bluuebunny/crossref_metadata_2025 huggingface dataset:
Effect of Drawing Processes on Wire Breaking in Steel Wire Production
Authors: Xu Ying Lei
Published: June 2014

Wire breaking is a major factor in the impact of wire drawing production, and drawing process is an important factor causing the wire breaking, which cannot be ignored. In this paper, the impact of tension, bending stresses, centrifugal stresses, compression ratio of die arrangement and drawing speed in the process of the wire drawing process on wire breaking were calculated theoretically. Then the corresponding measurements to reduce the rate of wire breaking were proposed. The results show that the the tension of drawing process was the main factor, while choosing the right compression ratio and drawing speed according to the actual situation, the rate of wire breaking could be reduced effectively.
Study on Deformation Law of Drum-Shaped Blank and Collapse Defect in Rolling Process
Authors: Wang Lei Gang , Kong De Zhi , He Jia Yang , Huang Yao
Published: June 2014

Based on the FEM software simufact.forming, a finite element model of the radial-axial ring rolling for one ring product was constructed and the rolling process under different drum-shaped blanks were simulated in this paper, which revealed the variation of drum-shaped blank in the rolling process, analyzed the formation process and further proposed measures of eliminating collapse defect. The results show that the drum disappearing rate in initial rolling stage is greater than in later stage and it becomes increasingly difficult to disappear, which leads to collapse defect in the end. The drum-shape can be reduced by greater radial feed in initial rolling stage in the case of small drum-shape or rounding before rolling on ring rolling machine in the case of large drum-shape for avoiding collapse defect. The results provide valuable guiding significance for practical production.
Study on Spring-Back of CU11000 Clad AL1050 Sheets
Authors: Liu Shou Fa , Xue Fei , Wu Song Lin
Published: June 2014

This study is aimed to investigate the spring-back angle of clad metal sheet in bending process by using finite element simulation and experiment to meet the growing requires in the application of clad metals. In this study, the clad metals processed into 1mm thick from CU11000 and AL1050 were bent 90o over a die with a bend radius of 1mm. The results show that there is not any relative sliding, crushing or peeling occurred in the junction of the clad material during the bending process, the spring-back angle of the clad metal is always smaller than each single metal and the CU content increasing also caused spring-back angle become small. The configuration of a harder material (CU11000) in tensile side also has a smaller spring-back angle.
Experimental Study on Three-Dimensional Flexible Stretch Bending Formability for Complex Cross-Sectional Profiles of TWB
Authors: Shen Ya Jing , Xia Qin Xiang , Zhong Guo Feng , Wu Feng
Published: June 2014

Taking the upper strip of automobile doorframe which is complex profiles roll bending part of high-strength steel welded blanks as the research object, and then to Investigate its three-dimensional flexible stretch-bending formability under force control mode; the law of tensile force and clamp rotation angles’ influences on forming precision of the product is obtained. The results show that the springback of the line contour precision is largely affected by the comprehensive impact of tensile force and the clamp rotation angles, the values mentioned above reached minimum when the tensile force is 1.1 times the material yield strength, the springback will increase when greater or less than this value. Because of the surface torsion springback, internal and external surface contour accuracy mainly affected by the stage rotation angle when the profile bending curvature is large enough, and the effect is not obvious when the bending curvature is small.
Coupled Thermo-Mechanical FEM Simulation of Multi-Pass Vertical-Horizontal Rolling Process
Authors: Xu Hong Bin , Ding Shu Rong , Huo Yong Zhong
Published: June 2014

The governing equations and the finite element model for the coupled thermo-mechanical multi-pass vertical-horizontal rolling process of a zircaloy strip are established. Considering the temperature-dependent and strain rate-dependent constitutive relation of zircaloy, the numerical simulation of the three-pass V-H rolling process is realized by the coupled thermo-mechanical dynamic explicit finite element method. The computational results such as the plastic deformation, the size variations and the temperature variations in three passes are discussed. The research results indicate that edging by vertical roller benefits improving the sizes of the strip and the temperature variations are rather obvious during the three-pass hot rolling process. The research provides experience and foundations for the FEM simulation of the hot rolling process of composite slabs for nuclear fuel elements.
Technique of Extrusion Die Tolerance Analysis Based on CAT
Authors: Gao Yuan Lou , Li Zhe , Wang Xin
Published: June 2014

As traditional screw extrusion die tolerance analysis has characteristics like manual calculation, experience dependence so far, this paper aims at applying CAT (Computer Aided Tolerancing) into extrusion field with the assistance of tolerance modeling and self-generation algorithm of retrieval dimension chain to analyze tolerance and reassign tolerance based on the technology used for aircraft assembly referring to chemical characteristics of the manufacturing process. Practice on production line testified the rationality of improved tolerance design.
On-Line Measurement of Rheological Properties of LDPE, HDPE and LDPE/MICA Systems in Single-Screw Extrusion
Authors: He Hong , Zhou Jian Guo
Published: June 2014

