Surface Integrity of Inconel 738LC Parts Manufactured by Selective Laser Melting Followed by High-speed Milling

This study is concerned with the surface integrity of Inconel 738LC parts manufactured by selective laser melting(SLM)followed by high-speed milling(HSM).In the investigation process of surface integrity,the study employs ultradepth three-dimensional microscopy,laser scanning confocal microscopy,scanning electron microscopy,electron backscatter diffractometry,and energy dispersive spectroscopy to characterize the evolution of material microstructure,work hardening,residual stress coupling,and anisotropic effect of the building direction on surface integrity of the samples.The results show that SLM/HSM hybrid manufacturing can be an effective method to obtain better surface quality with a thinner machining metamorphic layer.High-speed machining is adopted to reduce cutting force and suppress machining heat,which is an effective way to produce better surface mechanical properties during the SLM/HSM hybrid manufacturing process.In general,high-speed milling of the SLM-built Inconel 738LC samples offers better surface integrity,compared to simplex additive manufacturing or casting.

Extraction Fuzzy Linguistic Rules from Neural Networks for Maximizing Tool Life in High-speed Milling Process

In metal cutting industry it is a common practice to search for optimal combination of cutting parameters in order to maximize the tool life for a fixed minimum value of material removal rate（MRR）. After the advent of high-speed milling（HSM） pro cess, lots of experimental and theoretical researches have been done for this purpose which mainly emphasized on the optimization of the cutting parameters. It is highly beneficial to convert raw data into a comprehensive knowledge-based expert system using fuzzy logic as the reasoning mechanism. In this paper an attempt has been presented for the extraction of the rules from fuzzy neural network（FNN） so as to have the most effective knowledge-base for given set of data. Experiments were conducted to determine the best values of cutting speeds that can maximize tool life for different combinations of input parameters. A fuzzy neural network was constructed based on the fuzzification of input parameters and the cutting speed. After training process, raw rule sets were extracted and a rule pruning approach was proposed to obtain concise linguistic rules. The estimation process with fuzzy inference showed that the optimized combination of fuzzy rules provided the estimation error of only 6.34 m/min as compared to 314 m/min of that of randomized combination of rule s.

Influence of High-Speed Milling Process on Mechanical and Microstructural Properties of Ultrafine Grained Profiles Produced by Linear Flow Splitting

The effects of milling parameters on the surface quality,microstructures and mechanical properties of machined parts with ultrafine grained(UFG)gradient microstructures are investigated.The effects of the cutting speed,feed per tooth,cutting tool geometry and cooling strategy are demonstrated.It has been found that the surface quality of machined grooves can be improved by increasing the cutting speed.However,cryogenic cooling with CO_2 exhibits no significant improvement of surface quality.Microstructure and hardness investigations revealed similar microstructure and hardness variations near the machined groove walls for both utilized tool geometries.Therefore,cryogenic cooling can decrease more far-ranging hardness reductions due to high process temperatures,especially in the UFG regions of the machined parts,whilst it cannot prevent the drop in hardness directly at the groove walls.

Investigation of Surface Roughness in High-Speed Milling of Aeronautical Aluminum Alloy

An approach is presented to optimize the surface roughness in high-speed finish milling of 7050- T7451 aeronautical aluminum alloy. In view of this, the multi-linear regression model for surface roughness has been developed in terms of slenderness ratio, cutting speed, radial depth-of-cut and feed per tooth by means of orthogonal experimental design. Variance analyses were applied to check the adequacy of the predictive model and the significances of the independent input parameters. Response contours of surface roughness were generated by using response surface methodology （RSM）. From these contours, it was possible to select an optimum combination of cutting parameters that improves machining efficiency without increasing the surface roughness.

