Research on the Influence of Cutting Condition on the Surface Microstruct ure of Ultra-thin Wall Parts in Ultrasonic Vibration Cutting

In many fields of high-tech industry the ultra-t hi n wall parts are employed. In this paper the experiments were carried out to dis cuss the surface microstructure of the camera’s guided drawtube by applying ult rasonic vibration cutting device to the traditional lathe. The influence rule of the cutting condition on the surface roughness was put forward, which was drawn by comparing the ultrasonic cutting with the common cutting by use of the cemen ted carbide tool and the polycrystalline diamond (PCD) tool. The test results sh owed that the ultrasonic cutting performs better than the common cutting in the same condition. According to the test results analyzing, the surface characteriz ation is influenced clearly by the rigidity of the acoustic system and the machi ne tool, as well the setting height of the tool tip. Otherwise, the dense regula r low frequency vibration ripples will be scraped on the machined surface. When the tool tip is set higher than the rotating center of the work piece by three t imes of the amplitude of ultrasonic vibration, the vibration ripples behave alig ht; they turn light and shade alternatively when the tool tip is lower than the rotating center of the work piece by three times of the amplitude of ultrasonic vibration. According to the test result analyzing, the following conclusions are put forward: 1) The surface roughness in ultrasonic cutting is better than that in common cutting. Under a one third critical cutting velocity, the value of th e surface roughness in ultrasonic cutting rise slightly along with the cutting v elocity, while in common cutting it decreases contrast to the cutting velocity; the curves of the surface roughness in ultrasonic cutting and common cutting see m to be alike, both increase along with the feed rate and the cutting depth, but the value in ultrasonic cutting is smaller in the same condition.2) The influen ce of the coolant on the surface roughness cannot be ignored. The kerosene can b e employed to improve the surface roughness in ultrasonic machining.3) In ultras onic cutting process of aluminum alloy ultra-thin wall work piece, the PCD tool performs better than the cemented carbide tools.4) The vibration ripples result from the not enough rigidity of the acoustic system and the improper setting he ight of the tool tip. The departure of the tool tip from the rotating center of the work piece to some extent causes the vibration ripples on the machined surfa ce.

Research on Influence of Cutting Conditions on Roundness of Ultra-thin Wall Parts in Ultrasonic Vibration Cutting

In the paper, the experimental researches were carr ie d out to discuss the roundness forming rule and the influence of cutting paramet ers on roundness by ultrasonic vibration cutting of the camera’s guiding drawtu be with 47.75 mm diameter and 0.6～1.5 mm wall thickness. The research results s h ow that the roundness error of ultra-thin wall parts in ultrasonic vibration cu tting is only one third of that in common cutting. The relations between the rou ndness error and the cutting parameters behave as: (1) The roundness error in co mmon cutting decreases gradually with the rise of cutting speed, while in ultras onic cutting, the roundness changes not obviously till the cutting speed is up t o a value, which is nearly equal to one third of the critical velocity. Then the roundness of workpiece will begin to increase slowly. (2) The roundness error i ncreases along with the feed rate both in common cutting and ultrasonic cutting. (3) Within the range of cutting depth in experiment, the influence of cutting d epth on the roundness error is more obvious in common cutting than that in ultra sonic vibration cutting. The conclusions are useful in machining such precise ul tra-thin wall parts. According to the tests, the following conclusions can be o btained: 1) Compared with common cutting, ultrasonic cutting can decrease effect ively roundness error of the workpiece. Under the same condition, the roundness error of the ultra-thin wall part in ultrasonic turning is about one third of t hat in common cutting. 2) In common cutting, cutting depth and feed rate have mu ch influence on the roundness and the influence of cutting velocity is little. W hile in ultrasonic cutting, the roundness was influenced heavily only when feed rate is more than 0.1 mm/r and cutting speed is more than 1/3 of the critical ro tation speed, cutting depth has little influence on the roundness in the experim ent. 3) Kerosene-oil is an optimum cutting fluid in machining ultra-thin wall workpiece. 4) To machine the ultra-thin wall precision part, ultrasonic cutting is the perfect method which can decrease the roundness error effectively an d ensure high quality of the surface.

