Taper Angle Correction in Cutting of Complex Micro-mechanical Contours with Ultra-Short Pulse Laser

The objective of this work was to investigate the possibility of taper angle correction in cutting of complex micro-mechanical contours using a TruMicro ultra-short pulse laser in combination with the SCANLAB precSYS micro machining sub system. In a first step, the influence of the process parameters on the kerftaper angle of metallic alloys was systematically investigated without beam inclination. A set of base parameters was derived for the subsequent investigations. In a second step, the kerftaper angle was controlled by static beam inclination. In a third step, the same optics was used in its dynamic precession mode to fabricate micro-mechanical components of complex contours with perpendicular 0~ taper angles. It was found that taper angle adjustments of up to 7.5~ are possible with the used setup for cutting applications. Taper angle control is possible both in the static beam inclination mode and in the dynamic precession mode. The static mode could be interesting for contours with sharp inner radii and for achieving faster cutting times similar to results with fixed optics, but would require excellent synchronization of beam inclination and axis motion. The dynamic precession mode would allow an easier integration of the optics into a laser machine but will result in longer cutting times and limitations with respect to achievable inner radii.

AUTOMATIC CONTROL OF REGENERATIVE CUTTING CHATTER BASED ON OPTIMAL REGULATION OF SPINDLE SPEED

An applicable method to control regenerative cutting chatter automatically based on the optimal regulation of spindle speed is introduced. The optimal value of the phase shift angle of the regenerative chatter signal between the two successive cuts is 270°. The cutting process can be adjusted from the unstable region to stable one whenever regenerative chatter occurs if the phase shift angle is kept 270° by the optimal regulation of spindle speed. The theoretical analysis and the experimental results prove that the optimal regulation of spindle speed can effectively control regenerative cutting chatter. In addition, a reliablelly optimal control system of reliable spindle speed is presented. There is no need for system identification of the machine tool, and it is easy to put this regenerative chatter control method into practice, so the method has excellent application prospect.

Method to determine installing angle of conical point attack pick

In order to obtain the determining method of the installing angle and decrease the performance indices (cutting force and wearing rate) of the pick, the relationships among the installing angles (impact angle, inclination angle and the skew angle) were studied, and the static model of installing angles of the pick was built. The relationships among the impact angle, the tip angle of pick and the kinematics parameters of the pick were built, too. Moreover, the mechanic models of the maximum clearance angle and the wearing angle of the pick were set up. To research the relationships of the installing angles and the change law of the wearing angle along with the kinematics parameters, the simulation was done. In order to verify the correctness of the models, the cutting experiments were done by employing two picks with different pick tip angles. The results indicate that, the cutting force is the smallest when the direction of the resultant force of pick follows its axis, and the relationship derived among the installing angles should be satisfied. In addition, to decrease the cutting force and the wearing of the pick, the tip angle of pick should not be larger than the half of the difference between the minimum wearing angle and the impact angle of the pick, and the clearance angle must not be less than zero.

Mesoplasticity Approach to Studies of the Cutting Mechanism in Ultra-precision Machining

There have been various theoretical attempts by researchers worldwide to link up different scales of plasticity studies from the nano-, micro- and macro-scale of observation, based on molecular dynamics, crystal plasticity and continuum mechanics. Very few attempts, however, have been reported in ultra-precision machining studies. A mesoplasticity approach advocated by Lee and Yang is adopted by the authors and is successfully applied to studies of the micro-cutting mechanisms in ultra-precision machining. Traditionally, the shear angle in metal cutting, as well as the cutting force variation, can only be determined from cutting tests. In the pioneering work of the authors, the use of mesoplasticity theory enables prediction of the fluctuation of the shear angle and micro-cutting force, shear band formation, chip morphology in diamond turning and size effect in nano-indentation. These findings are verified by experiments. The mesoplasticity formulation opens up a new direction of studies to enable how the plastic behaviour of materials and their constitutive representations in deformation processing, such as machining can be predicted, assessed and deduced from the basic properties of the materials measurable at the microscale.