Radial Grip Rigidity of the Matching of Lengthened Shrink-fit Holder and Cutter in High-speed Milling

Though the lengthened shrink-fit holder (LSFH) is widely applied in high speed milling of the parts characterized by deep cavities at present, its design and selection mainly depends on the experience and lacks a correct theoretical guidance. In this paper, attention is focus on the radial grip rigidity of the matching of LSFH and cutter in high speed milling. Based on the experiment modal analysis (EMA) technique, an accurate finite element model of the matching of LSFH and cutter is established firstly. Subsequently, the influence of different interference, grip length and spindle speed on the grip rigidity of LSFH are analyzed. The analysis results show that there is a reasonable interference and grip length between the LSFH and cutter so that to have a steepless grip and have a good radial grip rigidity and at the same time to avoid the strength of LSFH to exceed it’s yield limit which will reduce the precision and service life of LSFH, besides when spindle speed reach a extension the weakening influence of the centrifugal force on the radial grip rigidity of the matching of LSFH and cutter should been taken into account. Finally, the finite element analysis results are verified based on the construction of measurement method of the grip rigidity and the results fit very well. The studies provide a theoretical basis for the design, selection and the serialization and standardization of the matching of LSFH and cutter.

State Dependent Regenerative Delay Model for High-Speed Milling Processes

A 2 DOF dynamic model of regenerative chatter model with state-dependent time delay is developed in milling processes. Regenerative effects, ＂ploughing＂ or ＂rubbing＂ effects between the flank of the cutting edge and the machined surface, and feed effects are considered. It is shown that the regenerative delay is determined by the combination of the cutter rotation and the tool vibrations resulting in a state-dependent time delay. The governing equation is a delay-differential equation with state-dependent delay （SD-DDE）, as op- posed to the standard models with constant time delay. Based on Frechet derivative theory, the linearization of periodic state-dependent delay differential equation is also investigated. For a system with practical milling parameters, the incorporation of the state-dependent delay into the model does not essentially affect the linear stability properties of the system.

Expert Experience and Data-Driven Based Hybrid Fault Diagnosis for High-SpeedWire Rod Finishing Mills

The reliable operation of high-speed wire rod finishing mills is crucial in the steel production enterprise.As complex system-level equipment,it is difficult for high-speed wire rod finishing mills to realize fault location and real-time monitoring.To solve the above problems,an expert experience and data-driven-based hybrid fault diagnosis method for high-speed wire rod finishing mills is proposed in this paper.First,based on its mechanical structure,time and frequency domain analysis are improved in fault feature extraction.The approach of combining virtual value,peak value with kurtosis value index,is adopted in time domain analysis.Speed adjustment and side frequency analysis are proposed in frequency domain analysis to obtain accurate component characteristic frequency and its corresponding sideband.Then,according to time and frequency domain characteristics,fault location based on expert experience is proposed to get an accurate fault result.Finally,the proposed method is implemented in the equipment intelligent diagnosis system.By taking an equipment fault on site,for example,the effectiveness of the proposed method is illustrated in the system.

Tool Life and Surface Integrity in High-speed Milling of Titanium Alloy TA15 with PCD/PCBN Tools

Titanium alloys are widely used in aeronautics that demand a good combination of high strength, good corrosion resistance and low mass. The mechanical properties lead to challenges in machining operations such as high process temperature as well as rapidly increasing tool wear. The conventional tool materials are not able to maintain their hardness and other mechanical prop- erties at higher cutting temperatures encountered in high speed machining. In this work, the new material tools, which are poly- crystalline diamond （PCD） and polycrystalline cubic boron nitride （PCBN） tools, are used in high-speed milling of Ti-6.5AI-2Zr-IMo-IV （TA15） alloy. The performance and wear mechanism of the tools are investigated. Compared to PCBN tool, PCD tool has a much longer tool life, especially at higher cutting speeds. Analyses based on the SEM and EDX suggest that attrition, adhesion and diffusion are the main wear mechanisms of PCD and PCBN tools in high-speed milling of TA 15. Oxida- tion wear is also observed at PCBN tool/workpiece interface. Roughness, defects, micro-hardness and microstructure of the ma- chined surface are investigated. The recorded surface roughness values with PCD/PCBN tools are bellow 0.3 μm at initial and steady cutting stage. Micro-hardness analysis shows that the machined surface hardening depth with PCD and PCBN tools is small. There is no evidence of sub-surface defects with PCD and PCBN tools. It is concluded that for TA15 alloy, high-speed milling can be carried out with PCD/PCBN tools.

