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An Approach to Optimize Mig Welding Parameters by Using Design of Experiments 用试验设计优化Mig焊接参数的方法
Pub Date : 2015-03-01 DOI: 10.11127/IJAMMC.2015.03.04
Priti Sonasale
The Metal arc Welding (MIG) process finds wide application because all commercially important applicable metals such as carbon steel, high-strength, low-alloy steel, and stainless steel, aluminum, copper, titanium, and nickel alloys can be welded in all positions with this process by choosing the appropriate shielding gas, electrode, and welding variables.In this work, the five control factors such as wire feed rate, arc voltage, welding speed, nozzle to plate distance and gas flow rate are considered.The welding parameters such as bead width, dilution and depth of HAZ have been considered.By using DOE method, the weld parameters were optimized. Analysis is done using ANOVA to determine the significance of parameters.Finally the confirmation test is carried out to compare the predicated values with the experimental values confirm its effectiveness in the analysis of bead width, dilution and depth of HAZ.
金属电弧焊(MIG)工艺具有广泛的应用,因为所有商业上重要的适用金属,如碳钢,高强度,低合金钢,不锈钢,铝,铜,钛和镍合金,都可以通过选择适当的保护气体,电极和焊接变量在此工艺的所有位置焊接。在这项工作中,考虑了送丝速度、电弧电压、焊接速度、喷嘴到板的距离和气体流量等五个控制因素。考虑了焊头宽度、热影响区稀释度、热影响区深度等焊接参数。采用DOE法对焊接参数进行了优化。分析使用方差分析来确定参数的显著性。最后进行了验证试验,将预测值与实验值进行了比较,验证了其在热影响区粒径、稀释度和深度分析中的有效性。
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引用次数: 18
Multi-Objective Optimization in CNC Milling Process of Al-Cu-Zn Alloy Matrix Composite by Using Taguchi-Grey Relational Analysis Technique 基于田口灰关联分析的铝铜锌合金基复合材料数控铣削加工多目标优化
Pub Date : 2015-03-01 DOI: 10.11127/IJAMMC.2015.03.05
V. Saikumar, V. Venkatesh, P. Sivaiah
A B S T R A C T In present the improved demand of lightweight materials by high strength to weight ratio in the aerospace and automotive industries has managed to the development and custom of Al-alloy-based composites. In this paper an effort has been prepared the Al6082+Cu+Zn composite material and the optimization of CNC milling process parameters for two different work materials of compositions are Al6082 96%+Cu3%+Zn1%, Al6082 89%+Cu7%+Zn4% composite material. .The characteristics of these alloys have strength as well as weight ratio makes the extensive research on Al-Cu-Zn alloy MMC is carried out universally because of it is widely used in automotive & aerospace industries. Tribological behavior of aluminum alloy matrix is fabricated by using the stir casting process was investigated. The concept of grey system stands a innovative optimizing technique for accomplishment the estimate, grey relational analysis and resolution building in various regions. In this paper, usage of grey relational analysis aimed to optimizing the machining process parameters for the work piece is surface roughness and the metal removal rate is familiarized. In directive to increase the quality and productivity by using the optimization of CNC milling process parameters like speed, feed rate, depth of cut and different coated HSS tools to afford a good surface finish as well as high material removal rate. Therefore a multi objective optimization problem has been obtained which can be solved by the hybrid Taguchi method comprising of grey relational analysis.. Finally, Taguchi method has been used to solve the optimization problem.
