bluuebunny/crossref_metadata_2025 huggingface dataset:
Preparation and Microstructural Studies of Electrodeposited FeSe Thin Films
Authors: Kim Kyung Sik , Thanikaikarasan S. , Mahalingam T. , Subramaniam Velumani , Kim Tae Kyu , Kim Yong Deak , Asomoza Rene
Published: September 2009

Iron selenide (FeSe) thin films were electrodeposited onto tin oxide coated conducting glass substrates using aqueous solution mixture containing FeSO4 and SeO2 at various bath temperatures and deposition potentials. The deposited films were characterized by x-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive analysis by x-rays (EDX) for their structural, morphological and compositional properties. X-ray diffraction patterns revealed that the deposited films are found to be tetragonal structure with preferential orientation along (100) plane. The x-ray line profile analysis technique by the method of variance has been used to evaluate the microstructural parameters such as, crystallite size, R.M.S strain, dislocation density and stacking fault probability. The influence of bath temperature and deposition potential on the microstructual parameters was investigated. The SEM observation reveals uniform surface morphology for films deposited at higher bath temperatures. The experimental observations are discussed in detail.
Structural and Optical Studies of Hot Wall Vacuum Evaporated CdTeSn Thin Films
Authors: Sakthivel Kuppusamy , Subramaniam Velumani , Venkatachalam T. , Ganesan S.
Published: September 2009

Bulk compounds of CdTe, Cd0.25Sn0.75Te and Cd0.25Te0.75Sn have been prepared by direct reaction of their high purity (99.9999%) elemental constituents employing rotating furnace. The hot wall system is optimized for the deposition of prepared alloys by using molecular flow studies with Monte Carlo simulation technique. Thin films have been deposited on well cleaned glass substrates using the prepared alloys by the optimized hot wall vacuum evaporation system. The compositions of the prepared bulk and thin films have been identified using energy dispersive X-ray analysis. The compositions are found to be same for both the bulk and thin films as the prepared alloys. The structural properties of the deposited films have been studied using X-ray diffraction technique. The results show that all the films are crystalline in nature and the peaks in the XRD graph of CdTe correspond to cubic zinc blende structure and that of Cd0.25Sn0.75Te and Cd0.25Te0.75Sn compounds to rock salt structure. The lattice parameters and grain sizes of all the films have been evaluated. The surface morphology of the thin films is studied using Scanning Electron Microscope (SEM). The SEM analysis shows that surface of the films are smooth and crystalline in nature. The optical transmittance spectra of thin films were recorded using spectrophotometer in the range of wavelength from 190 nm to 2500 nm. All the films exhibit direct optical band gap and their values are 1.45eV (CdTe), 0.9eV (Cd0.25Sn0.75Te) and 1.1eV (Cd0.25Te0.75Sn). Thicknesses of the thin films have been determined by multiple beam interferometric technique.
Nanocrystalline Sm0.5Y0.5Co5 Alloys with Enhanced Magnetic Properties
Authors: Hidalgo-González José Luis , Elizalde Galindo José Trinidad , Botez Christian E. , Matutes-Aquino José Andrés
Published: September 2009

Nanocrystalline Sm0.5Y0.5Co5 powders (average crystal size d = 12 nm) were produced by arc melting pure metals followed by mechanical milling and annealing. Different milling/annealing times and annealing temperatures were used to optimize the hard magnetic properties of these nanopowders. A noticeably enhanced coercivity and remanence (coercivity of 2.1 MA/m, and σr/σmax = 0.7 respectively) were observed in samples milled for 240 minutes and then annealed for 1 minute at Temperatures ~1200K. Such remarkable magnetic properties stem from the high magnetocrystalline anisotropy field and the homogeneous grain size of the Sm0.5Y0.5Co5 nanocrystals.
Borides Precipitation in the FeAl40 Intermetallic Compound Produced by Atomization-Deposition Process
Authors: Flores Osvaldo , Zagal Juan M. , Contreras-Cuevas Antonio , Rosas Trejo Gerardo Antonio , Pérez Ramiro , Martínez L.
Published: September 2009

The microstructure of FeAl40 intermetallic alloy produced by spray atomization and deposition, with boron additions and reinforced with Al2O3 particles was studied. This technique allowed the co-deposition of particulate reinforcement and the addition of boron in order to obtain a boron concentration of 0.4 at. %. The additions of alumina particles produce a grain refinement. High resolution transmission electron microscopy observations shows a precipitation of boron in the FeAl matrix in despite of the rapid solidification process. Fe3B precipitates were found which is a metastable phase formed during the rapid solidification process. In addition, FeB precipitates were observed.
Study on the Mechanical Properties of Sapphire by Numerical Simulation and Nanoindentation Technology
Authors: Zhang Ke Hua , Wen Dong Hui , Hong Tao , Yuan Ju Long
Published: September 2009