Chip morphology and cutting temperature of ADC12 aluminum alloy during high-speed milling

The ADC12 aluminum alloy is prone to severe tool wear and high cutting heat during high-speed milling because of its high hardness.This study analyzes the highspeed milling process from the perspective of different chip morphologies.The influence of cutting temperature on chip morphology was expounded.A two-dimensional orthogonal cutting model was established for finite element analysis(FEA)of high-speed milling of ADC12 aluminum alloy.A theoretical analysis model of cutting force and cutting temperature was proposed based on metal cutting theory.The variations in chip shape,cutting force,and cutting temperature with cutting speed increasing were analyzed via FEA.The results show that,with the increase in cutting speed,the chip morphology changes from continuous to serrated,and then back to continuous.The serrated chip is weakened and the cutting temperature is lowered when the speed is lower than 600 m·min^(-1)or higher than 1800 m·min^(-1).This study provides a reference for reducing cutting temperature,controlling chip morphology and improving cutting tool life.

Effects of Milling Methods on Rice Flour Properties and Rice Product Quality:A Review

High-quality rice flour is the foundation for the production of various rice-based products.Milling is an essential step in obtaining rice flour,during which significant changes occur in the physicochemical and quality characteristics of the flour.Although rice flour obtained through mainstream wet milling methods exhibits superior quality,low production efficiency and wastewater discharge limit the development of the industry.Dry milling,on the other hand,conserves water resources,but adversely affects flour performance due to excessive heat generation.As an emerging powder-making technique,semi-dry milling offers a promising solution by enhancing flour quality and reducing environmental impact.This is achieved by minimizing soaking time through hot air treatment while reducing mechanical energy consumption to reach saturated water absorption levels.However,continuous production remains a challenge.This comprehensive review summarizes the effects of various milling technologies on rice flour properties and product qualities.It also discusses key control indicators and technical considerations for rice flour processing equipment and processes.

A discussion about the limitations of the Eurocode’s high-speed load model for railway bridges

High-speed railway bridges are subjected to normative limitations concerning maximum permissible deck accelerations.For the design of these structures,the European norm EN 1991-2 introduces the high-speed load model(HSLM)—a set of point loads intended to include the effects of existing high-speed trains.Yet,the evolution of current trains and the recent development of new load models motivate a discussion regarding the limits of validity of the HSLM.For this study,a large number of randomly generated load models of articulated,conventional,and regular trains are tested and compared with the envelope of HSLM effects.For each type of train,two sets of 100,000 load models are considered:one abiding by the limits of the EN 1991-2 and another considering wider limits.This comparison is achieved using both a bridge-independent metric(train signatures)and dynamic analyses on a case study bridge(the Canelas bridge of the Portuguese Railway Network).For the latter,a methodology to decrease the computational cost of moving loads analysis is introduced.Results show that some theoretical load models constructed within the stipulated limits of the norm can lead to effects not covered by the HSLM.This is especially noted in conventional trains,where there is a relation with larger distances between centres of adjacent vehicle bogies.

