Theoretical Modeling and Surface Roughness Prediction of Microtextured Surfaces in Ultrasonic Vibration-Assisted Milling

Textured surfaces with certain micro/nano structures have been proven to possess some advanced functions,such as reducing friction,improving wear and increasing wettability.Accurate prediction of micro/nano surface textures is of great significance for the design,fabrication and application of functional textured surfaces.In this paper,based on the kinematic analysis of cutter teeth,the discretization of ultrasonic machining process,transformation method of coordinate systems and the cubic spline data interpolation,an integrated theoretical model was established to characterize the distribution and geometric features of micro textures on the surfaces machined by different types of ultrasonic vibration-assisted milling(UVAM).Based on the theoretical model,the effect of key process parameters(vibration directions,vibration dimensions,cutting parameters and vibration parameters)on tool trajectories and microtextured surface morphology in UVAM is investigated.Besides,the effect of phase difference on the elliptical shape in 2D/3D ultrasonic elliptical vibration-assisted milling(UEVAM)was analyzed.Compared to conventional numerical models,the method of the cubic spline data interpolation is applied to the simulation of microtextured surface morphology in UVAM,which is more suitable for characterizing the morphological features of microtextured surfaces than traditional methods due to the presence of numerous micro textures.The prediction of surface roughness indicates that the magnitude of ultrasonic amplitude in z-direction should be strictly limited in 1D rotary UVAM,2D and 3D UEVAM due to the unfavorable effect of axial ultrasonic vibration on the surface quality.This study can provide theoretical guidance for the design and fabrication of microtextured surfaces in UVAM.

A gas kick early detection method outside riser based on Doppler ultrasonic wave during deepwater drilling

The feasibility of gas kick early detection outside the riser was analyzed based on gas-liquid multiphase flow theory.Then an experimental platform for gas kick early detection based on Doppler ultrasonic wave was established and the propagation experiments in two-phase flow of gas-water(sucrose solutions)were conducted.The time and frequency domains of the Doppler ultrasonic wave signals during the experiments were analyzed.The results show that:(1)No matter the pump was on or off,the detected average Doppler ultrasonic signal voltage increased first and then decreased with the increase of the gas void fraction,and had a quadratic function relation with gas void fraction,so the average voltage change of the monitored signals can be used to deduce the approximate gas void fraction.The Doppler ultrasonic wave signal voltage was significantly reduced in magnitude and variation in the solution with higher viscosity,and the viscosity has stronger impact on the magnitude of signal than density.(2)When the pump was stopped,the Doppler shift increased with the increase of gas void fraction,and the two showed a nearly linear relation,so the detected amount of Doppler shift can reflect the variation of gas void fraction quantitatively.When the pump was on,the sound energy produced by frequency converter had a more significant impact on amplitude spectrum than gas void fraction,so it is impossible to determine whether gas kick occurs by frequency domain signal analysis.(3)This method is a non-contact measurement,with no contact with the drilling fluid and no disruption to the drilling operation.It can quantitatively characterize the gas void fraction according to the change of Doppler ultrasonic signal,enabling earlier detection of gas kick.

STUDY ON ULTRASONIC VIBRATION DRILLING IN CARBON FIBER REINFORCED POLYMERS

This paper researches ultrasonic vibration drilling of carbon fiber reinforced polymers composites that are hard, brittle, and have low shear strength between layers. An experiment plan has been developed to reduce the axial force. Experimental studies have been done on the influence of process parameters, tool structures on the drilling axial force. The drilling mechanism is specially investigated. Thus an effective method is presented to reduce the drilling axial force. The authors suppose that ultrasonic vibration drilling is feasible for carbon fiber reinforced polymers composites.