This paper presents a finite element (FE) modeling of the nanoindentation test of sapphire, in which the finite element method was employed to study the mechanical characteristic of sapphire under the nanoindentation process. The results demonstrated that the nanoindentation FE models were able to simulate the indentation loading-unloading curves of the sapphire. The load and unload displacement curves of the simulation and experiment results can match with each other well, and then the properties used in the simulation should be the actual properties of the sapphire. The Mises stress field distribution of the sapphire sample was calculated to reveal the alteration from elastic region to plastic region, which are useful for indentifying the ductile to brittle change in the sapphire abrasive process.
Investigation to Semi-Fixed Abrasives Plate Lapping SUS440 Stainless Steel
Authors: Deng Qian Fa , Wen Dong Hui , Chen Feng , Tao Li , Yuan Ju Long
Published: September 2009

To obtain high surface quality and high finishing efficiency in machining SUS440 stainless steel, a novel machining technology employing a semi-fixed abrasive plate (SFAP) is adopted. The SFAP is developed for preventing lapped surface from damage caused by larger particles (from grain size dispersion or from outside of processing area, larger particles could bring uneven load distribution on processing region). The effects of different parameters on the surface quality and the material removal rate (MRR) of SUS440 stainless steel which is lapped by SFAP are investigated in this paper. The control parameters of the lapping process include the lapping time, the load, the rotating speed of the lapping plate, and etc. SFAP of 800# SiC abrasive used, Experimental results indicate that SFAP can avoid the large scratch effectively and the surface roughness (Ra) of the workpiece could be improved from 250 nm to 50 nm in 12 Min. A nearly mirror-like surface can be obtained.
Numerical Simulation on Grinding of Advanced Ceramics
Authors: Bao Yu Mei , Chai Guo Zhong , Gu Sheng Ting
Published: September 2009

Ceramics are increasingly used in many advanced science and technology due to their excellent properties. Grinding is the most efficient and effective technique to achieve high dimensional accuracy and surface integrity of ground ceramic workpiece at optimum cost efficiency. The indentation/ scratch approaches are widely used in studying the grinding process. In this paper, the grinding technology and grinding induced damage of advanced ceramics are briefly reviewed. Based on MSC.Marc software, a FEM model for the Vicker’s indentation/scratch is established to simulate the abrasive grinding process, the stress and strain distribution in the advanced ceramics under a Vicker’s indenter are presented and discussed. The related elastic modulus is obtained by the nanoindentation tests.
Experimental Research of Micro Reversible Electrical Discharge Machining
Authors: Peng Zi Long , Wang Zhen Long , Dong Ying Huai , Chen Hui
Published: September 2009

Based on the principle of micro electrical discharge machining (EDM), a reversible machining method is proposed, which can achieve depositing or removing selectively metal material for the fabrication of micro structures. It is easy to transform the machining process from deposition to removal in one machining system. The characteristics of the deposited material show that the components of deposited material are almost the same as those of the tool electrode, and the metallurgical bonding has formed on the interface between the deposited material and the base. Moreover, the deposited material has well machinability in different micro EDM selective removal process, including micro EDM die-sinking and micro EDM milling. As a result, a micro square column with 0.1mm in side length, 0.88mm in height and a micro cylinder with 0.14mm in diameter, 1.18mm in height were fabricated by using the micro reversible EDM process.
Masked and Unmasked Machining of Glass by Micro Abrasive Jet
Authors: Qiu Y.F. , Wang Cheng Yong , Wang J. , Song Yue Xian
Published: September 2009

The micro abrasive jet machining is used to make the microfluidic channels on the glass substrate. Based on the tests with or without masks, the structure profile and erosion rate with different basic machining parameters, such as nozzle standoff distance, scanning speed, abrasive mass flow rate etc. are investigated. The optimum parameters for micro-structure machining of glass is discussed. The effect of the secondary rebounding particles in mask underetching was analyzed using oblique machining. And the flux effect was also studied comparing with the unmasked machining.
Study on the White Layer of Hard Turned GCr15 Bearing Steel
Authors: Wen Dong Hui , Liu Xian Li , Hong Tao
Published: September 2009

The formation mechanisms and properties of white layers produced in precision hard part machining of GCr15 hardened steels are not clearly understood to date. Microstructure of white layers formed during machining of GCr15 hardened steel (62±2 HRC) was investigated. Hard turned surface with white layer usually consists of three layers: a white layer (untempered martensite), a transition layer (over-tempered martensite), and the bulk material. Martensite, austenite and carbide are observed in the white layer, hardness of white layer is larger than that of bulk material and transition layer, it was caused by extremely small grain size and high dislocation density. The depth of white layer is about 7-14µm with the flank wear reached 0.1mm, the optimal width of the flank wear which generated low depth of white layer is essential to perform the super-finishing process.
Modeling the Minimum Chip Thickness in Orthogonal Micro-Cutting Based on Plastic Strain Gradient
Authors: Wu Ji Hua , Liu Zhan Qiang
Published: September 2009

