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Experimental Investigation of Tapped Thread Surface Roughness for Cast Aluminum Alloys 铸铝合金丝锥表面粗糙度的实验研究
Pub Date : 1997-11-16 DOI: 10.1115/imece1997-1092
Tengyun Cao, S. Batzer, J. Sutherland
Thread surface roughness is an important issue both in terms of thread quality and the lubricating effect of cutting fluid in the tapping process. In this work, experiments were conducted to investigate the flank surface roughness of tapped threads produced in cast aluminum alloy workpieces. A full factorial experiment was performed to study the effects of the machining parameters (workpiece material, cutting fluid and spindle speed) on the resulting thread flank surface roughness. Metallographic and Scanning Electronic Microscope (SEM) examinations of the thread flank surfaces were performed. Effects were calculated for the variables under study. Workpiece material type was identified as a statistically significant variable in influencing the thread surface roughness. Several other factors that appeared to play a role in producing the thread surface roughness variation observed in the experiments were also examined.
在攻丝过程中,螺纹表面粗糙度是影响螺纹质量和切削液润滑效果的重要因素。通过实验研究了铝合金铸件丝线的表面粗糙度。通过全因子实验研究了加工参数(工件材料、切削液和主轴转速)对加工后的螺纹面粗糙度的影响。对螺纹侧面进行了金相和扫描电镜(SEM)检查。计算了所研究变量的影响。工件材料类型被确定为影响螺纹表面粗糙度的统计显著变量。在实验中观察到的螺纹表面粗糙度变化中似乎起作用的其他几个因素也进行了检查。
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引用次数: 0
A Review of Changes and Trends Affecting Military Electronics Manufacturing 影响军用电子制造业的变化和趋势综述
Pub Date : 1997-11-16 DOI: 10.1115/1.2792608
A. Rafanelli
Dramatic business changes in the aerospace and military defense industries have caused contractors to drastically alter their design and manufacturing processes. These changes appear to have been influenced by recent events or movements: The U.S. Department of Defense initiative (Perry, 1994 and U.S. DoD, 9 December 1994) discourage dependence on military specifications/standards (the “Perry Initiative”) which resulted in trends within the electronics industry to use commercial materials in typical military environments (alternative component initiatives). Consequently, changes are underway regarding some of the traditional technologies used in defense electronics. Specifically, this paper will present an overview of the changing nature of some of these technologies, e.g. interconnections, coatings, and plastic encapsulated microcircuits (PEMs) and the standards/practices related to these from a manufacturing aspect. The information, provided, is by no means all-inclusive, but does identify a focus for increased discussion and study.
航空航天和军事国防工业的巨大商业变化导致承包商彻底改变他们的设计和制造过程。这些变化似乎受到最近事件或运动的影响:美国国防部倡议(Perry, 1994年和美国国防部,1994年12月9日)不鼓励对军事规格/标准的依赖(“Perry倡议”),这导致电子工业在典型的军事环境中使用商业材料的趋势(替代组件倡议)。因此,国防电子中使用的一些传统技术正在发生变化。具体来说,本文将从制造方面概述其中一些技术的变化性质,例如互连,涂层和塑料封装微电路(PEMs)以及与这些技术相关的标准/实践。所提供的信息并非包罗万象,但确实确定了增加讨论和研究的重点。
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引用次数: 0
Evaluation of Interfacial Fracture Toughness of a Bi-Material System Under Thermal Loading Conditions 热载荷条件下双材料体系界面断裂韧性的评价
Pub Date : 1997-11-16 DOI: 10.1115/imece1997-1118
Jianjun Wang, D. Zou, Sheng Liu
In this paper, the interfacial fracture toughness of a bi-material (molding compound/silicon) specimen subjected to a series of thermal loads was evaluated using a high density laser moiré interferometry coupled with FEA technique. The moiré interferometry technique was used to monitor and measure the crack length during the test. A finite element technique was simultaneously used to determine the near crack tip displacement fields of the bi-material specimen. The interfacial fracture toughness and phase angle were computed by using these near tip displacement variables through the analytical energy release rate and phase angle expressions derived by authors. The results show that the interfacial fracture toughness of the bi-material specimen considered is strongly related to the phase angle in terms of the defined phase angle expression in this paper. The interfacial fracture toughness Gc and the phase angle ϕ of the tested bi-material specimen at the interface corresponding to the crack length a = 3.0mm under the temperature rise thermal load from room temperature (20° C) to 120° C are 13.64 J/m and −54.28° respectively, while the interfacial fracture toughness Gc and the phase angle ϕ of the tested bi-material specimen at the interface of the molding compound/silicon with the crack length a = 3.3mm under the temperature rise thermal load from room temperature (20° C) to 138° C are 20.02 J/m2 and −54.8° respectively.
