神经网络在压合过程中的应用

针对将圆锥体压入薄壁筒的控制技术中,对位移传感器和压力传感器在线实时检测及执行机构气液增力缸的控制问题,在分析受外界干扰的情况下,为保证系统的稳定性和收敛性,采用基于递推最小二乘法的多层前向神经网络算法,并对它的条件参数进行了一般性的推导。该神经网络为3层前向网络,其隐含层神经元数为10个,输出层神经元数1个。包括输出层与隐含层、输入层与隐含层间权的调整算法。用典型PID算法和神经网络的控制算法分别仿真结果可见,神经网络控制解决了压合过程纯滞后的非线性问题,达到了预期的技术要求。

Microstructural characteristics of near-liquidus cast AZ91D alloy during semi-solid die casting

Near-liquidus cast ingot was reheated to semi-solid firstly, and then a bracket of motor was prepared by die casting the semi-solid ingot into mould. The microstructural characteristics of AZ91D alloy in these processes were investigated. In the process of near-liquidus casting, primary α-Mg grains tend to be rosette-like because of the increase of plentiful quasi-solid atom clusters in molten alloy with the decrease of pouring temperature. These rosette-like a-Mg grains in ingots fabricated by near-liquidus casting are fused off and refined into near-globular structure owing to the solute diffusion mechanism and the minimum surface energy mechanism during reheating. After semi-solid die-casting, a-Mg grains, located in biscuit, impact and connect with each other; α-Mg grains, located in inner gate, congregate together; while α-Mg grains, located in component, distribute uniformly and become into globularity or strip. Because the inner gate limits the flowing of semi-solid slurry, and the pressure acted on the semi-solid slurry decreases gradually along the filling direction of semi-solid slurry in Cavity, microstructural segregation of unmelted a-Mg grains appears along this direction. Shrinkage holes in casting are caused by two different reasons. For biscuit, the shrinkage holes are caused by the blocked access of feeding liquid to the shrinkage zone for the agglomerated unmelted α-Mg grains. For component, the shrinkage holes are caused by the lack of feeding of liquid alloy.

Plastic deformation behavior of Mg97Zn1Y2 extruded alloys

The mechanical properties of the Mg97ZnlY2 extruded alloy containing the long-period stacking ordered phase, the so-called LPSO-phase, with a volume fraction of 24%-25%, were examined by compression tests and cyclic tension-compression deformation tests. The plastic behavior of the extruded alloys with compositions of Mg99.2Zn0.2Y0.6 and Mg89Zn4Y7 （molar fraction, %）, which were almost the same compositions of Mg matrix phase and LPSO phase in Mg97Zn1Y2 Mg/LPSO two-phase alloy, respectively, were also prepared. By comparing their mechanical properties, the strengthening mechanisms operating in the Mg97Zn1 Y2 extruded alloy were discussed. Existence of the LPSO-phase strongly enhanced the refinement of Mg matrix grain size during extrusion, which led to a large increment of the strength of alloy. In addition, the LPSO-phases, which were aligned along the extrusion direction in Mg97Zn1Y2 extruded alloy, acted as hardening phases, just like reinforced fibers.

Characterization of hot deformation behavior of Al-Zn-Mg-Mn-Zr alloy during compression at elevated temperature

The hot deformation behavior of Al-6.2Zn-0.70Mg-0.30Mn-0.17 Zr alloy and its microstructural evolution were investigated by isothermal compression test in the deformation temperature range between 623 and 773 K and the strain rate range between 0.01 and 20 s^(-1).The results show that the flow stress decreased with decreasing strain rate and increasing deformation temperature.At low deformation temperature(≤673 K) and high strain rate(≥1 s^(-1)),the main flow softening was caused by dynamic recovery;conversely,at higher deformation temperature and lower strain rate,the main flow softening was caused by dynamic recrystallization.Moreover,the slipping mechanism transformed from dislocation glide to grain boundary sliding with increasing the deformation temperature and decreasing the strain rate.According to TEM observation,numerous Al_3Zr particles precipitated in matrix,which could effectively inhibit the dynamic recrystallization of the alloy.Based on the processing map,the optimum processing conditions for experimental alloy were in deformation temperature range from 730 K to 773 K and strain rate range from 0.033 s^(-1) to 0.18 s^(-1) with the maximum efficiency of 39%.