Study on Numerical Simulation for Control of Winding Process of Thin Wall Spiral Tube

Being aimed at the inside wall wrinkling and sinking phenomenon of palladium-yttrium alloy thin wall spiral tube used for preparation of high purity hydrogen, extraction of hydrogen isotope, and purification and separation of hydrogen in the winding process, this article analyzed the reasons for above phenomena, established a numerical simulation model of winding process of above tube, using elastic-plastic Finite Element method analyzed the max. tensile stress and max. compression stress and their locations, thereby provides a theory base for the control of working forming course of thin wall spiral tube.

Partial Surface Damper to Suppress Vibration for Thin Walled Plate Milling

The material removal rate and required workpiece surface quality of thin-walled structure milling are greatly limited due to its severe vibration, which is directly associated with the dynamic characteristics of the system.Therefore, the suppression of vibration is an unavoidable problem during milling. A novel partial surface damping method is proposed to modify the mode of the thin walled cantilever plate and to suppress vibration during milling.Based on classical plate theory, the design criterion is analyzed and configuration of the partial surface damper is introduced, in which viscoelastic plate and constraining plate are attached to the surface of the plate to increase the system's natural frequency and loss factor. In order to obtain the energy expression of the cutting system, the Ritz method is used to describe the unknown displacements.Then, with Lagrange's equation, the natural frequency and loss factor are calculated. In addition, the plate is divided into a finite number of square elements, and the regulation of treated position is studied based on theoretic and experimental analysis. The milling tests are conducted to verify its damping performance and the experimental results show that with treatment of partial surface damper,the deformation of the bare plate is reduced from 0.27 mm to 0.1 mm, while the vibration amplitude of the bare plate is reduced from 0.08 mm to 0.01 mm. The proposed research provides the instruction to design partial surface damper.

Residual stress modeling of thin wall by laser cladding forming

The residual stress generated in the laser cladding could lead to undesirable distortions or even crack formation. In order to better understand the evolution/yielding process of stress field,a 3 D finite-element thermo-mechanical model was established for the laser cladding formation of thin wall with the 17-4 PH powder on the FV520( B) steel. The temperature field was firstly analyzed,based on which the stress field and strain field of the laser cladding forming process were analyzed.In order to validate the prediction,the final residual stress field in the obtained thin wall was tested by X-ray diffraction in comparison with the predicted results.

Reflection and Transmission of Regular Waves from/Through Single and Double Perforated Thin Walls

In this paper, reflection and transmission coefficients of regular waves from/through perforated thin walls are investigated. Small scale laboratory tests have been performed in a wave flume firstly with single perforated thin Plexiglas plates of various porosities. The plate is placed perpendicular to the flume with the height from the flume bottom to the position above water surface. With this thin wall in the flume wave overtopping is prohibited and incident waves are able to transmit. The porosities of the walls are achieved by perforating the plates with circular holes.Model settings with double perforated walls parallel to each other forming so called chamber system, have been also examined. Several parameters have been used for correlating the laboratory tests' results. Experimental data are also compared with results from the numerical model by applying the multi-domain boundary element method(MDBEM)with linear wave theory. Wave energy dissipation due to the perforations of the thin wall has been represented by a simple yet effective porosity parameter in the model. The numerical model with the MDBEM has been further validated against the previously published data.

Nonlinear Stability Analysis of Long Span Continuous Rigid Frame Bridge with Thin Wall High Piers

By utilizing the current finite element program ANSYS, two types of finite element models (FEM), the beam model (BM) and shell model (SM), are established for the nonlinear stability analysis of a practical rigid frame bridge—Longtanhe Great Bridge. In these analyses, geometrical and material nonlinearities are simultaneously taken into account. For geometrical nonlinearity, updated Lagrangian formulations are adopted to derive the tangent stiffness matrix. In order to simulate the nonlinear behavior of the plastic hinge of the piers, the multi lines spring element COMBIN39 is used in the SM while the bilinear rotational spring element COMBIN40 is employed in the BM. Numerical calculations show that satisfying results can be obtained in the stability analysis of the bridge when the double coupling nonlinearity effects are considered. In addition, the conclusion is significant for practical engineering.