目前,航空航天和汽车工业对高强度重量比轻量化材料的需求不断提高,这促使了铝合金基复合材料的开发和定制。本文制备了Al6082+Cu+Zn复合材料,并对组成为Al6082 96%+Cu3%+Zn1%和Al6082 89%+Cu7%+Zn4%的复合材料进行了数控铣削工艺参数的优化,这些合金具有强度和重量比的特点,使得Al-Cu-Zn合金在汽车和航空航天工业中得到了广泛的应用,对其进行了广泛的研究。研究了搅拌铸造法制备铝合金基体的摩擦学性能。灰色系统的概念是一种创新的优化技术,用于完成各区域的估计、灰色关联分析和分辨率的建立。本文采用灰色关联分析方法对工件表面粗糙度和金属去除率进行了优化。通过优化数控铣削工艺参数,如速度、进给速度、切削深度和不同涂层的高速钢刀具,以提供良好的表面光洁度和高材料去除率,从而提高质量和生产率。由此得到了一个多目标优化问题,该问题可以用混合田口法求解。最后,采用田口法求解优化问题。
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引用次数: 9
Prediction of Chatter Vibration and Stability Mapping In Cylindrical Turning of AISI 1045 Steel AISI 1045钢圆柱车削颤振预测及稳定性映射
Pub Date : 2015-03-01 DOI: 10.11127/IJAMMC.2015.03.06
N. Mandal, Tanmoy Roy
Introduction Metal cutting process involves continuous removal of material from the work piece in the form of chips. Cutting process with a single point cutting tool like forming on a lathe, the heterogeneity of work piece material, the run-out or misalignment of the work piece may cause occasional disturbances to the cutting process resulting vibration of the work piece with respect to the cutting tool. If the cutting process is stable, the resulting vibration dies out quickly because of damping. However, under certain conditions, the magnitude of the ensuing vibration becomes ever increasing. This phenomenon is termed as chatter. In case of occurrence of chatter, the amplitude of the self-excited vibration increases until nonlinearity limits [1]. Results of chatter are rough surface finish, poor accuracy, shortened tool life and low metal-removal rate. Chatter becomes even more critical when machining materials that are difficult to cut. Some advanced cutting tool materials such as ceramic, silicon nitride and CBN require strict chatter control to prevent brittle breakage [2]. For high precision manufacturing, even mild vibration is undesirable. Furthermore, since modern machining systems, have become more flexible, frequently changing working conditions increase the possibility of bringing machining process into unstable operating regions [3].The productivity of expensive. Machining systems is often limited by chatter. Chatter is defined as self-generative vibrations that occur when the chip width is too great versus dynamic stiffness. This phenomenon leads to a bad surface aspect and high noise level. As it reduces tool life, it increases production costs. For instance, the cost due to chatter is estimated to be around 0.35 h per piece on a cylinder block. With such a cost, prediction of chatter becomes highly necessary and a chatter criterion has to be chosen. First evocations of chatter are due to Taylor in 1907 and then to Schlesinger in 1936. A first comprehensive study was led by Doi in 1937 [2] and then with Kato in 1956 [3]. Tlusty and Polacek published their criterion the next year [4] and