In micro-cutting, the uncut chip thickness is comparable or even less than the tool edge radius and as a result a chip will not be generated if the uncut chip thickness is less than a critical value, viz., the minimum chip thickness. Knowledge of the minimum chip thickness plays a key role of the selection of appropriate machining conditions and optimization the micro-cutting processes. An analytical model is developed to predict the minimum chip based on the strain gradient plasticity theory in this paper, and the model accounts for the effect of material property in micro-scale such as the shear modulus, intrinsic length scale, fracture toughness and the Burgers vector. Predicted results are validated by experimental data obtained from the orthogonal micro-cutting experiments.
Study of Good Yield and Efficiency in TFT-LCD Module Process
Authors: Chen Zai Liang , Wang C.Y. , Tang Zheng Qiang
Published: September 2009

This paper introduces the TFT-LCD (Tablet Film Transistor Liquid Crystal Displayer) module process that is composed by two stages, JI (JISO) process and MA (Module Assy) process. In JI process, the main defect phenomena are bonding particle and bonding defect, which have a bad effect on the product yield. In MA process, the key factor of the output is the inequality workload to every worker and unbalance of the production line. With the solution of plasma cleaning and pressure diversification, the bonding defect ratio descent from 0.34% to 0.14%. By making workload balance, the efficiency of MA process has been increased.
Experimental Research on UV Laser and High-Pressure Water-Assisted YAG Laser Dicing SiC Wafer
Authors: Yang Li Jun , Huang H. , Cai N. , Wang Yang , Tang J.
Published: September 2009

In this paper, the comparative experimental research on DPSS UV laser (wavelength is 355nm) and high-pressure water-assisted YAG laser dicing SiC wafer was done. The results show that is strict with the performance of laser source and the dicing technique parameters in UV laser dicing the SiC wafer, and the dicing surface of good quality can be obtained only when the parameters of laser source and dicing technology vary in a narrow range. Contrarily, the SiC wafer dicing technology using high-pressure water-assisted YAG laser has a perfect flexibility with the laser source and dicing apparatus, and the good dicing surface can be obtained even if the process parameters vary in a wide range.
Observation in the Surface Roughness of Silicon Wafer during Semi-Fixed Abrasive Machining with Large Grains
Authors: Zhao Ping , Chen Jia Jie , Yang Fan , Tang K.F. , Yuan Ju Long , He X.H.
Published: September 2009

Semi-fixed abrasive is a novel abrasive. It has a ‘trap’ effect on the hard large grains that can prevent defect effectively on the surface of the workpiece which is caused by large grains. In this paper, some relevant experiments towards silicon wafers are carried out under the different processing parameters on the semi-fixed abrasive plates, and 180# SiC is used as large grains. The processed workpieces’ surface roughness Rv are measured. The experimental results show that the surface quality of wafer will be worse because of higher load and faster rotating velocity. And it can make a conclusion that the higher proportion of bond of the plate, the weaker of the ‘trap’ effect it has. Furthermore the wet environment is better than dry for the wafer surface in machining. The practice shows that the ‘trap’ effect is failure when the workpiece is machined by abrasive plate which is 4.5wt% proportion of bond in dry lapping.
Simulation and Analysis of Planetary Precise Ball Lapping Mode
Authors: Hang Wei , Dai Yong , Li Zhi Qiang , Feng J.F.
Published: September 2009

Series of simulation of planetary precise ball lapping modes are put forward in this article, which use solid abrasives to get a high lapping efficiency. In this case, it is very important to obtain a better quality especially a better uniformity. Based on the simulation. of this new lapping mode, it is found that the lapping trace are mainly influenced by the eccentric distance and other factors.
A Method of Parameters Estimation of Water-Lubricated Hybrid Journal Bearings for Ultra-Precision Machine Tool Spindle
Authors: Yang Xue Bing , Xiong Wan Li , Hou Zhi Quan , Yuan Ju Long
Published: September 2009

Water-lubricated hybrid journal bearings have been developed to support the ultra-precision machine tool spindles, due to the prominent properties of high load capacity and stiffness, high rotational accuracy, excellent thermal stability, low power consuming and environmental friendliness. Quasi-analytical procedures are deduced to present a relatively easy and rapid method for estimating of the parameters of the water-lubricated hybrid bearings without resorting to complex full numerical calculation. The procedures are based on the lumped resistance method, which have been extended to the situation dominated by the turbulence and inertia effects. The results show good agreement with the full numerical solution, especially when the bearing operating at moderate eccentricities. The procedures can be taken as a real time analytical tool for parametric study and preliminary engineering design of water-lubricated hybrid journal bearings.
Study on the Finishing Process for the Aluminum Nitride Substrates
Authors: Zhou Zhao Zhong , Yuan Ju Long , Lv Bing Hai
Published: September 2009

Aluminum nitride (AlN) ceramic has excellent electrical insulation and dielectric properties. The ultra-precision lapping and polishing techniques for the AlN substrate are studied in this paper, and the influence of the lapping parameters such as load and slurry on the surface roughness, material removal rate of AlN is discussed. The surface of workpiece after processing is observed with microscope to analyze the material removal mechanism. An extremely smooth surface with roughness 6nm Ra is obtained after the finishing process. It is also found that the gap between grains will decrease the precision and quality of AlN substrate.
Laser and Water-Jet Fiber Coupling Technology for Water-Jet Guided Laser Micromachining
Authors: Wang Yang , Yang Li Jun , Tang J. , Li L. , Chen Yan Bin
Published: September 2009

