Numerical analysis on mixed lubrication performance of journal-thrust coupled microgroove bearings with different bottom shapes

The purpose of the present study is to establish a mixed lubrication model for the journal-thrust coupled microgroove bearings(also referred as coupled bearings)used for the ship shaftless rim-driven thrusters.During the hydrodynamic modelling,the coupling hydrodynamic pressure between the journal bearing and the thrust bearing is considered.The mixed lubrication performances of the microgroove journal-thrust bearing with five different bottom shapes,including rectangle,semi-ellipse,right triangle,isosceles triangle and left triangle,are compared.Based on the numerical results,the optimal microgroove bottom shape of the journal bearing and tilting angle of the thrust pad are determined.Additionally,the comparative analysis shows that the coupled bearing with left triangle microgroove bottom shape exhibits the optimal mixed lubrication performance.The numerical result also indicates that the optimal inclination angle of the thrust bearing pad is 0.01°for the current simulation case.

Performance Analysis of the Effects of Microgrooved Surface on A Marine Current Turbine with Underwater Mooring Platform

Marine current turbine(MCT),which is designed for the power supply of underwater mooring platform(UMP),is investigated in this article.To reduce its flow noise,the microgrooved surface is applied at the suction surface of the turbine blades.Comprehensive analyses of the effects of the UMP on MCT with microgrooved surface in different working conditions are presented.The transient turbulent flow field is obtained by incompressible large eddy simulation(LES),and then the Ffowcs Williams and Hawkings(FW-H)acoustic analogy is adopted to forecast the flow noise generated from the pressure fluctuations and loadings of the UMP shell and MCT blade surfaces.The numerical methods are first validated with experimental data and good agreements are obtained.Then,the influence of several key parameters on the performance of the MCT is then systematically studied,including interval distance,angle of pitch and angle of sideslip.For each case,the hydrodynamic parameters(thrust coefficient,torque coefficient and power coefficient),the vortical structures behind the model and the overall sound pressure level(OASPL)directionality are analyzed.Additionally,the noise reduction effect of the microgrooved surface is also presented.The present investigation could provide an overall understanding for the performance of MCT combined with UMP.

Performances of electrically heated microgroove vaporizers

An electrically heated microgroove vaporizer was proposed. The vaporizer mainly comprised an outer tube, an inner tubeand an electrical heater cartridge. Microgrooves were fabricated on the external surface of the inner tube by micro-cutting method,which formed the flow passage for fluid between the external surface of the inner tube and the internal surface of the outer tube.Experiments related to the temperature rise response of water and the thermal conversion efficiency of vaporizer were done toestimate the influences of microgroove’s direction, feed flow rate and input voltage on the performances of the vaporizer. The resultsindicate that the microgroove’s direction dominates the vaporizer performance at a lower input voltage. The longitudinalmicrogroove vaporizer exhibits the best performances for the temperature rise response of water and thermal conversion efficiency ofvaporizer. For a moderate input voltage, the microgroove’s direction and the feed flow rate of water together govern the vaporizerperformances. The input voltage becomes the key influencing factor when the vaporizer works at a high input voltage, resulting inthe similar performances of longitudinal, oblique and latitudinal microgroove vaporizers.

金属板材大深宽比微沟槽特征辊压成形工艺分析

提出一种新型的辊压成形的工艺,对主辅成形辊轮的轮廓设计提出新的设计思路,并对0.1 mm的厚度TA1钛板微沟槽(深度2.5 mm,深宽比86.2%)进行辊压成形的试验,将最大减薄率、最大深度偏差作为评价指标,验证工艺的合理性与科学性。结果表明:辅助成形辊轮在满足挠度(<0.02 mm)的前提下,应尽可能减少辅助成形辊轮的特征数,使其在辊压过程中板材折弯变形而非拉延,其最大减薄率为小于0.4%,深度偏度小于0.5%,配合冲压模具可以对大深宽比的微沟槽成形,而不受拔模角度的影响,此新型成形工艺可以促进金属板材微沟槽产品的产业化。

