Influences of tool plunge speed and tool plunge depth on friction spot joining of AA5454-O aluminum alloy plates with different thicknesses

AA5454-O aluminum alloy plates with the thicknesses of 1.4 and 1.0 mm were friction-spot-joined (FSJed).The plunge speed of the joining tool was changed in a range of 100 500 mm/min under a constant rotation speed of 500 r/min.The plunge depth was ranged from 1.6 mm to 2.2 mm.The tool plunge speed did not make a remarkable effect on the surface appearance and macro-structure of the FSJed zone.The average hardness of the FSJed zone was greater than or equal to that of the base metal.However,there was no remarkable tendency in the average hardness change of the FSJed zone in spite of the variation in the tool plunge speed and tool plunge depth.The increase of the tool plunge depth resulted in the increase of the tensile shear load.However,the change of the tool plunge speed did not lead to the remarkable variation in the tensile shear load of the FSJed plates.It was noteworthy that the FSJed plate exhibited the highest tensile shear load of about 4.0 kN.

Effect of tool plunge depth on reinforcement particles distribution in surface composite fabrication via friction stir processing

Aluminium matrix surface composites are gaining alluring role especially in aerospace, defence, and marine industries. Friction stir processing(FSP) is a promising novel solid state technique for surface composites fabrication. In this study, AA6061/SiC surface composites were fabricated and the effect of tool plunge depth on pattern of reinforcement particles dispersion in metal matrix was investigated. Six varying tool plunge depths were chosen at constant levels of shoulder diameter and tool tilt angle to observe the exclusive effect of plunge variation. Process parameters chosen for the experimentation are speed of rotation, travel speed and tool tilt angle which were taken as 1400 rpm, 40 mm/min, and 2.5 °respectively. Macro and the microstructural study were performed using stereo zoom and optical microscope respectively. Results reflected that lower plunge depth levels lead to insufficient heat generation and cavity formation towards the stir zone center. On the other hand, higher levels of plunge depth result in ejection of reinforcement particles and even sticking of material to tool shoulder. Thus, an optimal plunge depth is needed in developing defect free surface composites.

Effect of tool plunge depth on joint formation and mechanical performance of friction stir forming joints made between AA 5052-H32 and AA 6061-T6 sheet metals

The potential of friction stir forming for joining dissimilar grades of aluminum alloys namely,AA 5052-H32 and AA 6061-T6,was investigated.Study on the effect of tool plunge depth revealed that,lap shear load of 7.16 kN and cross-tensile load of 3.51 kN,recorded at medium tool plunge depth range from 0.5 to 0.7 mm,measured using a universal testing machine,were much larger than those of friction stir welded and friction stir spot welded joints fabricated on the same materials.Joint macrostructure observed with optical microscope revealed that joints were strengthened either by mechanical pin interlocking or by metallurgical bonding.The effect of tool plunge depth on the stir zone formation and the influence of frictional heat flux on the lower sheet were revealed through the microhardness measurement using Vickers hardness tester.Morphological studies revealed that tool plunge depth has a significant influence on the pin formation and the geometric features,generated in these joints.Occurrence of various failure modes such as pin pull-out,pin shear,partial bond delamination,and tear-off,were governed by the formation of critical weak zones at various tool plunge depths.

Influence of tool plunge depth and welding distance on friction stir lap welding of AA5454-O aluminum alloy plates with different thicknesses

AA5454-O aluminum alloy plates with thicknesses of 1.4 and 1.0 mm were friction-stir-lap-welded (FSLWed).The influences of the tool plunge depth and welding distance on surface appearance,macrostructure and mechanical properties of the FSLWed plates were experimentally investigated.The tensile shear load of the FSLWed plates was compared with that of the adhesive-bonded plates.Defect-free FSLWed zones were successfully obtained in all the tool plunge depths and the welding distances.The FSLWed zones exhibited the relatively smooth surface morphologies.Under all the FSLWed conditions,the FSLWed zone exhibited higher average hardness than the base metal.In addition,the upper plate exhibited a higher average hardness than the lower plate,although there was no special tendency in spite of the change in the tool plunge depth and the welding distance.The maximum tensile shear load of the FSLWed plates was much higher than that of the adhesive-bonded aluminum alloy plate.Especially,under the FSLW condition of the plunge depth of 1.8 mm and the welding distance of 40 mm,the tensile shear load of the FSLWed plate reached a level about 41% greater than that of the adhesive-bonded aluminum alloy plate.In addition,the maximum tensile shear load of the FSLWed plate was increased with the increase of the welding distance.

