Surface integral analogy approaches for predicting noise from 3D high-lift low-noise wings

Three surface integral approaches of the acoustic analogies are studied to predict the noise from three concep- tual configurations of three-dimensional high-lift low-noise wings. The approaches refer to the Kirchhoff method, the Ffowcs Williams and Hawkings （FW-H） method of the permeable integral surface and the Curle method that is known as a special case of the FW-H method. The first two approaches are used to compute the noise generated by the core flow region where the energetic structures exist. The last approach is adopted to predict the noise specially from the pressure perturbation on the wall. A new way to con- struct the integral surface that encloses the core region is proposed for the first two methods. Considering the local properties of the flow around the complex object-the actual wing with high-lift devices-the integral surface based on the vorticity is constructed to follow the flow structures. The surface location is discussed for the Kirchhoff method and the FW-H method because a common surface is used for them. The noise from the core flow region is studied on the basis of the dependent integral quantities, which are indicated by the Kirchhoff formulation and by the FW-H formulation. The role of each wall component on noise contribution is analyzed using the Curle formulation. Effects of the volume integral terms of Lighthill＇s stress tensors on the noise pre-diction are then evaluated by comparing the results of the Curle method with the other two methods.

Effect of PCBN cutting tools wear on surface integrality in high-speed hard turning

In this paper, the effect of of flank wear polycrystalline cubic boron nitride （PCBN） tools on residual stresses, white layer and roughness of machined workpiece surfaces is studied. Experimental results indicate that with the increase of the tool wear, the surface of the machined workpiece tends to generate tensile residual stresses, and white layer becomes clearly thicker and uneven on the workpiece surface. The effect of the flank wear on the surface roughness is less within some range of flank wear value. The results show that it is possible to produce ideal surface integrality levels by controlling the tool flank wear.

Improving fatigue properties of normal direction ultrasonic vibration assisted face grinding Inconel 718 by regulating machined surface integrity

Fatigue properties are crucial for critical aero-engine components in extreme serviceenvironments,which are significantly affected by surface integrity(SI)indexes(especially surface topography,residual stressσ_(res),and microhardness)after machining processes.Normal-direction ultrasonic vibration-assisted face grinding(ND-UVAFG)has advantages in improving the machinability of Inconel 718,but there is a competitive relationship between higher compressiveσ_(res)and higher surface roughness R_(a)in affecting fatigue strength.The lack of a quantitative relationship between multiple SI indexes and fatigue strength makes theindeterminacy of a regulatory strategy for improving fatigue properties.In this work,a model of fatigue strength(σ_f)_(sur)considering multiple SI indexes was developed.Then,high-cycle fatigue tests were carried out on Inconel 718 samples with different SI characteristics,and the influence of ND-UVAFG process parameters on SI was analyzed.Based on SI indexes data,the(σ_f)_(sur)distribution in the grinding surface layer for ND-UVAFG Inconel 718 samples was determined using the developed model,and then the fatigue crack initiation(FCI)sites were furtherpredicted.The predicted FCI sites corresponded well with the experimental results,therebyverifying this model.A strategy for improving the fatigue life was proposed in this work,which was to transfer the fatigue source from the machined surface to the bulk material by controlling the SI indexes.Finally,a critical condition of SI indexes that FCI sites appeared on the surface or in bulk material was given by fitting the predicted results.According to the critical condition,an SI field where FCI sites appeared in the bulk material could be obtained.In this field,thefatigue life of Inconel 718 samples could be improved by approximately 140%.

Boosting rate performance of layered lithium-rich cathode materials by oxygen vacancy induced surface multicomponent integration