本文采用高密度激光干涉法结合有限元分析技术,对双材料(模塑复合材料/硅)试样在一系列热载荷作用下的界面断裂韧性进行了评价。在试验过程中,采用涡流干涉法对裂纹长度进行了监测和测量。同时采用有限元方法确定了双材料试样的近裂纹尖端位移场。利用这些近尖端位移变量,通过作者导出的解析能量释放率和相角表达式,计算界面断裂韧性和相角。结果表明,根据本文定义的相角表达式,所考虑的双材料试样的界面断裂韧性与相角密切相关。在室温(20℃)至120℃的温升热载荷作用下,双材料试样在裂纹长度a = 3.0mm处的界面断裂韧性Gc和相位角φ分别为13.64 J/m和- 54.28°;在室温(20℃)至138℃的温升热载荷下,裂纹长度为a = 3.3mm的复合材料/硅的界面断裂韧性Gc和相位角φ分别为20.02 J/m2和- 54.8°。
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引用次数: 0
Development of Force-Control Model for Edge-Deburring With Filamentary Brush 丝状毛刷边去毛刺力控制模型的建立
Pub Date : 1997-11-16 DOI: 10.1115/imece1997-1102
Lienjing Chen, R. Stango, V. Cariapa
In recent years, edge finishing with filamentary brushes has received much attention within the applied research and manufacturing engineering communities. This interest may be attributed, in part, to the ease with which brushing tools can be introduced into an automated machining environment. That is, such tools exert relatively small machining forces, remove material incrementally, and minimize the risk of generating abrupt, unstable forces that can lead to tool/workpart damage during the finishing operation. Although brushes have been successfully used in automated finishing applications, much uncertainty remains regarding the proper use of brushes for removal of edge burrs. Consequently, the implementation of automated brush deburring operations is often accompanied by costly trial-and-error experimentation, and in many cases, is met with only marginal success. This paper is concerned with the development of a force-control model for edge deburring with filamentary brushes. The model is based upon experimentally obtained “master curves”; that is, material removal data that corresponds to the actual machining performance of the brush/workpart system during the incremental burr removal process. Such master curves are generated by machining specially prepared edge projections having a geometry similar to flash that is produced along the edges of cast components. This information is used in conjunction with the on-line brush machining force to compute the brush feed rate that ensures complete removal of the edge burr. Example problems are reported for two cases, namely, the removal of edge flash having (i) unknown, constant height, and (ii) unknown variable height. The results indicate that the present force-control model provides straight forward approach for computing brush feed rates that lead to complete removal of edge burrs, and suggests that implementation can be carried out without the use of sophisticated sensing apparatus or complex control strategies.
近年来,丝状毛刷毛边整理技术受到了应用研究界和制造工程界的广泛关注。这种兴趣可能部分归因于刷刷工具可以轻松地引入自动化加工环境。也就是说,这种刀具施加相对较小的加工力,逐步去除材料,并最大限度地减少在精加工过程中产生突然的、不稳定的力的风险,这些力可能导致刀具/工件损坏。虽然刷子已经成功地应用于自动化精加工,但关于刷子去除毛刺的正确使用仍然存在许多不确定性。因此,自动刷去毛刺操作的实施往往伴随着昂贵的试错实验,在许多情况下,只有边际成功。本文研究了丝状毛刷边去毛刺的力控制模型的建立。该模型基于实验得到的“主曲线”;即在增量去毛刺过程中,与毛刷/工件系统实际加工性能相对应的材料去除数据。这种主曲线是通过加工特别准备的边缘投影产生的,其几何形状类似于沿铸造部件边缘产生的闪光。该信息与在线电刷加工力一起使用,以计算确保完全去除边缘毛刺的电刷进给速率。报告了两种情况的示例问题,即去除具有(i)未知恒定高度和(ii)未知可变高度的边缘闪光。结果表明,目前的力控制模型提供了一种直接的方法来计算导致完全去除边缘毛刺的刷进给速率,并且表明可以在不使用复杂的传感设备或复杂的控制策略的情况下实现。
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引用次数: 2
Automated Scarfing and Surface Finishing Apparatus for Curved Composite Structures 弯曲复合材料结构的自动切割和表面精加工装置
Pub Date : 1997-11-16 DOI: 10.1115/imece1997-1105
Edwin A. Erlbacher, Lester E. Godwin
This paper describes the justification and design of a Scarfing Tool for Automated Repair of Composites (STARC) system. The repair of aircraft composites is currently a manual process that subjects workers to adverse working conditions often leading to costly mistakes and poor repair quality. Commercial robots are finishing many types of materials in many industries, but none are performing scarfing repairs. A lightweight, portable manipulator is needed to automate the scarfing process. A pneumatic, parallel link Stewart Platform manipulator will provide necessary grinding trajectories. The primary benefits of Stewart Platform manipulators is their high stiffness to weight ratio and their simple modular design. For the STARC, a commercially available Adjustable Force Device (AFD) would be mounted on the underside of the movable platform. In this configuration, the platform would meet all the major design goals of providing a substantial work envelope, the required six degrees-of-freedom, and relatively light weight portability without sacrificing rigidity.