Design of Plunge Shaving Cutters for Finishing internal Gears

The mathematical model of tooth flanks of a plunge shaving cutter for finishing internal gears is established, and the correction to tooth profile and tooth curve of the cutter is proposed. Moreover, the tooth profile error and the convex tooth curve of internal gears, when the cutter is not modified, are offered, and then a simple, convenient, reliable and practical method to design and finish convex teeth of internal gears is presented.

Mathematical Model and Simulation of Cutting Force in Plunge Milling Process

Plunge milling is a high-speed machining way and the cutter is fed in the direction of the Z axis, which is used to remove excess material rapidly in roughing operations. In this paper, the orthogonal cutting theory was used to study the plunge milling of LY12 alloy. A mathematic model for cutting force in plunge milling was established, and the milling process was simulated by using Matlab. It is found that the single tooth cutting experimental result is unstable because of unsymmetrical single tooth in the milling process, which leads to the difference between the simulation and experimental results. The trend of multiple teeth cutting experimental result is similar to that of the simulation result; however, the peak values in the experimental result are different, which is caused by the error of cutter’s position, and the error of peak value is less than 10%.

Response characteristics of plunge pool slabs of Xiaxiluodu Hydropower deformation conditions

The key problem of the energy dissipation scheme of the arch dam body flood discharge and plunge pool below the dam is the stability problem of the plunge pool slab.As the protection structure of the underwater bed,the plunge pool slab bears the continuous impact of high-speed water flow.The hourly average dynamic water pressure on the slab is one of the main loads directly affecting the stability of the slab and is the main factor causing its erosion destruction.After the impoundment of the Xiluodu Hydropower Station,the measuring line of valley width in the plunge pool area has been continuously shrinking.By 2020,the cumulative shrinking value is about 80 mm.In light of the general background condition of valley shrinkage,daily inspection,annual detailed inspection,underwater inspection and drainage inspection of the plunge pool found that the plunge pool has experienced different degrees of damage,which greatly influences the long-term safety stability of the plunge pool.In this paper,the prototype observation data of flood discharge is used as the input load of pulsatingpressure,and the stress and displacement distribution of the plunge pool structure under the vibration load of flood discharge is analyzed under the condition that the stress and strain state of the plunge pool is changed under the influence of valley displacement.The results show that the stress,strain,and displacement distribution of the plunge pool are mainly caused by valley deformation,the vibration caused by flood discharge is little in influence,and the impact effect of deep hole flood discharge tongue on the plunge pool slab is weak.

A new type of plunge pool―Multi-horizontal submerged jets

Based on the understanding of the mechanism of energy dissipation,a new type of plunge pool is presented with the advantages of high rate of energy dissipation,low impact pressure,and small close-to-bed velocity on the soleplate of the plunge pool.The first advantage owes to enlarged shearing energy dissipation areas in the plunge pool,while the other two are caused by the jet that enters in a nearly horizontal level to keep the soleplate from being scoured directly.All of the above arrangements make this new type of energy dissipator distinct from the underflow energy dissipation.Through experiments on the physical model,the authors found that the water flow maintained stable and submerged in horizontal direction when the flow was narrow in horizontal but thick in vertical direction.However,the wide flat nappe was ready to submerge or float as the downstream water level rised or dropped.The entire flow fields of multi-horizontal submerged jets into plunge pool were also numerically simulated.The numerical results of water surface curve,close-to-bed velocity and floor pressure agree well with the experimental data.The flow pattern in the plunge pool was analyzed after combining the laboratory data and numerical simulation.

Wing load investigation of the plunge-diving locomotion of a gannet Morus inspired submersible aircraft

In this paper,we studied the wing root pivot joint’s radial load of a submersible airplane which imitates the locomotion of gannet’s Morus plunge-diving,by implementing a test device name Mimic-Gannet.The housing of the device was designed by mimicking the morphology of a living gannet,and the folding wings were realized by the mechanism of variable swept back wing.Then,the radial loads of the wing root were obtained under the conditions of different dropping heights,different sweptback angles and different water-entry inclination angles(i.e.,the angle between the longitudinal body axis and the water surface),and the relationships between the peak radial load and the above three parameters were analyzed and discussed respectively.In the studied areas,the minimum peak radial load of the pivot joint is 50.93 N,while the maximum reaches up to1135.00 N.The largest peak load would be generated for the situation of vertical water entry and zero wing sweptback angle.And it is of great significance to choose the three parameters properly to reduce the pivot joint’s radial load,i.e.,larger wing sweptback angle,smaller dropping height and water-entry inclination angle.It is also concluded that the peak radial load on the wing root is closely linear with the water-entry dropping height and the wing sweptback angle with a significant correlation.Eventually,the relationship between the wing load and the dropping height,water-entry inclination angle or wing sweptback angle,could be used to calculate the wing load about plunge-diving of a submersible aircraft,and the conclusions reveal the wing load characteristic of the gannet’s plunge process for the biologists.

