (TCR). However, the effect of TWW on the strip shape is not well understood. This paper presents a quantitative study about the effect of TWW on the strip crown and strip flatness based on a novel 3D multi-pass elastic-plastic finite element (EPFE) model that has been validated by industrial trials in the TCR. The results show that the thermal crown introduces the centre wave and quarter wave, while the wear crown brings in the edge wave and edge-centre coupled wave; the thermal crown has a larger influence efficiency on the quadratic strip shape than the wear crown does, while the wear crown exerts a larger influence efficiency on the quartic strip shape than the thermal crown does. In addition, the influence efficiency of TWW on the strip crown decreases nonlinearly with an increase in strip plastic rigidity from Pass 1 (P1) to Pass 5 (P5). This is the first scientific report on the link between the strip plastic rigidity and the effect of TWW on the strip crown, affording the mathematical models for predicting the influence efficiency of TWW based on the strip plastic rigidity at each pass.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"1 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-07-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"89632383","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-29DOI: 10.1177/09544054231189012
Chiranjibi Champatiray, M. V. A. Raju Bahubalendruni, Rabindra Mahapatra, Debasisha Mishra
Developing a practical and feasible assembly sequence plan for industrial applications is still challenging during product design and planning. Because of the need for more consideration of practical uncertainties, most of the assembly sequence plans generated by planners are inapplicable to real industrial-based problems. We have considered a crucial practical uncertainty attribute, tool uncertainties, in the current research. A novel approach has been proposed to generate optimal robotic assembly sequence plans by combining tool accessibility and part geometry. This research introduces two essential assembly tool accessibility attributes: tool-integrated geometric feasibility and tool-swept volume. In addition, the automatic extraction of tool accessibility attributes has been proposed. The proposed method is explained with a proper model and essential details such as liaison data, tool-integrated bounding box coordinates, tool-integrated geometric feasibility, and tool-swept volume data. Finally, the practical feasibility of the proposed method is verified for a different product configuration.
{"title":"Optimal assembly sequence planning with tool uncertainties","authors":"Chiranjibi Champatiray, M. V. A. Raju Bahubalendruni, Rabindra Mahapatra, Debasisha Mishra","doi":"10.1177/09544054231189012","DOIUrl":"https://doi.org/10.1177/09544054231189012","url":null,"abstract":"Developing a practical and feasible assembly sequence plan for industrial applications is still challenging during product design and planning. Because of the need for more consideration of practical uncertainties, most of the assembly sequence plans generated by planners are inapplicable to real industrial-based problems. We have considered a crucial practical uncertainty attribute, tool uncertainties, in the current research. A novel approach has been proposed to generate optimal robotic assembly sequence plans by combining tool accessibility and part geometry. This research introduces two essential assembly tool accessibility attributes: tool-integrated geometric feasibility and tool-swept volume. In addition, the automatic extraction of tool accessibility attributes has been proposed. The proposed method is explained with a proper model and essential details such as liaison data, tool-integrated bounding box coordinates, tool-integrated geometric feasibility, and tool-swept volume data. Finally, the practical feasibility of the proposed method is verified for a different product configuration.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"64 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-07-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"73784621","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-25DOI: 10.1177/09544054231189097
A. Sharma, N. Kumar, Alokekumar Das, Monty Kumar
Thrust plate in an external gear pump is one of the most important element which aligns the rotating gears and prevents the leakage through lateral clearances between rotating and non-rotating surfaces. It acts as a sacrificing element and fails frequently under fluctuating load pressure condition. The present research aims at enhancing the relative mechanical and tribological properties of the sacrificial thrust plate through electroless Ni-Mo-P coatings. Molybdenum (Mo) concentration in the electroless bath were tested for their effects on surface morphology, hardness, phase formation, wear rate, and wettability. A hard and self-lubricating layer (Al, Ni, Si, and Mo phases) on the coated surface was indicated by the compositional analysis performed using EDS and XRD. Results show that the microhardness of the coated surfaces has increased significantly by 149.5% (maximum hardness ~ 183.45 HV0.2) for 32 g L−1 Mo concentration. With 32 g L−1 Mo, the maximum coating thickness and water contact angle were 58 µm and 111°, respectively. The base material’s coefficient of friction was 0.5, whereas it was 0.25, 0.10, 0.06, and 0.03 for the samples made with 8, 16, 24, and 32 g L−1 Mo concentration, respectively. Compared to the uncoated sample, the maximum decrement in corrosion rate was found to be about six to seven times in the coated sample (with 32 g L−1 Mo). As a result, the developed coating surfaces provide hardness, lubricity, hydrophobicity, corrosion, and wear resistance simultaneously. The methodology of surface treatment can be used to modify the surface of critical hydraulic components having significant wear like in case of hydraulic cylinders.