The quality of extrudate is closely related to its rheological properties during extrusion. Therefore, on-line measurement of rheological properties of polymer is important in extrusion process. In the present work, comparisons between the on-line viscosities of LDPE in single screw extruder and that in lab under the same condition were made by using online rheometer. Effects of set temperature of on-line rheometer, screw configuration and different positions, as well as weight proportions of filler, size of MICA particles of LDPE/MICA multiphase system on the melt viscosity in single screw extrusion are discussed.
Study on Convergence, Calculation Speed and Precision of Flatness Analysis Method for Cold Rolling Strip
Authors: Wang Dong Cheng , Zhang Zhu Qing , Liu Hong Min
Published: June 2014

The key models of flatness analysis method are the strip plastic deformation model (SPDM) and the roll stack elastic deformation model (REDM). The traditional method uses the SPDM to calculate the distribution of rolling force, and the REDM is adopted to calculate the profile of exit strip. The reverse iteration method uses the REDM to calculate the distribution of rolling force, while the SPDM is adopted to calculate the profile of exit strip. The model coupling method integrates SPDM and REDM as one set equations through their internal relation. In this paper, the basic thoughts of three methods are introduced. Through a typical example, the convergence, calculation speed and precision of three different methods are analyzed. It is found that the calculation precision of the three methods are almost the same, but the model coupling method is more outstanding than other two methods on the convergence and calculation speed, so the model coupling method is the best choice for flatness analysis.
Research of Producing Reduction Steel Powder from GCr15 Steel Scrap
Authors: Zhang Xin Xin , Han Jing Tao , Liu Jing
Published: June 2014

In order to use GCr15 steel scrap from Wuxi, production process of reduction steel powder was studied according to its characteristic, including the effect of magnetic separation process on removing impurity, the selection of reduction process parameters. The results showed that bake in air at 500°C should be conducted to burn lubricant off. Magnetic separation on removing impurity should be conducted after burning lubricant off, and ball-milling in water should be added before wet magnetic separation. Effect of magnetic separation and recovery rate of steel scrap were comprehensive best when magnetic induction was selected at 80mT. Reduction system should be adopted at 850°C, 5 h in reducing atmosphere of dissociated ammonia.-100 mesh particle size and 20mm in material thickness should be selected. Through the above process, performance of GCr15 reduction steel powder produced by steel scrap from polishing process was as follows, TFe content was 97.18%, acid insoluble content was 0.38%, and it can be used to produce powder metallurgy structural parts. Performance of GCr15 reduction steel powder produced by steel scrap from grinding process was as follows, TFe content was 95.14%, acid insoluble content was 2.49%, and it can be used as steel powder for welding electrode.
Preliminary Investigations on Preparation of Cu-Al Bi-Metallic Tubes Using Swaging-Diffusion Method
Authors: Hao Qing Le , Han Jing Tao , Song Jing Jie , Ji Shuai
Published: June 2014

Bi-metallic tubes (BMTs) combine performance advantages of two different tubes and are usually used in particular conditions where corrosion resistance is important. Traditionally, BMTs are manufactured by plastic processes such as extrusion, explosive welding/cladding, hydroforming and even combinations thereof. However, rotary swaging, which is commonly used to produce tubes, was seldom mentioned when preparing BMTs. In this work, Cu-Al BMTs were achieved using swaging-diffusion method (SDM). The effect of process on formability of BMTs are investigated. The experimental results indicate that with the increasing of deformation, metallurgical bonding layer, which is more desirable than mechanical bonding layer, can be achieved. And the metallurgical bonding layer will thicken to 2μm after diffusion. Besides, some failures produced in the swaging process are presented.
Technology of Finite Element Analysis for Roll Forming Process
Authors: Peng Xue Feng , Han Jing Tao , Liu Jing , Yan Pei Jie
Published: June 2014

With deepening of roll forming technology and the proficiency of computer aided design and finite element Analysis (FEA) technology, it is widely noted that using the technology of FEA to simulate the roll forming process. In this paper, the current status of finite element simulation for roll forming process at home and abroad is summarized. And the finite element theories of deformation zone in roll forming process are analyzed. The new issues on roll forming process faced by finite element simulation, including advanced high strength steel (AHSS), multipass heterosexual cross section and coupling thermo-mechanical-metallurgical (TMM) coupling etc. are discussed. Moreover, the future trends of numerical simulation about the roll forming process are forecasted.
Analysis of Metal Deformed Flow under Adhesive Friction by Ring Upsetting
Authors: Li Wei Qi , Ma Qing Xian
Published: June 2014

It is a complex coupling of multi-physics field for metal deformed flow behavior under the condition of adhesive friction, which has been studied in this paper. In this paper, ring upsetting has been carried out with various press amounts. By comparisons of the transient displacement figure of internal & external metal particles under different press quantities, deformed flow state of metal particles is obtained, and inverse flow is found under the adhesive friction. Based on transient displacement obtained by ring upsetting, the flow orientation of the whole specimen is specifically acquired by means of piecewise cubic hermite polynomial interpolation. In the end, representation model of deformed flow behavior is put forward to illustrating and predicting the flow behavior of metal particles.
Investigation on the Effect of Liquid Hammer Geometry to the Pressure Distribution of Innovative Hybrid Impact Hydroforming
Authors: Marai Murhaf , Lang Li Hui , Wang Shao Hua , Lin Li Jin , Yang Chun Lei , Luo Xuan
Published: June 2014