Tobias proposed his chatter maps the year after [5]. During the early 1960s, Peters and Vanherck ran some tests and developed measurement techniques in order to discuss Tlusty and Tobias criterions [6]. The 1970s have shown some work on the dynamic parameters. Hanna and Tobias worked on the non-linearity of the stiffness [7] while the Peters and Vanherck team produces highly interesting thesis on the identification of dynamic parameters during the cutting 44 operations [8, 9]. At the end of 1970s, Tusty presented his CIRP keynote paper on the topic [10]. Up to now major developments have been designed for aeronautic industry where tools are mostly more compliant than work pieces. In this way, Altintas and Budak have proposed an analytic method for computing stability lobes corresponding to Tobias’s chatter maps in 1995 [11]. This work has been exten
金属切削过程包括以切屑的形式不断地从工件上去除材料。单点切削刀具的切削过程,如在车床上成形,工件材料的非均匀性,工件的跳动或错位可能会对切削过程造成偶尔的干扰,从而导致工件相对于切削刀具的振动。如果切削过程稳定,产生的振动会因为阻尼而迅速消失。然而,在一定条件下,随之而来的振动幅度会越来越大。这种现象被称为喋喋不休。当颤振发生时,自激振动幅值增大,直至非线性极限[1]。颤振的结果是表面光洁度不高,精度差,刀具寿命缩短,金属去除率低。当加工难以切削的材料时,颤振变得更加关键。一些先进的刀具材料,如陶瓷、氮化硅和CBN,需要严格控制颤振,以防止脆性断裂[2]。对于高精度制造,即使是轻微的振动也是不可取的。此外,由于现代加工系统变得更加灵活,频繁变化的工作条件增加了将加工过程带入不稳定操作区域的可能性[3]。生产成本昂贵。加工系统经常受到颤振的限制。颤振被定义为当切屑宽度相对于动刚度过大时发生的自生振动。这种现象导致不良的表面外观和高噪音水平。由于它降低了刀具寿命,增加了生产成本。例如,由于颤振的成本估计约为0.35小时每件缸体。有了这样的代价,颤振预测就变得非常必要,必须选择一个颤振准则。第一次引起颤振的是1907年的泰勒,然后是1936年的施莱辛格。第一次全面的研究是由Doi于1937年[2]领导的,然后与加藤于1956年[3]。次年,托比亚斯和波拉切克发表了他们的标准[4],次年,托比亚斯提出了他的颤振图[5]。在20世纪60年代初,Peters和Vanherck进行了一些测试并开发了测量技术,以讨论trusty和Tobias准则[6]。20世纪70年代对动态参数进行了一些研究。Hanna和Tobias对刚度的非线性进行了研究[7],而Peters和Vanherck团队对切削过程中动态参数的识别进行了非常有趣的研究[8,9]。20世纪70年代末,Tusty发表了关于该主题的CIRP主题论文[10]。到目前为止,主要的发展是为航空工业设计的,其中工具大多比工件更柔顺。这样,Altintas和Budak在1995年提出了计算Tobias 's颤振图对应的稳定叶的解析方法[11]。这项工作在1998年得到了扩展[12],在两个方向的柔度-阻尼系统形式下考虑了工件的行为。Altintas和Weck以CIRP主题演讲的形式对该主题的最新发展进行了全面总结[13]。在车削过程中,工件材料的非均匀性导致切削力的变化,从而产生振动(Lin, 1990)。在大多数实际情况下,在车削操作中观察到的颤振是由于再生效应(Rao和Shin, 1998)。当单点切削刀具切削表面时,前一次旋转产生的波动维持了刀具工件的振动,这种振动与切削力耦合在一起。一些外部扰动或工件材料中的硬点会引起切削力的初始变化,并导致动力系统的振动。振动在工件表面留下波浪形的刀具轨迹。由于切削力的变化,这种波浪形表面将影响随后的切屑厚度。由于这种不均匀的芯片厚度,系统振动。如果这种振动的幅度没有消失,系统就会变得不稳定。这种现象被称为再生颤振。3.0颤振的数学建模假设平面正交开槽刀具垂直于夹在车床卡盘和尾座中心之间的圆柱轴轴线进给(图1)。如图2所示,在第一次旋转时,轴的初始表面是光滑的,没有波浪,但由于轴在进给方向上的弯曲振动,刀具开始留下波浪表面,当第二次旋转开始时,刀具切割的内部表面(内调制y(t))和切割的外部表面(由于前一次旋转时的振动)都有波浪。 由此可以表示出一般的动态切屑厚度。图2:再生颤振动力学h(t) = h0−[y(t)−y(t−t)]......... (Eq.1)式中,h0为预期切屑厚度或进给速率,y(t)为内调制,y(t- t)为外调制。系统的运动方程可表示为:[14]my(t) + c y(t) + ky(t) = Ff(t) = Kf ah(t) = Kf a[h0 + y(t−t)−y(t)]...........................(2)式中,F(t)为进给切削力,a为切削宽度或切削深度,h(t)为动态切屑厚度,将基本方程代入拉普拉斯域,得到特征方程1 +(1−e)Kf aФ(s) = 0,特征方程的根为s = σ + jωc,当实部为零时,系统处于临界稳定状态,工件在颤振频率下以恒定振幅振荡。颤振频率不等于固有频率,仍然接近于结构的固有模态。对于临界边界稳定性分析,特征函数变为{1 + Kf alim[G(1−cos ωcT)−H sin ωcT]} + J{Kf alim[G sin ωcT + H(1−cos ωcT)]} = 0..........