Active-passive radial-additive friction stir repairing of mechanical hole out of dimension tolerance of AZ31 magnesium alloy

In order to avoid the depth increasing of repaired hole and eliminate the super-fine grain band in stir zone by radial-additive friction stir repairing(R-AFSR), a solid-state repairing technique of active-passive radial-additive friction stir repairing(AP-RAFSR) assisted by the truncated cone-shaped filling material was proposed in this study. The mechanical hole out of dimension tolerance of AZ31 magnesium alloy was chosen as the repaired object. The results indicated that the AP-RAFSR process rather than the R-AFSR process avoided the kissing bond in the bottom of the repairing interface under the condition of the tool pin length equal to the height of the standard mechanical hole.The continuously-distributed and large-length super-fine grain bands were eliminated in the stir zone by AP-RAFSR. The maximum tensile and compressive-shear strengths of repaired hole by AP-RAFSR reached 190.6 MPa and 138.9 MPa at 1200 rpm respectively, which were equivalent to 97.7% and 89.6% of those of the standard mechanical hole. This AP-RAFSR process assisted by the truncated cone-shaped filling material provides a new technique to obtain a no-depth-increasing, defect-free and high-strength repaired mechanical hole.

Radial Additive Friction Stir Repairing of Mechanical Hole Out of Dimension Tolerance of AZ31 Magnesium Alloy Assisted by Stationary Shoulder:Process and Mechanical Properties

Radial additive friction stir repairing(R-AFSR)assisted by stationary shoulder was put forward in the present study,which can be employed to repair the mechanical hole out of dimension tolerance of AZ31 magnesium alloy sheet.The results show that the stationary shoulder has sealed-barrier,heat-sink and extra-forging effects.The heat-sink effect improves the microstructure uniformity along the stir zone(SZ)thickness and the surface appearance of repaired hole,and the sealedbarrier and extra-forging effects eliminate the super-fine grain band in the SZ.Therefore,these three effects improve the formation quality of repaired region,thereby enhancing the mechanical properties of repaired mechanical hole compared with conventional R-AFSR.The tensile and compressive shear strengths of the repaired hole by stationary shoulder R-AFSR both increase first and then decrease when the rotating speed changes from 1200 to 1800 rpm,and these maximum values,respectively,reach 190±3 MPa and 64.5±2 MPa at 1400 rpm.The addition of stationary shoulder during R-AFSR can obtain a higher-quality repaired hole and broaden the repairing process window.

Effects of Dimensional Tolerances on the Friction Power Loss of Hydrodynamic Journal Bearing System

According to the dimensional tolerances on hydrodynamic journal bearing system, a nonlinear oil film force model was established,and the Reynolds' equation was solved by adopting finite difference method. In order to fulfill different dimensional tolerances in the system,adopting 2kfactor design and using the eccentricity ratio corresponding to the stability critical curve,the effects of the friction power loss brought by the dimensional tolerances of the dynamic viscosity,bearing width,bearing diameter and journal diameter were analyzed. The effect on dynamic characteristics of the hydrodynamic journal bearing system was quantitatively analyzed,and the nonlinear dynamic analysis, modeling and calculation methods were studied while considering the manufacturing tolerances. The results show that in contrast to the impacts of the tolerances in journal diameter,dynamic viscosity and bearing width,the bearing diameter tolerance would lead to the rise in the power loss, and the dimensional tolerances have different degrees of impacts on the journal bearing system. The friction power loss decreased as the eccentricity ratio increased, and when the eccentricity ratio was 0. 695 the power loss came to the minimum.The investigation would find the best solution and reduce energy consumption,then control varieties of nonlinear dynamical behavior effectively,and provide a theoretical basis for hydrodynamic journal bearing system in parameter design.

Modeling and Optimal Design of Planar Linkage Mechanism of Coupled Joint Clearances for Manufacturing

The uncertainty of the mechanism motion error is mostly caused by the manufacturing process,so the motion error cannot be effectively predicted at the design phase.The problems of manufacturing complexity and the relationship between design and manufacturing are analyzed,and the influence of dimensional tolerance and fit tolerance on the motion accuracy of the system is considered in the design process.Then based on the Monte Carlo simulation,an optimal design model of planar linkage mechanism is set up.A typical offset slider-crank mechanism is used as an illustrative example to carry out the optimal design.Compared with the result of typical robustness design,the similar variation characteristics of the mean value and the standard deviation can be found,so the proposed method is effective.The method is furthermore applied in the optimization of the schemes with different fit tolerances and the prediction of motion errors in the design phase is achieved.A set of quantitative evaluation system for mechanism optimal design is provided.Finally,a basic strategy is presented to balance the motion precision and manufacturing cost.