Ironing effect on surface integrity and fatigue behavior during ultrasonic peening drilling of Ti-6Al-4V

Imposing compressive residual stress field around a fastening hole serves as a universal method to enhance the hole fatigue strength in the aircraft assembly filed.Ultrasonic Peening Drilling(UPD)is a recently proposed hybrid hole making process,which can achieve an integration of strengthening and precision-machining with a one-shot-drilling operation.Due to the ironing effect of tool flank surface,UPD introduces large compressive residual stress filed in hole subsurface.In order to reveal the strengthening mechanism of UPD,the influence of ultrasonic vibration and tool dynamic relief angle on ironing coverage rate and its corresponding effect on surface integrity in UPD were analyzed.The experiments were conducted to verify the influence of ironing effect on surface integrity and fatigue behavior of Ti-6Al-4V hole in UPD.The results indicate that the specimen features smaller surface roughness,higher micro-hardness,plastic deformation degree and circumferential compress residual stress under higher ironing coverage rate.The fatigue life increases with the raise of ironing coverage rate,and the fatigue source site in UPD shifts from surface to subsurface comparing with that without vibration assistance.The results demonstrates that a better strengthening effect can be obtained by reasonably controlling the ironing coverage rate in UPD.

Hole surface strengthening mechanism and riveting fatigue life of CFRP/aluminum stacks in robotic rotary ultrasonic drilling

Carbon fiber reinforced plastic(CFRP)and aluminum stacks are widely used in aviation industry due to light weight and high performance.Millions of rivet holes need to be drilled on body materials,and more than 80%of fatigue cracks occur at the connection holes,so the damage and residual stress of hole surface have crucial effect on the riveting fatigue life of CFRP/aluminum stacks and the flight performance.Recently,robotic rotary ultrasonic drilling(RRUD)technology is a promising method to machine the stacks.However,the hole surface strengthening mechanism in RRUD and the service performance of the riveting joint are not verified.Thus,in this paper,the hole surface strengthening mechanism of RRUD for CFRP/aluminum stacks is investigated,a theoretical residual stress model is established,and the fatigue life experiment of riveted joints is conducted.Firstly,analysis on residual stress in RRUD is carried out with consideration of strengthening force and cutting temperature.Residual stress model is established based on the calculation of elastic stress,plastic stress and stress release.Validation experiment results show that ultrasonic vibration changes residual stress from tensile stress to compressive stress.At the same time,comparative damage analysis of CFRP hole exit and hole surface in robotic conventional drilling(RCD)and RRUD is presented.Finally,fatigue strength experiments of riveted joints are conducted for performance verification.Experimental results indicate that fatigue life of single-hole riveted joints is increased by 68%with ultrasonic vibration,and four-hole riveted joint arranged according to aerospace design standards is increased by more than 86%.

Experimental study on ultrasonic propagation in water-based bentonite slurry

Drilling fluid is a common flushing medium used in pile foundation, geological drilling and petroleum drilling. Study on ultrasonic propagation properties in drilling fluid is of vital importance, not only for developing equipments to non-contact measuring concrete casting level for bored pile, but also for developing equip- ments considering drilling fluid as signal channel. The existence of clay particles makes the ultrasonic propagation and attenuation in drilling fluid much different from pure water. In order to know the relation among ultrasound frequency, slun-y density and depth, a series of laboratory experiments about ultrasound propagation in water-based bentonite slurry were finished. Wavelet method was adopted to process the gained original waves of ultrasonic propagation in slurry, so we knew the velocity and attenuation coefficient of ultrasound propagated in different drilling fluids with different density. The first group experiments shows that with density of drilling fluid increase, ultrasonic velocity will decrease but attenuation coefficient will increase if ultrasonic frequency keep constant. The second group experiments shows that the power of ultrasound will intensify in small bore hole, the attenuation coefficient is much smaller than theoretical value.