THE ANALYSIS OF THIN WALLED COMPOSITE LAMINATED HELICOPTER ROTOR WITH HIERARCHICAL WARPING FUNCTIONS AND FINITE ELEMENT METHOD

In the present paper, a series of hierarchical warping functions isdeveloped to analyze the static and dynamic problems of thin walled composite lami-nated helicopter rotors composed of several layers with single closed cell. This methodis the development and extension of the traditional constrained warping theory ofthin walled metallic beams, which had been proved very successful since 1940s. Thewarping distribution along the perimeter of each layer is expanded into a series of suc-cessively corrective warping functions with the traditional warping function causedby free torsion or free bending as the first term, and is assumed to be piecewise linearalong the thickness direction of layers. The governing equations are derived basedupon the variational principle of minimum potential energy for static analysis andRayleigh Quotient for free vibration analysis. Then the hierarchical finite elementmethod is introduced to form a numerical algorithm. Both static and natural vibra-tion problems of sample box beams are analyzed with the present method to show themain mechanical behavior of the thin walled composite laminated helicopter rotor.

Manufacture of Extra-Thin Wall Steel Pipe by LD Cluster Mill

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Strength Characteristics of Inoculated and Nodularised Thin Wall Ductile Iron Castings

Carbide precipitates in Thin Wall Ductile Iron (TWDI) used for automotive applications needs to be eliminated or reduced for improved strength, ductility, crack propagation resistance and good machinability. Ductile iron thin section profiles (≤3 mm) present danger of massive carbide precipitations in the as-cast sample. Precipitated carbide phase is brittle and negatively affects the mechanical properties of the iron matrix. The suppression of carbide formation is associated with the nucleating properties of the nodularizer and innoculant alloys. This treatment is vital in ensuring that carbide precipitation, flake graphite structure and non-nodular graphite phases are reduced or completely eliminated in the TWDI castings. Therefore, the temperature and technique of treatment would influence the yield of the process, and ultimately the mechanical properties. In this study, the effect of nodularization and inoculation treatment temperature on the microstructure and mechanical properties of TWDI castings is examined. The results indicate that good nodularity and nodule count with better percent elongations are achieved using low treatment temperatures in descending order of 1490°C, 1470°C and 1450°C, but have negative effect at lower treatment temperature of 1430°C. However, TWDI castings have superior properties in terms of nodule counts and nodularity at 1450°C. Treatment temperature does not produce significant influence on ultimate tensile strength (UTS) and hardness of TWDI castings. TWDI castings show poor nodularity, nodule count and ductility at higher inoculation treatment temperatures of 1550°C, 1530°C and 1510°C.

Modelling and analysis of metal flowing behaviors in constraining ring rolling of tapered ring with thin wall and three high ribs

Tapered ring with thin wall and three high ribs(TRTWTHR),showing complicated geometry(wall thickness is less than 4 mm and rib height exceeds 20 mm),is extensively utilized to fabricate the critical structural parts of aerospace equipment such as spacecraft cabin,rocket body and fuel tank because of light weight and high carrying capacity.How to fabricate TRTWTHR with high performance is a critical problem that aerospace area needs to solve.In this work,constraining ring rolling(CRR)technique is first adopted to form TRTWTHR.However.unreasonable metal streamlines(UMS)and uncoordinated growth of three ribs easily occur in CRR of TRTWTHR,which makes the forming quality of TRTWTHR difficult to be controlled.Faced with this difficulty,an analytical model that can predict UMS and the height of three ribs in CRR of TRTWTHR is established so as to guide the process design of CRR.Subsequently,the reliability of the established analytical model and the feasibility of CRR of TRTWTHR are confirmed by FE simulation and experiment.Then,using the established analytical model,the window of UMS occurring relevant to the tapered angle of TRTWTHR and the location of the rib of middle end is developed.Finally,three uncoordinated growth modes among three ribs are found when the width of three ribs is identical and UMS do not occur,and the mechanisms of three uncoordinated growth modes are revealed.