The processing effect using water-jet guided laser micromachining technology is determined by the accurate coupling of focused laser and high speed water-jet. In order to realize the effective coupling, based on the analysis and calculation, a coupling unit with special structures was designed. The maximum angle of incidence was researched, which determined whether the total reflection occurred when laser transported in the water-jet. By the aid of fluid dynamical simulation, the coupling unit with uniform distribution of inner-cavity fluid field was designed. The attenuation of laser energy in water-jet fiber was investigated. Using appropriate laser wavelength, pulse energy and filtered and de-ionized water, energy attenuation in fiber was reduced. Experimental results showed that applying this coupling technology, perfect water-jet guided laser micromachining can be achieved.
On the Characteristic Parameters of the Semi-Fixed Abrasive Plate
Authors: Zhao Ping , Tang K.F. , Wang Zhi Wei , Chen Jia Jie , Yuan Ju Long , He X.H.
Published: September 2009

To evaluate the characteristics of semi-fixed abrasive plate (SAP), several parameters and relevant measurement methods are developed. The characteristic parameters include shore hardness, compression ratio, resilience ratio and shear strength. Five semi-fixed abrasive plates are manufactured with different bond concentration. The test results of five characteristic parameters of the SAP show the shore hardness, resilience ratio and shear strength increase, and compression ratio decreases with the bond concentration increasing. This test can provide instructive guides to the manufacture of SAP which can fit different occasions by changing the concentration of adhesives.
2D FEM Estimate of Tool Wear in Hard Cutting Operation: Extractive of Interrelated Parameters and Tool Wear Simulation Result
Authors: Yue Cai Xu , Liu Xian Li , Pen Hong Min , Hu Jing Shu , Zhao Xing Fa
Published: September 2009

Tool wear plays an important part during cutting process, and wear loss has a close relationship with cutting condition, which affects machined surface mostly. In order to accomplish tool wear prediction in way of FEM, based on founding of cutting model under steady state, interrelated parameters needed for tool wear prediction, such as cutting temperature, contact pressure and raletive sliding velocity are extracted. By compiling Python subprogram and using Abaqus tool in hard cutting process PCBN tool wear is predicted, which provide foundation for optimizing cutting condition.
The Diamond Wire Saw with a Nonmetallic Core
Authors: Yao C.Y. , Peng Wei , Wang Ming Huan , Liu F.Q.
Published: September 2009

Diamond wire saw is the leading technology for use in cutting hard brittle material. Its smaller kerf and faster cutting time make it replacing the conventional slurry technology for those materials. Turned over the traditional router, this paper presents a novel approach that replaces the typical metallic core with a nonmetallic core, for manufacturing of ultraviolet curing resin fixed-abrasive diamond wire saw (DWS). The experiments show that the diamond wire saw made by this manufacturing method can obtain a good performance as well as taking many other advantages.
Numerical Simulation on the Temperature Field of Water-Jet Guided Laser Micromachining
Authors: Yang Li Jun , Wang M.L. , Wang Yang , Tang J. , Chen Yan Bin
Published: September 2009

Water-jet guided laser micromachining is the new development orientation of laser machining. This paper set up the numerical model on the action between the water-jet guided laser and the material. By using the software ANSYS, simulated the processing of the water-jet guided laser micromachining. This paper gave the investigation on the machining laws and the distributing of temperature fielding in processing of water-jet guided laser micromachining. And the results of the correlative experiment prove the model aright. The result provided the theoretical foundation for the next research on the water-jet guided laser machining.
The Design of Powder Feeding System for Laser Remanufacturing
Authors: Hu Xiao Dong , Zhang Y. , Yao Jian Hua , Chen Z.J.
Published: September 2009

The stability of powder feeding is important to guarantee the quality of the laser remanufacturing. In order to detect and control the powder flow, a new powder feeding device is designed for laser remanufacturing. Scraper-type conveyer and capacitance sensor are used into the device which is tested by 2Cr13 and H13 powder. The results show that: Using H13 metal powder as medium will get a better effect，and when the changes of powder density are more than 10-1g/min, the device acts better distinguish-ability. The experimental results demonstrate that the system can be used to control the steel base powder feeding.
Research on Modeling of Cutting Wire Deflection of Multi-Wire Saw
Authors: Tang R. , Dai Y.X. , Zhang Y.B. , Yuan Ju Long , Xiong Wan Li
Published: September 2009

The deflection of cutting wire on multi-wire saw is determined by cutting wire tension, diameter ingot feed force and some other factors, and it affects the quality of silicon wafers greatly. In this paper, the initial stage of cutting process is analyzed and modeled with three ODEs. Then the numerical solutions are solved by finding out the BVPs of each ODE. The numerical solutions showed the relationship between the deflection and the cutting parameters such as cutting wire tension, diameter and ingot feed force. This method is helpful for the further research of modeling the entire cutting process.
A Compound Vibratory Mode in High Speed Vibratory Tapping
Authors: Wang L. , Wang Gui Cheng , Zhu J.H. , Pei Hong Jie , Lin L.F.
Published: September 2009