(Eq.3)阿利姆是喋喋不休的方式削减的最大轴向深度加工,可以找到削减的临界轴向深度等同的实部特征方程为零:1 + Kf阿利姆(G(1−因为ωcT)罪ω−H cT) = 0阿利姆=−1 Kf G (cT)(1−因为ω−(H G)罪ωcT)替换和重新安排这个方程收益率[14]H G =罪ωcT(因为ωcT−1)和阿利姆=−1 2 Kf G(ωc ) ... ... ... ... ... ... ... ... ... .(式4)式中G(ωc) = 1k(1−r)[(1−r2) + (2ζr)2]激励与固有频率之比r = ω ωn, ζ为阻尼系数。主轴转速与颤振频率对动态切屑厚度、切屑厚度、切屑厚度、切屑厚度、切屑厚度均有一定的影响。在工件表面留下的振动波的量为-2πfc T = 2kπ + ε 45其中K为整数no。的波,ε-内外调制之间的相移,T主轴旋转周期T = 2kπ + ε 2πfc其中,N = 60 T ... ... ...(Eq. 5) 4.0试验研究采用正交湿式车削进行加工试验。将中碳钢AISI1045切割成外径32毫米、长70厘米的试样(轴),在全齿轮车床上进行。刀具采用高速钢刀具。这里给出了确定稳定性极限所选择的切削参数。主轴转速[110、160、240、400、575转/分],进给速度[0.625、1.25、2.5、5、8mm/转],切削深度[0.15、0.25、0.35、0.45、0.6mm],同时用于研究再生效果。使用的仪器是压电加速度计,信号调节器和分析仪(Picoscope-2202)。在频率范围(x1, x10增益)0.15 ~ 100,000 Hz范围内,采用电流和电压灵敏度分别为(1±1%)和(1±2%)的加速度计采集振动强度,加速度计探头固定在刀柄上靠近切削点的一点,采集刀具在进给方向的振动频率,使用便携式振动分析仪进行频率计算,研究振动频谱。表1:动态试验提取的动态切削系数kt切削刚度(MPa) kf切削常数(MPa)阻尼系数(c) 5600 985 0.054 5.0梁的CATIA模型假设刀具为矩形截面的悬臂梁结构,端部加载点。横梁规格:长12.0cm,宽2.5cm,高3.0cm,材质为铸铁,密度7800kg/m3,杨氏模量2.1x1011 N/m2,泊松比0.3。6.0有限元建模与模态分析建模完成后,将刀具用CATIA模型导出到ANSYS-V13环境中。我们取具有8721个元素和1214个节点的模型,其力学性能如上所述。然后,应用支承的边界条件,最后进行模态分析,得到固有频率。图4和图5显示了梁的模
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引用次数: 1
Mechanical Properties of Hybrid Composite Polyester Matrix Reinforced Glass Fibres 杂化复合聚酯基增强玻璃纤维的力学性能
Pub Date : 2015-03-01 DOI: 10.11127/GMT.2014.12.08
A. Shirisha, B. Ramji
The mechanical properties of hybrid composite material i.e. polyester matrix composites (ECMAS 411) reinforced with BS3496 E-glass fibres i.e. woven roving, chopped strand mat (CSM) fibers were evaluated. There are indications that the incorporation of both glass fibers into a single matrix which is polyester resin will stabilize mechanical properties and lowering manufacturing costs. In this research the impact strength, tensile strength, flexural strength, and compressive strength of GFRP hybrid composite material were studied.
对BS3496 e -玻璃纤维增强聚酯基复合材料(ECMAS 411)的力学性能进行了评价。有迹象表明,将两种玻璃纤维掺入单一的聚酯树脂基体中,将稳定机械性能并降低制造成本。研究了GFRP混杂复合材料的冲击强度、拉伸强度、抗弯强度和抗压强度。
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引用次数: 3
Review And Scope Of Scavenging micro Energy using Piezoelectric materials 压电材料清除微能量的研究进展及范围
Pub Date : 2014-08-30 DOI: 10.11127/IJAMMC.2014.08.07
K. V. Allamraju, K. Srikanth
A B S T R A C T This paper reviews the energy harvesting for micro level devices such as mobile phones, low powered signal lights and energy storage batteries by using Lead Zirconite Titanite (PZT) with the help of vibration on cantilever beams and batteries. Recent advances on micro power portable devices require limitless battery life for improving performance. A lot of energy is being wasted which is around us and also research has been conducted to develop energy harvesting devices by using PZT materials. This paper gives innovative ideas to develop energy harvesting devices for future scientific community.