Radial envelope forming mechanism and process design method for cylindrical rings with thin wall and high web ribs

Cylindrical rings with thin wall and high web ribs(CRTWHWR)are widely used as the key load bearing structures such as rocket body and space station cabin in aerospace field.However,it is still difficult to efficiently manufacture CRTWHWR with high performance because of their extreme geometry with thin-walled skins,high web ribs and large size.In this paper,a novel radial envelope forming process is put forward to efficiently achieve the plastic forming of CRTWHWR with high performance.Firstly,the principle of radial envelope forming process is clarified.Then,an efficient design method for the tool motion and geometry is proposed based on the reverse envelope principle,i.e.,CRTWHWR is adopted to reversely envelope the tool and thus the tool which does not interfere with CRTWHWR can be efficiently obtained in a single operation.Finally,a reasonable 3D FE model of the radial envelope forming process of CRTWHWR is established and the radial envelope forming mechanism of CRTWHWR is comprehensively revealed.Through the FE simulation and experiments with material of plastic mud,a typical CRTWHWR with diameter of 300 mm,axial height of 192 mm,the maximum rib height of 25 mm,the minimum rib thickness of 3 mm and skin thickness of 5 mm is radial envelope formed,i.e.,the ratio of the maximum rib height to the minimum rib thickness reaches 8.33,the ratio of the maximum rib height to skin thickness reaches 5 and the ratio of diameter to the minimum rib thickness reaches 100.The above results verify that the proposed radial envelope forming process has great potentials in efficiently manufacturing CRTWHWR with extreme geometry.

Supramolecular electrostatic self-assembly of mesoporous thin-walled graphitic carbon nitride microtubes for highly efficient visible-light photocatalytic activities

For efficient solar energy conversion,the morphology engineering of hollow graphitic carbon nitride(gC3 N4)is one of the promising approachs benefiting from abundant exposed active sites and short photocarrier transport distances,but is difficult to control on account of easy structural collapse.Herein,a facile supramolecular electrostatic self-assembly strategy has been developed for the first time to fabricate mesoporous thin-walled g-C3N4 microtubes(mtw-CNT)with shell thickness of ca.13 nm.The morphological control of g-C3N4 enhances specific surface area by 12 times,induces stronger optical absorption,widens bandgap by 0.18 e V,improves photocurrent density by 2.5 times,and prolongs lifetimes of charge carriers from bulk to surface,compared with those of bulk g-C3N4.As a consequence,the transformed g-C3N4 exhibits the optimum photocatalytic H2-production rate of 3.99 mmol·h^-1·g^-1(λ>420 nm)with remarkable apparent quantum efficiency of 8.7%(λ=420±15 nm)and long-term stability.Moreover,mtw-CNT also achieves high photocatalytic CO2-to-CO selectivity of 96%(λ>420 nm),much better than those on the most previously reported porous g-C3N4 photocatalysts prepared by the conventional hard-templating and soft-templating methods.

GEOMETRICALLY NONLINEAR FINITE ELEMENT MODEL OF SPATIAL THIN-WALLED BEAMS WITH GENERAL OPEN CROSS SECTION

Based on the theory of Timoshenko and thin-walled beams,a new finite element model of spatial thin-walled beams with general open cross sections is presented in the paper,in which several factors are included such as lateral shear deformation,warp generated by nonuni-form torsion and second-order shear stress,coupling of flexure and torsion,and large displacement with small strain. With an additional internal node in the element,the element stiffness matrix is deduced by incremental virtual work in updated Lagrangian (UL) formulation. Numerical examples demonstrate that the presented model well describes the geometrically nonlinear property of spatial thin-walled beams.

Closed-form solution to thin-walled box girders considering effects of shear deformation and shear lag

Considering three longitudinal displacement functions and uniform axial displacement functions for shear lag effect and uniform axial deformation of thin-walled box girder with varying depths,a simple and efficient method with high precision to analyze the shear lag effect of thin-walled box girders was proposed.The governing differential equations and boundary conditions of the box girder under lateral loading were derived based on the energy-variational method,and closed-form solutions to stress and deflection corresponding to lateral loading were obtained.Analysis and calculations were carried out with respect to a trapezoidal box girder under concentrated loading or uniform loading and a rectangular box girder under concentrated loading.The analytical results were compared with numerical solutions derived according to the high order finite strip element method and the experimental results.The investigation shows that the closed-form solution is in good agreement with the numerical solutions derived according to the high order finite strip method and the experimental results,and has good stability.Because of the shear lag effect,the stress in cross-section centroid is no longer zero,thus it is not reasonable enough to assume that the strain in cross-section centroid is zero without considering uniform axial deformation.