The innovative hybrid impact hydroforming (IHF) technology is a kind of high energy forming technique which can be used for forming complex parts with small features, such as convex tables, bars etc. which are widely employed in automotive and aircraft industries. The impact hydroforming technology means the most features are formed by hydroforming and the small features are rapidly reshaped by high intensity impact energy in a very short time after the traditional hydroforming. The impact pressure rises to the peak in 10ms which belongs to dynamic loading. The present work investigates IHF using a numerical /experimental approach. Finite element simulations using MSC.Patran were carried out changing the geometrical shape of liquid hammer.. Using this shock wave loading condition we did forming experiments. During forming process, stress distribution in the blank is comparatively better as compared with traditional methods so possibility of fracture is reduced. Inertia is also an important factor which affects control quality. Therefore, the research is very useful for improving forming quality of complicated products. It will be widely applied in automotive and aircraft industries.
Research on Finite Element Simulation of the Big Size Spring Steel in Continuous Grooveless Rolling
Authors: Wang Bao Yuan , Dai Jiang Bo , Zhang Ye Hua , Xu Da Qing
Published: June 2014

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he basis of
the
rolling
process parameters
of large size
spring steel
for the simulation calculation
,t
he fini
te element model was establishe
.
the
calculation results
reveal
the reasons
about
the billet
heap
and
the l
ow precision products
,
the
rolling
program file
about
continuous rolling pass and technology of the
rolling mill
was revised and
perfect
ed
, the continuity and stability
of
the
large size spring flat steel in continuous slotless roughing rolling
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t
he unit operation efficiency increased
.
The Ring’s Axial Deformation Control Method of Vertical Hot Ring Rolling Process
Authors: Hu Ke , Wang Xiao Kai , Luo Jian Lan , Wu Xi Jun
Published: June 2014

Axial deformation of the ring during the traditional vertical hot ring rolling (VHRR) process has a considerable effect on the ring products’ quality. In this paper, the ring’s axial deformation of VHRR process of three different rolling modes, that is, open-die mode, close-die mode and open-die mode with conical rolls like the radial-axial ring rolling (RARR) process is analyzed. Three groups of 3D coupled thermo-mechanical FE models of VHRR process are established in software ABAQUS, and the axial deformation and the width spread of the rings are studied in detail. Finally, a special conical roll device was designed and equipped on the traditional VHRR mill, and series of VHRR experiments are conducted, the results of both simulation and VHRR process show that the formed rings utilizing open-die rolling with a special pair of conical rolls has lower axial deformation, smoother end surface and higher precision than the formed rings utilizing open-die rolling and close-die rolling. The research results can supply an effective approach to axial deformation control of traditional VHRR process.
Efficiency Analysis on the Synthetically De-Icing Technology Combining Thermal Water-Jet Cutting with Mechanical Milling
Authors: Liu Ai Hua , Zhou Jian Zhao , Xu Xiao Pan , Chu Wei Jun
Published: June 2014

Transportation always plays a significant role in national economy, of which roads and bridges are the most important facilities. The conditions of the road surface have an overwhelming influence on the traffic flow and road safety, especially in winter and the regions with frequent snowfall, thus closely affected the development of the urbanization and economic prosperity. In view of this, this article has analyzed the characteristics of the existed de-icing technologies, coming up with a new synthetically de-icing method which consists of thermal water-jet cutting with mechanical milling technology. These two kinds of de-icing methods are combined as a set of multi-functional system, in which the thermal water-jet cuts the ice layer into separated sections, and the mechanical milling unit then easily removes the remaining sections out of the road. To obtain the prime influential factors in this new de-icing device, repeated indoor experiments were conducted, which provides some theoretical references to further advance the de-icing efficiency and make structural optimization.
Study on Cutting Performance of the Alumina Based Nanocomposite Ceramic Tool
Authors: Zhou Qi Fen , Zhou Peng , Zhang Hai Ying
Published: June 2014

In this paper, the oxide nanometer composite cutting performance of ceramic tools cutting cast iron were studied. And the tool failure modes were mainly analyzed. Through the study found that, with the increase of tool wear with cutting speed, failure forms mainly adhesion wear. When the cutting speed is low, the knife before the crater wear become the main form of ceramic cutting tool wear, boundary wear and the surface of the knife after wear is also very serious. And in the process of cutting, the collapse edge can also occur now; With the increase of cutting speed, collapse become the main failure forms of cutter blade.
TC4 Titanium Alloy Surface Crack Detection and Analysis
Authors: Chen Zhen Ya , Shen Xing Quan , Xin Zhi Jie
Published: June 2014

The mechanism of surface cracks penetration testing are studied, as well as, the cracks’ width and depth of penetration testing formulas are given in the paper, which provide the basis for TC4 titanium alloy structure's penetration testing. The process of fluorescent penetrating testing is analyzed, and the result that detection experiments of TC4 titanium alloy structure's surface crack indicating the changes in the curvature is larger the structure is easier to produce surface cracks. The reason that the surface cracks of structure of TC4 titanium alloy is theoretical analyzed and experimental studied. In process of machining TC4 titanium, cutting parameters are important factors causing stress concentration, particularly, the larger cutting depth will generate surface cracks.
A Processing Predictive Model of Ultrasonic Vibration Grinding Assisted Electric Discharge Machining Based on Support Vector Machines
Authors: Yang Guang Mei , Zhang Yun Peng , Li Kai Yue , Chen Guo Ding
Published: June 2014