New extrusion process of Mg alloy automobile wheels

The recent research and development of forged magnesium road wheel were reviewed.Methods of flow-forming,spin forging of manufacturing a forged magnesium alloy wheel were introduced.A new extrusion method was investigated especially. Extrusion from hollow billet was proposed in order to enhance the strength of spoke portion and reduce the maximum forming load. By means of the developed technique,the one-piece Mg wheels were produced successfully by extrusion from AZ80+alloy.At the same time,the existing problems on the research and development of forged magnesium road wheel were analyzed.The impact testing,radial fatigue testing and bending fatigue testing results show that AZ80+wheel can meet application requirement in automobile industry.

Optimization of extrusion process parameters of Incoloy028 alloy based on hot compression test and simulation

True stress?true strain curves of Incoloy028alloy at high temperature and strain rate were investigated by hot compression test.These curves show that the maximum flow stress decreases with the increase in temperature and the decrease in strain rate.FEM simulation was employed to investigate the influence of temperature,extrusion speed and friction coefficient on the extrusion load,stress,strain and strain rate in the extrusion process.The increase of extrusion temperature results in decrease of load and deformation resistance,but has little influence on strain and strain rate.When extrusion speed changes between200and350mm/s,no obvious change about extrusion load can be found.Sharp peak value up to42500kN emerges in the extrusion load curve and the extrusion process becomes unstable seriously when extrusion speed rises up to400mm/s.Both stress and strain rate increase with the raise of extrusion speed.When friction coefficient is between0.02and0.03,deformation resistance is about160MPa and the strain rate can be limited below70s?1.Successful production of Incoloy028tube verifies the optimized parameters by FEM simulation analysis,and mechanical tests results of the products meet the required properties.

Microstructure evolution during reheating of extruded Mg-Gd-Y-Zr alloy into semisolid state

The microstructure evolution of an extruded Mg-8.57Gd-3.72Y-0.54Zr （mass fraction, %, GW94） alloy during reheating into the semisolid state was investigated using optical microscopy （OM）, scanning electron microscopy （SEM）, and energy dispersive X-ray spectroscopy （EDX）. Typical semisolid microstructure with globular solid particles distributed in the liquid matrix is obtained over 600 ℃. The solid content of （Gd＋Y） in the primary a-Mg particles decreases with increasing the semisolid temperature. With the prolongation of isothermal holding time, the liquid fraction does not change significantly, while the grains grow up and spheroidize. Three methods used to determine the liquid fraction as a function of temperature, namely quantitative metallography on quenched microstructures, cooling curve thermal analysis, and thermodynamic calculations were further compared.

Processing map and hot working mechanisms of Cu-Ag alloy in hot compression process

For Gu-Ag alloy, an important parameter called workability in the forming process of materials can be evaluated by processing maps yielded from the stress-strain data generated by hot compression tests at temperatures of 700-850 °C and strain rates of 0.01-10 s-1. And at the true strain of 0.15, 0.35 and 0.55, respectively, the responses of strain-rate sensitivity, power dissipation efficiency and instability parameter to temperature and strain rate were studied. Instability maps and power dissipation maps were superimposed to form processing maps, which reveal the determinate regions where individual metallurgical processes occur and the limiting conditions of flow instability regions. Furthermore, the optimal processing parameters for bulk metal working are identified clearly by the processing maps.

Reheating and thixoforging of ZK60+RE alloy deformed by ECAE

The two-pass equal channel angular extrusion (ECAE) process was introduced into strain-induced melt activation (SIMA) to predeform a ZK60 alloy with rare earth (RE) addition. Microstructure evolution of ECAE-formed ZK60+RE alloy during reheating was investigated. Furthermore, tensile properties of thixoforged components were determined. The results show that the SIMA process can produce ideal microstructures, and spheroidized solid particles with little entrapped liquid can be obtained. With prolonging holding time, the size of solid particles increases and the degree of spheroidization is improved. The tensile properties of the thixoforged ZK60+RE samples are close to those of two-pass ECAE-formed samples.

Liquid Axial Mixing in Packed Tower at Elevated Pressure

Liquid phase axial mixing was measured with the tracer technique in a packed column with inner diameter of 0.15m, in which the structured packing, Mellapak 350Y, was installed. Tap water as the liquid phase flowed down through the column and stagnant gas was at elevated pressure ranging from atmospheric to 2.0MPa. The model parameters of Bo and 9 were estimated with the least square method in the time domain. As liquid flow rate was increased, the liquid axial mixing decreased. Under our experimental conditions, the effect of pressure on Bo number on single liquid phase was negligible, and eddy diffusion was believed to be the primary cause of axial mixing in liquid phase.