Effects of process parameters on numerical control bending process for large diameter thin-walled aluminum alloy tubes

Numerical control(NC) bending experiments with different process parameters were carried out for 5052O aluminum alloy tubes with outer diameter of 70 mm, wall thickness of 1.5 mm, and centerline bending radius of 105 mm. And the effects of process parameters on tube wall thinning and cross section distortion were investigated. Meanwhile, acceptable bending of the 5052O aluminum tubes was accomplished based on the above experiments. The results show that the effects of process parameters on bending process for large diameter thin-walled aluminum alloy tubes are similar to those for small diameter thin-walled tubes, but the forming quality of the large diameter thin-walled aluminum alloy tubes is much more sensitive to the process parameters and thus it is more difficult to form.

Energy-absorption forecast of thin-walled structure by GA-BP hybrid algorithm

In order to analyze the influence rule of experimental parameters on the energy-absorption characteristics and effectively forecast energy-absorption characteristic of thin-walled structure, the forecast model of GA-BP hybrid algorithm was presented by unifing respective applicability of back-propagation artificial neural network (BP-ANN) and genetic algorithm (GA). The detailed process was as follows. Firstly, the GA trained the best weights and thresholds as the initial values of BP-ANN to initialize the neural network. Then, the BP-ANN after initialization was trained until the errors converged to the required precision. Finally, the network model, which met the requirements after being examined by the test samples, was applied to energy-absorption forecast of thin-walled cylindrical structure impacting. After example analysis, the GA-BP network model was trained until getting the desired network error only by 46 steps, while the single BP-ANN model achieved the same network error by 992 steps, which obviously shows that the GA-BP hybrid algorithm has faster convergence rate. The average relative forecast error (A RE ) of the S EA predictive results obtained by GA-BP hybrid algorithm is 1.543%, while the A RE of the S EA predictive results obtained by BP-ANN is 2.950%, which clearly indicates that the forecast precision of the GA-BP hybrid algorithm is higher than that of the BP-ANN.

Finite element modeling of power spinning of thin-walled shell with hoop inner rib

A 3D elasto-plastic finite element(FE)model of power spinning of thin-walled aluminum alloy shell with hoop inner rib was established under software ABAQUS.Key technologies were dealt with reasonably.The reliability of the FE model was verified theoretically and experimentally.The forming process was simulated and studied.The distribution of the thickness and stress,and the variations of spinning force were obtained.The workpiece springback was analyzed with ABAQUS/Standard.The results show that the FE model considering elastic deformation can not only be used to analyze the workpiece springback in the complex spinning process,but also serve as a significant guide to study the local deformation mechanism and choose the reasonable parameters.

Development of pressure control system in counter gravity casting for large thin-walled A357 aluminum alloy components

Counter gravity casting equipments(CGCE) were widely used to produce large thin-walled A357 aluminum alloy components. To improve the pressure control precision of CGCE to get high quality castings, a pressure control system based on fuzzy-PID hybrid control technology and the digital assembled valve was developed. The actual pressure tracking experiment results show that the special system by applying PID controller and fuzzy controller to varied phases, is not only able to inherit the small error and good static stability of classical PID control, but also has fuzzy control’s advantage of fully adapting itself to the object. The pressure control error is less than 0.3 kPa. By using this pressure control system, large complex thin-walled A357 aluminum alloy castings with high quality was successfully produced.

Numerical analysis of flow-thermal coupling in micro-plasma welding pool of thin-wall part

The formed characteristics of thin-wall part is studied when it is in the process of MPAW. Finite element method is used to simulate the temperature field coupling flow field in the welding of thin-wall part. It is found that because of the obvious effect of heat accumulation in cross-section,where the distribution of temperature field area presents trapezoidal inverted approximately in the molten pool and the non-molten pool area presents level. The surface tension,the electromagnetic force and buoyancy are considered for analyzing the effects on the fluid flow of welding-pool. It can be obtained that the surface tension is the main driving force in the welding pool,which is far greater than electromagnetic force and buoyancy.