Effect of Helix Pitch Angle on the Modal Dispersion Characteristic of Step-Index Optical Fiber

The general characteristic equation is derived for the helically cladded step-index optical fiber. The dispersion curves are drawn for the different pitch angles Ψ and mode order ν = 1. The effect of helix pitch angle on the dispersion characteristics and also on the modal cut-off condition is examined. Except for the lowest order mode, all the modes appear in pairs. The lowest order mode displays the negative dispersion for the some value of normalized frequency V and depends on the helix pitch angle Ψ.

Application of FVM Analysis for Elastic Characteristics on Cutting Process of a Composited Coating Iron

A composite material as a work piece is taken into account to investigate the elastic characteristics displaying during the cutting process. The magnitude of the elastic behaviors such as displacements and stresses reacts sensitively to the cutting angle and the vertical force increase, and the magnitude increases along the increments of the cutting angle and the vertical force increase. The buffering mechanism at the bond coat is described well by the fluctuation phenomenon for the horizontal displacement distribution profiles at the substrate. The variation of cutting angle under high vertical force yields profound influence on the behaviors of the longitudinal stress and the shear stress.

爆炸切割网络传爆中的间隙与角度效应

为研究爆炸切割网络中传爆节点处传爆能力的关键影响因素,通过改变切割索对传爆药柱的传爆间隙进行了平板传爆试验,将试验结果结合仿真分析确定了JO-11C传爆药柱的仿真材料参数,并进一步分析了传播角度对传爆能力的影响。研究结果表明:随着传爆间隙的增加,传爆能力下降,切割索对传爆药柱的最大传爆间隙区间为2.0~2.5 mm;同时,传爆角度的增大能够显著提高传爆能力。本研究为爆炸切割网络的传爆性能研究以及提高武器系统的可靠性提供了参考。

Effects of blade sliding cutting angle and stem level on cutting energy of rice stems

Previous studies highlighted the significance of optimizing the cutting blade for crop harvesting and size reduction.This study investigated the effect of blade sliding cutting angle and stem level on cutting energy of single rice stem using a cutting apparatus that combined with texture analyzer.The cutting energy was determined for four blade angles.The results showed that the average cutting energy was the highest for cutting stem upper level and the lowest for cutting stem lower level.It was found that the peak cutting force per unit stem area decreased with blade sliding cutting angle increased.However,the least average cutting energy was 9.12 J/mm^(2) of 45°sliding angle when cutting without counter support blade and 32.3%less than that of 60°sliding angle.When cutting with counter support blade,the cutting energy per unit stem area varied from 6.57 to 12.54 J/mm 2 as the sliding angle varied from 0°to 60°,whereas the peak cutting force per unit stem area varied from 2.46 to 0.98 N/mm 2.It was concluded that the optimal sliding cutting angle was 45°without support blade and 30°with support blade,respectively.The experiments on rice stems in this study indicated that optimization of sliding cutting angle and stem level have a significant effect on cutting energy savings.Also this study emphasized the need to further investigate the effect of the case of more moisture content and cutting speed on the cutting energy to help in selection of optimum cutting speed and harvesting time.

双定刀滑切防缠式香蕉秸秆粉碎还田机设计与试验

针对我国香蕉秸秆粉碎还田作业过程中香蕉秸秆粉碎质量差,秸秆缠绕堵塞等问题,设计了一种双定刀滑切防缠式香蕉秸秆粉碎还田机。基于滑切定理,解析了粉碎刀随轴转动过程中的动态滑切角和粉碎定刀滑切角的相对作用原理,以等速螺线设计L形粉碎定刀刀刃曲线,确定了粉碎刀结构参数;对香蕉秸秆缠绕粉碎刀辊进行受力分析,设计防缠绕板并确定装配数量与结构参数;以装置前进速度、粉碎刀辊转速、防缠绕板高度为试验因素,以香蕉秸秆粉碎合格率、抛撒不均匀度和香蕉秸秆缠绕数量为评价指标进行三因素三水平正交试验,建立因素与指标的响应面数学模型。试验结果表明,最优参数组合为作业机前进速度1.5 m/s、防缠绕板高度41.6 mm、粉碎刀辊转速1800 r/min,此时香蕉秸秆粉碎合格率为93.8%,香蕉秸秆缠绕数量为26,香蕉秸秆抛撒不均匀度为12.1%。以最优组合进行田间试验验证,试验结果表明双定刀滑切防缠式香蕉秸秆粉碎还田机整机防缠性能优越,满足设计要求。