Based on the investigation of two traditional vibratory modes, this paper puts forward a novel vibratory mode in high speed tapping. Vibratory tapping on stainless steel with all kinds of vibratory modes is carefully studied. Experimental results show that the new vibratory mode not only preserves the machining effect of the separable vibratory tapping, but also increases the life of tap. Therefore this study provides a new solution to increase the performance of high speed vibrat- ion tapping.
Heat Conduction Analysis of Coated Cutting Tools with Temperature-Dependent Properties
Authors: Zhang S.J. , Liu Zhan Qiang
Published: September 2009

The heat generation during metal cutting processes affects accuracy of the machined surface and strongly influences cutting forces and tool wear. Material property of coated tools is one of the most important factors effecting heat conduction and temperature on the rake face of coated tools. To find the action of thermal properties of coated cutting tools on cutting temperature, the temperature distributions were obtained with temperature-dependent properties and temperature-independent properties of coated tools using numerical method. The results indicated that temperature-dependent properties should be considered when calculating cutting temperature. To simplify calculation, selecting the thermal conductivities at average temperature to substitute for temperature-dependent properties can reduce calculating error. The conclusion provides a methodology for analysis of cutting temperature of coated tools, design of cutting tools and analysis of thermal stress within coated tools in manufacturing industries.
Effect of Helix Angle and Normal Rake Angle on Stability in End Milling
Authors: Tang A.J. , Liu Zhan Qiang
Published: September 2009

Chatter phenomenon often occurs during end milling of metal-cutting and becomes a common limitation to achieve high productivity and part quality. This paper studies the relationship expression between the parameters of oblique cutting and milling coefficients by analyzing the geometrical relationship of oblique cutting, and derives the mathematic expressions in theory between the cutter parameters and chatter. For the purpose of chatter avoidance, this paper studies the effect of helix angle and normal rake angle on milling stability under the condition of the same milling parameters, and plots the three-dimensional stability lobes of the spindle speed, axial and radial depths. It can be found that the milling stability is increased with the increment of helix angle and normal rake angle. Through the three-dimensional lobe, it is possible to choose the appropriate cutter parameters to reduce and avoid the chatter.
Correlation between Cutting Forces and Tool Wear in High Speed Milling of Graphite
Authors: Zhou Li , Wang Cheng Yong , Wang Xiao Jun , Qin Zhe
Published: September 2009

Cutting tools suffer severe abrasive friction and wear in high speed milling of graphite. Cutting forces were measured and analyzed using time-frequency analysis method to reveal the correlation between cutting force variations and tool wear evolution. The static and dynamic force components increased prominently with tool wear. The cutting force Fy was found the most sensitive to the tool wear evolution. The waveform of cutting force became periodic and irregular with the increase of tool wear. Good correlation was found between the first force harmonic and tool wear.
Stability Prediction during Thin-Walled Workpiece High-Speed Milling
Authors: Song Qing Hua , Wan Yi , Yu Shui Qing , Ai Xing , Pang J.Y.
Published: September 2009

A method for predicting the stability of thin-walled workpiece milling process is described. The proposed approach takes into account the dynamic characteristics of workpiece changing with tool positions. A dedicated thin-walled workpiece representative of a typical industrial application is designed and modeled by finite element method (FEM). The workpiece frequency response function (FRF) depending on tool positions is obtained. A specific 3D stability chart (SC) for different spindle speeds and different tool positions is then elaborated by scanning the dynamic properties of workpiece along the machined direction throughout the machining process. The dynamic optimization of cutting parameters for increasing the chatter free material removal rate and surface finish is presented through considering the chatter vibration and forced vibration. The investigations are compared and verified by high speed milling experiments with flexible workpiece.
Study on 5-Axis Machining Key Technology of High-Precision Aluminum Alloy Integral Impeller
Authors: Wang X.J. , Li S.L. , Zhao Can
Published: September 2009

Using the typical CAD/CAM software UG, an aero-engine integral impeller was studied in this paper, including 3-D modeling, tool-path planning and simulation. A regular impeller was machined with a 5-axis machine tool, which showed the process plan was feasible.
High Speed Machining of AISI 52100 Steel
Authors: Liu Ya Jun , Huang Jia Bin , Qin Meng Yang , Xia Wei , Tang Yong
Published: September 2009

This paper gives the details of High Speed Milling experiments with AISI 52100 steel (HRC52) by using coated carbide end mills. Cutting force and Surface roughness data are presented. The effects of cutting speeds (1000-8000rpm), widths of cut (0.05-0.4mm) and cutting conditions (dry cutting and dry cutting with air coolant) are investigated. The results show that in high speed milling of hardened steels, when cutting speed surpasses a critical value, cutting forces decrease as cutting speed increasing; and the increasing of widths of cut causes the increase of cutting forces approximately linearly; surface roughness does not experience obvious increase or decrease and has a minimum in a specific condition; the machining results of dry cutting with air.
Surface Topography and Roughness Simulations for 5-Axis Ball-End Milling
Authors: Han Shi Guo , Zhao Jun , Zhang Xiao Feng
Published: September 2009