The rapid development of electric vehicles and portable energy storage systems demands improvements in the energy density and cost-effectiveness of lithium-ion batteries,a domain in which Lithium-rich layered cathode(LLO)materials inherently excel.However,these materials face practical challenges,such as low initial Coulombic efficiency,inferior cycle/rate performance,and voltage decline during cycling,which limit practical application.Our study introduces a surface multi-component integration strategy that incorporates oxygen vacancies into the pristine LLO material Li1.2Mn_(0.6)Ni_(0.2)O_(2).This process involves a brief citric acid treatment followed by calcination,aiming to explore rate-dependent degradation behavior.The induced surface oxygen vacancies can reduce surface oxygen partial pressure and diminish the generation of O_(2)and other highly reactive oxygen species on the surface,thereby facilitating the activation of Li ions trapped in tetrahedral sites while overcoming transport barriers.Additionally,the formation of a spinel-like phase with 3D Li+diffusion channels significantly improves Li^(+)diffusion kinetics and stabilizes the surface structure.The optimally modified sample boasts a discharge capacity of 299.5 mA h g^(-1)at a 0.1 C and 251.6 mA h g^(-1)at a 1 C during the initial activation cycle,with an impressive capacity of 222.1 mA h g^(-1)at a 5 C.Most notably,it retained nearly 70%of its capacity after 300 cycles at this elevated rate.This straightforward,effective,and highly viable modification strategy provides a crucial resolution for overcoming challenges associated with LLO materials,making them more suitable for practical application.

Machining the Integral Impeller and Blisk of Aero-Engines:A Review of Surface Finishing and Strengthening Technologies

The integral impeller and blisk of an aero-engine are high performance parts with complex structure and made of difficult-to-cut materials. The blade surfaces of the integral impeller and blisk are functional surfaces for power transmission, and their surface integrity has signif- icant effects on the aerodynamic efficiency and service life of an aero-engine. Thus, it is indispensable to finish and strengthen the blades before use. This paper presents a comprehensive literature review of studies on finishing and strengthening technologies for the impeller and blisk of aero-engines. The review includes independent and inte- grated finishing and strengthening technologies and dis- cusses advanced rotational abrasive flow machining with back-pressure used for finishing the integral impeller and blisk. A brief assessment of future research problems and directions is also presented.

Adaptive integral dynamic surface control based on fully tuned radial basis function neural network

An adaptive integral dynamic surface control approach based on fully tuned radial basis function neural network （FTRBFNN） is presented for a general class of strict-feedback nonlinear systems,which may possess a wide class of uncertainties that are not linearly parameterized and do not have any prior knowledge of the bounding functions.FTRBFNN is employed to approximate the uncertainty online,and a systematic framework for adaptive controller design is given by dynamic surface control. The control algorithm has two outstanding features,namely,the neural network regulates the weights,width and center of Gaussian function simultaneously,which ensures the control system has perfect ability of restraining different unknown uncertainties and the integral term of tracking error introduced in the control law can eliminate the static error of the closed loop system effectively. As a result,high control precision can be achieved.All signals in the closed loop system can be guaranteed bounded by Lyapunov approach.Finally,simulation results demonstrate the validity of the control approach.

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.

Optimize Multiple Peening Effects on Surface Integrity and Microhardness of Aluminum Alloy Induced by LSP

Laser shock peening is a modernized surface enhancement performed methodically to improve fatigue life, enhance the hardness of the material and make coarse grains flat under the superficial layer. In this current study, the effect of varying optimized multiple laser shock peening (LSP) is studied on the surface integrity, microhardness, and mechanical properties. The results show that the LSP-treated specimens have visible signs of valleys, wavy and varying height distribution as well as dimples. However, the presence of non-uniformity and sharp protrusions was detected from the superficiality of the as-received specimen and this was so because of the SiC abrasive material used to polish the superficial layer of the specimen before the test experiment. Prior to LSP, the surface roughness was 2 μm, however, after LSP the roughness increased to 4 μm, 6 μm and 17 μm for 1, 2, and 4 impacts, respectively. High-density dislocation can also be observed close to the grain boundary because the grain boundary prevents the migration of dislocation which could lead to dislocation walls and dislocation tangles. The increase in impacts decrease the average grain size, nevertheless, the micro-strain increased after multiple impacts. Furthermore, coarse grains after LSP were transformed into finer grains. The increase in the number of impacts increases the micro-strain likewise the full-width half maximum (FWHM). Finally, the increase in microhardness increases as the LSP impacts increase.