铡草机切碎辊作物喂入矢角参数模型建立与试验

饲草收获机作物喂入矢角(辊(叶片)轴心至喂入点矢径的水平夹角)对切碎辊转矩负荷及切碎性能有重要影响,通过检测传动带压力与作物喂入矢角的关系,对收获机切碎特性与作物切碎过程进行了运动学、动力学分析,揭示了饲草作物切碎质量、能耗与作物喂入矢角的关系,建立收获机切碎辊作物喂入矢角数学模型并进行了优化。试验结果表明,当优化参数组作物单位长度喂入量为5.5 kg/s、切碎辊转速为1600 r/min、传动带初始压力为1.2 MPa时,该作业参数组下切碎作物喂入矢角数学模型精度最高,准确率达79.52%,模型偏差为0.491 MPa(0.957 rad),能够有效表征铡草机切碎作业负荷,同时在保证作物切碎质量下提高了铡草机作业能力,优化的切碎喂入矢角模型下切碎扰动响应时间缩短约26.41%,单位作业能耗减小约11.36%。该切碎作物喂入矢角模型丰富了铡草机切碎作业的建模方法,为饲草作物类铡草机负荷控制系统设计提供了参考。

磨料水射流冲击角对砂岩切割性能影响的试验研究

磨料水射流是一种高效的切割技术,通过砂岩切割试验对岩石类材料的最佳冲击角和倾斜切割机理等问题展开研究,在对切缝内壁进行宏观和微观观测的基础上,开展水晶玻璃切割试验,探究不同冲击角下磨料水射流的切割运动过程,揭示了不同切割压力及冲击角下的切缝深度、切缝内壁特征、磨料颗粒运动轨迹与晶体破坏类型等变化规律。试验结果表明:平均切缝深度随切割压力的增加逐渐增大,同时改变冲击角能明显改变射流的切割能力,在75°冲击角获得的切割效果最佳;随切缝深度增加在切缝内壁逐渐出现弯曲射流轨迹纹理,且在其底部均形成典型的冲蚀坑与拖尾现象;切缝内壁主要表现为穿晶断裂、沿晶断裂、切槽或凹坑、胶结物覆盖等4类破坏特征,值得注意的是,不同冲击角下4类破坏特征在切缝中出现的位置不同,该种现象主要是因为射流的偏转情况、反射流的运动方向、冲击波和膨胀波的反射作用改变;对靶件破坏起主导作用的是垂直向及水平向射流分量(与推进方向同向),与推进方向反向的水平向射流分量则对已形成切缝起二次冲蚀及抛光作用,但不同冲击角下的作用程度不同;结合切缝表面观测和射流切割过程观察结果,建立了磨料水射流切割过程的宏观模型。