In five-axis high speed milling of freeform surface with ball-end cutters, unwanted machining results are usually introduced by some error effects. Hence precise modeling and simulation of milled sculptured surfaces topography and roughness is the key to obtain optimal process parameters, satisfactory surface quality and high machining efficiency. In this paper, a predictive model for sculptured surface topography and roughness of ball-end milling is developed. Firstly, a mathematical model including both the relative motion of the cutter-workpiece couple and some influential factors on machined surface quality such as the tool runout, tool deflection and tool wear is proposed, and subsequently the analytical form of the tool swept envelope is derived by means of homogeneous coordinate transformation. Then the minimal z-values of the corresponding points lied in discrete cutting edges model and Z-map workpiece model are used to update the workpiece surface topography and to calculate 3D surface roughness. Finally, the simulation algorithm is realized with Matlab software. A series of machining tests on 3Cr2MoNi steel are conducted to validate the model, and the machined surface topography is found in good accordance with the simulation result.
Numerical Simulation of Adiabatic Shear Behavior in High-Speed Machining of Hardened Steel GCr15
Authors: Chen Tao , Liu Xian Li , Luo G.T. , Yan Fu Gang , Jia Dong Kai
Published: September 2009

In this paper, FEM is used to simulate the three stages of catastrophic shear occurrence, expansion and shear band formation when serrated chips are formed under adiabatic shear behavior in high-speed machining of hardened steel GCr15 with PCBN tool. By comparing data of simulation and experiment on chip morphology characters, it is indicated that they are in good accordance. Hereby, the author has analyzed strain and temperature distribution in adiabatic shear band, and dynamic characters of cutting force . The research results show that adiabatic shear band begins from tool tip and extends to workpiece free surface, and it is characterized by large strain and high temperature. In addition, it results from adiabatic shear behavior that cutting force waves regularly in a numerical range.
Study on the Surface Topography and Residual Stress for Dry Turning of GH80A
Authors: Guo X.D. , An Qing Long , Zou B. , Chen Ming
Published: September 2009

GH80A has been widely used in industry for its excellent property under high temperature. The surface integrity is one of the key factors that determine the lifetime. Hence, it’s worth to study surface topography and residual stress which are two important indexes used for evaluating the surface integrity. They are both resulted from the coupling of the mechanical and thermal effect during the turning which can not be well explained with experiment and numerical calculation. In this paper, workpiece surface topography was studied under different cutting parameters. The residual stress is measured and simulated to show more details about the effect of cutting parameters. The cutting temperature which is difficult to pick up in experiments is also simulated to explain the machining process.
Study on the Machinability of Two Different Sulfur Free Cutting Steels
Authors: Zhang G.L. , An Qing Long , Zhang Yun Shan , Liu Gang , Chen Ming
Published: September 2009

Research has been done on microstructure and machinability of two different free-cutting steels by using cutting tools coated and uncoated at the condition of different cutting parameters. The cutting force, surface quality, chip morphology and tool wear are investigated, which reveal the influence of the size and shape of sulphide inclusion on machinability. The experiment shows that the shape of spindled sulphide inclusion has relatively better machinability than stripped sulphide inclusion and the size of sulphide inclusion also plays some influence.
Design of Integration Tool-Holder System for Ultrasonic Vibration Machining Using Contactless Inductive Power Transfer
Authors: Pi Jun , Xu Xi Peng
Published: September 2009

Contactless inductive power transfer system with conventional inductive technology was studied and a design method was presented after applying it to ultrasonic vibration machining systems. The compensation techniques are used for piezoelectricity transducer. Nodal plane support of transducer is researched and models of different structures for nodal plane support are got. Influence of rotary precision for different support due to centrifugal force and displacement vibration of nodal plane support to toolholder are analyzed. The system integrated with ultrasonic-vibration toolholder based on contactless inductive power transfer is designed. Power transfer and dynamic tests show that the design procedures and result based on theoretical analysis are comparative.
Optimization of Plastic Injection Molding Process Parameters for Thin-Wall Plastics Injection Molding
Authors: Jin Jie , Yu H.Y. , Lv S.
Published: September 2009

The effects of the process parameters on the warpge and shrinkage of parts in different thickness are analyzed by Taguchi optimization method. Taguchi optimization method was used for exploiting mold analysis based on three level factorial designs. Orthogonal arrays of Taguchi, the signal-to-noise (S/N) ratio, the analysis of variance (ANOVA) are utilized to find the optimal levels and the effect of process parameters on warpage. It can be concluded that Taguchi method is suitable to solve the quality problem of the injection-molded thermoplastic parts.
Research on Technics of Laser Direct Metal Deposition Forming Technology
Authors: Zhang Wei , Yao Jian Hua
Published: September 2009