INTEGRAL SURFACES WITH VARIABLE INTEGRAL NEIGHBORS ON N-SIDED REGIONS

This paper presents a new approach to construct C1 continuous surfaces on N-sided regions. For C0 continuous surfaces on N-sided regions their smoothed surfaces are constructed by the integral smoothing operation with displaced integrals. The final smoothed surfaces are C1 continuous with the original surfaces on the boundary.

ANALYSIS ON SURFACE INTEGRITY DURING HIGH SPEED MILLING FOR NEW DAMAGE-TOLERANT TITANIUM ALLOY

Surface integrity of a new damage-tolerant titanium alloy （TC21）, including surface roughness, microhardness and metallurgical structure is investigated when normal and high speed milling are used at different tool wear status. Results show that good surface integrity of TC21 can be obtained in high speed milling. In addition, even in acutely worn stages, there is no so-called serious hardening layer （or white layer） according to the studies on microhardness and metallurgical structure.

Characterization and Analysis of Inconel 718 Alloy Ground at Different Speeds

Inconel 718(IN718)alloy is widely applied to fabricate high temperature resistant or corrosion resistant parts due to its excellent mechanical performance.However,the machining of IN718 alloy is difficult as it may cause serious tool wear and poor surface quality(SQ)of the workpiece.In this work,grinding experiments on IN718 alloy at different speeds were conducted by using a CBN grinding wheel.The relationship between grinding speed,SQ and subsurface damage(SSD)was well studied.With increasing grinding speed,surface roughness decreased,and SQ was greatly improved.Meanwhile,the microhardness of the grinding surface declined as the grinding speed increased.The SSD depth was almost unchanged when the grinding speed was lower than 15 m/s,then it decreased with higher grinding speeds.It was attributed to the mechanical-thermal synergistic effect in the grinding process.The results indicated that increasing grinding speed can effectively improve the SQ and reduce the SSD of IN718 alloy.The conclusion in the work may also provide insight into processing other hard-to-machining materials.

Field-assisted machining of difficult-to-machine materials

Difficult-to-machine materials (DMMs) are extensively applied in critical fields such as aviation,semiconductor,biomedicine,and other key fields due to their excellent material properties.However,traditional machining technologies often struggle to achieve ultra-precision with DMMs resulting from poor surface quality and low processing efficiency.In recent years,field-assisted machining (FAM) technology has emerged as a new generation of machining technology based on innovative principles such as laser heating,tool vibration,magnetic magnetization,and plasma modification,providing a new solution for improving the machinability of DMMs.This technology not only addresses these limitations of traditional machining methods,but also has become a hot topic of research in the domain of ultra-precision machining of DMMs.Many new methods and principles have been introduced and investigated one after another,yet few studies have presented a comprehensive analysis and summarization.To fill this gap and understand the development trend of FAM,this study provides an important overview of FAM,covering different assisted machining methods,application effects,mechanism analysis,and equipment design.The current deficiencies and future challenges of FAM are summarized to lay the foundation for the further development of multi-field hybrid assisted and intelligent FAM technologies.

EXPERIMENT ON SURFACE INTEGRITY OF MILLING TOOL FOR HARDENED STEEL SKD11

To evaluate the new designed cutting tools for high-efficiency milling of the hardened die steel SKD11,surface integrities of millers with different geometric structures are analyzed, considering the surface roughness, micrograph of chips, surface microhardness, residual stress and metallurgical texture of the surface layer. The in fluences of geometric characteristics of different cutting tools and their wear characteristics on the surface integrity are studied. Results show that the milling tool with rake angle; 5 of the hardened diesteel. The generation of saw-tooth chips is depressed when a reasonable positive rake angle is selected. And the compressive residual stress is induced on the machined surface in milling the hardened die steel. The occurrence of surface softening is postponed by increasing the clearance angle and reducing the tool flank wear.

Efficient Computation of Scattering from Targets with Negative Impedance Surface

Current surface integral equations used for computing scattering from targets with negative impedance boundary condition（IBC）are not efficient.A modified surface dual integral equation（M-SDIE）for targets with negative IBC is presented.A pure imaginary number is used to balance the formulations.It is proved that the M-SDIE is accurate and efficient with three numerical examples.The first numerical example shows that the M-SDIE is accurate compared with Mie.The second example shows that the presented SIE is efficient.In the third example,a missile head is selected to present the computing power of the M-SDIE.All the examples show that the M-SDIE is an efficient algorithm for negative IBC.