倾斜煤层厚硬顶板切顶留巷关键参数优化研究

为解决回采巷道倾斜厚硬顶板应力集中问题,降低顶板覆岩突然垮落的冲击扰动风险及提高倾斜厚硬顶板切顶留巷围岩控制效果,以长城六矿1301N运输巷切顶留巷为工程背景,综合采用理论分析、数值模拟及现场监测的研究方法开展倾斜煤层厚硬顶板切顶留巷关键参数优化研究。首先,基于岩石碎胀系数、砌体梁理论及现场地质资料,推导计算了1301N运输巷切顶高度和切顶角度的理论最小值。其次,为进一步验证并优化理论推导结果,利用PFC^(2D)数值软件建立了1301N工作面切顶留巷模型,采用控制变量法分析了不同切顶高度和切顶角度下留巷顶板应力、位移及组构张量响应特征。分析结果表明:切顶高度与卸压效果之间存在底数大于1的对数增长关系,即随着切顶高度增加,卸压效果逐渐增强但其增长幅度逐渐减小;切顶角度与卸压效果之间存在“S”型增长关系,即随着切顶高度增加,卸压效果先增强后减弱。卸压参数与卸压效果之间的变化规律揭示了切顶高度选择存在最适值,切顶角度选择存在最优解。综合理论分析、经济收益及数值模拟结果,确定长城六矿1301N运输巷倾斜厚硬顶板切顶留巷过程中最适切顶高度为13 m,最优切顶角度为10°。现场监测获得该切顶参数下围岩控制效果较好,留巷围岩变形量较小,可有效满足下一工作面开采需求,验证了优化切顶参数的有效性,为类似地质条件切顶留巷参数的选取提供理论依据和实践参考。

等滑切角锯齿型刀片优化设计与试验

基于已设计出的藤茎类秸秆切割刀片,创建切割功耗模型,将切割功耗最小作为目标函数并进行优化计算,获得最优滑切角为40°。对切割功耗的三个主要影响因素进行正交试验,结果表明:当秸秆含水率增加时,切割功耗随含水率的增加而增大;当单次切割量增加时,切割功耗也随之增大;相同的切割情况下,滑切角为40°的锯齿型刀片的切割功耗最低、切割效率最高。两种统计学方法分析的结果都表明:刀片种类对切割功耗的影响最显著,然后是秸秆含水率,最后是单次切割量。最优组合为:秸秆含水率为20%左右,单次切割量为6 kg,滑切角为40°的锯齿型刀片。

多分支水平井岩屑运移模型与实验研究

随着多分支水平井及复杂结构井钻井技术的不断发展,井眼清洁技术面临着新的困难和挑战。如何解决复杂地质条件与复杂井型条件下的岩屑床问题,对于判断与处理井下复杂情况是当前钻井工程面临的重要科学问题之一。通过岩屑颗粒受力分析建立了岩屑运移环空临界流速模型;基于室内可视化岩屑运移实验,探究了岩屑运移影响规律。结果表明:井斜角为36°时岩屑临界启动速度最大,携岩最为困难;模型预测结果与实验结果吻合度较好,且基于实例井的预测结果与现场作业情况一致,验证了所建模型的可靠性。该研究可为大位移大井斜井及水平井井眼清洁提供理论依据和技术支持。

基于三维粗糙度的多向CFRP铣削加工刀具切入角度的优化方法研究

碳纤维增强复合材料(Carbon fiber reinforced plastic,CFRP)因其优良的力学性能,被广泛应用于航空航天领域。CFRP的应用在保证飞机刚度强度的前提下,有效地提高了飞行性能,减轻了飞机重量,从而达到了节能减排的目的,提高了航空工业的经济效益。CFRP属于典型的难加工材料,为了保证结构件在多个方向具有一定的承载能力,航空发动机工业中一般采用CFRP多向铺层,这就使得材料的各向异性及不均匀性更为复杂。本文对CFRP单向层合板和两种CFRP多向层合板的铣削加工断裂机制进行了分析,发现CFRP铣削加工时,不同的纤维方向角对断裂机制有较大的影响从而导致了不同的表面质量。其中,弯曲断裂会导致表面质量急剧下降,应尽量避免,并且不同角度下的弯曲断裂的表面质量也具有一定差异。基于此,提出了多向CFRP铣削加工时的刀具切入角度优化方法,并通过试验验证了该方法的合理性,该方法可以有效提高某型号发动机的第一级复合材料风扇叶片的加工质量。