本文介绍了一种用于复合材料自动修复(STARC)系统的切割工具的论证和设计。目前,飞机复合材料的修复是一个手工过程,工人们在恶劣的工作条件下工作,经常导致代价高昂的错误和较差的修复质量。商业机器人正在完成许多行业中许多类型的材料,但没有一个进行切割修复。需要一个轻便、便携的机械手来自动化切割过程。气动并联Stewart平台机械手将提供必要的磨削轨迹。Stewart平台机械手的主要优点是其高刚度重量比和简单的模块化设计。对于STARC,商用可调力装置(AFD)将安装在可移动平台的底部。在这种配置下,该平台将满足所有主要的设计目标,提供大量的工作范围,所需的六个自由度,以及相对轻的重量可移植性,而不会牺牲刚性。
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引用次数: 0
Mechanics of Polishing 抛光机械
Pub Date : 1997-11-16 DOI: 10.1115/1.2789069
V. H. Bulsara, Y. Ahn, S. Chandrasekar, T. Farris
A model has been developed to determine the number and sizes of abrasive particles involved in material removal in polishing, and the forces acting on these particles. The effect of particle size on these parameters has been simulated for a range of particle sizes. It is shown that when polishing with abrasive powders having relatively broad size distributions, only a very small percentage of the particles are involved in material removal. Further, these particles are comprised of the larger particles occurring in the tail end of the particle size distribution. The average force on a particle is found to be in the range of 5–200 mN under typical polishing conditions, which is of the order of loads used in micro-indentation hardness testing. These predictions of the model are consistent with observations pertaining to polished surfaces and the polishing process.
已开发出一种模型,用于确定抛光过程中材料去除所涉及的磨料颗粒的数量和尺寸,以及作用在这些颗粒上的力。针对一系列颗粒大小,模拟了颗粒大小对这些参数的影响。结果表明,当使用粒度分布相对较广的研磨粉进行抛光时,只有很小一部分颗粒参与材料去除。此外,这些颗粒由粒度分布尾端的较大颗粒组成。在典型的抛光条件下,颗粒受到的平均力在 5-200 mN 之间,与微压痕硬度测试中使用的载荷相当。模型的这些预测与抛光表面和抛光过程的观测结果一致。
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引用次数: 49
Accurate Assessment of Flatness Tolerance Using Direct Search Optimization 利用直接搜索优化技术精确评估板形公差
Pub Date : 1997-11-16 DOI: 10.1115/imece1997-1095
S. Damodarasamy, S. Anand
This paper presents a new method for determining the minimum zone for flatness of a point set obtained from a coordinate measuring machine. The two parallel planes that enclose the entire point set with minimum separation form the minimum zone for flatness. In this method, parallel planes are formed through each point in the point set for a range of plane orientations. Simplex search is used to determine the orientation of parallel planes that form the minimum zone. This method is applied to six example point sets and results are compared with other methods.
本文提出了一种确定坐标测量机测得的点集平面度最小区域的新方法。以最小的间距包围整个点集的两个平行平面形成平坦度的最小区域。在该方法中,通过点集中的每个点在一定范围的平面方向上形成平行平面。单纯形搜索用于确定形成最小区域的平行平面的方向。将该方法应用于六个样例点集,并与其他方法的结果进行了比较。
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引用次数: 0
Striation Formation and Surface Finish in Laser Cutting of Mild Steel 低碳钢激光切割中的条纹形成与表面光洁度
Pub Date : 1997-11-16 DOI: 10.1115/imece1997-1104
Kai Chen, Y. Yao
The mechanisms of melt ejection and striation formation in laser cutting of mild steel are discussed. It is argued that the melt ejection from the cutting front is not a steady state process, but rather shows a cyclic phenomenon. The striation are strongly affected by the unstable characteristic of the thin liquid film on the cutting front during the melt ejection, together with the oxidation and heat transfer process. Dependent on the cutting speed, the liquid film will either rupture or generate waves on the cutting front. Theoretical explanation is given according to the instability theory of a thin liquid film in a high velocity gas jet and the diffusion controlled oxidation theory. The striation frequency and depth can be estimated according to the above theories. Experimental investigations were carried out and the results are consistent with the calculations. The better understanding has shed light on further investigations and optimal process development.
