Effect of wire tension on different output responses during wire electric discharge machining on AISI 304 stainless steel

WEDM is used in machining conductive materials where it is required to obtained complicated and intricate shapes with high accuracy. Various applications are in the field of automobile, medical industries, aerospace etc. WEDM is an economical machining option with short product development cycle. Surface roughness, kerf width, Material removal rate, Recast layer hardness and surface microhardness in WEDM are most important responses. In this paper, effect of varied Wire tension on SR, KW, MRR, RCL hardness and surface microhardness on AISI 304 have been investigated. Pulse on time, pulse off time, current and dielectric fluid are taken as fixed parameter. Results show that Wire tension influences the SR, MRR and Surface microhardness and has no effect on kerf width in case of Stainless steel 304.     

Investigating the surface integrity of aluminium based composites machined by EDM

In the present work, the surface characteristics of Electrical Discharge Machined (EDM) Al (6351)SiC and Al (6351)SiCB₄C composites are investigated. The composites are prepared by employing the conventional stir casting technique, as it can produce better particle dispersion in the matrix. The detailed experimental study is performed on the composites by varying current (I), duty factor (τ), pulse on time (T_on), and the gap voltage (V) in order to analyze the Heat Affected Zone (HAZ) formed in the sub surface and the average crater diameter formed on the machined surface of the composites as an output function. The formation of recast layers, presence of bubbles and the surface texture of the composites at various machining conditions are observed. The results show that the increased Metal Removal Rate (MRR) increases the depth of HAZ and the average crater diameter on the machined area. Further, the addition of B₄C particles to the composite produces more surface defect than the AlSiC composite.     

卫星柔性热控薄膜材料充放电效应试验

针对柔性热控薄膜材料导电/绝缘多层复合、微纳尺寸厚度的结构特点,采用10～70 KeV电子辐照的方法开展了kapton基二次表面镜薄膜材料充放电特性的测试试验,获得了表面充电电位、静电放电频次等关键参数,并采用蒙特卡罗方法研究了辐照电子在多层薄膜材料内的输运规律。研究结果表明由于kapton基二次表面镜薄膜结构的特殊性,当辐照电子能量为10 KeV时未发生静电放电现象,随着电子能量不断增加,薄膜材料的表面充电电位幅值与静电放电频次呈先上升后下降的变化规律,且在电子能量为25 KeV时空间充放电效应最为显著。     

慢刀伺服加工环曲面的刀具路径规划方法

如何规划刀具路径、进而获得高质量的数控加工代码,是应用慢刀伺服技术加工环曲面的关键技术之一。提出了基于等距面规划刀位点轨迹的刀具路径规划方法,推导了外凸环曲面的面形方程及其等距面方程,对比分析了两种导动曲线及两种数据点离散方法,优选了刀具路径规划方案,应用VB.net语言编写了慢刀伺服加工环曲面用数控代码生成软件,在Vericut平台上对数控代码进行了仿真验证,直观地展示了虚拟加工面相对理论曲面的残留区域,仿真结果验证了方法的可行性。结果表明:将外凸环曲面方程中的非一次常数项a变为a+r_d,即得到外凸环曲面的等距面方程;所提刀具路径规划方法适用于慢刀伺服加工外凸环曲面;该方法对应用慢刀伺服技术加工其他面型的光学镜面具有借鉴价值。     

接近速度和放电电压对空气式静电放电参数的影响

对影响空气式静电放电的一个重要因素——电弧结构进行了理论分析。在此基础上，利用新研制成功的静电放电模拟测试系统，分析了接近速度和放电电压对静电放电电流峰值、上升时间以及感应电压峰-峰值的影响。试验得出，在放电电压一定的情况下，放电电流峰值和感应电压峰-峰值随接近速度的增大而增大；上升时间随接近速度的增大而减小。这些试验结果为建立静电放电抗扰度试验新方法提供了依据。     

碳化硼涂覆的碳纤维的抗热氧化性研究

用自己合成的裂解能得到碳化硼的聚碳硼烷,对碳纤维进行涂层,并详细测试了涂层碳纤维的抗热氧化性能。     

用于SiC光学材料高效加工的电弧增强等离子体加工方法*

由于SiC光学材料具有高化学稳定性,使其在普通的等离子体加工中难以获得较高的加工效率。在等离子体加工实验中,我们发现提高等离子体的自身射频电压,可增强等离子体与SiC材料之间的电弧放电作用,而借助电弧的增强作用提高SiC材料的加工效率,因此本文提出了电弧增强等离子体加工方法。为研究电弧的形成原理,本文使用自制的探针分别测量了普通电感耦合等离子体和电弧增强等离子体的电压。并分别使用传统方法和电弧增强方法对S-SiC进行直线扫描加工实验,证明了电弧增强等离子加工方法在加工过程中具有更高的加工效率。     