To predict the machining results of ultrasonic vibration grinding assisted electric discharge machining (UVGAEDM) in the condition of building predictive model with a few samples but fluctuant values, a predictive model based on SVM was proposed in this paper. Taking machining SiCp/Al as an example, the samples for modeling were obtained through orthogonal test, and then the predictive model was established utilizing MATLAB. Finally, the model was optimized to further improve the prediction accuracy about the processing indicatorssurface roughness and processing velocity. It shows that the predictive results are in good accord with the test results, with the maximum relative error being less than 12%, meaning the predictive model is reliable and effective.
Study on Virtual Machining Process of Peripheral Milling of Thin-Walled Workpiece
Authors: Liu Yuan Xiang , Chen Feng , Liang Chu Jun
Published: June 2014

Thin-walled workpiece is easy to deform in machining. In order to predict the dimensional error of machined surface of thin-walled workpiece, computer simulation technology is studied, which is called virtual machining process. For the simulation of workpiece deformation, much numerical analysis should be done. Research indicates using FEA (Finite Element Analysis) in each step of simulation process needs too much time to meet the requirements of industrial application. Therefore it is important to decrease the simulation time. In this paper, a new method is proposed to realize rapid analysis of workpiece deflection in virtual machining process, which combines rapid analytical solution method with a few times of accurate FEA, thus greatly decreases the time required for whole simulation. For the simulation, several peripheral milling process models are presented with increasing order of sophistication and accuracy, which can be applied to simulate cutting process with the effect of workpiece deformation caused by cutting force. In the final section, the comparison between simulation results and experiments shows the proposed methods and models can closely predict dimensional error and texture of machined surface of flexible workpiece.
Experimental Study on Electrochemical Drilling of Micro Holes with High Aspect Ratio
Authors: Liu Yong , Huang Shao Fu
Published: June 2014

It is a difficult problem to fabricate deep and micro holes on the difficult-to-cut metals in the field of aviation manufacturing. The experimental research of electrochemical drilling technology with high-speed micro electrode for fabricating deep micro holes is carried out. The influences of rotary speed on machining precision and stability are studied. The holes, which the diameter is about 400μm, the aspect ratio is more than 10, and have steep wall and sharp edges were fabricated successfully on the nickelbase superalloys on self-developed high-precision micro-electrochemical machining system. It is proved that the high-speed electrochemical drilling process for fabricating deep and micro holes has a huge potential and broad application prospects.
Research and Development of Ultrasonic CNC Cutting Path Generation System for Nomex Composite Materials
Authors: Liu En , Hu Xiao Ping , Yu Bao Hua
Published: June 2014

There are a number of problems with the traditional way of machining Nomex composite materials, Ultrasonic vibration cutting as a new method can overcome most of the problems. This paper presents the machining process characteristics of ultrasonic cutting honeycomb structures of Nomex composite materials using two kinds of specials tools, and has a research on Ultrasonic machining tools posture control strategy, then proposed calculation method of generating the cutter location date. The main system was developed to meet the automatic generation cutting path of Nomex composite materials based on VS2008 and UG commercial software. The result of experiment shows this system can automatic generate rational machining path and correct NC date.
Optimization of Electric Discharge Machining Parameters of Al-7%Si-4%Mg with 20% of Red Mud Metal Matrix Composites
Authors: Geetha B. , Ganesan K.
Published: June 2014

An investigation was carried out to find out the influence of process parameters on surface roughness (SR) and material removal rate (MRR) in electric discharge machine of Al-7%Si-4%Mg with 20% of red mud Metal Matrix Composites since electric discharge machining is a thermo-electric machining process, an electronic die sinking electric discharge machine was used to drill holes in the composite work piece, copper is used as tool material. Experiment was carried out to find surface roughness, material removal rate and tool wear rate by varying the peak current, flushing pressure of dielectric fluid and pulse on time. It was found that the surface roughness of composite metal increases with the increase peak current ,pulse on time and flushing pressure due larger and deeper craters on the drilled surface. It was also found that there was increase in metal removal rate with the increase in peak current and flushing pressure and slightly decreases with the increase in pulse on time due carbon deposits on the electrodes. Experimental analysis is carried using Taguchi’s Design of Experiment method with various parameters like peak current, flushing pressure of dielectric fluid and pulse on time to identify the key factors that influence the surface roughness, material removal rate and tool wear rate. It was found that the peak current was the most significant parameter that influences surface roughness, material removal rate and tool wear rate. The Taguchi experiments results confirm the actual results obtained from the numerical calculation.
Simulation of Residual Stress in Cold Working of Flat Spiral Springs
Authors: Li Zhan Hua , Han Jing Tao , Cheng Jing , Ji Shuai
Published: June 2014

Spring residual stress is a great influence on the overall performance of springs. In this paper, a flat spiral spring is taken as the research object, based on ABAQUS, the finite element model of residual stress during cold working of flat spiral springs is built. The magnitude and distribution of residual stress in cold working of flat spiral springs are simulated under different parameters. The effect of residual stress on the use performance of flat spiral springs is investigated. Optimization of process parameters is acquired. A reasonable processing technology is formulated, which provides theoretical basis for the cold working process.
Machinability Assessment of Titanium Alloy Ti-6Al-4V for Biomedical Applications
Authors: Polishetty Ashwin , Littlefair Guy , Praveen Kumar K.
Published: June 2014