高温合金蜂窝芯加工振动分析与试验研究

高温合金蜂窝芯具有薄壁、多孔、面内弱刚性等特点,加工过程中易出现毛刺、撕裂、塌边等缺陷,采用冰固持加工后改善了加工质量,但仍然存在振动幅值较大的问题。针对高温合金蜂窝芯冰固持加工的振动问题,分析并确定冰固持条件下的高温合金蜂窝芯加工振动的主要形式是非谐波非周期性激励下的强迫振动,求解切入角变化导致的强迫振动激励间隔时间的变化规律。通过试验获得切削用量对高温合金蜂窝芯冰固持加工振动的影响规律,试验结果表明,当主轴转速为7000r/min、进给速度为4000mm/min、切削深度为0.5~1.5mm、切削宽度为0.5mm时,振动幅值较小,加工状态稳定,加工质量较好。

行进间地面机动目标射击诸元解算方法

针对地面机动目标运动模式未知、无源跟踪缺乏距离量测信息导致传统射击诸元解算方法解命中精度下降的问题,提出一种基于纯角度测量的行进间地面机动目标射击诸元解算方法。在传统固定参数的当前统计(CS)模型基础上,利用模糊推理动态调整机动频率,并根据加速度历史估计信息设置机动加速度方差,提高目标方位角的估计精度;在一次测距的基础上,基于简化刚体弹道模型,利用割弦迭代法计算出命中点坐标,并在每次迭代中利用虚拟脱靶量对射击诸元进行修正,减少对弹道方程的计算次数,提高射击诸元解算的实时性和精度。仿真结果表明,该方法有效可行,基于模型参数自适应的CS模型提高了目标角度跟踪的精度,基于虚拟脱靶量的迭代修正算法提高了诸元解算的实时性,解命中精度相对于传统射击诸元解算方法得到了显著改善。

截齿截割角度对截割性能的影响研究

以悬臂式掘进机为主的机械开挖是实现金属矿山连续化开采、推动智能矿山建设的重要手段,截齿截割角度是影响截齿受力情况的重要参数,从而影响掘进机掘进效率。为了优化截齿参数,采用Rhino软件和PFC3D软件建立了截齿截割岩石模型,在对试验数据进行验证的基础上,开展了不同截割角度(45°、50°、55°、60°和65°)下截齿截割花岗岩数值模拟试验研究。结果表明:基于PFC3D软件的截齿模拟试验具有可靠的精度,模拟试验与室内试验结果之间的相对误差分别为13.59%和16.92%。同时,不同截割角度下截齿的受力情况不同,在55°时截齿截割角度能够得到较好的改善。

锯形PDC齿破岩与温度特性数值模拟研究

目前关于PDC仿生齿的研究多集中在波浪齿形上,鲜有与锯形齿破岩特性相关研究的报道。鉴于此,基于弹塑性力学与Drucker-Prager岩石失效准则,建立锯形PDC齿与花岗岩相互作用的有限元模型,对锯形PDC齿的破岩以及破岩温度特性展开研究。研究结果表明:相比普通PDC齿,锯形PDC齿在破岩过程中所产生切削力峰值和均值更小,且该切削力均值减小约12.7%,机械比能减少约19%;后倾角增大情况下,锯形齿的机械比能和切削力均先减小后增大,最佳后倾角为10°时,锯形齿的机械比能和切削力最小,切削深度增加情况下,存在临界切削深度1.5 mm,超过1.5 mm后,切削力与机械比能呈现跳跃式增加,锯形齿在模拟范围内,最佳设计方案为3个锯齿。所得结论对钻头布齿和优化设计具有指导意义。

工艺参数对磨料水射流切割钢板效果的影响

基于有限元(FEM)与光滑粒子流体动力学(SPH)耦合方法,利用数值模拟手段研究了磨料水射流切割钢板的加工机理,重点分析了磨料浓度、射流压力、射流角度对切割钢板效果的影响。结果表明,加入磨料的水射流对钢板的切割能力明显提高,切割截面呈“U”型;随着磨料浓度的增大,钢板切割深度呈增加趋势,切口宽度则变化不大;钢板切割深度随射流压力的提高则呈近似线性增加的趋势;当射流角度由垂直(90°)转变为一定倾斜角后,钢板切割深度有所降低,材料的整体去除量略有减少。