Ultrasonic constitutive model and its application in ultrasonic vibration-assisted milling Ti3Al intermetallics

Ultrasonic vibration-assisted technology is widely utilized in the performance research and manufacturing process of metallic materials owing to its advantages of introducing highfrequency acoustic systems. However, the acoustic plasticity constitutive model and potential mechanism, involving Ti3Al intermetallic compounds, have not yet been clarified. Therefore, the Ultrasonic-K-M hybrid acoustic constitutive model of Ti3Al was established by considering the stress superposition, acoustic thermal softening, acoustic softening and acoustic residual hardening effects according to the dislocation density evolution theory and crystal plasticity theory. Meanwhile, the mechanical behavior of ultrasonic vibration-assisted tension(UVAT) and microstructure of ultrasonic vibration-assisted milling(UVAM) for Ti3Al was investigated. Dislocation density to be overcome from initial deformation to failure of Ti3Al was calculated in UVAT and was verified in UVAM. The results indicated that the Ultrasonic-K-M model showed a good agreement with the experimental data. There was an obviously softening phenomenon after introducing the ultrasonic energy field in the Ti3Al whole deformation region, and the degree of softening was positively correlated with amplitude. Furthermore, the maximum reduction ratio in yield strength of Ti3Al was16 % and the maximum reduction value in ultimate tensile strength was 206.91 MPa. The elongation rose first and then fell as amplitude enlarged, but only as the vibration was applied in the whole deformation region, the elongation was always greater than 14.58 %. In addition, The UVAM process significantly reduced the dislocation density increment to be overcome for Ti3Al material removal by 1.37 times, and promoted dislocation motion and cancellation to make twisted dislocations evolve into parallel dislocations. As the amplitude increased to 4 μm, the depth of the disturbed area of the plastic deformation layer increased by a maximum of 2.5 times.

Study of Oil-Bearing Drill Cuttings Cleaning and De-Oiling Treatment Method for Shale Gas Reservoirs

Due to its extensive use in shale gas exploration and development,oil-based drilling fluids generate large amounts of oil-bearing drill cuttings during the drilling process.The large amount of oil-bearing drill cuttings generated during the drilling process can lead to serious secondary contamination.In this study,a wetting agent FSC-6 with good hydrophobic and oleophobic properties was synthesized to construct an efficient oil removal system.For the first time,the mechanism of this system was analyzed by using the theory of adhesion function,interfacial tension and wettability.At the same time,a combined acoustic-chemical treatment process was applied to the wastewater and slag generated after the cleaning of the oil-bearing drill cuttings.The experimental results show that the application of this pollution-free technology can effectively solve the environmental pollution and resource recovery problems of oil-bearing drill cuttings.It meets the standard of drilling chips with oil content less than 2%in SY/T7422-2018“Oil-based drilling fluid drilling chips treatment system for oil and gas drilling equipment”.

超声波钻谐振控制算法设计及试验验证

为解决小天体表面引力小及温差变化大难以实现锚固的问题,提出以超声波钻作为锚固工具并采用模糊控制和恒流控制相结合的策略,实现了低钻压力和高低温环境条件下的超声波钻钻进锚固。压电驱动的超声波钻将高频电能转化为高频机械振动,驱动钻具高频破碎岩石,具有极低钻压力的显著优势,尤其适用于弱引力小天体的钻进锚固作业。针对超声波钻的驱动,对超声波钻的谐振控制算法进行研究。首先,建立超声波钻换能器的等效电路模型,在等效模型基础上研究换能器的阻抗特性、负载特性、温度特性和滞后特性。其次,根据超声波钻的工作特性研究谐振频率识别算法、谐振频率跟踪算法和恒电流控制算法,针对谐振频率跟踪算法研究了基于递归最小二乘估计的频率跟踪算法和基于模糊控制的频率跟踪算法,并对实际控制效果进行对比分析。最后,进行常温常压和高低温环境下钻进试验,试验结果表明,在不同温度环境和不同的钻进对象条件下,所设计的谐振控制算法能够实现对超声波钻的稳定驱动。研究结果表明,所提出的模糊控制和恒流控制能够有效的在低钻压力以及不同温度下实现有效钻进。

