Surface Integrity of Inconel 738LC Parts Manufactured by Selective Laser Melting Followed by High-speed Milling

This study is concerned with the surface integrity of Inconel 738LC parts manufactured by selective laser melting(SLM)followed by high-speed milling(HSM).In the investigation process of surface integrity,the study employs ultradepth three-dimensional microscopy,laser scanning confocal microscopy,scanning electron microscopy,electron backscatter diffractometry,and energy dispersive spectroscopy to characterize the evolution of material microstructure,work hardening,residual stress coupling,and anisotropic effect of the building direction on surface integrity of the samples.The results show that SLM/HSM hybrid manufacturing can be an effective method to obtain better surface quality with a thinner machining metamorphic layer.High-speed machining is adopted to reduce cutting force and suppress machining heat,which is an effective way to produce better surface mechanical properties during the SLM/HSM hybrid manufacturing process.In general,high-speed milling of the SLM-built Inconel 738LC samples offers better surface integrity,compared to simplex additive manufacturing or casting.

Surface Topography and Roughness of High-speed Milled AlMn1Cu

The aluminum alloy AlMn1Cu has been broadly applied for functional parts production because of its good properties. But few researches about the machining mechanism and the surface roughness were reported. The high-speed milling experiments are carried out in order to improve the machining quality and reveal the machining mechanism. The typical topography features of machined surface are observed by scan electron microscope（SEM）. The results show that the milled surface topography is mainly characterized by the plastic shearing deformation surface and material piling zone. The material flows plastically along the end cutting edge of the flat-end milling tool and meanwhile is extruded by the end cutting edge, resulting in that materials partly adhere to the machined surface and form the material piling zone. As the depth of cut and the feed per tooth increase, the plastic flow of materials is strengthened and the machined surface becomes rougher. However, as the cutting speed increases, the plastic flow of materials is weakened and the milled surface becomes smoother. The cutting parameters （e.g. cutting speed, feed per tooth and depth of cut） influencing the surface roughness are analyzed. It can be concluded that the roughness of the machined surface formed by the end cutting edge is less than that by the cylindrical cutting edge when a cylindrical flat-end mill tool is used for milling. The proposed research provides the typical topography features of machined surface of the anti-rust aluminum alloy AlMn1Cu in high speed milling.

Extraction Fuzzy Linguistic Rules from Neural Networks for Maximizing Tool Life in High-speed Milling Process

In metal cutting industry it is a common practice to search for optimal combination of cutting parameters in order to maximize the tool life for a fixed minimum value of material removal rate（MRR）. After the advent of high-speed milling（HSM） pro cess, lots of experimental and theoretical researches have been done for this purpose which mainly emphasized on the optimization of the cutting parameters. It is highly beneficial to convert raw data into a comprehensive knowledge-based expert system using fuzzy logic as the reasoning mechanism. In this paper an attempt has been presented for the extraction of the rules from fuzzy neural network（FNN） so as to have the most effective knowledge-base for given set of data. Experiments were conducted to determine the best values of cutting speeds that can maximize tool life for different combinations of input parameters. A fuzzy neural network was constructed based on the fuzzification of input parameters and the cutting speed. After training process, raw rule sets were extracted and a rule pruning approach was proposed to obtain concise linguistic rules. The estimation process with fuzzy inference showed that the optimized combination of fuzzy rules provided the estimation error of only 6.34 m/min as compared to 314 m/min of that of randomized combination of rule s.

Influence of High-Speed Milling Process on Mechanical and Microstructural Properties of Ultrafine Grained Profiles Produced by Linear Flow Splitting

The effects of milling parameters on the surface quality,microstructures and mechanical properties of machined parts with ultrafine grained(UFG)gradient microstructures are investigated.The effects of the cutting speed,feed per tooth,cutting tool geometry and cooling strategy are demonstrated.It has been found that the surface quality of machined grooves can be improved by increasing the cutting speed.However,cryogenic cooling with CO_2 exhibits no significant improvement of surface quality.Microstructure and hardness investigations revealed similar microstructure and hardness variations near the machined groove walls for both utilized tool geometries.Therefore,cryogenic cooling can decrease more far-ranging hardness reductions due to high process temperatures,especially in the UFG regions of the machined parts,whilst it cannot prevent the drop in hardness directly at the groove walls.

Investigation of Surface Roughness in High-Speed Milling of Aeronautical Aluminum Alloy

An approach is presented to optimize the surface roughness in high-speed finish milling of 7050- T7451 aeronautical aluminum alloy. In view of this, the multi-linear regression model for surface roughness has been developed in terms of slenderness ratio, cutting speed, radial depth-of-cut and feed per tooth by means of orthogonal experimental design. Variance analyses were applied to check the adequacy of the predictive model and the significances of the independent input parameters. Response contours of surface roughness were generated by using response surface methodology （RSM）. From these contours, it was possible to select an optimum combination of cutting parameters that improves machining efficiency without increasing the surface roughness.

