Study of machining indentations over the entire surface of a target ball using the force modulation approach

A modified five-axis cutting system using a force control cutting strategy was to machine indentations in different annuli on the entire surface of a target ball.The relationship between the cutting depths and the applied load as well as the microsphere rotation speed were studied experimentally to reveal the micromachining mechanism.In particular,aligning the rotating center of the high precision spindle with the microsphere center is essential for guaranteeing the machining accuracy of indentations.The distance between adjacent indentations on the same annulus and the vertical distance between adjacent annuli were determined by the rotating speed of the micro-ball and the controllable movement of the high-precision stage,respectively.In order to verify the feasibility and effect of the proposed cutting strategy,indentations with constant and expected depths were conducted on the entire surface of a hollow thin-walled micro-ball with a diameter of 1 mm.The results imply that this machining methodology has the potential to provide the target ball with desired modulated defects for simulating the inertial confinement fusion implosion experiment.

An automated AFM for nanoindentation and force related measurements

A fully automated atomic force microscope(AFM)is presented.The mechanical motion of the AFM stage was controlled by three steppers.The fine motion of the AFM was controlled by an MCL one-axis piezo plate.A32.768kHz crystal tuning fork(TF)was used as the transducer with a probe attached.An acoustic sensor was used to measure the interactions between the probe and the sample.An SR850lock-in amplifier was used to monitor the TF signals.An additional lock-in amplifier was used to monitor the acoustic signal.A field programmable gate array(FPGA)board was used to collect the data in automatic mode.The main controller was coded with LabVIEW,which was in charge of Z-axis scan,signal processing and data visualization.A manual mode and an automatic mode were implemented in the controller.Users can switch the two modes at any time during the operation.This AFM system showed several advantages during the test operations.It is simple,flexible and easy to use.

Volume, Side-Area, and Force Direction of Berkovich and Cubecorner Indenters, Novel Important Insights

The iteration-free physical description of pyramidal indentations with closed mathematical equations is comprehensively described and extended for creating new insights in this important field of research and applications. All calculations are easily repeatable and should be programmed by instrument builders for even easier general use. Formulas for the volumes and side-areas of Berkovich and cubecorner as a function of depth are deduced and provided, as are the resulting forces and force directions. All of these allow for the detailed comparison of the different indenters on the mathematical reality. The pyramidal values differ remarkably from the ones of so-called “equivalent cones”. The worldwide use of such pseudo-cones is in severe error. The earlier claimed and used 3 times higher displaced volume with cube corner than with Berkovich is disproved. Both displace the same amount at the same applied force. The unprecedented mathematical results are experimentally confirmed for the physical indentation hardness and for the sharp-onset phase-transi- tions with calculated transition energy. The comparison of both indenters provides novel basic insights. Isotropic materials exhibit the same phase transition onset force, but the transition energy is larger with the cube corner, due to higher force and flatter force direction. This qualifies the cube corner for fracture toughness studies. Pile-up is not from the claimed “friction with the indenter”. Anisotropic materials with cleavage planes and channels undergo sliding along these under pressure, both to the surface and internally. Their volumes add to the depression volume. These volumes are essential for the exemplified pile-up management. Phase-transitions produce polymorph interfaces that are nucleation sites for cracks. Technical materials must be developed with onset forces higher than the highest thinkable stresses (at airliners, bridges, etc.). This requires urgent revision of ISO 14577-ASTM standards.

Cyclic testing of moment-shear force interaction in reinforced concrete shear wall substructures

Previous quasi-static cyclic tests of shear walls,which routinely used an incremental lateral displacement test protocol with a constant axial load,failed to reflect the character of moment-shear force interaction of prototype buildings.To study the effect of the moment-shear force interaction on the seismic performance of shear walls,three identical 2-story shear wall specimens with different loading patterns were constructed at 1/2 scale,to represent the lower portion of an 11-story high-rise building,and were tested under reversed cyclic loads.The axial force,shear force and bending moment were simultaneously applied to simulate the effects of gravity loads and earthquake excitations on the prototype.The axial force and bending moment delivered from the upper structure were applied to the top of the specimens by two vertical actuators,and the shear force was applied to the specimens by two horizontal actuators.A mixed force-displacement control test program was adopted to ensure that the bending moment and the lateral shear were increased proportionally.The experimental results show that the moment-shear force interaction had a significant effect on the failure pattern,hysteretic characteristics,ductility and energy dissipation of the specimens.It is recommended that moment-shear force interaction should be considered in the loading condition of RC shear wall substructures cyclic tests.