音圈电机驱动的超精密快刀伺服系统的性能研究

基于快刀伺服系统的超精密金刚石车削加工技术是光学自由曲面高效率、高精密的加工手段。本文介绍了一种新的音圈电机驱动的超精密快刀伺服系统,行程达到30mm,最大加速度为920m/s₂。通过实验手段获得了系统的运动模型,来用于控制器的设计。针对一类典型的光学自由曲面-微透镜阵列进行了加工,并对加工结果进行了测试与分析。测试结果表明,所研制的快刀伺服系统达到了加工技术要求,为以后该系统在实际加工中更广泛的应用研究打下了基础。     

静电放电过程电荷量和能量分析

分别采用四指数表达式拟合的方法和数值计算求解双RLC人体静电放电（ESD）模型的方法得到了符合标准要求的ESD电流波形，计算这两种方法下各自的放电电荷量和放电电阻消耗的能量；测量空气式和接触式两种ESD模式下的放电电流波形，并分别计算放电电荷量和能量情况；通过比较得出，放电电荷量和放电电阻消耗的能量都能够超过放电前的3／4，用数值拟合的电流波形虽能满足四个关键参数的要求，但其它部分电流值偏大。     

Analysis of some critical aspects in hot machining of Ti-5553 superalloy: Experimental and FE analysis

In this study, a newly developed titanium superalloy, i.e., the Ti-5553 alloy has used for hot machining. This material replaced Ti-grade-5 alloy in the application of aerospace, automobile, and biomedical sector. However, similar to Ti-grade-5 alloy, the Ti-5553 alloy has a low thermal conductivity which makes it difficult-to-cut material categories hence, high tool wear, cutting force and bad surface finish. Hot machining of Ti-5553 has been studied at different machining condition (room and hot) using Deform-2D finite element analysis. The result from the simulation test was compared with the experimental value and reduction of cutting and thrust forces was observed. The experiment was carried out with the same input parameters as simulation, and good coherence between them observed. Additionally, cutting zone temperature, effective stress, etc. for both room and elevated the temperature are also discussed.     

激光加热辅助引弧微爆炸加工工程陶瓷的试验研究

为验证激光加热辅助技术改善引弧微爆炸加工质量和提高加工效率的可行性,探索加工工艺参数对加工过程的影响规律,设计了激光加热辅助引弧微爆炸加工试验系统,并通过试验研究了工艺参数对材料去除率和崩碎的影响规律。试验结果表明：激光加热辅助引弧微爆炸加工陶瓷可以提高材料去除率,改善崩碎情况;加工效率随激光功率的增加而提高,随光斑尺寸的增大而降低,随距离的增加先提高后降低;崩碎随激光功率的增加而减少,随光斑尺寸的增大先减少后增多,随距离的增加先减少后增多。研究结果为激光加热辅助引弧微爆炸加工机理的研究和工艺参数的优化提供了参考依据。     

化学气相沉积碳化硅超光滑抛光机理与表面粗糙度影响因素

为实现化学气相沉积碳化硅(CVD SiC)的超光滑抛光,采用纳米划痕试验研究了化学气相沉积碳化硅脆塑转变的临界载荷,根据单颗磨粒受力对其抛光机理进行了分析,并从材料特性、工艺参数以及抛光液pH值三个方面对其表面粗糙度影响因素进行了系统的试验研究.研究结果表明:化学气相沉积碳化硅的稳定抛光过程是磨粒对碳化硅表面的塑性域划痕过程;CVD SiC的晶粒不均匀与表面高点会降低晟终所能达到的表面质量;表面粗糙度在一定范围内随磨粒粒度增加呈近似线性增长,随抛光模硬度的增加而增长;抛光压强对表面粗糙度的影响规律与抛光模的变形行为相关,当抛光模处于弹性或弹塑性变形阶段时,表面粗糙度随抛光压强的增加呈小幅增长,而当抛光模包含塑性变形之后,表面粗糙度基本与抛光压强无关;此外,抛光速度和抛光液pH值对表面粗糙度的影响不大.研究结论为CVD SiC超光滑抛光的工艺参数优化选择提供了定量的试验依据.     

光学阵列器件的慢刀伺服车削加工技术

慢刀伺服技术是相对于快刀伺服提出的方法.采用C轴、X轴、Z轴联动的方法在极坐标或圆柱坐标内进行加工.光学阵列如微透镜阵列、微反射镜阵列在高速数据、声音和视频信号传输中具有重要作用.将光学阵列看作一个自由曲面,使用慢刀伺服车削技术一次加工成形,可以解决传统加工中将光学阵列分块加工后拼装和调整的困难.但是由于光学阵列表面形状复杂,其表面法线的突变可能会使机床运动超出伺服轴执行能力.根据慢刀伺服加工技术的特点,建立了伺服轴执行能力限制曲线,研究了不同刀具半径补偿方式对加工的影响.实验结果表明,根据机床伺服轴执,厅能力合理选择刀具半径补偿方式可实现微光学阵列器件高精度加工.     