Surface Integrity of Ultrasonically-Assisted Milled Ti6Al4V Alloy Manufactured by Selective Laser Melting

The Ti6Al4V parts produced by the existing selective laser melting(SLM)are mainly confronted with poor surface finish and inevitable interior defects,which substantially deteriorates the mechanical properties and performances of the parts.In this regard,ultrasonically-assisted machining(UAM)technique is commonly introduced to improve the machining quality due to its merits in increasing tool life and reducing cutting force.However,most of the previous studies focus on the performance of UAM with ultrasonic vibrations applied in the tangential and feed directions,whereas few of them on the impact of ultrasonic vibration along the vertical direction.In this study,the effects of feed rate on surface integrity in ultrasonically-assisted vertical milling(UAVM)of the Ti6Al4V alloy manufactured by SLM were systemically investigated compared with the conventional machining(CM)method.The results revealed that the milling forces in UAVM showed a lower amplitude than that in CM due to the intermittent cutting style.The surface roughness values of the parts produced by UAVM were generally greater than that by CM owing to the extra sinusoidal vibration textures induced by the milling cutter.Moreover,the extra vertical ultrasonic vibration in UAVM was beneficial to suppressing machining chatter.As feed rate increased,surface microhardness and thickness of the plastic deformation zone in CM raised due to more intensive plastic deformation,while these two material properties in UAVM were reduced owing to the mitigated impact effect by the high-frequency vibration of the milling cutter.Therefore,the improved surface microhardness and reduced thickness of the subsurface deformation layer in UAVM were ascribed to the vertical high-frequency impact of the milling cutter in UAVM.In general,the results of this study provided an in-depth understanding in UAVM of Ti6Al4V parts manufactured by SLM.

Study of machining induced surface defects and its effect on fatigue performance of AZ91/15%SiCp metal matrix composite

The quality of surface generated in a peripheral milling of AZ91/SiCp/15%for varying machining conditions and its effect on the fatigue performance are investigated in this study.The machined surface quality was evaluated through roughness measurements and SEM micrographs of ine machined surface.Tensile iesis were pcifumicu io iiieasure the mechanical properties of the composite.Subsequently,fatigue life of milled specimens was measured through axial fatigue tests at four loading conditions.Optical and SEM/EDS micrographs of the fractured surface were studied to identify the crack initiation site and propagation mechanism.Specimens machined at a lower feed rate of 0.1 mm/rev was found to have excellent surface finish and consequently higher fatigue life.At 0.3 mm/rev,the presence of feed marks and other surface defects resulted in a drastic decrease in fatigue life.Five distinct regions were identified on the fractured surface,particle fracture along and perpendicular to the surface,voids in the matrix due to particle debonding and pull out and typical ductile failure of matrix with embedded SiC particles.

Effect of Machined Surface Integrity on Fatigue Performance of Metal Workpiece:A Review

Fatigue performance is a serious concern for mechanical components subject to cyclical stresses,particularly where safety is paramount.The fatigue performance of components relies closely on their surface integrity because the fatigue cracks generally initiate from free surfaces.This paper reviewed the published data,which addressed the effects of machined surface integrity on the fatigue performance of metal workpieces.Limitations in existing studies and the future directions in anti-fatigue manufacturing field were proposed.The remarkable surface topography(e.g.,low roughness and few local defects and inclusions)and large compressive residual stress are beneficial to fatigue performance.However,the indicators that describe the effects of surface topography and residual stress accurately need further study and exploration.The effect of residual stress relaxation under cycle loadings needs to be precisely modeled precisely.The effect of work hardening on fatigue performance had two aspects.Work hardening could increase the material yield strength,thereby delaying crack nucleation.However,increased brittleness could accel-erate crack propagation.Thus,finding the effective control mechanism and method of work hardening is urgently needed to enhance the fatigue performance of machined components.The machining-induced metallurgical structure changes,such as white layer,grain refinement,dislocation,and martensitic transformation affect the fatigue performance of a workpiece significantly.However,the unified and exact conclusion needs to be investigated deeply.Finally,different surface integrity factors had complicated reciprocal effects on fatigue performance.As such,studying the comprehensive influence of surface integrity further and establishing the reliable prediction model of workpiece fatigue performance are meaningful for improving reliability of components and reducing test cost.