The technological parameters of laser direct metal deposition (DMD) were researched by DMD forming experiments using 2Cr13 powder. Fixing other parameters, the lower of laser power, the smaller the characteristic sizes of cladding layer are. Increasing of laser power, cladding height would firstly increase and then decrease, cladding width would firstly increase and then almost maintain constant, while cladding depth would gradually increase. When other parameters are invariable, with increasing of powder feeding speed, cladding height would increase, cladding width and cladding depth would decrease. When other parameters are invariable, cladding width, cladding height and cladding depth would decrease with the adding of scanning speed. The microstructure of single track cladding had three typical patterns, cellular dendritic, column dendritic and equiaxed crystal. The patterns depended on the temperature gradient and the solidification velocity. Under different technical parameters, the average hardness of specimens would change from 300HV0.2 to 550HV0.2.
The Multidimensional Manufacturing Resource Modeling and Integration of Multistage Manufacturing System Based on Meta-Model
Authors: Gui Yuan Kun , Dong Qiao Ying , Kan Shu Lin
Published: September 2009

In order to achieve the manufacturing resource sharing inside and outside the enterprise in the multistage manufacturing system, the multidimensional manufacturing resource concept model was presented from two aspects. The manufacturing resource application integration model faced application systems and the capacity manufacturing unit model faced manufacturing capacity were established respectively. The structure and modeling method of multidimensional manufacturing resource model based on meta-model was presented. The meta-model consisted of information layer, model layer and meta-model layer and unified the multidimensional model in the same model frame. Finally, the integration method of the model based on eXtensible Markup Language(XML) was established. The presented multi-dimensional manufacturing resource model can achieve the internal and exterior sharing in the networked manufacturing environment.
Experimental and Numerical Modal Analysis of Gearbox Casing in a Polishing Machinery
Authors: Wang Yang Yu , Ji Shi Ming , Wen Dong Hui , Zhang Xian
Published: September 2009

Vibrations in polishing machinery may affect the manual or automatic controls and reduce the efficiency of the operations to be carried out. In this article, an experimental and numerical analysis on the dynamic characteristic of a gearbox casing in polishing machinery have been carried out. The numerical investigation was achieved with NASTRAN based on a 3D FEM model and the experimental modal analysis for the determination of the natural frequencies and the associated eigenmodes of the gearbox casing with LMS structural vibration test system was performed. The fundamental modal parameters including the first 10-order natural frequencies, damping ratios and mode shapes were estimated and identified. Analytical and experimental results have been compared and discussed. Agreement between measurements and calculations is satisfactory and the results can be used as reliable reference for improving the dynamic behavior of the gearbox casing.
WEB-Based Process Planning System for Hydraulic Disk Brake
Authors: Jiang Shao Fei , Lu Cong Da
Published: September 2009

Process planning system for hydraulic disk brake for motorcycle based on Microsoft .Net platform is presented. Two modes of process planning which called retrieved process and generated process are studied for assembly process planning and machining process planning. Then process planning system for hydraulic disk brake for motorcycle is developed base on Browse/Sever mode. An example of hydraulic disk brake shows validity of the system.
Optimal Design of a Parallel Micromanipulator for Precision Machining
Authors: Wang Z.F. , Wang Guan , Ji Shi Ming , Sun J.H.
Published: September 2009

A parallel micromanipulator (PmM) which can be applied into the precision machining is optimized in the paper. This paper adopts a methodology to determine a set of optimal design parameters of PmM whose workspace is as close as possible of being equal to a prescribed cuboid dexterous workspace (PCDW). The kinematic problem is analyzed in brief to determine the design parameters and their relation. Then, an optimal design procedure which adopts the generalized pattern search algorithm in the genetic algorithm and direct search toolbox of Matlab is proposed to solve these problems. As an applying example, the results of four cases PCDW to PmM are presented. And the design result is compared with a concept of the distance between the best state of the PmM and the requirement of the operation task. The method and result of this paper are very useful for the design of micromanipulator for the machining field which requires the high precision and accuracy.
Common Platform Identification for Product Family on Extension Clustering Method
Authors: Wang Wan Liang , Zhao F.G. , Zhao Yan Wei , Su N. , Zhang F.
Published: September 2009

Common platform design for product families is an important step in the modularity field. It is impossible to find the similar components in alterative design stages for the traditional similarity measure used in module division. So, a new common platform design method on extension-distance is presented. In different design environments, three distance concepts are discussed, namely, feature-to-feature, feature-to-set and set-to-set. The first concept will be employed as the base for extension-cluster method in the platform design on the thought of each structure’ s features between two adjacent structure components, while the second is used to build the tolerance-constraint function in the customized components division for the common platform generation. Last the adaptability measure is used to find the optimal case in the database. The method took the gasoline saw as an example.
Extension Case-Based Reasoning for Product Configuration Design
Authors: Zhao Yan Wei , Zhang F. , Zhang M.Y. , Chen Jian , Su N.
Published: September 2009