Friction stir surfacing of cast A356 aluminiumesilicon alloy with boron carbide and molybdenum disulphide powders

Good castability and high strength properties of Ale Si alloys are useful in defence applications like torpedoes,manufacture of Missile bodies,and parts of automobile such as engine cylinders and pistons.Poor wear resistance of the alloys is major limitation for their use.Friction stir processing(FSP) is a recognized surfacing technique as it overcomes the problems of fusion route surface modification methods.Keeping in view of the requirement of improving wear resistance of cast aluminiumesilicon alloy,friction stir processing was attempted for surface modification with boron carbide(B4C) and molybdenum disulfide(Mo S2) powders.Metallography,micro compositional analysis,hardness and pin-on-disc wear testing were used for characterizing the surface composite coating.Microscopic study revealed breaking of coarse silicon needles and uniformly distributed carbides in the A356 alloy matrix after FSP.Improvement and uniformity in hardness was obtained in surface composite layer.Higher wear resistance was achieved in friction stir processed coating with carbide powders.Addition of solid lubricant Mo S2 powder was found to improve wear resistance of the base metal significantly.     

B4C／Al复合板中应力波行为分析（Ⅱ）

在已建立的应力波传播模型和研究弹、板间作用力所获结果的基础上，为分析复合板应力的变化，对复合板弹板碰撞承受的应力进行了简化处理，根据应力波传播特性，确定了复合板内能量集中区域，研究了应力波在复合板巾的传播和能耗，并讨论了应力波对陶瓷的作用。通过近似计算，发现烧蚀消耗的弹丸动能较大，在复合板中，Al板的塑性变形吸收了19％的弹丸动能。     

导线绝缘层火灾痕迹研究

以铜芯聚氯乙烯绝缘软导线作为实验材料,使用火灾痕迹物证综合实验台和箱式电阻炉等模拟火场条件,分别制备出导线绝缘层在过负荷、火烧和短路三种状态下的炭化痕迹样品,宏观观察结果表明这三种情况下导线绝缘层破坏显示出不同的特征。将导线绝缘层过负荷、火烧和短路三种痕迹样品碳化物分别制成碳管并测其导电性能,发现它们的导电性能存在规律性,短路形成的绝缘层碳化物导电性优于过负荷、火烧形成的碳化物导电性,而对于火烧形成碳化物,在一定温度范围内随着温度升高导电性有增强的规律。     

2D and 3D milled surface roughness of high volume fraction Si Cp/Al composites

This paper presents a study on surface roughness generated by high speed milling of high volume fraction(65%) silicon carbide particlereinforced aluminum matrix(Si Cp/Al) composites.Typical 2D(Raand Rz) and 3D(Saand Sq) surface roughness parameters were selected to evaluate the influence of the milling parameters on the surface quality in comparison with aluminum alloy.The 3D topography of the milled surface was studied as well.The results indicate that 3D parameters(Saand Sq) are more capable to describe the influence of the milling parameters on the surface quality,and among them Sqis preferable due to its good sensitivity.Sqdecreases with milling speed and increases with feed rate.The influence of axial depth of cut(ADOC) is negligible.     

基于表层及芯材阻尼特性的夹层结构导纳分析

针对复合材料夹层板结构,综合开展芯材材料阻尼特性动力学热分析(DMTA)试验、表层玻璃钢和芯材试件阻尼衰减特性研究,通过夹层板结构的模态激振试验得到结构的模态阻尼比。从结构动力学方程出发探讨了影响多自由度系统结构传递导纳的相关参量,试验对比分析了钢质板和复合材料夹层板两型结构的传递导纳特性,并研究了激振点与响应点间距对复合材料夹层结构传递导纳的影响。研究表明:当尺寸和边界条件相同时,影响结构传递导纳的主要因素是结构的固有频率和模态阻尼。试验还得到了复合材料夹层板较钢质板的基频提高值和传递导纳降低均值,该试验结果可为工程设计提供参考。     

集成电路ESD注入损伤效应及注入电压与能量间的关系

利用静电放电(ESD)模拟器对集成电路芯片进行电压注入损伤效应实验,通过存贮示波器记录的波形进行乘法和积分运算,得到对应注入电压下芯片上吸收的平均峰值功率和能量。对放电电压与平均峰值能量作散点图,采用曲线拟合的方法对离散点进行拟合,针对该曲线拟合的方法进行了分析,最终建立了ESD注入电压与平均峰值能量之间的数学模型。     

One-step synthesis of FeO(OH) nanoparticles by electric explosion of iron wire underwater

In this study,we investigated electric explosion of iron wire in distilled water with different energy input adjusted by charging voltage.The as-prepared samples were characterized by X-ray diffraction (XRD),scanning electron microscopy (SEM),transmission electron microscopy (TEM) and X-ray photoelectron spectroscopy (XPS),showing the presence of iron and multiple iron-based compounds oxides with contents influenced by the experimental conditions.In particular,pure FeO(OH) nanoparticles were obtained using electric explosion of iron wire with energy input of 1125 J at charging voltage of 15 kV.Analysis of discharge current and resistive voltage data indicate that the high energy input induced by strong plasma discharge at high charging voltage is a key factor to form FeO(OH).This study presents a one-step method to synthesize FeO(OH) nanoparticles using electric explosion of iron wire.