Radial Grip Rigidity of the Matching of Lengthened Shrink-fit Holder and Cutter in High-speed Milling

Though the lengthened shrink-fit holder (LSFH) is widely applied in high speed milling of the parts characterized by deep cavities at present, its design and selection mainly depends on the experience and lacks a correct theoretical guidance. In this paper, attention is focus on the radial grip rigidity of the matching of LSFH and cutter in high speed milling. Based on the experiment modal analysis (EMA) technique, an accurate finite element model of the matching of LSFH and cutter is established firstly. Subsequently, the influence of different interference, grip length and spindle speed on the grip rigidity of LSFH are analyzed. The analysis results show that there is a reasonable interference and grip length between the LSFH and cutter so that to have a steepless grip and have a good radial grip rigidity and at the same time to avoid the strength of LSFH to exceed it’s yield limit which will reduce the precision and service life of LSFH, besides when spindle speed reach a extension the weakening influence of the centrifugal force on the radial grip rigidity of the matching of LSFH and cutter should been taken into account. Finally, the finite element analysis results are verified based on the construction of measurement method of the grip rigidity and the results fit very well. The studies provide a theoretical basis for the design, selection and the serialization and standardization of the matching of LSFH and cutter.

Expert Experience and Data-Driven Based Hybrid Fault Diagnosis for High-SpeedWire Rod Finishing Mills

The reliable operation of high-speed wire rod finishing mills is crucial in the steel production enterprise.As complex system-level equipment,it is difficult for high-speed wire rod finishing mills to realize fault location and real-time monitoring.To solve the above problems,an expert experience and data-driven-based hybrid fault diagnosis method for high-speed wire rod finishing mills is proposed in this paper.First,based on its mechanical structure,time and frequency domain analysis are improved in fault feature extraction.The approach of combining virtual value,peak value with kurtosis value index,is adopted in time domain analysis.Speed adjustment and side frequency analysis are proposed in frequency domain analysis to obtain accurate component characteristic frequency and its corresponding sideband.Then,according to time and frequency domain characteristics,fault location based on expert experience is proposed to get an accurate fault result.Finally,the proposed method is implemented in the equipment intelligent diagnosis system.By taking an equipment fault on site,for example,the effectiveness of the proposed method is illustrated in the system.

A discussion about the limitations of the Eurocode’s high-speed load model for railway bridges

High-speed railway bridges are subjected to normative limitations concerning maximum permissible deck accelerations.For the design of these structures,the European norm EN 1991-2 introduces the high-speed load model(HSLM)—a set of point loads intended to include the effects of existing high-speed trains.Yet,the evolution of current trains and the recent development of new load models motivate a discussion regarding the limits of validity of the HSLM.For this study,a large number of randomly generated load models of articulated,conventional,and regular trains are tested and compared with the envelope of HSLM effects.For each type of train,two sets of 100,000 load models are considered:one abiding by the limits of the EN 1991-2 and another considering wider limits.This comparison is achieved using both a bridge-independent metric(train signatures)and dynamic analyses on a case study bridge(the Canelas bridge of the Portuguese Railway Network).For the latter,a methodology to decrease the computational cost of moving loads analysis is introduced.Results show that some theoretical load models constructed within the stipulated limits of the norm can lead to effects not covered by the HSLM.This is especially noted in conventional trains,where there is a relation with larger distances between centres of adjacent vehicle bogies.

Numerical Study on Reduction in Aerodynamic Drag and Noise of High-Speed Pantograph

Reducing the aerodynamic drag and noise levels of high-speed pantographs is important for promoting environmentally friendly,energy efficient and rapid advances in train technology.Using computational fluid dynamics theory and the K-FWH acoustic equation,a numerical simulation is conducted to investigate the aerodynamic characteristics of high-speed pantographs.A component optimization method is proposed as a possible solution to the problemof aerodynamic drag and noise in high-speed pantographs.The results of the study indicate that the panhead,base and insulator are the main contributors to aerodynamic drag and noise in high-speed pantographs.Therefore,a gradual optimization process is implemented to improve the most significant components that cause aerodynamic drag and noise.By optimizing the cross-sectional shape of the strips and insulators,the drag and noise caused by airflow separation and vortex shedding can be reduced.The aerodynamic drag of insulator with circular cross section and strips with rectangular cross section is the largest.Ellipsifying insulators and optimizing the chamfer angle and height of the windward surface of the strips can improve the aerodynamic performance of the pantograph.In addition,the streamlined fairing attached to the base can eliminate the complex flow and shield the radiated noise.In contrast to the original pantograph design,the improved pantograph shows a 21.1%reduction in aerodynamic drag and a 1.65 dBA reduction in aerodynamic noise.