外啮合齿轮泵的推力板是一种最重要的元件之一，它可以使旋转齿轮对准，防止通过旋转表面和非旋转表面之间的横向间隙泄漏。它作为一个牺牲元件，在波动载荷压力条件下经常失效。本研究旨在通过化学镀Ni-Mo-P涂层来提高牺牲推力板的相对力学性能和摩擦学性能。测试了化学镀液中钼(Mo)浓度对表面形貌、硬度、相形成、磨损率和润湿性的影响。EDS和XRD分析表明，涂层表面存在一层坚硬的自润滑层(Al、Ni、Si和Mo相)。结果表明，当Mo浓度为32 g L−1时，涂层表面的显微硬度显著提高了149.5%(最大硬度为183.45 HV0.2);当浓度为32 g L−1 Mo时，涂层最大厚度为58µm，水接触角为111°。基材的摩擦系数为0.5，而在8、16、24和32 g L−1 Mo浓度下，基材的摩擦系数分别为0.25、0.10、0.06和0.03。与未涂覆样品相比，涂覆样品(含32 g L−1 Mo)的腐蚀速率最大衰减约为6 ~ 7倍。因此，开发的涂层表面同时提供硬度、润滑性、疏水性、腐蚀性和耐磨性。表面处理方法可用于对液压缸等磨损较大的关键液压元件进行表面处理。
{"title":"Ni-Mo-P coatings on thrust plate of a gear pump to enhance its mechanical, tribological, and corrosion resistance properties","authors":"A. Sharma, N. Kumar, Alokekumar Das, Monty Kumar","doi":"10.1177/09544054231189097","DOIUrl":"https://doi.org/10.1177/09544054231189097","url":null,"abstract":"Thrust plate in an external gear pump is one of the most important element which aligns the rotating gears and prevents the leakage through lateral clearances between rotating and non-rotating surfaces. It acts as a sacrificing element and fails frequently under fluctuating load pressure condition. The present research aims at enhancing the relative mechanical and tribological properties of the sacrificial thrust plate through electroless Ni-Mo-P coatings. Molybdenum (Mo) concentration in the electroless bath were tested for their effects on surface morphology, hardness, phase formation, wear rate, and wettability. A hard and self-lubricating layer (Al, Ni, Si, and Mo phases) on the coated surface was indicated by the compositional analysis performed using EDS and XRD. Results show that the microhardness of the coated surfaces has increased significantly by 149.5% (maximum hardness ~ 183.45 HV0.2) for 32 g L−1 Mo concentration. With 32 g L−1 Mo, the maximum coating thickness and water contact angle were 58 µm and 111°, respectively. The base material’s coefficient of friction was 0.5, whereas it was 0.25, 0.10, 0.06, and 0.03 for the samples made with 8, 16, 24, and 32 g L−1 Mo concentration, respectively. Compared to the uncoated sample, the maximum decrement in corrosion rate was found to be about six to seven times in the coated sample (with 32 g L−1 Mo). As a result, the developed coating surfaces provide hardness, lubricity, hydrophobicity, corrosion, and wear resistance simultaneously. The methodology of surface treatment can be used to modify the surface of critical hydraulic components having significant wear like in case of hydraulic cylinders.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"149 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"87654487","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Shimming position and amount have a significant influence on the weight and mechanical performance of the thin-walled product that having assembly gap during aerospace components assembly process. An analytical method for assembly-induced deformation prediction of the bolted composite joints with assembly gap was developed. The assembly-induced deformation under the preloading force was computed as bending deformation and bolt head compression deformation by evaluating whether assembly gap can be eliminated and whether the calculating point is within the conical and spherical envelope of the fastener. The proposed method was validated by the preloading experiment of three-bolt composite joints with relative error less than 10%. Then it was applied to analyse the assembly-induced deformation of a composite box structure including composite spars and skins. Under the guide of the analytical result, shimming assembly of the composite box structure was carried out. The proposed analytical method has a good application prospect to predict the assembly-induced deformation during preloading process for composite/composite joints or composite/metal joints.