车用CFRP材料超声振动钻孔工艺优化及质量分析

为了提高难加工增强体碳纤维复合材料(CFRP)的钻孔加工性能,在螺旋铣加基础上增加了超声振动辅助。设计了不同工艺条件对CFRP超声振动螺旋铣孔实施测试,对比了各条件下CFRP超声辅助螺旋铣孔的切削力差异,测试了孔加工质量状态。研究结果表明:采用超声振动螺旋铣方法处理可以避免引起分层现象,保证同一部位纤维与树脂基体相互形成更紧密结构。综合工艺参数对切削力和切削温度的影响,确定一下参数范围是比较优秀的:主轴转速4000r/min,螺距0.15mm,切向进给量0.04mm。CFRP分层状态受到切削刃锋利性以及材料去除率的综合影响,调整工艺参数能够有效的控制材料去除量,对切削力和切削温度起到很好的调节效果,进而减小分层损伤。

碳纤维复合材料纵扭超声振动辅助钻孔仿真研究

针对碳纤维复合材料(CFRP)钻孔易发生缺陷、孔的质量难保证和效率低等问题,基于Hashin准则和PUCK准则构建碳纤维复合材料本构模型子程序,建立CFRP纵扭超声振动辅助钻孔三维实体有限元模型。与普通钻孔过程的轴向力变化情况进行对比,分析主轴转速、进给速度、频率、振幅、纤维铺层角度和钻头顶角对轴向力的影响。结果表明:轴向力随进给速度、频率和钻头顶角的增大而增大,随主轴转速增大而减小,随振幅增大先减小后增大,随纤维铺层角度增大先增大后减小。

一种月球熔岩管钻进的超声波钻探器

提出一种采用多点驱动旋转的螺旋槽圆锥复合型变幅杆结构,并研制了适用于熔岩管内壁钻进的高性能超声波钻探器;为预测超声波钻探器响应特性,利用等效阻抗网络模型对超声波钻探器进行了建模与分析。通过低重力多角度模拟钻进试验与数据分析,验证了该钻探器在熔岩管复杂地况应用中的可能性。结果表明,钻杆直径为3 mm、钻压力为10 N时,钻进速度随开孔角度的增加而增加,垂直钻进时钻探器最大空载回转速度为506 rad/min,钻进速度为6.4 mm/min,钻进时回转转速为259 rad/min。

随钻超声阵列测井仪激励电路设计

通过随钻超声阵列测井仪获得的井壁反射特性可实时跟踪井身剖面,获取裂缝地层信息。随钻超声阵列测井仪激励电路的稳定性直接决定声波数据的质量。采用双极性脉冲激励的方式设计了一种随钻超声阵列测井仪激励电路,介绍了该电路的软、硬件设计,并进行了电路性能测试和实际测井试验。试验结果表明,该电路激励能量强,波形调节灵活,能够有效压制后续拖尾信号;同时测井信号清晰稳定,能够有效反映地层性质,为随钻阵列超声测井提供了技术参考。

CFRP/Ti叠层超声辅助变参数钻削界面温度试验研究

碳纤维复合材料(CFRP)与金属合金的叠层结构材料常应用于航空航天等领域的制造过程中,其中CFRP与钛合金(Ti)的叠层材料的应用较为广泛。在CFRP/Ti叠层材料的钻孔工艺中,由钻削热引起的在两材料相接触的界面处出现的加工缺陷较为显著,故对影响此类材料钻孔加工过程中的界面温度的主要因素进行了研究。设计了借助热电偶测定CFRP/Ti叠层材料钻削过程中界面温度的试验,在试验中改变了加工参数及超声辅助参数。获得了加工参数对界面温度的影响规律,同时确定了超声辅助加工对界面温度的改变规律。

基于BLBL模型的超声波在钻井液中的传播衰减规律

通过BLBL声波衰减模型,并利用MATLAB进行数值模拟,探究了超声波在不同性质钻井液中的传播衰减规律。研究结果表明,超声波频率的增加会加剧钻井液中超声波的衰减,其衰减呈现先下降后上升的趋势,且频率越高,上升速度越快;同时,钻井液黏度、温度、体积浓度的增加均导致超声波衰减程度增加;运用正交试验研究后发现,4种因素对超声波衰减的影响程度排序为:钻井液黏度>钻井液温度>超声波频率>钻井液体积浓度。该研究结果为超声波在钻井液测量中的应用提供了理论支持和指导。