落石撞击钢筋混凝土箱梁数值仿真与损伤分析

为研究落石撞击对钢筋混凝土箱梁的影响,通过ANSYS/LS-DYNA有限元软件对落石撞击某匝道桥箱梁的过程进行数值模拟,计算竖直方向的落石撞击力,分析桥面破损情况和箱梁开裂形态,并与现场检测结果进行对比。结果表明:落石与箱梁发生了5次撞击,产生了多个撞击力峰值,桥面出现5处凹坑;落石撞击力类似三角形脉冲荷载,瞬时峰值大,持续时间短;首次撞击时落石撞击力最大,瞬时峰值达到10705 kN,基于瑞士公式和日本道路公团公式计算的最大落石撞击力比模拟值小,将其直接用于落石-箱梁碰撞计算是偏不安全的;有限元计算得到的桥面凹坑分布和箱梁开裂破损情况与事故测量结果吻合较好,再现了落石撞击钢筋混凝土箱梁的过程;落石撞击箱梁所造成病害主要是碰撞接触区域的局部损伤,首次撞击时病害最严重,桥面破损范围大,箱梁翼缘板上表面混凝土开裂并向下延伸至翼缘与腹板交界处。

缝衣针包装机的主要结构设计研究

大部分缝衣针用铝箔纸、外包装纸进行包装,该包装方式主要采用纯手工操作,针对该情况,充分考量包装机的工作稳定性、自动化程度和生产效率,并注重细节的处理,设计出高效的缝衣针包装机,以满足安全、环保等方面的要求.

铁基粉末冶金零件蒸汽处理膜层的影响因素及评价体系

蒸汽处理技术是一种应用广泛的铁基粉末冶金产品化学强化方法,能够在产品表层形成一层结合性强、硬度高且致密的保护膜,具有耐腐蚀、抗磨损、提升产品硬度的效果。本文系统阐述了蒸汽处理技术的反应原理,讨论了反应热力学和动力学过程对蒸汽处理保护膜质量的影响。由于目前对蒸汽处理层的检验检测手段不统一,为推动铁基粉末冶金零件蒸汽处理工艺的标准化,本文结合生产现状系统总结了蒸汽处理保护膜膜厚、结构、成分以及结合力的检测方法,并结合实际实验结果说明了各检测方法的优劣势。

考虑岩石破碎程度的数字化钻进单齿推力模型

数字化超前钻探依赖于建立随钻参数与围岩特征之间的定量关系,如何定量分析围岩破碎程度对于推力的影响是个重要难题,对于预测不良地质地层具有重要意义。提出一个基于小孔扩张理论的单齿推力理论模型,模型采用HoekBrown破坏准则和非关联流动法则,描述岩石破碎程度对于岩石强度的影响。基于弹塑性力学,推导小孔扩张模型的应力场和位移场,并将模型应用到岩石贯入试验中,建立单齿贯入岩石过程中贯入深度与无量纲塑性区半径的定量关系。该理论模型考虑了刀头形状参数、岩石破坏程度和围压等重要参数对于推力的影响,并可以得到单齿贯入岩石过程中贯入深度与贯入力的定量关系。为验证模型的准确性,开展2种不同地质强度指标的楔形探头贯入岩石试验,试验结果与模型曲线趋势及数量级一致。将模型预测结果与文献中试验数据相对比,进一步验证了模型的可靠性,且表明本文模型在实际工程利用贯入力预测掌子面围岩破碎程度时更趋于安全。参数分析研究表明,岩石破坏程度、围压和岩石强度参数对于推力影响较大,推力与地质强度指标呈负相关关系,与围压和楔形刀头倾角呈正相关关系。结合钻头中单齿分布情况,该理论模型可以用来探讨实际工程推力参数与围岩参数的关系,推进实现数字化超前钻探。