Effects of strain rate and temperature on microstructure and texture for AZ31 during uniaxial compression

In order to investigate the effects of strain rate and temperature on the microstructure and texture evolution during warm deformation of wrought Mg alloy,AZ31 extruded rods were cut into cylinder samples with the dimension of d8 mm×12 mm.The samples were compressed using a Gleeble 1500D thermo-mechanical simulation machine at various strain rates(0.001,0.01,0.1,1 and 5 s- 1)and various temperatures(300,350,400 and 450℃).The microstructure and texture of the compressed samples at the same strain under different deformation conditions were studied and compared by electron backscatter diffraction(EBSD)in scanning electron microscope(SEM).The results show that the size of recrystallized grains in the deformed samples generally increases with the decrease of strain rate and the increase of temperature.After 50%reduction,most basal planes are aligned perpendicular to the compression direction at relatively high strain rate(>0.01 s- 1)or low temperature(<350℃).The optimized strain rate is 0.1 s- 1for uniaxial compression at 300℃,which produces about 80%of small grains(<5μm).

Simulation Based Synthesis, Design and Optimization of Actual Pressure Swing Adsorption （PSA） Unit

The present study demonstrates the potential of the simulation based on-line synthesis, design and optimization strategy for pressure swing adsorption （PSA） processes developed in our earlier study by implementing on an actual two-bed unit. The unit is very flexible and allows process synthesis from the PSA cycle configuration point of view. The model parameters are regressed and updated using live experimental data. The on-line monitoring and controlling of the operating parameters and operating configurations are done by multi-loop processor programmable logic controller. Separation of air into nitrogen free oxygen as raffinate stream and enriched nitrogen as extract stream using 5A zeolite as adsorbent has been chosen as a specific system for implementing the strategy. The philosophy of the typical optimization and process synthesis exercise implemented on the unit is described. The results show the successful implementation of the developed strategy on the two-bed O2-PSA unit and the application of this general approach to commercial PSA processes.

Damage prediction for magnesium matrix composites formed by liquid-solid extrusion process based on finite element simulation

A damage prediction method based on FE simulation was proposed to predict the occurrence of hot shortness crocks and surface cracks in liquid-solid extrusion process. This method integrated the critical temperature criterion and Cockcroft ＆ Latham ductile damage model, which were used to predict the initiation of hot shortness cracks and surface cracks of products, respectively. A coupling simulation of deformation with heat transfer as well as ductile damage was carried out to investigate the effect of extrusion temperature and extrusion speed on the damage behavior of Csf/AZ91D composites. It is concluded that the semisolid zone moves gradually toward deformation zone with the punch descending. The amplitude of the temperature rise at the exit of die from the initial billet temperature increases with the increase of extrusion speed during steady-state extrusion at a given punch displacement. In order to prevent the surface temperature of products beyond the incipient melting temperature of composites, the critical extrusion speed is decreased with the increase of extrusion temperature, otherwise the hot shortness cracks will occur. The maximum damage values increase with increasing extrusion speed or extrusion temperature. Theoretical results obtained by the Deform^TM-2D simulation agree well with the experiments.

On the governing equations for the compressing process and its coupling with other processes

As a continuation of a recent linear analysis by Mao et al.(Acta Mech Sin,2010,26:355),in this paper we propose a general theoretical formulation for the compressing process in complex Newtonian fluid flows,which covers gas dynamics,aeroacoustics,nonlinear thermoviscous acoustics,viscous shock layer,etc.,as its special branches.The principle on which our formulation is based is the maximally natural and dynamic Helmholtz decomposition of the Navier-Stokes equation,along with the kinematic Helmholtz decomposition of the velocity field.The central results are the new dilatation equation and velocity-potential equation,which are the counterparts of vorticity transport equation and vector stream-function equation for the shearing process,respectively.Various couplings of the compressing process with shearing and thermal processes,including its physical sources,are carefully identified.While the possible applications and influences of the new formulation are yet to be explored,our preliminary discussion on the pros and cons of previous formulations pertain to acoustic analogy and that on the process splitting and coupling in highly compressible turbulence indicates that at least the formulation can serve as a new frame of reference by which one may gain some additional insight and thereby develop new approaches to the multi-process complex flow problems.