Research on the Casting-forging Precision Forming Process of Alternator Poles

The casting-forging combined technique and the closed die forging without flash-less are both new developed material working methods. The former can not only decrease forming operations of forgings, but also increase the material utilization ratio. Therefore, it is applied to produce more complex forgings. The latter is required for forging precise parts without burrs. The alternator pole is a complex forging, which was usually produced by hot forging, upsetting-extrusion or upsetting-extrusion and bending processes. During these processes, not only the forming force is higher, but the material of burrs accounts for 30 percent or so of total required material. And burrs are difficult to remove in the sequential machining process. In accordance with defects exiting in current manufacturing of alternator poles by upsetting-extruding process, such as more material demand, higher forming force and difficulty of next machining, a casting-forging precision process of alternator poles was developed and investigated in this paper. In the process, the pole was formed by two operations. One is the pre-forming operation by casting. The other is the final forming operation by the closed precision forging process. This can not only shorten processes, decrease material and power demand, but also increase precision of forgings. First, the casting blocker was designed considering the casting process and the forging ratio and the mode of deformation. Then the die structure for closed precision forging was designed, and the closing device for forging dies with spring assemblies in order to provide the necessary closing force was also designed. Finally the forming processes was investigated by test and numerical simulation method to optimum process parameters and die structure design parameters. The result can provide basis for applying the process to manufacture poles in practice.

Spurious-mode vibrations caused by alternating current poling and their solution process for Pb(Mg_(1/3)Nb_(2/3))O_(3)-PbTiO_(3) single crystals

The effects of alternating current poling(ACP)at 80℃on electrical properties of[001]-oriented 0.72 Pb(Mg_(1/3)Nb_(2/3))O_(3)-0.28PbTiO_(3)(PMN-28PT)single crystals(SCs)have been investigated.The square-wave ACP SCs poled at high voltage(HV,5 kV_(rms)/cm)occasionally showed large fluctuations and low opposite values of piezoelectric coefficient(d_(33)=±1370 pC/N)in one plate.This revealed spuriousmode vibrations(SMV)of impedance spectrum.However,after depolarizing and repolarizing the sample with a sine-wave ACP at low voltage(LV,3.5 kV_(rms)/cm),the d_(33) enhanced to be 1720 pC/N(+26%)and did not exhibit large fluctuation or opposite values in one plate any more.The impedance spectrum became clean and the abnormal SMV disappeared.We proposed four possible mechanisms of the SMV,and speculate that the main cause maybe by macro-scale sub-domain structure and/or phase change in the main domain structure and/or phase in the SC plate due to the specific poling conditions not eternal mechanical damage of PMN-PT SCs.This study will be useful to realize a high d_(33) and improve other properties of PMN-PT ACP SC ultrasonic transducers without any SMV for high-frequency medical imaging equipment.

High temperature and low voltage AC poling for 0.24Pb(In_(1/2)Nb_(1/2))O_(3)- 0.46Pb(Mg_(1/3)Nb_(2/3))O_(3)-0.30PbTiO_(3) piezoelectric single crystals manufactured by continuous-feeding Bridgman method

Alternating current poling(ACP)in air by changing poling temperature(70e130℃)and voltages(2e6 kVrms/cm)on pseudo-ternary 0.24 Pb(In_(1/2)Nb_(1/2))O_(3)-0.46 Pb(Mg1/3Nb_(2/3))O3-0.30PbTiO_(3)(PIMN-0.30PT)single crystals(SCs)manufactured by continuous-feeding Bridgman(CF BM)method was investigated.Free dielectric permittivity(εT 33/ε0)and piezoelectric constant(d33)were improved to be 7000 and 2340 pC/N,which were 29%higher than those of direct current poling(DCP)at 90℃ with 4 kV/cm(εT 33/ε0=5440,d_(33)=1810 pC/N).However,phase change temperature(Tpc)decreased from 94℃ to 78℃ as opposite results reported by other groups.We demonstrated that the high temperature(HT)ACP improved piezoelectric performance of CF BM SCs,however,the Tpc were different from other crystal growth method.The well-designed ACP process was a promising method for mass production not only to enhance the electrical properties for the pseudo-ternary SCs but also reduce the risk of breakdown and realizes organic solvent-free poling process.

High piezoelectricity after field cooling AC poling in temperature stable ternary single crystals manufactured by continuous-feeding Bridgman method

After field cooling(FC)alternating current poling(ACP),we investigated the dielectric and piezoelectric properties of[001]_(pc)-oriented 0.24Pb(In_(1/2)Nb_(1/2))O_(3)(PIN)-0.46Pb(Mg_(1/3)Nb_(2/3))O_(3)(PMN)-0.30PbTiO3(PT)(PIMN-0.30PT)single crystals(SCs),which were manufactured by continuous-feeding Bridgman(CF BM)within morphotropic phase boundary(MPB)region.By ACP with 4 kVrms/cm from 100 to 70℃,the PIMN-0.30PT SC attained high dielectric permittivity of 8330,piezoelectric coefficient(d_(33))of 2750 pC/N,bar mode electromechanical coupling factorκ_(33)of 0.96 with higher phase change temperature(T_(pc))of 103℃,and high Curie temperature(7c)of 180℃.These values are the highest ever reported as PIMN-xPT SC system with Tpc>100℃.The enhancement of these properties is attributed to the induced low symmetry multi-phase supported by phase analysis.This work indicates that FC ACP is a smart and promising method to enhance piezoelectric properties of relaxor-PT ferroelectric SCs including PIMN-xPT,and provides a route to a wide range of piezoelectric device applications.