Safety evaluation and the static-dynamic coupling analysis of counter-arched slab in plunge pool

The stability of plunge pool slab of drainage structure is crucial to energy dissipation,but the working conditions of counter-arched slab are very complex and its stress procedure is considerably nonlinear and coupling.Therefore,a nonlinear static and dynamic coupling method to analyze the counter-arched slab configuration is put forward,which can reflect the coupling of dynamic loads,slab,anchor bars,groundwork and abutment as well as the dynamic procedure of instability.Various nonlinear factors and static-dynamic coupling are taken into consideration,and the working conditions,stress mechanism,dynamic instability procedure and influential instability factors are revealed.The proposed method thus provides a comprehensive safety evaluation method of plunge pool,which further pro-vides an important theoretical basis for engineering design of counter-arched slab in plunge pool.

EXPERIMENTAL RESEARCH ON CHARACTERISTICS OF HYDRODYNAMIC PRESSURE SPREADING IN THE BASE GAP OF ARCH INVERTED PLUNGE POOL

A detailed experimental research on characteristics of the hydrodynamicpressure spreading in the base gap of the arch inverted plunge pool was carried out. The features ofthe distributon of its ampitudes and spectral density and its characteristics in time domain fortwo conditions, i. e. , (1) a through gap and (2) a blind gap were given. The influence of the dampat the joint opening upon the hydrodynamic pressure inside the gap was also investigated.Accordingly, the stabilization mechanism of the arch invert plunge pool was worked out.

NUMERICAL SIMULATION OF 3-D TURBULENT FLOWS OF PLUNGE POOL AND ENERGY DISSIPATION ANALYSIS

A 3-D numerical model for simulating the complicated turbulent flows was developed and the code was made. A numerical calculation of the plunge pool of Laxiwa project in China was carried on. Those 3-D distributions of velocity,pressure on bottom wall,turbulence kinetic energy and turbulence energy dissipation rate are revealed in detail and the detailed flow patterns of plunge pool were shown. By studying on the characteristics of turbulent diffusion and energy dissipation,the calculated results show that the major turbulence and energy dissipation are taken place near the axis of water jet. The calculated results also indicated that the calculated maximum impact pressures on the bottom wall of the plunge pool have a good agreement with those obtained by physical hydraulic model test.

Hydrogen Ion Implantation Induced Cutting Behavior Variation in Plunge Cutting of the Monocrystalline Silicon

In this study,surface modification of monocrystalline silicon with two doses of hydrogen ion implantation and the plunge cutting process were conducted to explore the influence of hydrogen ions on the cutting behavior of silicon.The results show that ion implantation is capable of deteriorating or improving the machinability of silicon,depending on the implantation dose.More cleavages and a reduction of critical depth of cut(CDoC)were observed for the silicon with a low implantation dose in the cutting direction of<100>in comparison to bare silicon,while no cleavage and an increase of CDoC were achieved after implantation with a high dose in the same cutting direction.Besides,the ductile cutting and thrust forces of the silicon with the low dose are larger than the bare silicon,but the forces are significantly reduced for the silicon after the high dose of implantation.The variation of the cutting forces is due to the different required stresses to overcome ductile and fracture deformation of silicon.

Effect of Submillimeter Variation in Plunge Depth on Microstructure and Mechanical Properties of FSLW 2A12 Aluminum Alloy Joints

Friction stir lap welding was conducted on 2 mm + 2 mm sheets of aluminum alloy 2 A12-T4. The plunge depth(PLD) was designed as 2.45–2.58 mm, which was varied in submillimeters as 2.45, 2.50, 2.53, 2.55, and 2.58 mm, and the axial force was recorded in the welding process. The results show that the PLD fluctuation in submillimeters causes significant variation in the axial force and affects the voids(i.e., Void I and Void II), hook, and effective sheet thickness(EST), among which Void I is the main factor that affects the EST. The fracture load–PLD function in the tensile shear test of the joints follows the rule of the EST–PLD function. An optimized PLD is approximately 2.55 mm, at which the EST reaches 1.71 mm, corresponding to a peak fracture load of 11.03 kN. Thus, a PLD of 2.55 mm is suggested with a tolerance of 0.02 mm, corresponding to a fracture load of 9.6–11.0 kN, i.e., within a fluctuation of 12%.

Experimental investigation of submerged impinging jets in a plunge pool downstream of large dams

Submerged impinging jets in a plunge pool downstream of large dams are experimentally investigated in details. By use of the hot\|film anemometer, the velocity field in the plunge pool produced by middle orifices of 1∶400 scale Xiluodu spillway model is measured. The diffusive characteristics and energy dissipation mechanism of the submerged impinging jet in the plunge pool are analyzed.