本文综述了基于悬臂梁和电池振动的铅锆钛矿(PZT)在手机、低功率信号灯和储能电池等微级器件中的能量收集研究进展。微功率便携式设备的最新进展需要无限的电池寿命来提高性能。我们周围有很多能源被浪费了,人们也在研究利用PZT材料开发能量收集装置。本文为未来科学界开发能量收集装置提供了创新思路。
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引用次数: 6
A356 Aluminum Alloy and applications- A Review A356铝合金及其应用综述
Pub Date : 2014-08-10 DOI: 10.11127/IJAMMC.2014.08.01
S. Dwivedi, Satpal Sharma, R. Mishra
A B S T R A C T A356 alloys are ever more accepted in aircraft and automobile due to their high strength-toweight ratio and its thixotropic structure (designated SSM-A356). Its specific tensile strength and rigidity are superior to other Aluminum alloys. These qualities lead to less vehicle and aircraft weight and better fuel economy. A356 based alloys have been developed with significant ductility, strength, elongation, hardness and toughness at room temperature in as-cast state. Therefore, in the present work an attempt has been made to review A356alloy based systems and it application that possesses exceptionally high ductility as well as good mechanical strength
A356合金因其高强度重量比和触变结构(定名SSM-A356)而在飞机和汽车领域得到越来越多的应用。其比抗拉强度和刚度优于其他铝合金。这些特性减少了车辆和飞机的重量,提高了燃油经济性。在铸态下,A356基合金具有显著的室温延展性、强度、伸长率、硬度和韧性。因此,在目前的工作中,已经尝试审查了a356合金为基础的系统及其应用,具有极高的延展性和良好的机械强度
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引用次数: 39
Tribological properties of Hot forged Al2024-TiB2 in-situ composite 热锻Al2024-TiB2原位复合材料的摩擦学性能
Pub Date : 2014-08-10 DOI: 10.11127/IJAMMC.2014.08.02
R. Keshavamurthy
A B S T R A C T Al2024-TiB2 in-situ composite was fabricated by liquid metallurgy route using Al-Titanium and Al-Boron master alloys. The developed composites were subjected to hot forging at a temperature of 500oC using a 200T hydraulic hammer. Microstructure studies, X-ray diffraction studies(XRD), grain size analysis, microhardness and dry friction and wear tests were carried out on as cast and hot forged matrix alloy and its composites. Pin on disc type machine was employed to perform friction and wear tests over a load range of 20-100N and sliding velocities of 0.314-1.57m/s. Microstructure and XRD studies reveal presence of fine TiB2 particles in both as cast and hot forged condition. It is observed that, both as cast and hot forged composites do exhibit significant grain refinement. When compared with as cast matrix alloy and its composite, hot forged alloy and its composite exhibits higher extent of grain refinement. Both as cast and hot forged composites exhibit improved microhardness, wear resistance and lower coefficient of friction when compared with the unreinforced alloy under identical test conditions.
以al -钛和al -硼中间合金为基体,采用液相冶金法制备了Al2024-TiB2原位复合材料。采用200T液压锤在500℃温度下进行热锻。对铸态和热锻态基体合金及其复合材料进行了显微组织研究、x射线衍射(XRD)、晶粒尺寸分析、显微硬度和干摩擦磨损试验。采用销盘式试验机,在20-100N的载荷范围内,在0.314-1.57m/s的滑动速度下进行摩擦磨损试验。显微组织和XRD研究表明,在铸态和热锻态均存在细小的TiB2颗粒。结果表明,无论是铸造复合材料还是热锻复合材料,均表现出明显的晶粒细化。与铸基合金及其复合材料相比,热锻合金及其复合材料的晶粒细化程度更高。在相同的试验条件下,与未增强合金相比,铸态和热锻态复合材料的显微硬度、耐磨性和摩擦系数都有所提高。
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引用次数: 12
Hardness Prediction Model for En Grade Steels Subjected to Different Heat Treatment Processes 不同热处理工艺下En级钢硬度预测模型
Pub Date : 2014-08-10 DOI: 10.11127/IJAMMC.2014.08.05
S. Jyothirmai, I. A. Devi, I. Sudhakar, R. Ramesh
A B S T R A C T It is more often witnessed that the hardness of the steel depends on environment conditions, type of heat treatment adopted, composition and morphology. The selection of process parameters plays a vital role in obtaining the required hardness. It opens up scope for extensive research to map the relationship between the process parameters which is coherent with hardness of the steel. In the present investigation, an attempt has been made to accomplish this task with the help of a support vector machines (SVM) model for mapping process parameters with hardness. The basis for the development of SVM prediction model for the hardness at any condition within the conducted domain has been obtained by the data base comprising of set of input variable such as process, temperature, metal grade and output variable such as hardness. This is achieved by conducting several experimentations at different temperatures for various heat treatment processes such as annealing, normalizing, hardening and quenching using two different grades of steels namely EN19 and EN24 (with and without nickel). The presence of Nickel, which is an austenite stabilizer, promotes the formation of needle like fine grain martensite phase and its effect on hardness has been reported.