{"title":"Analytical method for assembly-induced deformation prediction of composite bolted joints with assembly gap","authors":"Yuxing Yang, Yu-Zhao Ma, Zhenghao Liu, Y. Bao, Jinlong Wang, Chen Chen","doi":"10.1177/09544054231188997","DOIUrl":"https://doi.org/10.1177/09544054231188997","url":null,"abstract":"Shimming position and amount have a significant influence on the weight and mechanical performance of the thin-walled product that having assembly gap during aerospace components assembly process. An analytical method for assembly-induced deformation prediction of the bolted composite joints with assembly gap was developed. The assembly-induced deformation under the preloading force was computed as bending deformation and bolt head compression deformation by evaluating whether assembly gap can be eliminated and whether the calculating point is within the conical and spherical envelope of the fastener. The proposed method was validated by the preloading experiment of three-bolt composite joints with relative error less than 10%. Then it was applied to analyse the assembly-induced deformation of a composite box structure including composite spars and skins. Under the guide of the analytical result, shimming assembly of the composite box structure was carried out. The proposed analytical method has a good application prospect to predict the assembly-induced deformation during preloading process for composite/composite joints or composite/metal joints.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"44 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"75196296","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-25DOI: 10.1177/09544054231188991
Z. Zhang, HS Zhou, ZJ Tan, DS Kong, YF. Wang
Both recrystallization and solid state phase transformation take key role for the determination of final mechanical properties in friction stir additive manufacturing (FSAM) of titanium alloy. Monte Carlo model is developed to simulate the microstructural changes and a two scale strategy is used to simulate both the recrystallization and the solid state phase transformation in FSAM of duplex titanium alloy. Results indicate that the selection of the building direction can lead to different temperature variations in FSAM due to the different heat accumulations. Lower temperature leads to lower cooling rate in FSAM. This is the reason that the volume fraction of α phase is decreased when the process temperature is decreased. Higher temperature leads to the formation of bigger grains when the rotating speed is increased or the transverse speed is decreased.
{"title":"The simulation of microstructural evolutions in friction stir additive manufacturing","authors":"Z. Zhang, HS Zhou, ZJ Tan, DS Kong, YF. Wang","doi":"10.1177/09544054231188991","DOIUrl":"https://doi.org/10.1177/09544054231188991","url":null,"abstract":"Both recrystallization and solid state phase transformation take key role for the determination of final mechanical properties in friction stir additive manufacturing (FSAM) of titanium alloy. Monte Carlo model is developed to simulate the microstructural changes and a two scale strategy is used to simulate both the recrystallization and the solid state phase transformation in FSAM of duplex titanium alloy. Results indicate that the selection of the building direction can lead to different temperature variations in FSAM due to the different heat accumulations. Lower temperature leads to lower cooling rate in FSAM. This is the reason that the volume fraction of α phase is decreased when the process temperature is decreased. Higher temperature leads to the formation of bigger grains when the rotating speed is increased or the transverse speed is decreased.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"1 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"85657657","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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