非对称微沟槽表面液滴各向异性润湿行为研究

液滴在各向异性表面的润湿行为对于液滴操作和运动控制具有重要的科研与工程价值.采用重力式测试系统对非对称沟槽表面上液滴各向异性润湿行为进行表征,分析了沟槽几何结构非对称性、沟槽高度和宽度以及浸油处理对液滴静润湿与动润湿行为的影响规律.结果表明,沟槽几何结构不对称性会影响液滴润湿状态,液滴在非对称沟槽表面不同方向上接触角差异比对称沟槽更大,使得各向异性更显著;浸油处理会减小沟槽表面液滴接触角,从而表现出更明显的各向异性;非对称沟槽表面的接触角随沟槽高度增大而减小,随宽度增大而增大,表面浸油处理会缩小试件间接触角的差异,高度和宽度对浸油处理后的非对称表面的调控作用基本失效;当沟槽宽度增加时,浸油处理后的非对称沟槽表面滑动角减小,同时液滴沿非对称沟槽大顶角向小顶角方向运动时的滑动角大于沿反方向运动时的滑动角,且液滴体积越大,滑动角越小.最后,对上述规律进行了接触线理论分析,并从表面能模型角度推导出滑动角理论公式,与实验结果基本吻合.

紫外纳秒激光加工高深宽比且高一致性微槽的研究

高深宽比微槽广泛应用于生物学以及电子学等各领域。然而,在制备高深宽比微槽时,微槽的一致性仍然是一个技术上的难题。通过一种新颖的多次扫描技术,利用355纳米纳秒激光成功制备了同时具有高深宽比和高一致性的微槽。研究了脉冲能量、离焦量和扫描次数对微槽深度和宽度的影响。结果表明:略微增加负离焦量和脉冲能量可以显著提高微槽的深宽比,但过大的脉冲能量会导致一致性下降。提出一种多次扫描的方法,通过在每次扫描的同时调整激光离焦量,制备了一组高深宽比且高一致性的微槽。所获得的微槽的平均深宽比高达6.84,深度和宽度的一致性也得到了显著提高。深度和宽度的相对标准偏差分别低至4.8%、4.4%。由于其高深宽比和高一致性,这些微槽有望在生物医学科学、3D微型电池和超疏水表面等领域得到广泛应用。

微槽结构对前刀面润湿性能影响及参数优化

在刀具前刀面合理置入微槽织构可以改善刀具表面润湿性。为探究微槽槽宽、间距以及槽深对刀具表面润湿性能的影响,基于Wenzel理论,建立微槽表面液滴润湿数值模型,分析表观接触角随微槽结构参数变化的趋势,并通过COMSOL软件进行接触角数值模拟。结果表明,随着微槽结构参数的变化,液滴的润湿呈现Wenzel状态和Wenzel与Cassie的复合状态,对于Wenzel状态的微槽结构参数,表观接触角随着槽宽和间距的减小而减小,随着槽深的增大而减小;并且在槽宽为30μm,间距40μm,槽深70μm时,表观接触角最小,为54.4°,相对于本征接触角,降低了22%。

结构化砂轮磨削蓝宝石微沟槽底面质量的研究

针对蓝宝石这类超硬材料表面微结构难加工的问题,提出一种基于结构化砂轮的磨削表面微结构方法.采用电火花线切割(Wire Electrical Discharge Machining,WEDM)技术对砂轮表面进行结构化修整,利用修整后的结构化砂轮磨削蓝宝石表面微结构,研究顺磨和逆磨方式下,结构化砂轮磨削速度、磨削深度和进给速度对蓝宝石微沟槽底部表面粗糙度的影响规律.研究结果表明,结构化砂轮磨削蓝宝石表面微沟槽形貌基本完整,且相对120µm的加工深度,尺寸误差仅为1.4µm,微沟槽的垂直度较好,垂直度偏差仅为4.9°;顺、逆磨方式下,随着磨削速度增大,磨削深度和进给速度减小,都可以减小蓝宝石微沟槽底部表面粗糙度;相较于逆磨方式,顺磨方式下微沟槽底面微坑较小,底面质量更优;在较优加工参数砂轮磨削速度35m/s、磨削深度1µm、工件进给速度200mm/min下,表面粗糙度从4.487µm降低至2.923µm.