动静载荷耦合作用下岩石破碎理论分析及试验研究

根据压头侵入岩石的断裂特征,确定了动静载荷耦合侵入岩石过程中所形成的中间、径向和侧向裂纹长度与侵入载荷、冲锤质量和冲击速度关系式,分析了冲击–静压切削组合破岩模式下冲击间距(频率)对破岩效果的影响。在自行研制的动静态多功能岩石破碎试验台上,以花岗岩为试验对象分别进行了动静耦合载荷侵入岩石试验和冲击–静压切削破岩试验。结果表明:组合载荷模式能大幅度提高破岩效果,冲击间距与切削深度之比值对破岩比能耗有很大影响,并且存在最优比值可使破岩达到最佳效果;合理的加载方式应是冲击载荷使岩石产生足够大的开裂区,再与之匹配适当的静压和切削力将开裂区岩石切削下来;大冲击能、高冲击频率、小冲击间距对于破碎脆性硬岩有较好的效果。

两种不同形状压头与单晶铜基体间接触力和摩擦力的纳观分析

在考虑单晶铜基体弹塑性形变和晶体各向异性情况下,基于原子尺度,采用混合势函数(EAM和Morse)和Verlet算法动态模拟了半球形和圆锥形两种不同形状压头与单晶铜基体的黏着接触和滑动摩擦过程,分析了接触力和摩擦力对单晶铜基体内失效原子变化情况.研究表明:当压头下压位移为0.9 nm时,由于半球形压头比圆锥形压头底部表面积大,导致半球形压头与基体之间的引力更大而更易产生黏着接触现象.在下压接触过程中,与半球形压头相接触的基体内出现位错原子长大成位错环,而与圆锥形压头相接触的基体未出现此位错环现象,但位错原子数均随压深的增加而增多;在滑动过程中,因半球形压头对基体的摩擦力和法向力比圆锥形压头对基体的摩擦力和法向力大,使得半球形压头比圆锥形压头正前方堆积的位错原子数多,但均随滑动距离的增加而增多.

刚性块体压入颗粒体系时的受力及力链演变

颗粒体系由大量离散颗粒组成,普遍存在于自然界中,比如砂土地基、泥石流及滑坡体等。外荷载通常沿着准直形的路径在体系内传递,形成区别于单个颗粒和整个体系的细观结构——力链,亦即颗粒物质具有典型的多尺度特征。采用颗粒离散元方法模拟刚性块体压入颗粒体系的过程,计算得到了刚性块体底部所受阻力与压入深度的幂率关系;给出力链的判断准则和搜索强力链程序,构建颗粒体系强力链网络,并分析了压入试验过程中力链的演变及其长度的分布规律。

高性能陶瓷零件的磨削加工

采用压痕损伤理论研究和分析高性能陶瓷材料的磨削加工过程及其对加工表面和零件性能的影响。提出了陶瓷零件的两种磨削加工机理：（１）类似于过域值压痕的脆性断裂机理，（２）类似于亚域值压痕的塑性变形机理。分析了高性能陶瓷零件磨削加工过程中，工件材料、加工机床性能、金刚石砂轮等方面参数对零件加工质量的影响。

考虑级配颗粒物质间接触力力链的分布概率分析

为了揭示颗粒物质间接触力力链的分布规律,选取10mm、13mm、16mm、19mm和20mm五组粒径的刚性颗粒进行复写纸压痕试验,利用概率分析方法研究了单一粒径和考虑级配不同粒径颗粒体内部接触力力链的分布概率。研究结果表明:两种单一粒径的法向力与平均法向力比值f的分布概率呈先增大达到峰值后减小的趋势,分布概率达到峰值处所对应的f值接近1;10mm颗粒的分布概率曲线所产生的误差较小,20mm颗粒的分布概率曲线产生的误差相对较大;考虑级配的颗粒体,其分布概率均呈指数形式单调衰减,未出现分布概率峰值,并且强力链比例基本小于10mm和20mm的单一粒径颗粒体。

基于AFM纳米硬度测量系统的实验(英文)

为了解决用AFM自身压痕软件进行纳米硬度测量时无法直接获得载荷-压深曲线和由于受到扫描陶管扫描范围的限制而进行多点压痕实验范围有限的问题,建立了三维微动工作台和原子力显微镜相结合的纳米压痕硬度测量系统．基于该系统,对单晶薄膜材料进行了单点压痕实验,得出该系统适合进行纳米硬度测量的结论;并对薄膜材料的纳米硬度和弹性模量进行了分析,讨论了尺寸效应对两者的影响．另外,进行了40×40的点阵压痕实验,得到了材料整个压痕面的三维形貌图和三维硬度图．