Mg,Ti-base surface integrated layer and bulk doping to suppress lattice oxygen evolution of Ni-rich cathode material at a high cut-off voltage

The Nickel-rich layered cathode materials charged to 4.5 V can obtain a specific capacity of more than 200 m Ah g^(-1).However,the nickel-rich layered cathode materials suffer from the severe capacity fade during high-voltage cycling,which is related to the phase transformation and the surface sides reactions caused by the lattice oxygen evolution.Here,the simultaneous construction of a Mg,Ti-based surface integrated layer and bulk doping through Mg,Ti surface treatment could suppress the lattice oxygen evolution of Nirich material at deep charging.More importantly,Mg and Ti are co-doped into the particles surface to form an Mg_(2)TiO_(4) and Mg_(0.5–x)Ti_(2–y)(PO_(4))_(3) outer layer with Mg and Ti vacancies.In the constructed surface integrated layer,the reverse electric field in the Mg_(2)TiO_(4) effectively suppressed the outward migration of the lattice oxygen anions,while Mg_(0.5–x)Ti_(2–y)(PO_(4))_(3) outer layer with high electronic conductivity and good lithium ion conductor could effectively maintained the stability of the reaction interface during highvoltage cycling.Meanwhile,bulk Mg and Ti co-doping can mitigate the migration of Ni ions in the bulk to keep the stability of transition metal–oxygen(M-O)bond at deep charging.As a result,the NCM@MTP cathode shows excellent long cycle stability at high-voltage charging,which keep high capacity retention of 89.3%and 84.3%at 1 C after 200 and 100 cycles under room and elevated temperature of 25 and 55°C,respectively.This work provides new insights for manipulating the surface chemistry of electrode materials to suppress the lattice oxygen evolution at high charging voltage.

Microstructure-based three-dimensional characterization of chip formation and surface generation in the machining of particulate-reinforced metal matrix composites

Particulate-reinforced metal matrix composites(PRMMCs)are difficult to machine due to the inclusion of hard,brittle reinforcing particles.Existing experimental investigations rarely reveal the complex material removal mechanisms(MRMs)involved in the machining of PRMMCs.This paper develops a three-dimensional(3D)microstructure-based model for investigating the MRM and surface integrity of machined PRMMCs.To accurately mimic the actual microstructure of a PRMMC,polyhedrons were randomly distributed inside the matrix to represent irregular SiC particles.Particle fracture and matrix deformation and failure were taken into account.For the model’s capability comparison,a two-dimensional(2D)analysis was also conducted.Relevant cutting experiments showed that the established 3D model accurately predicted the material removal,chip morphology,machined surface finish,and cutting forces.It was found that the matrix-particle-tool interactions led to particle fractures,mainly in the primary shear and secondary deformation zones along the cutting path and beneath the machined surface.Particle fracture and dilodegment greatly influences the quality of a machined surface.It was also found that although a 2D model can reflect certain material removal features,its ability to predict microstructural variation is limited.

Optimization of press bend forming path of aircraft integral panel

In order to design the press bend forming path of aircraft integral panels,a novel optimization method was proposed, which integrates FEM equivalent model based on previous study,the artificial neural network response surface,and the genetic algorithm.First,a multi-step press bend forming FEM equivalent model was established,with which the FEM experiments designed with Taguchi method were performed.Then,the BP neural network response surface was developed with the sample data from the FEM experiments.Furthermore,genetic algorithm was applied with the neural network response surface as the objective function. Finally,verification was carried out on a simple curvature grid-type stiffened panel.The forming error of the panel formed with the optimal path is only 0.098 39 and the calculating efficiency has been improved by 77%.Therefore,this novel optimization method is quite efficient and indispensable for the press bend forming path designing.