镍磷合金微沟槽金刚石切削泊松毛刺形成机理

为了探究镍磷合金超精密切削过程中泊松毛刺的形成原因及规律,并且寻求泊松毛刺尺寸更精准的表征方式,本文通过对镍磷合金泊松毛刺的形成机理进行理论分析,建立其正交切削过程中的泊松毛刺高度和宽度预测模型,并通过实验分析切削参数对泊松毛刺高度和宽度的影响,通过实验观察可知,切削深度对毛刺尺寸影响显著,切削深度由3μm增加至9μm时,毛刺高度增加了0.0998μm,毛刺宽度增加了1.06μm,而切削速度对毛刺高度及宽度的影响很小。且通过对比实验得到的毛刺数据和预测数据可知,毛刺高度和宽度预测模型的平均相对误差值分别为5.43%和8.17%,验证了预测模型的准确性。同时目前的泊松毛刺高度和宽度表征方法具有一定的误差,因此本文提出了利用积分法计算泊松毛刺体积的方法,并基于体积法建立了更准确的泊松毛刺尺寸表征方法,通过计算得到体积的预测模型平均相对误差值为4.81%,可知泊松毛刺体积的预测模型准确度相对更高。研究结果为镍磷合金正交切削过程中合理选择切削参数和泊松毛刺尺寸评估方法提供了理论指导。

Electrochemical micromachining of microgroove arrays on phosphor bronze surface for improving the tribological performance

A high friction coefficient and a low wear rate of contacted surfaces are essential elements to friction pairs between the stator and the rotor in ultrasonic motors. It has been shown that surface textures have a significant effect on improving the tribological performance of friction pairs.In this paper, microgroove arrays are introduced to the stator surface for improving the tribological performance of friction pairs between the stator and the rotor in ultrasonic motors. Microgrooves were fabricated on a phosphor bronze surface by through-mask electrochemical micromachining（TMEMM）. Parameters, namely, the electrolyte inlet pressure, applied voltage, pulse duty cycle,and frequency, were varied to investigate their influences on the dimensions and morphology of the microgrooves. Results showed that the width and depth of the microgrooves were strongly affected by the applied voltage and frequency, while the morphology of the microgrooves was dependent on the electrolyte inlet pressure and the pulse duty cycle. Compared with a smooth surface, the friction coefficient increased from 0.245 to 0.334 and less abrasion was obtained when a surface was textured with microgrooves of which the width and depth were 185.6 and 57.6 lm,respectively. Microgroove arrays might play an important role in enhancing the performance of ultrasonic motors.

Laser-induced oxidation assisted micro milling of high aspect ratio microgroove on WC-Co cemented carbide

Severe tool wear and poor surface quality are the main problems during micro machining of cemented carbide.In this work,an innovative hybrid process of laser-induced oxidation assisted micro milling(LOMM)was proposed to solve the problems.A nanosecond laser was utilized to induce oxidation of the WC-20%Co material,producing loose oxide which was easy to remove.The micro machinability of the material was improved by laser-induced oxidation.The oxidation mechanisms of cemented carbide were studied.A microgroove with a depth of 2.5 mm and aspect ratio of 5 was fabricated successfully.The milling force,surface quality and tool wear mechanisms were investigated.For comparison,a microgroove was also fabricated with conventional micro milling(COMM)using identical milling parameters.Results revealed that in LOMM the milling force and tool wear rate were extremely low during removing the oxide.The machined surface quality and dimensional accuracy achieved by LOMM were superior to those obtained by COMM.The surface roughness Saof the microgroove bottom reached 88 nm in LOMM,while the cross-sectional geometry of the microgroove was a trapezoid.Perpendicularity of the microgroove sidewall machined by LOMM was better than that by COMM.The tool wear forms in LOMM were coating spalling and slight tool nose breakage.Compared with COMM,the tool life in LOMM was prolonged significantly.It indicates that the proposed hybrid process is an effective and efficient way to fabricate high aspect ratio micro-features with high dimensional accuracy.