Milling degree affects the fermentation properties of rice:perspectives from the composition of nutrients and gut microbiota via in vitro fermentation

Fermentation substrates of rice with different milling degrees(MDs) were prepared and fermented with human feces to compare their fermentation properties and effects on gut microbiota.MD 0s,MD 5s and MD 60s represented brown rice,moderately-milled rice and white rice,respectively.After in vitro fermentation,the MD 5s group showed higher starch utilization,compared with the MD 0s and 60s groups evaluated by Fourier transform infrared spectrometer,and confocal laser scanning microscope.Effects of fermentation substrates of rice with different MDs on gut microbiota were evaluated by 16S rDNA sequencing.All the sample groups reduced the pH and produced short-chain fatty acids(SCFAs) and branched-chain fatty acids.The MD 5s group exhibited higher α-diversity than the MD 0s and 60s groups.Abundances of Phascolarctobacterium,Blautia and norank_f_Ruminococcaceae were higher in the MD 0s and 5s groups,compared with the MD 60s group.These bacteria were also positively correlated with the SCFAs production via Spearman correlation analysis.In vitro culture assay revealed that fermentation substrates of MD 0s and 5s promoted the growth of two probiotics(Akkermansia muciniphila and Bifidobacterium adolescentis).Our results showed that moderate milling might be an appropriate way to produce rice products with richer nutrients and better fermentation properties.

Aerodynamic Features of High-Speed Maglev Trains with Different Marshaling Lengths Running on a Viaduct under Crosswinds

The safety and stability of high-speed maglev trains traveling on viaducts in crosswinds critically depend on their aerodynamic characteristics.Therefore,this paper uses an improved delayed detached eddy simulation(IDDES)method to investigate the aerodynamic features of high-speed maglev trains with different marshaling lengths under crosswinds.The effects of marshaling lengths(varying from 3-car to 8-car groups)on the train’s aerodynamic performance,surface pressure,and the flow field surrounding the train were investigated using the three-dimensional unsteady compressible Navier-Stokes(N-S)equations.The results showed that the marshaling lengths had minimal influence on the aerodynamic performance of the head and middle cars.Conversely,the marshaling lengths are negatively correlated with the time-average side force coefficient(CS)and time-average lift force coefficient(Cl)of the tail car.Compared to the tail car of the 3-car groups,the CS and Cl fell by 27.77%and 18.29%,respectively,for the tail car of the 8-car groups.It is essential to pay more attention to the operational safety of the head car,as it exhibits the highest time average CS.Additionally,the mean pressure difference between the two sides of the tail car body increased with the marshaling lengths,and the side force direction on the tail car was opposite to that of the head and middle cars.Furthermore,the turbulent kinetic energy of the wake structure on the windward side quickly decreased as marshaling lengths increased.

Numerical Study on Reduction in Aerodynamic Drag and Noise of High-Speed Pantograph

Reducing the aerodynamic drag and noise levels of high-speed pantographs is important for promoting environmentally friendly,energy efficient and rapid advances in train technology.Using computational fluid dynamics theory and the K-FWH acoustic equation,a numerical simulation is conducted to investigate the aerodynamic characteristics of high-speed pantographs.A component optimization method is proposed as a possible solution to the problemof aerodynamic drag and noise in high-speed pantographs.The results of the study indicate that the panhead,base and insulator are the main contributors to aerodynamic drag and noise in high-speed pantographs.Therefore,a gradual optimization process is implemented to improve the most significant components that cause aerodynamic drag and noise.By optimizing the cross-sectional shape of the strips and insulators,the drag and noise caused by airflow separation and vortex shedding can be reduced.The aerodynamic drag of insulator with circular cross section and strips with rectangular cross section is the largest.Ellipsifying insulators and optimizing the chamfer angle and height of the windward surface of the strips can improve the aerodynamic performance of the pantograph.In addition,the streamlined fairing attached to the base can eliminate the complex flow and shield the radiated noise.In contrast to the original pantograph design,the improved pantograph shows a 21.1%reduction in aerodynamic drag and a 1.65 dBA reduction in aerodynamic noise.