Dynamic analysis of axle box bearings on the high-speed train caused by wheel-rail excitation

To explore the impact of wheel-rail excitation on the dynamic performance of axle box bearings,a dynamic model of the high-speed train including axle box bearings is developed.Subsequently,the dynamic response characteristics of the axle box bearing are examined.The investigation focuses on the acceleration characteristics of bearing vibration under excitation of track irregularities and wheel flats.In addition,experiments on both normal and faulty bearings are conducted separately,and the correctness of the model and some conclusions are verified.According to the research,track irregularity is unfavorable for bearing fault detection based on resonance demodulation.Under the same speed conditions,the acceleration peak of bearing is inversely proportional to the length of the wheel flat and directly proportional to its depth.The paper will contribute to a deeper understanding of the dynamic performance of axle box bearings.

High-speed penetration of ogive-nose projectiles into thick concrete targets:Tests and a projectile nose evolution model

The majority of the projectiles used in the hypersonic penetration study are solid flat-nosed cylindrical projectiles with a diameter of less than 20 mm.This study aims to fill the gap in the experimental and analytical study of the evolution of the nose shape of larger hollow projectiles under hypersonic penetration.In the hypersonic penetration test,eight ogive-nose AerMet100 steel projectiles with a diameter of 40 mm were launched to hit concrete targets with impact velocities that ranged from 1351 to 1877 m/s.Severe erosion of the projectiles was observed during high-speed penetration of heterogeneous targets,and apparent localized mushrooming occurred in the front nose of recovered projectiles.By examining the damage to projectiles,a linear relationship was found between the relative length reduction rate and the initial kinetic energy of projectiles in different penetration tests.Furthermore,microscopic analysis revealed the forming mechanism of the localized mushrooming phenomenon for eroding penetration,i.e.,material spall erosion abrasion mechanism,material flow and redistribution abrasion mechanism and localized radial upsetting deformation mechanism.Finally,a model of highspeed penetration that included erosion was established on the basis of a model of the evolution of the projectile nose that considers radial upsetting;the model was validated by test data from the literature and the present study.Depending upon the impact velocity,v0,the projectile nose may behave as undistorted,radially distorted or hemispherical.Due to the effects of abrasion of the projectile and enhancement of radial upsetting on the duration and amplitude of the secondary rising segment in the pulse shape of projectile deceleration,the predicted DOP had an upper limit.

Torque effect on vibration behavior of high-speed train gearbox under internal and external excitations

The high-speed train transmission system,experiencing both the internal excitation originating from gear meshing and the external excitation originating from the wheel-rail interaction,exhibits complex dynamic behavior in the actual service environment.This paper focuses on the gearbox in the high-speed train to carry out the bench test,in which various operat-ing conditions(torques and rotation speeds)were set up and the excitation condition covering both internal and external was created.Acceleration responses on multiple positions of the gearbox were acquired in the test and the vibration behavior of the gearbox was studied.Meanwhile,a stochastic excitation modal test was also carried out on the test bench under different torques,and the modal parameter of the gearbox was identified.Finally,the sweep frequency response of the gearbox under gear meshing excitation was analyzed through dynamic modeling.The results showed that the torque has an attenuating effect on the amplitude of gear meshing frequency on the gearbox,and the effect of external excitation on the gearbox vibration cannot be ignored,especially under the rated operating condition.It was also found that the torque affects the modal param-eter of the gearbox significantly.The torque has a great effect on both the gear meshing stiffness and the bearing stiffness in the transmission system,which is the inherent reason for the changed modal characteristics observed in the modal test and affects the vibration behavior of the gearbox consequently.

Investigations on High-Speed Flash Boiling Atomization of Fuel Based on Numerical Simulations

Flash boiling atomization(FBA)is a promising approach for enhancing spray atomization,which can generate a fine and more evenly distributed spray by increasing the fuel injection temperature or reducing the ambient pressure.However,when the outlet speed of the nozzle exceeds 400 m/s,investigating high-speed flash boiling atomization(HFBA)becomes quite challenging.This difficulty arises fromthe involvement ofmany complex physical processes and the requirement for a very fine mesh in numerical simulations.In this study,an HFBA model for gasoline direct injection(GDI)is established.This model incorporates primary and secondary atomization,as well as vaporization and boilingmodels,to describe the development process of the flash boiling spray.Compared to lowspeed FBA,these physical processes significantly impact HFBA.In this model,the Eulerian description is utilized for modeling the gas,and the Lagrangian description is applied to model the droplets,which effectively captures the movement of the droplets and avoids excessive mesh in the Eulerian coordinates.Under various conditions,numerical solutions of the Sauter mean diameter(SMD)for GDI show good agreement with experimental data,validating the proposed model’s performance.Simulations based on this HFBA model investigate the influences of fuel injection temperature and ambient pressure on the atomization process.Numerical analyses of the velocity field,temperature field,vapor mass fraction distribution,particle size distribution,and spray penetration length under different superheat degrees reveal that high injection temperature or low ambient pressure significantly affects the formation of small and dispersed droplet distribution.This effect is conducive to the refinement of spray particles and enhances atomization.