Titanium alloy (Ti-6Al-4V) has a wide range of application in various fields of engineering. Titanium is mainly used to manufacture aerospace components like landing gear, fuselage, wings, engines etc. and biomedical components like hip joint, knee joint, dental implants etc. Titanium has outstanding material properties such as corrosion resistance, fatigue strength, tensile strength and a very good biocompatibility which makes this material very alluring for biomedical applications. Contrary, the machinability of the material is problematic because of the phase transformations and thus, titanium alloy is a challenge for machining operation. This research is a comparative analysis between the implants manufactured by traditional method of casting and machining. The femoral stem of the hip joint replacement is designed and the component is machined using a five-axis CNC machine. The machined component was subjected to surface roughness testing, tensile testing and bulk hardness testing. The values were compared with the values of titanium implants manufactured by casting.
Study on Key Technologies of Handheld High Velocity Arc Machining Equipment
Authors: Tang Xiu Jian , Liu Qian , Zhou Ze Yun , Ge Hui , Wang Long
Published: June 2014

Remanufacture is an important way for green manufacture. To materialize the field processing of surface fatigue layers for some bulky and heavy waste productions, the processing principle and some key technologies such as discharge gap control, conductive wheel design for handheld high velocity arc machining equipment are introduced in this paper. The new machining technology and equipment is very fit to the remove of surface fatigue layers for some bulky and heavy parts under field conditions for its small volume, low costs and high efficiency.
Microstructure and Bending Property of Welding Joint Prepared by 5356 Welding Wire Added Sc, Zr and Er
Authors: Wang Xiao Ming , Zhu Sheng , Zhao Zhi Hao , Wang Qi Wei , Peng Xi Hua
Published: June 2014

7A52 aluminum alloy was welded by using 5356 welding wire added Sc, Zr and Er. Microstructure of the welding joint was observed by using optical microscope (OM). Bending property was tested by bending tester. The results demonstrated that, compared to employ traditional 5356 welding wire, the grains in welding zone (WZ) were much finer; The grains in fused zone (FZ) nucleated and grew from the matrix; The grain size along heat affected zone (HAZ) dercearsed gradually.The welding joint prepared by using 5356 welding wire added single 0.3%Sc possessed maxium face bending strength. The welding joint fabricated by using 5356 welding wire added compond 0.1%Sc+0.2% Er possessed maxium rear bending strength. The fine isometric crystal and isometric dendrite generated at the welding zone when the new type 5356 wire added gingle Sc or compound Sc+Er was employed, which make the welding joint represent excellent bending property, respectively.
Microstructure and Properties of Mg/Al Dissimilar Joints by GTAW with Al-Si Filler Wire
Authors: Du Hong Yan , Li Ya Jiang , Wang Juan
Published: June 2014

Mg/Al dissimilar materials were welded successfully by GTAW with SAlSi welding wire of Al-Si system. The nice surface forming and free defects of joints are formed. Mg/Al welded joint were tested and analyzed by means of optical microscope, scanning electron microscope, microhardness tester. The test results show that in the fusion zone of Mg side, it shows the intense columnar crystalline structure and little intergranular precipitates, and has more dendritic intergranular precipitates. However, the weld zone shows the typical columnar structure zone. There is no high hardness brittle phase in fusion zone of Mg side. The hardness of weld zone is slightly higher than one of Mg substrate, and far less than the Al substrate.
Research on Surfacing Welding and Machining Process of Large Valve Corrosion Resistant Layer
Authors: Zhang Yue , Zhang Xi Chuan , Ma Yu Qiang
Published: June 2014

The corrosion resistance layers can be surfaced in the valve casted by carbon steel, to enhance the corrosion resistance performance. By the 3D solid model, the weight and internal area of valve body was obtained. The surfacing process was designed and the welding rods theory amount was calculated. And the actual amount was close to the theory one. The surfacing and cutting process was designed for the fit surfaces and the dimension chain was calculated to meet the fit accuracy and the corrosion resistance layer thickness. The results show that it has the engineering significance by using 3D solid model to estimate the producing costs; the fit accuracy and the corrosion resistance layer thickness can be obtained together based on the surfacing and cutting process; in this way, the cost can be cut down more than 30%, compared the whole stainless steel valve.
The Microstructure and Properties of TIG Welded Joint of AZ31B/Cu Dissimilar Metal
Authors: Du Shuang Ming , Hu Jie , Lan Tian
Published: June 2014

AZ31B magnesium alloy and T2 Cu metal plates with the thickness of 2mm were bonded by argon tungsten arc welding (TIG) under the conditions that the welding current is 100A and the welding speed is 150 mm/min. The microstructure, phase composition and properties of welded joint were studied by scanning electron microscopy (SEM), X-ray diffraction (XRD), micro-hardness test. The results show that AZ31B magnesium alloy and T2 Cu combined well with no cracks, porosities, incomplete penetration and other metallurgical defects. A transition zone composed of equiaxed and columnar crystals of α-Cu exists between the weld metal and base metal Cu, its width is about 80μm. The central area of the weld is made up of α-Mg matrix and Mg-Cu eutectic. The joint consists of α-Cu, α-Mg, Cu2Mg, Mg2Cu and little MgO, CuO phase. The micro-hardness of weld zone is significantly higher than that of the base metals, and its heat affected zone appears softening phenomenon.
Performance of Cohesive Zone Models for Brittle and Ductile Adhesives
Authors: Zhang Jun , Jia Hong
Published: June 2014