Dynamic analysis of axle box bearings on the high-speed train caused by wheel-rail excitation

To explore the impact of wheel-rail excitation on the dynamic performance of axle box bearings,a dynamic model of the high-speed train including axle box bearings is developed.Subsequently,the dynamic response characteristics of the axle box bearing are examined.The investigation focuses on the acceleration characteristics of bearing vibration under excitation of track irregularities and wheel flats.In addition,experiments on both normal and faulty bearings are conducted separately,and the correctness of the model and some conclusions are verified.According to the research,track irregularity is unfavorable for bearing fault detection based on resonance demodulation.Under the same speed conditions,the acceleration peak of bearing is inversely proportional to the length of the wheel flat and directly proportional to its depth.The paper will contribute to a deeper understanding of the dynamic performance of axle box bearings.

Torque effect on vibration behavior of high-speed train gearbox under internal and external excitations

The high-speed train transmission system,experiencing both the internal excitation originating from gear meshing and the external excitation originating from the wheel-rail interaction,exhibits complex dynamic behavior in the actual service environment.This paper focuses on the gearbox in the high-speed train to carry out the bench test,in which various operat-ing conditions(torques and rotation speeds)were set up and the excitation condition covering both internal and external was created.Acceleration responses on multiple positions of the gearbox were acquired in the test and the vibration behavior of the gearbox was studied.Meanwhile,a stochastic excitation modal test was also carried out on the test bench under different torques,and the modal parameter of the gearbox was identified.Finally,the sweep frequency response of the gearbox under gear meshing excitation was analyzed through dynamic modeling.The results showed that the torque has an attenuating effect on the amplitude of gear meshing frequency on the gearbox,and the effect of external excitation on the gearbox vibration cannot be ignored,especially under the rated operating condition.It was also found that the torque affects the modal param-eter of the gearbox significantly.The torque has a great effect on both the gear meshing stiffness and the bearing stiffness in the transmission system,which is the inherent reason for the changed modal characteristics observed in the modal test and affects the vibration behavior of the gearbox consequently.

High-speed penetration of ogive-nose projectiles into thick concrete targets:Tests and a projectile nose evolution model

The majority of the projectiles used in the hypersonic penetration study are solid flat-nosed cylindrical projectiles with a diameter of less than 20 mm.This study aims to fill the gap in the experimental and analytical study of the evolution of the nose shape of larger hollow projectiles under hypersonic penetration.In the hypersonic penetration test,eight ogive-nose AerMet100 steel projectiles with a diameter of 40 mm were launched to hit concrete targets with impact velocities that ranged from 1351 to 1877 m/s.Severe erosion of the projectiles was observed during high-speed penetration of heterogeneous targets,and apparent localized mushrooming occurred in the front nose of recovered projectiles.By examining the damage to projectiles,a linear relationship was found between the relative length reduction rate and the initial kinetic energy of projectiles in different penetration tests.Furthermore,microscopic analysis revealed the forming mechanism of the localized mushrooming phenomenon for eroding penetration,i.e.,material spall erosion abrasion mechanism,material flow and redistribution abrasion mechanism and localized radial upsetting deformation mechanism.Finally,a model of highspeed penetration that included erosion was established on the basis of a model of the evolution of the projectile nose that considers radial upsetting;the model was validated by test data from the literature and the present study.Depending upon the impact velocity,v0,the projectile nose may behave as undistorted,radially distorted or hemispherical.Due to the effects of abrasion of the projectile and enhancement of radial upsetting on the duration and amplitude of the secondary rising segment in the pulse shape of projectile deceleration,the predicted DOP had an upper limit.

Improving hydrogen storage thermodynamics and kinetics of Ce-Mg-Ni-based alloy by mechanical milling with TiF_(3)