The interface was regarded as standard and not considered in traditional configuration design, which made it difficult to apply to the existence product configuration. The paper proposes an extension case-based reasoning for product configuration design. With matter-elements, reasoning model of Extension Case-Based Reasoning (ECBR) is established, and its corresponding algorithm is proposed. During the configuration design, the solution space of configuration schemes is obtained by the similarity calculation, and then the overall evaluation of similarity and compatible degrees is adopted to form the final configuration scheme. A prototype system of reducer configuration design is successfully developed according to the method, and it proves the proposed method that is feasible and effective.
Optimal Design of the Compression Coil Spring in the Tool-in-Use System of the Jade Carving Machine Based on Dynamic Analysis
Authors: Shi Huai Rong , Rui R.Y. , Wen Yi Fang
Published: September 2009

While to consider the function of compression coil spring in a static state, the most important is the needs of dynamic characteristics. We infer a design mode with link up the static state and development, and bring both to the constraint condition of optimal design. It is basis of the development function of compression coil spring is the property of vibrate displacement. And we adopt the optimal design of MathCAD in the computer, simplified the handle of several scaling functions. The effect proves that in the living example of compression coil spring from tool-in-use system, it makes that simple and valid. Thus provide a basis for the function design of machine structure.
Study on the Ceramic Grinding Crack Propagation Mechanism under the Ultrasonic Action by Using Nonlocal Theory
Authors: Zhao Bo , Ma Hui , Xie Ping
Published: September 2009

This paper presents a research on the attenuation of cyclic stress amplitude and the variation of microstructure under the action of ultrasonic vibration in crack propagation for Al2O3-ZrO2 composite nano-ceramics. To interpret this phenomenon, the nonlocal theory is introduced to establish the constitutive model under the ultrasonic condition based on the specified 2D attenuating function. The mechanics behavior of the ceramics under the action of ultrasonic vibration is analyzed according to the relationship between the internal character length and the external character length (i.e. ultrasonic wave length). In addition, the variation law of the cyclic stress amplitude and microstructure with different ultrasonic frequencies is also studied in this paper. It is shown that the cyclic stress amplitude is attenuated under the action of ultrasonic vibration, and this attenuation phenomenon becomes more and more evident by increasing the ultrasonic frequency. The results of experiment are in accordance with the theoretical conclusions drawn from the nonlocal theory, which verifies that the action of ultrasonic vibration can actually accelerate the ceramic crack propagation.
Customer Churn Analysis Model in Manufacturing Industry
Authors: Liu D.S. , Ju Chun Hua
Published: September 2009

To address the problem of customer churn in CRM in manufacturing industry, this paper proposes a prediction model based on Support Vector Machine (SVM). Considering the large-scale and imbalanced churn data, principal component analysis (PCA) is adopted to reduce dimensions and eliminate redundant information, which makes the sample space for SVM more compact and reasonable. An improved SVM is used to predict customer churn. Firstly, PCA is adopted to process 17 dimensional feature vectors of customer churn data, and then the application in manufacturing industry verifies that this model based on both PCA and SVM performs better than the model based on SVM only and other traditional models.
Influence of Supporting Characteristics on Sphericity of Ceramic Balls in Rotated Dual-Plates Lapping Process
Authors: Lv Bing Hai , Yuan Ju Long , Cheng F. , Yang Fan
Published: September 2009

Ceramic balls have become an important component in advanced bearings, and the sphericity of balls is a key qualification focused in lapping process. An investigation on the effect of dynamic behavior of ball support system on the performance of ball lapping in rotated dual-plates lapping method is carried out. Sinusoidal waveform in terms of Fourier analysis is employed to express the shape error of the ball surface, and a dynamic model for support is setup. It is found with numerical calculation that the variation of lapping load lags behind the variation of the shape error for the damping of support. A lower natural frequency of the support system, higher spin speed of balls and a larger value of spin angle in RDP lapping are better to rectify the shape error of balls and reduce the lagged effect. It is concluded that dynamics of lapping system must be taken into consideration in order to understand comprehensively the spherical surface generation mechanism.
On Pneumatic Installation Technology of Modal Testing Suspension System
Authors: Sun J.H. , Gao Zhi Song , Shan X.H. , Zhang Li , Wang Yang Yu
Published: September 2009

Modal testing is essential to correct the structure of dynamics model and optimize structure designs. First, the principle and the application of modal testing system are introduced in this paper. Then, through the theoretical calculation, the frequency of the air spring is achieved in this suspension system. And the influence of the baric fluctuation to the rigid suspension system is analyzed. In order to achieve an ultra low frequency request at 0.03Hz, methods of reducing the baric fluctuation are proposed here. Through the analysis, we successfully design a modal testing suspension system which can test the natural frequency of the samples below 0.1Hz. Experimental results show the baric fluctuation of the suspension system is lower than 20Pa.
An Extended CPM for Resource-Constrained Project Scheduling
Authors: Ju Chun Hua , Xie Yi
Published: September 2009

In order to apply traditional CPM in resource-constrained project scheduling, the activity network is firstly formalized for resource-constrained project scheduling. Then Resource constraint in project is presented and an algorithm of the extended CPM is developed for resource-constrained project scheduling. Finally a case is conducted, which shows the accuracy and effectiveness of the extend CPM.