Damage modeling approach is increasingly used to simulate fracture and debonding processes in adhesively bonded joint. In order to understand the relation between the delamination behavior of different types of adhesives and the type of cohesive zone models (CZMs), the pure tension and pure shear experiments were conducted used two distinct adhesives, an epoxy-based adhesive in a brittle manner and VHBTM tape adhesive in a ductile manner. The traction-separation relations of the two adhesives were extracted from the tension and shear experimental results. Three types of cohesive zone models (CZMs) are adopted, including the exponential, bilinear, and trapezoidal models. VUMAT subroutine of CZMs as the adhesive layer is used to simulate the specimen tension and shear debonding procedures. The results demonstrate that (i) the bilinear CZM more suitably describes the brittle adhesive and the exponential CZM suitably describes the ductile adhesive to simulate the tension and shear failure. (ii) cohesive strength and work of separation are the significant affections on the simulation results. and (iii) the shape of CZM is a significant affections on the simulation the pure tension and shear debonding procedure.
Improvement of the Wear Resistance of A6061 Plate by Resistance Seam Welding with High Carbon Iron Alloy Powders
Authors: Wang Wen Qin , Yamaguchi Tomiko , Ohno Naoyuki , Nishio Kazumasa
Published: June 2014

To improve the wear resistance of A6061 plate, Fe alloy cladding layers consisting of FeAl3 intermetallic compound were synthesized by resistance seam welding with high carbon iron alloy powder (SHA). The effect of welding speed on the macrostructures, phase compositions, hardness, and wear resistance of the cladding layers were investigated. The results showed the hardness of the cladding layers were significantly improved to 455, 469, 479 and 615 HV in response to the welding speed of 0.1, 0.5, 1.0 and 1.5 m/min as compared with 60 HV of the A6061 substrate. The wear resistance of the cladding layer was also enhanced with decreasing the welding speed.
Welding Spark Parameters Determination for Cyclone Removal Calculation
Authors: Strelets Ksenia I. , Kitain Mikhail B. , Petrochenko Marina V.
Published: June 2014

Many factors have an essential impact on the air purification efficiency. Very important for a lot of industries is to choose right air purification system. Especially important is to take into account manufacturing including generation of combustible and explosive dust. One of the way to prevent possibilities of fire and explosion is using reverse flow cyclone as a pre-cleaning system. In the article the efficiency of such precleaner is showed and experimentally proved.
High-Speed, High-Precision Magnetic/Piezoelectric Hybrid Drive Actuator for Micro Electrical Discharge Machining
Authors: Zhang Xiao You , Uchiyama Kouki , Ishizuka Tomohiro
Published: June 2014

Electrical discharge machining (EDM) has the capability of machining all conductive materials regardless of hardness, and has the ability to deal with complex shapes. However, the speed and accuracy of conventional EDM are limited by probability and efficiency of the electrical discharges. To improve the machining speed and accuracy, we developed a 3-DOF controlled, high-speed, high-precision, magnetic/piezoelectric hybrid drive actuator. For the actuator, a voice coil motor type of magnetic bearing having a positioning stroke of a few millimeters is used to control the motion of an electrode in the thrust direction in order to speedily maintain a suitable distance from the workpiece. Moreover, two piezoelectric elements having high response speed and high precision are used to achieve the vibration of the electrode in the radial direction in order to immediately remove the debris between the electrode and the workpiece. The positioning performance of the actuator is evaluated through experiments, and the experimental results show that the actuator possesses a positioning resolution of 1μm, a bandwidth of 120Hz and a positioning stroke of 2mm in the thrust direction, and a positioning resolution of 0.05μm, a positioning stroke of 10μm at 1000Hz in the radial directions.
Study on the Effect of Tool Polarity and Tool Rotation during EDM of Non-Conductive Ceramics
Authors: Ojha Nirdesh , Zeller Florian , Mueller Claas , Reinecke Holger
Published: June 2014

The ability to machine advanced ceramic materials such as ZrO2, SiC, and AlN is of high interest for various industries because of the extraordinary material properties that these ceramics possess. Once sintered, these ceramics are characterized with high mechanical strength, high thermal stability and high chemical inertness. Therefore it is extremely difficult to machine these ceramics with dimensions in few microns using traditional techniques. Electrical discharge machining (EDM) is an electro-thermal machining process used to structure conductive materials. By applying a conductive layer on top of the non-conductive material, the EDM process can also be used to machine the non-conductive material. This paper presents a study on the effect of tool polarity and tool rotation on the material removal rate and electrode wear ratio during the EDM process of non-conductive SiC, ZrO2 and AlN ceramics. The reasons for the variation in the material removal rates among the different ceramics are examined by comparing the material properties. Relatively lower value of flexural strength, fracture toughness and melting temperature is the reason for AlN ceramic to have the higher MRR than SiC and ZrO2 ceramics.
The Periodical Translocation Gear-Grinding Technique to Improve the Indexing Accuracy of Ultra-Precision Gears
Authors: Ling Si Ying , Lou Zhi Feng , Liu Qiang , Wang Li Ding
Published: June 2014