Mg-based hydrides are too stable and the kinetics of hydrogen absorption and desorption is not satisfactory.An efficient way to improve these shortcomings is to employ reactive ball milling to synthesize the nanocomposite materials of Mg and additives.In this experiment,TiF_(3)was selected as an additive,and the mechanical milling method was employed to prepare the experimental alloys.The alloys used in this experiment were the as-cast Ce_(5)Mg_(85)Ni_(10),as-milled Ce_(5)Mg_(85)Ni_(10)and Ce_(5)Mg_(85)Ni_(10)+3 wt.%TiF3.The phase transformation,structural evolution,isothermal and non-isothermal hydrogenation and dehydrogenation performances of the alloys were inspected by XRD,SEM,TEM,Sievert apparatus,DSC and TGA.It revealed that nanocrystalline appeared in the as-milled samples.Compared with the as-cast alloy,ball milling made the particle dimension and grain size decrease dramatically and the defect density increase significantly.The addition of TiF_(3)made the surface of ball milling alloy particles markedly coarser and more irregular.Ball milling and adding TiF_(3)distinctly improved the activation and kinetics of the alloys.Moreover,ball milling along with TiF_(3)can decrease the onset dehydrogenation temperature of Mg-based hydrides and slightly ameliorate their thermodynamics.

Distribution of antioxidants and phenolic compounds in flour milling fractions from hard red winter wheat

Mature wheat kernels contain three main parts:endosperm,bran,and germ.Flour milling results in multiple streams that are chemically different;however,the distribution of antioxidants and phenolic compounds has not been well documented in terms of conventional milling by-product streams.In this study,multiple analytical methods were used to investigate antioxidant activity and phenolic compound compositions of hard red winter wheat(whole ground wheat),the parts of a wheat kernel(bran,flour,germ),and wheat by-product streams(mill feed,red dog,shorts)for the first time.For each mill stream,phenolic compounds(total,flavonoid,and anthocyanin contents)were determined and antioxidant activities were evaluated with 1,1-diphenyl-2-picrylhydrazyl(DPPH)radical-scavenging activity,ferric reducing/antioxidant power(FRAP),and total antioxidant capacity assays.Significant differences(P<0.05)were observed in phenolic concentrations among fractions of bran,flour,and germ milled from the same kernels and noted that germ accounts for the majority of antioxidant properties,whereas bran contains a substantial portion of phenolic compounds and anthocyanins.Mill feed was high in phenolic content(5.29 mg FAE/g),total antioxidant capacity(866 mg/g),and antioxidant activity(up to 75% DPPH inhibition and 20.26μmol FeSO_(4)/g).The comprehensive information on distribution of antioxidants and phenolic compounds provides insights for future human consumption of commonly produced co-products from flour milling,and for selecting and using different milling fractions to make foods with improved nutritional properties.

Reflection on methodology of the correlation between electromagnetic interference and safety in high-speed railway

Purpose – In the continuous development of high-speed railways, ensuring the safety of the operation controlsystem is crucial. Electromagnetic interference (EMI) faults in signaling equipment may cause transportationinterruptions, delays and even threaten the safety of train operations. Exploring the impact of disturbances onsignaling equipment and establishing evaluation methods for the correlation between EMI and safety isurgently needed.Design/methodology/approach – This paper elaborates on the necessity and significance of studying theimpact of EMI as an unavoidable and widespread risk factor in the external environment of high-speed railwayoperations and continuous development. The current status of research methods and achievements from theperspectives of standard systems, reliability analysis and safety assessment are examined layer by layer.Additionally, it provides prospects for innovative ideas for exploring the quantitative correlation between EMIand signaling safety.Findings – Despite certain innovative achievements in both domestic and international standard systems andrelated research for ensuring and evaluating railway signaling safety, there’s a lack of quantitative and strategic research on the degradation of safety performance in signaling equipment due to EMI. A quantitativecorrelation between EMI and safety has yet to be established. On this basis, this paper proposes considerationsfor research methods pertaining to the correlation between EMI and safety.Originality/value – This paper overviews a series of methods and outcomes derived from domestic andinternational studies regarding railway signaling safety, encompassing standard systems, reliability analysisand safety assessment. Recognizing the necessity for quantitatively describing and predicting the impact ofEMI on high-speed railway signaling safety, an innovative approach using risk assessment techniques as abridge to establish the correlation between EMI and signaling safety is proposed.