Effect of stagger angle on capillary performance of microgroove structures with reentrant cavities

Aluminum-based microgroove surfaces with reentrant cavities (MSRCs) were fabricated by two staggered ploughing/extrusion processes to meet the requirements of lightweight phase change heat transfer devices.Five MSRCs with different stagger angles between cavities and microgrooves (MGs) were fabricated to study the effect of stagger angle on capillary performance.Capillary rise and permeability tests were performed on all MSRCs and the results were compared with MGs having the same processing parameters.It was found that MSRCs with smaller stagger angles have higher capillary height,and the maximum enhancement maintained by MSRC45 was about 54.84%.However,MSRCs with larger stagger angles were found to have higher permeability.Therefore,the capillary parameter K·ΔP_(cap)was used as a comprehensive index to evaluate these wicks.MSRC90 and MSRC75 obtained the largest K·ΔP_(cap)values without and with the effect of gravity considered,respectively.Although all MSRCs had a higher capillary rise height than MGs,smaller stagger angles (≤60°) seriously reduced the permeability of MSRCs and even resulted in smaller K·ΔP_(cap)value than that of MGs when calculated considering the effect of gravity.Therefore,MSRCs with larger stagger angles (≥75°) may be the optimum wicks due to the good balance between capillary pressure and permeability.

Heat Transfer Performance of Microgroove Back Plate Heat Pipes with Working Fluid and Heating Power

Micro heat pipes(MHP) cooling is one of the most efficient solutions to radiate heat for high heat flux electronic components in data centers. It is necessary to improve heat transfer performance of microgroove back plate heat pipes. This paper discusses about influence on thermal resistance through experiments and numerical simulation with different working fluids, filling ratio and heat power. Thermal resistance of the CO2 filled heat pipe is 14.8% lower than the acetone filled heat pipe. In the meantime, at the best filling ratio of 40%, the CO2 filled heat pipe has the optimal heat transfer behavior with the smallest thermal resistance of 0.123 K/W. The thermal resistance continues to decline but the magnitude of decreases is going to be minor. In addition, this paper illustrates methods about how to enhance heat pipe performance from working fluids, filling ratio and heat power, which provides a theoretical basis for practical applications.

Fabrication and boiling heat transfer characterization of multiscale microgroove surfaces

Microstructural functional surfaces play an important role in energy conversion applications including power generation,air conditioning,and thermal management of electronics through the boiling process.In this study,multi-scale microgroove surfaces were fabricated by the combination of wire electrical discharge machining(WEDM)and electrical discharge shaped machining(EDSM)to achieve a better boiling performance.The WEDM,with the advantage of high efficiency,was used to fabricate the first microgroove array,and rougher surfaces were formed by intense discharge.A wavy electrode was used in EDSM to fabricate the second microgroove array.Reentrant cavities at the intersections of microgrooves and rougher micro fins with spacing distribution were formed after EDSM.The boiling performance of the multi-scale microgroove surface was studied with water as the working medium under atmospheric pressure.The results indicated that the boiling performance of the microgroove surface is significantly enhanced.The critical heat flux and maximum heat transfer coefficient of microgroove surface were higher than the surfaces fabricated only by WEDM or EDSM,which were 2.34 and 3.29 times that of smooth copper plate,respectively.This study demonstrated that the combination of WEDM and EDSM is a convenient and effective method to fabricate high-performance microgroove boiling surfaces.

Influence of 3D Microgrooves on C2C12 Cell Proliferation,Migration,Alignment,F-actin Protein Expression and Gene Expression

In this paper, we fabricated three kinds of 3D microgrooves with different depth on biocompatible poly（lactic-co-glycolic acid） （PLGA） substrate via combination of soft-lithography and melt-casting methods, and investigated in detail their influence on C2C12 cell behaviors. It is found that cell proliferation, migration, alignment, spatial distribution, F-actin protein expression and gene expression are all remarkably distinct on these microgrooved samples and the smooth control PLGA substrate. The associated underlying mechanisms were further analyzed and discussed using real-time living cell monitoring, confocal laser scanning microscopy and gene microarray. Our preliminary results suggested that 3D microstruc- ture could affect cell behaviors in a much more extensive manner than what we had understood before.

钛合金表面沟槽结构纳秒激光加工实验研究

为了在钛合金表面加工高质量的微小结构,探究不同因素对表面质量的影响规律,利用纳秒激光开展钛合金Ti6Al4V加工实验研究。通过3维显微镜和共聚焦显微镜测量了不同参数下的钛合金工件加工表面形貌,利用正交实验和单因素分析法探究扫描速率、激光功率、扫描线间距对加工形貌和粗糙度值的影响规律。结果表明,在低功率、高速率、大线间距条件下,材料去除不连续,加工表面呈现间断的凹坑结构;随着功率的增加、加工速率的降低和线间距的减小,材料去除逐渐连续,加工后材料表面质量得到明显改善;选择激光功率24 W、扫描速率2000 mm/s、线间距0.01 mm的参数在钛合金表面成功加工出宽度500μm、深度140μm的阵列微沟槽结构。该研究对激光加工钛合金表面微小结构具有较好的实用价值。