Effects of plunge pool configuration on downstream passage survival of juvenile blueback herring

Anadromous alosines are widespread throughout the Northern Hemisphere.Juveniles of this clade are notoriously fragile animals that are at high risk of injury and death associated with passage at hydroelectric facilities.Although turbine mortality is a common concern,conditions encountered when bypassed around these routes may also be hazardous.Downstream bypass structures typically discharge into plunge pools,which are highly turbulent and may cause mechanical injury.We subjected live,actively migrating juvenile blueback herring to a suite of realistic plunge pool conditions(3 m drop,pool depth of 60-180 cm,and discharge of 0.28-1.70 m^(3)/s)and monitored them for≥96 h.Survival was generally higher than expected(>80%in all cases).However,both plunge pool volume and total discharge affected survival with elevated discharge and shallow conditions associated with increased mortality.Mortality was often delayed:rates remained elevated throughout the monitoring period,indicating that survival studies based on shorter periods underestimate total mortality.

Girl, 6, Survives Four-Story Plunge

【选注者言:这是一则来自Calgary(卡尔加里,加拿大西南部城市)的消息,一个6岁的女孩从四楼,即12米的高度坠地,居然能保全性命,而仅有轻伤！文中的一个介词given,值得我们记学:Given the height that she fell,I think she’sextremely fortunate not to be more seriously injured。句首的介词Given的含义是“考虑到”。另如:Given ther imexperience,they’ve done a good job。汉译:考虑到他们缺乏经验,这工作他们做得不错。】

Numerical investigation of transonic flow over deformable airfoil with plunging motion

In this article, the transonic inviscid flow over a deformable airfoil with plunging motion is studied numerically. A finite volume method based on the Roe scheme developed in a generalized coordinate is used along with an arbitrary Lagrangian-Eulerian method and a dynamic mesh algorithm to track the instantaneous position of the airfoil. The effects of different governing parameters such as the phase angle, the deformation amplitude, the initial angle of attack, the flapping frequency, and the Mach number on the unsteady flow field and aerodynamic coefficients are investigated in detail. The results show that maneuverability of the airfoil under various flow conditions is improved by the deformation. In addition, as the oscillation frequency of the airfoil increases, its aerodynamic performance is significantly improved.

Scour process caused by multiple subvertical non-crossing jets

The scour process induced by plunging jets is an important topic for hydraulic engineers. In recent decades, several researchers have developed new strategies and methodologies to control the scour morphology, including different jet arrangements and structures located in the stilling basin. It has been found that multiple jets can cause less scouring than single plunging jets. Based on this evidence, this study aimed to investigate the equilibrium morphology caused by multiple non-crossing jets. A dedicated laboratory model was built and experimental tests were carried out under different combinations of jet inclination angles, by varying the tailwater level and the virtual crossing point location, which was set below the original channel bed level. It was experimentally shown that the equilibrium scour morphology depends on the jet discharge, the differences in non-crossing jet inclination angles, the downstream water level, and the distance of the virtual crossing point from the original channel bed level. In particular, the last parameter was found to be one of the most influential parameters, because of the resulting flow patterns inside the water body. Furthermore, the analysis of experimental evidence allowed for a complete and detailed classification of the scour hole typologies. Three different scour typologies were distinguished and classified. Finally, based on previous studies, two novel re-lationships have been proposed to predict both the maximum scour depth and length within a large range of hydraulic and geometric parameters.

Indicating the Role of Geological Conditions in Shaping the Hareer Anticline, Iraqi Kurdistan Region

The Hareer anticline is within the High Folded Zone, facing southwards towards the Low Folded Zone. Both zones are part of the Outer Platform of the Arabian Plate. Moreover, both zones are part of the Zagros Fold-Thrust Belt located within the Zagros Foreland Basin. Although the Hareer anticline is a double plunging anticline oriented in a NW-SE trend, both plunges are abnormal. The northwestern plunge is gradually passing to the southwestern limb of the Pirat anticline;although there is a very shallow syncline in between them, giving a right-hand en-echelon form to the plunge. Whereas, the southeastern plunge disappears between the Kamosk anticline located southeast wards and the Shakrook anticline is located southwards. Both the Hareer and the Kamosk anticlines are thrusted over the Shakrook anticline by means of two long thrust faults that run almost parallel to the Hareer anticline. It is clearly observed that the anticline is growing northwest wards;according to the recognized geomorphological and structural features. High-Quality satellite images were interpreted to elucidate the abnormal form of the Hareer anticline. The interpreted data and different types of geomorphological features including the estimation of the rate of stream incision were checked in the field.