讨论了低碳钢激光切割过程中熔体喷射和条纹形成的机理。认为熔体从切割前沿喷出不是一个稳态过程,而是一个循环现象。在熔体喷射过程中,切割面上液体薄膜的不稳定特性以及氧化和传热过程对条纹产生了强烈的影响。根据切削速度的不同,液膜要么破裂,要么在切削面上产生波浪。根据高速气体射流中液体薄膜的不稳定性理论和扩散控制氧化理论给出了理论解释。根据上述理论可以估计出条纹的频率和深度。进行了实验研究,结果与计算结果一致。更好的理解为进一步的研究和最佳工艺开发提供了光明。
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引用次数: 0
A Statistical Study of Factors Affecting Surface Finish in Five-Axis Machining 五轴加工表面光洁度影响因素的统计研究
Pub Date : 1997-11-16 DOI: 10.1115/imece1997-1087
Keith A. White, C. G. Jensen, Chuck Helquist, Troy Smalley
A statistical study of factors affecting the surface finish of parts machined on a five-axis mill was performed. The study was a 23 full factorial experiment. The following factors and levels for each factor were selected: cutter type (flat and filleted end mill), feedrate (12 and 20 inches per minute), and angle of inclination (7 and 15 degrees). All factors were statistically significant. Cutter type was the factor which most significantly affected surface finish, followed by feedrate, and angle of inclination. The effect of cutter type was more than four times greater than the other factors. All two-way interactions were also found to be significant, with the magnitude of the interactions involving cutter type approximately four times greater than the interaction between feedrate and angle of inclination. An acceptable mathematical model for predicting surface finish based on these factors was obtained which can be used in five-axis machining research and applications.
对影响五轴铣床加工零件表面光洁度的因素进行了统计研究。该研究是一个23全因子实验。选择了以下因素和每个因素的水平:刀具类型(平面和圆角立铣刀),进给速度(每分钟12英寸和20英寸),倾角(7度和15度)。所有因素均有统计学意义。刀具类型是影响表面光洁度最显著的因素,其次是进给速度和倾角。刀具类型的影响是其他因素的4倍以上。所有双向相互作用也被发现是显著的,涉及刀具类型的相互作用的幅度大约是进给速度和倾角之间相互作用的四倍。建立了基于这些因素的表面光洁度预测数学模型,可用于五轴加工的研究和应用。
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引用次数: 0
Interactive Tutorials on Manufacturing Processes Using Java™ 使用Java™的制造过程交互式教程
Pub Date : 1997-11-16 DOI: 10.1115/imece1997-1124
B. Klamecki
A series of tutorials describing some engineering science concepts underlying the development of manufacturing process models has been developed. The tutorials are available over networks so that access is easy. There are two unique aspects of the tutorials. One is the use of computer-independent software so that interactive exercises run on the user’s computer. This makes for fast response to user input and so useful interactive exercises are possible. The other different aspect is the presentation of process models in a non-typical way. Interactive exercises which call for the user to vary process parameter values, observe the effects on process performance and deduce the form of the process model are used. An example of one such computer-based tutorial is described — chip formation in machining. A world wide web location of the tutorial is provided so that individuals can use and evaluate the approach taken to presenting engineering science concepts and process models, http://www.menet.umn.edu/klamecki.
已经开发了一系列教程,描述了制造过程模型开发背后的一些工程科学概念。这些教程可以通过网络获得,因此访问起来很容易。本教程有两个独特的方面。一种是使用独立于计算机的软件,这样交互练习就可以在用户的计算机上运行。这使得对用户输入的快速响应成为可能,因此有用的交互练习成为可能。另一个不同的方面是以非典型的方式表示流程模型。交互练习要求用户改变过程参数值,观察对过程性能的影响,并推断过程模型的形式。本文描述了一个基于计算机的教程的例子——机械加工中的切屑形成。提供了教程的万维网位置,以便个人可以使用和评估呈现工程科学概念和过程模型的方法,http://www.menet.umn.edu/klamecki。
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引用次数: 0
期刊
Manufacturing Science and Engineering: Volume 1
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