真空玻璃支撑压痕控制准则

为避免过大的支撑物支撑应力导致真空玻璃基片赫兹裂纹的产生,首先建立了力学模型,分析了支撑物接触部位玻璃的应力分布特征.应用Griffith断裂理论和均强度理论,分别得到了玻璃基片在不产生压痕下支撑物的最大临界支撑力计算公式.通过与试验结果进行比较,发现两种理论计算结果均与试验结果相吻合,,但断裂力学理论得到的支撑物临界支撑力比试验结果偏小,而均强度准则结果偏大.对真空玻璃结构设计,在已知的真空玻璃材料参数下,根据上述理论,计算出玻璃基片不产生压痕下支撑物的最大临界支撑力,从而确定支撑物最佳排列间距,使真空玻璃达到"热学与力学"最佳配制.

材料表面硬度及形状的AFM分析方法

利用AFM测量软性材料如聚合体、生物物质时,AFM探针对被测软性材料表面施加一定的力而引起材料表面产生变形.通过测力 位移曲线,基于AFM测力 压痕曲线分析,探讨了减轻该影响并获得高精度软性材料表面形状测量结果的方法,进而计算材料表面微观杨氏弹性模量.该方法不仅可决定物体的表面弹塑性,获得高精度的表面形状测量结果,而且通过了解物体变形机理,进一步分析材料的微观特性.

纳米压痕硬度尺寸效应分析及其试验研究

针对材料纳米压痕硬度的压痕尺寸效应(Indentation size effect,ISE),利用纳米压痕技术测得单晶铝和单晶硅的载荷-压深曲线,获得最大载荷和最大压深,并结合原子力显微镜,获得压痕的三维形貌,计算出压痕的真实残余面积。根据最大压深和残余面积提出了一个新的模型——残余面积最大压深模型,此模型能更好地理解和描述材料硬度的压痕尺寸效应,并与其他几种典型的理论和模型进行了比较和分析。

船艏正撞刚性墙力—撞深关系的简化公式研究

面向工程应用,基于船艏正撞刚性墙的有限元碰撞计算,提出了撞击力—船艏撞深关系的基本简化公式,以应用于船撞桥的质量-弹簧体系简化动力分析模型的有限元计算。使用LS-DYNA软件,通过3000~50000 DWT（dead weight tonnage,载重吨）范围内4艘典型船舶的有限元碰撞分析,得到了船舶在1.0~5.0 m/s冲击速度范围内,与刚性墙面正撞的撞击力—撞深样本曲线。根据对样本曲线的观察,提出了一种基本的撞击力—撞深关系的简化数学公式,并统计得到了公式中各参数的表达式。船桥碰撞实际工况的有限元计算对比表明,提出的简化公式可以满足船桥碰撞简化动力分析的需要。

双层立管在船舶撞击作用下结构行为分析

以船舶与立管碰撞为研究对象,采用三维有限元模拟碰撞过程,显式动力求解分析双层立管在侧向碰撞作用下的结构行为,得到碰撞过程中撞击力、结构响应、损伤变形等一般性规律,计算分析了边界约束条件、撞击质量、撞击速度、立管内压以及轴向预拉力参数的影响。结果表明,边界条件对于结构的固有频率、撞击力、结构损伤变形影响较大;撞击质量及速度是决定撞击力及变形的最主要的因素;内压的存在使得最大撞击力变小以及立管局部变形变小;在一定范围内的轴拉力越大,碰撞引起最大撞击力越大,整体变形反而变小。

带有圆弧形凹槽金属薄壁圆管抗撞性优化设计

在金属薄壁圆管的基础上,引入圆弧形凹槽诱导结构并以其为研究对象,建立以凹槽数量及其半径为优化参数,以比吸能和压溃力效率为评价指标的多目标优化模型。分析研究均布设置诱导凹槽对结构吸能、最大峰值压溃力及压溃力曲线平稳性的影响。采用有限元软件LS-DYNA得到不同几何参数模型的碰撞响应,结合径向基函数法构造近似函数,并采用理想点法进行优化设计,得出使结构最优时的凹槽数量和半径,从而得到了理想的诱导凹槽优化结构。