济南某石灰岩区高速桥桩底沉渣缺陷处理研究

灌注桩的沉渣问题一直是业内关注和研究的重点之一,基本可分为沉渣的成因、沉渣厚度的测量、清孔除渣、后注浆、沉渣缺陷的检测、沉渣缺陷桩的处理这6个研究内容。沉渣缺陷桩的处理,可根据沉渣的严重程度归纳为5种方法。以济南平阴县石灰岩丘陵区某高速桥梁大直径嵌岩灌注桩项目为例,分析了岩溶及其充填物、风化砂岩夹层、泥质条带灰岩层等不良地层条件;选取某棵沉渣缺陷桩,分析了其声波透射法检测结果;重点论述沉渣厚度和分布范围;采用钻杆高压水旋喷、两孔连通交替冲洗清渣;用孔内电视确认清渣效果;最后采用压力注浆,向清渣后形成的空洞内注入P.O 52.5纯水泥浆,成功处理了沉渣缺陷。相关工艺可为相关工程提供参考。

浅谈探伤工艺在钻井中的应用

钻井行业是高风险的行业,需要采取一定的措施来降低风险,目前探伤主要采用超声波、涡轮及磁粉探伤等方式进行。本文通过对钻井中钻具进行探伤处理,从源头上尽可能降低其风险,减少矿井事故的发生。

多种检测方法在基桩缺陷检测中的应用及缺陷处治技术

以潍坊至青岛高速公路及连接线工程中的某桥梁基桩为背景,分别介绍声波透射法、钻孔取芯法和孔内成像法在基桩检测上的具体应用,对缺陷原因进行分析。研究发现,桩底缺陷是由于未考虑基桩超钻部分,导致导管悬空高度过大,进而导致桩底混凝土严重离析夹泥。同时,介绍了水磨钻在桩底缺陷处理的应用,并验证该方法的有效性,对其他类似项目基桩缺陷的处理具有指导意义。

口腔自体骨取骨术式对比分析

在种植修复中,为了将种植体植入在理想位置通常采用骨增量手术的方式解决牙槽骨骨量不足的问题。因自体骨具有骨引导性和骨诱导性,具有增强骨增量手术临床成骨效果的作用,所以其地位仍是骨替代材料无法取代的。目前获取自体骨材料的方式繁多,包括手用器械取骨、环钻取骨术和超声骨刀取骨术等。激光技术及低速钻等术式的兴起也为临床医生提供了更多选择。本文对“取骨术式”、“骨移植”等关键词进行检索,筛选相关文献,对各类取骨术式特点进行总结,并从各类术式的临床应用及对成骨能力的影响等多方面进行综合评价,以期为临床工作中选择取骨方式提供参考。

风电机组基础缺陷检测手段分析研究

[目的]随着我国陆上风机装机规模越来越大,风电机组基础质量缺陷问题屡见不鲜,直接影响到机组安全运行与设备安全。风电机组基础具有体积大、构造复杂等特点,常规检测手段在大尺寸、钢筋密集情况下适用性还需对比分析,研究风电机组缺陷检测手段具有重大的实际工程意义。[方法]以某风电加固项目为对象,采用地质雷达法、超声横波法、钻孔检测法,根据各种检测手段的检测原理及成果,分析了各检测手段的适用性和检测精度。[结果]分析结果显示:地质雷达法随着发射频率越高,缺陷定位精度越高,有效检测深度越低;超声横波法仅适用于混凝土浅层检测,检测精度较高;钻孔检测法具有极好的可视性,结果直观、准确。[结论]在风电机组基础缺陷检测中,地质雷达法、超声横波法适用于浅层混凝土缺陷检测,使用高频率波谱检测可获得较好的检测精度;钻孔检测法可用于混凝土基础浅层和深层缺陷检测,检测效果直观。