The ultra-precision master gears have important application in calibrating high precision gear measuring instruments or coordinate measuring machines and in military industry. Firstly based error interference of the angle-transferring curve, the periodical translocation technique (PTT) of gear-grinding to improve the indexing accuracy of ultra-precision gears is proposed. The conclusions are drawn by precision experiment: (1) controlling 2/3~3/4 of total teeth participating in regrinding process can obtain the smaller total cumulative pitch deviation; (2) with increasing of the number of teeth participating in regrinding processes, the effects on single pitch deviation is more obvious. Finally, the total pitch deviation Fp of the specimen reaches to 0.79 μm (2.7′′), and the single pitch deviation fp reaches to 0.30 μm (1.0′′) by adopting PTT technique and both of them reaches to submicron level.The precision gear-grinding experiments show the efficiency and practicability of the PTT technique.
Experimental Investigation of Fabrication of Double Tapered Hole Array by Using Electroforming and Mask Electrochemical Machining
Authors: Bao Xiao Hui , Ming Ping Mei , Lv Zhen Bin
Published: June 2014

Basing on an inert perforated metal mask, a hybrid electrochemical fabrication combining electroforming and mask electrochemical machining was proposed to manufacture metal through-hole array with double tapered openings. The feasibility of this novel process was investigated experimentally. The effects of pattern parameters of inert metal mask, such as wall angle, α, substrate thickness, H, hole spacing, L and hole size, D, on profiles of the resulting holes were analyzed. The experimental results show that the hybrid fabrication is able to manufacture high-aspect-ratio double tapered hole array with good surface quality.
Exploration of Hyperfine Micro-Machining Limit
Authors: Hu De Zhi
Published: June 2014

Combining the latest achievements of scientists to study cosmology, the machining accuracy of microelectronic devices is not the limit size of hyperfine micro-machining processing. In the future, it will develop a novel micro-machining method using dark energy and dark matter, and setup a new era. The paper introduces the Planck scale and the Heisenberg uncertainty relation into the Newtonian gravity for the model simplification. Newtonian gravity can be separated into two parts that is Dark Matter and Dark Energy. Every part is inverse relation to the distance.
Thermal Accumulation in Metal Micro-Parts Fabricated by Micro Droplet Deposition Manufacturing Technique
Authors: Zuo Han Song , Li He Jun , Qi Le Hua , Luo Jun , Zhong Song Yi
Published: June 2014

Thermal accumulation in micro droplet deposition manufacturing (MDDM) has a significant influence on geometric profile and microstructure of the fabricated metal micro-parts. In this paper, thermal behavior of a new aluminum droplet on the deposit surface was investigated using one-dimensional heat transfer model. Then several thin-walled aluminum cubic pipes were fabricated by MDDM to verify the numerical analysis result. The result shows that the thermal accumulation would increase gradually with the increase of the deposit height. It associated with thermal input and output on the top surface of the deposit, which could be controlled or eliminated by optimizing processing parameters such as deposition frequency.
Experimental Research on Affect of Water Jet to Laser Compound Processing of Crystalline Silicon
Authors: Yuan Gen Fu , Zhang Chong Tian , Chen Xue Hui , Zhang Cheng , Yao Yan Sheng
Published: June 2014

A wavelength of 1064nm Nd: YAG laser was used to groove on silicon, then studying the affect of quality and processing efficiency by incoming jet in laser etching course of silicon: Water jet reduced doss, cracks and other defects which might be produced on the surface of groove. Software of matlab was used to restore the topography of tank’s bottom; analysis shown that the water jet had a scouring effect influence on tank’s bottom. Introduction of the water jet caused the loss of the laser energy, but it could improve processing efficiency indirectly by blowing away the slag.
Directly Manufacturing Mouse Mold by Plasma Deposition Manufacturing
Authors: Xiong Xin Hong , Chen Jia Lin , Quan Dun Miao
Published: June 2014

Direct fabrication of end-use parts made of metal material has become one of the most interesting fields relevant to research and development of additive manufacturing technologies. This paper presents an effort of trial manufacture of a metal mouse mold with good performances of dimensional precision and fine surface roughness using direct manufacturing technology. The PDM (Plasma Deposition Manufacturing) process is adopted to couple with the milling process, which synthesizes plasma deposition as an additive technique, and milling as a subtractive technique during the processing. Plasma deposition manufacturing is demonstrated to allow rapidly fabricating the metal mouse mold directly from its CAD model without mold or tooling-based intermediary processes. The PDM method provides a new access to directly manufacture the metal parts and mold with short-process and high quality.
New Method of Plane to Plane Parallelism Error Measurement Based on Flatness Plane
Authors: Khan Muhammad Ilyas , Ma Shu Yuan , Samo Saifullah
Published: June 2014