更常见的是,钢的硬度取决于环境条件、所采用的热处理类型、成分和形貌。工艺参数的选择对获得所需硬度起着至关重要的作用。这为绘制与钢的硬度相关的工艺参数之间的关系开辟了广阔的研究空间。在本研究中,我们尝试使用支持向量机(SVM)模型来映射工艺参数与硬度。该数据库由工艺、温度、金属品位等输入变量和硬度等输出变量组成,为建立传导域内任意条件下的硬度支持向量机预测模型提供了依据。这是通过使用EN19和EN24两种不同牌号的钢(含镍和不含镍)在不同温度下进行各种热处理工艺(如退火、正火、硬化和淬火)的多次实验来实现的。镍是一种奥氏体稳定剂,它的存在促进了针状细晶马氏体相的形成,并对硬度产生了影响。
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引用次数: 11
Laminated composite stiffened saddle shells with cutouts under free vibration – a finite element approach 自由振动下带切口的层合复合材料加筋鞍壳有限元分析
Pub Date : 2014-08-10 DOI: 10.11127/IJAMMC.2014.08.06
S. Sahoo
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引用次数: 3
Wear Characteristics Optimization of Al-7.5%Sic Metal Matrix Composite Using Taguchi Method 用田口法优化Al-7.5%Sic金属基复合材料的磨损特性
Pub Date : 2014-08-10 DOI: 10.11127/IJAMMC.2014.08.03
Shouvik Ghosh, P. Sahoo, G. Sutradhar
In the present paper an attempt has been made to optimize the wear behaviour of Al7.5%SiC metal matrix composite using Taguchi Method. Al-7.5%SiC metal matrix composite is synthesized using LM6 aluminium alloy as matrix metal and Silicon carbide as reinforcement using Stir casting process. Using L27 orthogonal array and Taguchi method the optimization of wear behaviour of the composite is carried out. The L27 orthogonal array is constructed using three levels of each tribological testing parameter Load (L), Sliding Speed (S) and Time (T). The wear tests are conducted in a Multi-Tribotester (DUCOM TR-25) using a block on roller arrangement at various combinations of the testing parameters. The analysis of the result is carried out using wear depth as system response. Furthermore, ANOVA analysis is carried out to find out the significant test parameters and their interactions affecting the wear behaviour of the composite. Scanning electron microscopy (SEM) is carried out to identify the wear mechanism.
本文尝试用田口法优化Al7.5%SiC金属基复合材料的磨损性能。以LM6铝合金为基体金属,碳化硅为增强材料,采用搅拌铸造工艺合成了Al-7.5%SiC金属基复合材料。采用L27正交阵列和田口法对复合材料的磨损性能进行了优化。L27正交阵列使用三个级别的每个摩擦学测试参数负载(L),滑动速度(S)和时间(T)来构建。磨损测试在多摩擦测试仪(DUCOM TR-25)中进行,使用块对滚子排列,在各种测试参数组合下进行。利用磨损深度作为系统响应,对结果进行了分析。此外,还进行了方差分析,以找出影响复合材料磨损行为的重要测试参数及其相互作用。采用扫描电子显微镜(SEM)对磨损机理进行了分析。
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引用次数: 20
期刊
International Journal of Advanced Materials Manufacturing and Characterization
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