蒸发冷凝长度比对不同微槽平板铝热管热性能的影响

为研究不同蒸发段和冷凝段长度比值对平板铝热管热性能的影响,通过实验分析了相同截面尺寸、相同填充工质、矩形微槽道和三角形微槽道的平板热管90°安装,以及采用连续递增的输入热流和冷凝段强制风冷换热时,9种不同比值对平板热管热性能的影响。研究结果表明:提出的平板微槽道热管蒸发段冷凝段长度比值对平板微槽道热管热性能的影响明显。优选的两种类型蒸发段冷凝段长度比值在0.8~1.25范围内,传热性能良好。对比不同微槽道的平板热管发现,同等条件下矩形微槽道平板热管的传热性能优于三角形微槽道平板热管,并提出蒸发段冷凝段长度比值的最佳值为1,建议应用设计中蒸发段冷凝段长度比值范围为0.8~1.0。研究结果可对平板微槽道热管应用系统的设计提供准确参考。

超薄交替变径通道平板脉动热管的传热特性

采用印刷电路工艺,设计制作了厚度为1.00 mm的铜基平板脉动热管.宽度分别为1.00和2.20 mm的通道在平板脉动热管内交替排布,宽通道底部为刻蚀有平行微槽的阵列结构.以HFE-7100为工质,在充液率为30%~50%条件下,对有、无微槽结构的交替变径通道平板脉动热管的启动和传热性能开展比较研究.研究结果表明:平板脉动热管在水平和竖直放置时均可以正常启动,且实现稳定运行,引入微槽结构可以显著改善脉动热管的启动和传热性能,降低蒸发段温度,并增强其抗重力性能;在加热功率为24 W、充液率为30%条件下,超薄脉动热管分别呈水平和竖直放置时,其等效导热系数可分别达到1241和1226 W/(m·℃),比无微槽脉动热管分别提高25.6%和18.7%,能够较好满足部分芯片器件散热冷却的需要.

微槽-吸气组合控制平板边界层多模态稳定性研究

边界层转捩会使高超声速飞行器壁面摩阻和热流显著增加,因此在高超声速飞行器设计过程中往往占据重要地位.针对高超声速飞行器多模态转捩控制问题,提出了微槽道(1 mm)与边界层吸气的组合控制方法,并通过直接数值模拟和线性稳定性理论研究了Ma=4.5平板边界层的稳定性及组合控制效果.边界层在无控状态时,同时存在失稳的第一、二模态波,且二维第二模态波最不稳定;单纯施加微槽道控制时,边界层第二模态波会被抑制但第一模态波会被略微激发.对比而言,采用“微槽-吸气”组合控制后,不仅增强了对第二模态波的抑制效果,而且减弱了第一模态波的激发程度;同时随着吸气强度的增加,第二模态波不稳定区域明显收缩、频率显著增高,而第一模态波则变化不明显.相较于单纯的微槽道,吸气增强了“微槽吸收”与“声波散射”作用,因此中等吸气强度下该组合控制方法对第一和第二模态波的增长率分别实现了12.63%和28.02%的抑制效果.以上结果表明“微槽-吸气”组合控制手段具有适用宽频、布置区域灵活的优点,展现出了一定的多模态控制效果.

激光辅助水射流加工砷化镓晶片微槽的实验研究

对干激光、低压水射流辅助激光和激光辅助水射流技术加工砷化镓晶片微槽进行了对比实验,结果表明,激光辅助水射流技术适合加工砷化镓材料,它能够加工出晶片表面无污染、大深度、小热影响区宽度、大深宽比的高质量微槽,加工表面微观形貌均匀、微裂纹少,优于其他两种加工方式。实验研究了激光辅助水射流加工砷化镓晶片微槽的切割性能,结果表明,加工参数(激光脉冲能量、水射流压力、加工速度、水射流倾斜角度、焦平面位置和加工次数)对微槽深度、微槽宽度和材料去除率具有显著影响。微槽深度、微槽宽度和材料去除率随着激光脉冲能量的增大而增大,随着水射流压力的增大而减小,材料去除率随着加工速度的增大而显著增大。