Measurement of parallelism error is one of important icon in the measurement of orientation tolerances. This paper presents new method of parallelism error measurement and is based on the flatness plane using minimum zone technique. Real coded genetic algorithm has been proposed to determine the flatness plane coefficients and flatness error. Flatness plane has been developed using plane coefficients and then parallelism error has been determined from the flatness plane. One example has been presented to show the effectiveness of the proposed parallelism error measurement method. The result of the proposed method has been compared to co-ordinate measuring machine (CMM) built-in function for parallelism error measurement and the results are in good agreement. In addition to determination of parallelism error measurement, the proposed algorithms also calculate flatness error and can also be extended to measurement of other types of geometrical tolerances with slight modifications.
Modeling and Virtual Simulation of Hard Surface Milling and Forming Process Using Advanced CAE Systems
Authors: Dubovská Rozmarína , Majerik Jozef
Published: June 2014

This paper presents the influence of modeling and simulation techniques for hard milling and forming. The aim of these simulations is the ability to optimize the manufacturing technologies even before the real production of its own tools, because their manufacturing process is very difficult in terms of production time, materials and other costs. The simulated results visualize roughing and finishing process of milling and generate tool-paths in CATIA V5. Simulation results of forming realized in PAM-Stamp 2G using a 3D model of the punch and the blank confirm the suitability of the proposed design of the forming tool. Finally, hard milling and forming simulations in CAE systems CATIA V5 and PAM-Stamp 2G were performed in order to determine and evaluation of suitability of the proposed shapes of the forming tool.
Modeling of Multilayered Sheets for Thermoforming Applications
Authors: Oueslati Zied , Rachik Mohamed , Lacrampe Marie France
Published: June 2014

During the last decades, automotive industry has to meet many environmental constraints and to reduce the cost and the energy conception. Giving their mechanical properties and low manufacturing cost, thermoplastic multilayered materials have proven to be an adequate solution for such applications. In this paper, the particular combination of Thermoplastic PolyOlefin (TPO) sheets and Polypropylene (PP) foams is considered. The mechanical behavior of each material is studied and the multilayered material response is predicted and compared to measurements at a 120°C temperature. Despite the transversely isotropic behavior of the TPO sheets and the very high stretch ranges, the obtained results are very convincing and the used models proved to be very reliable.
Diffusion and Oxidation Wear of Superhard Cutting Tool Based on Thermodynamics Enthalpy
Authors: Shao Fang , Wang Yu Ting , Zou Li Jing , Wu Yan Ying , He Chuan
Published: June 2014

Cutting temperature always highly reaches over to 1000°C? when high speed machining with PCBN tools. Diffusion of tool material element may have important influence on tool wear at such high temperature, the diffusion wear and oxidation wear have become the major wear mechanism. In this paper, the rules of diffusion wear and oxidation wear for PCBN cutting tools are proposed and analyzed based on thermodynamics theory. Dissolution concentrations in typical normal workpice materials of PCBN tool material at different temperature are then calculated. Diffusion reaction rules in high temperature are developed and analyzed using Gibbs free energy criterion. The machining tests were conducted using the PCBN tools at different cutting speeds of 50, 95,100 and 180 m/min, feed of 0.1, 0.2 and depth of cut of 0.1, 0.8, 1, and 1.5 mm respectively on PUMA300LM numerically-controlled lathe. It was found that the theoretical results were uniform with the experimental data; the results will provide useful references for tool material design and selection.
The Properties of the Sodium Silicate Binder Composition Based on Quartzite Deposits
Authors: Myrzakhmetov M.M. , Zhuginisov M.T. , Sartaev D.T. , Orynbekov E.S. , Aidarova S.B. , Turganbay Seitzhan
Published: June 2014

Heat-resistant concrete with liquid and water glassis widely used for the lining of thermal units and equipment. In this paper we present the results of studies on the preparation and study of the properties of the sodium silicate composite binder (SNCR) on the basis of quartzite Kulantyubinsky field for heat-resistant concrete. Refractoriness quartzite 1450-1500 ° C. According to RFA quartzite consists of α - quartz, in addition, the sample contains kaolinite Al2O3 ∙ 2SiO2 ∙ H2O. SNCR is prepared jointly grinding quartzite and solid sodium silicate, a ball mill, taken from ootnoshenii: 90:10, 85:15, 80:20 to surface area 2800-3000 cm 2/g. To determine the optimal composition of the binder were determined flexural and compressive strength of samples, cross members 16х4х4 see Hardening SNCR carried drying in 2-stage operation in the temperature range 100-200 оC. Found that the bending strength of SNCR is 1.6-2.6 MPa, compressive 17,0-32,3 MPa.Refractoriness of 1320-1390 °C. The process of phase formation during heat treatment optimum binder composition.Was found that at temperatures of 1200-1300 ° C in SNCR by quartzite than β - quartz formed vykotemperaturnaya modification quartz β - cristobalite, which increases the fire resistance of binder. Presence of cristobalite phase was also found with the mineralogical On-petrographic method as well. resulting binder can be used for acid-and heat-resistant refractory Producth with 1300 оC and more.
Stress Modeling of Large Cylindrical Ingot Heating Process
Authors: Zheng Ji Ming , Gao Xing Yong
Published: June 2014

Discloses the variation of the thermal stress of the ingot heating process to cylindrical body ingot, for example, the thermal stress change in the heating process of the modeling obtained the variation of the axial, tangential and radial thermal stress,the research results provide a theoretical basis for the corresponding set of process parameters.