Aerodynamic Features of High-Speed Maglev Trains with Different Marshaling Lengths Running on a Viaduct under Crosswinds

The safety and stability of high-speed maglev trains traveling on viaducts in crosswinds critically depend on their aerodynamic characteristics.Therefore,this paper uses an improved delayed detached eddy simulation(IDDES)method to investigate the aerodynamic features of high-speed maglev trains with different marshaling lengths under crosswinds.The effects of marshaling lengths(varying from 3-car to 8-car groups)on the train’s aerodynamic performance,surface pressure,and the flow field surrounding the train were investigated using the three-dimensional unsteady compressible Navier-Stokes(N-S)equations.The results showed that the marshaling lengths had minimal influence on the aerodynamic performance of the head and middle cars.Conversely,the marshaling lengths are negatively correlated with the time-average side force coefficient(CS)and time-average lift force coefficient(Cl)of the tail car.Compared to the tail car of the 3-car groups,the CS and Cl fell by 27.77%and 18.29%,respectively,for the tail car of the 8-car groups.It is essential to pay more attention to the operational safety of the head car,as it exhibits the highest time average CS.Additionally,the mean pressure difference between the two sides of the tail car body increased with the marshaling lengths,and the side force direction on the tail car was opposite to that of the head and middle cars.Furthermore,the turbulent kinetic energy of the wake structure on the windward side quickly decreased as marshaling lengths increased.

Experimental and Numerical Investigation on the Aerodynamic Characteristics of High-Speed Pantographs with Supporting Beam Wind Deflectors

Aiming to mitigate the aerodynamic lift force imbalance between pantograph strips,which exacerbates wear and affects the current collection performance of the pantograph-catenary system,a study has been conducted to support the beam deflector optimization using a combination of experimental measurements and computational fluid dynamics(CFD)simulations.The results demonstrate that the size,position,and installation orientation of the wind deflectors significantly influence the amount of force compensation.They also indicate that the front strip deflectors should be installed downwards and the rear strip deflectors upwards,thereby forming a“π”shape.Moreover,the lift force compensation provided by the wind deflectors increases with the size of the deflector.Alternative wind compensation strategies,such as control circuits,are also discussed,putting emphasis on the pros and cons of various pantograph types and wind compensation approaches.

Reflection on methodology of the correlation between electromagnetic interference and safety in high-speed railway

Purpose – In the continuous development of high-speed railways, ensuring the safety of the operation controlsystem is crucial. Electromagnetic interference (EMI) faults in signaling equipment may cause transportationinterruptions, delays and even threaten the safety of train operations. Exploring the impact of disturbances onsignaling equipment and establishing evaluation methods for the correlation between EMI and safety isurgently needed.Design/methodology/approach – This paper elaborates on the necessity and significance of studying theimpact of EMI as an unavoidable and widespread risk factor in the external environment of high-speed railwayoperations and continuous development. The current status of research methods and achievements from theperspectives of standard systems, reliability analysis and safety assessment are examined layer by layer.Additionally, it provides prospects for innovative ideas for exploring the quantitative correlation between EMIand signaling safety.Findings – Despite certain innovative achievements in both domestic and international standard systems andrelated research for ensuring and evaluating railway signaling safety, there’s a lack of quantitative and strategic research on the degradation of safety performance in signaling equipment due to EMI. A quantitativecorrelation between EMI and safety has yet to be established. On this basis, this paper proposes considerationsfor research methods pertaining to the correlation between EMI and safety.Originality/value – This paper overviews a series of methods and outcomes derived from domestic andinternational studies regarding railway signaling safety, encompassing standard systems, reliability analysisand safety assessment. Recognizing the necessity for quantitatively describing and predicting the impact ofEMI on high-speed railway signaling safety, an innovative approach using risk assessment techniques as abridge to establish the correlation between EMI and signaling safety is proposed.

Theory and practice for assessing structural integrity and dynamical integrity of high-speed trains

Purpose–The safety and reliability of high-speed trains rely on the structural integrity of their components and the dynamic performance of the entire vehicle system.This paper aims to define and substantiate the assessment of the structural integrity and dynamical integrity of high-speed trains in both theory and practice.The key principles and approacheswill be proposed,and their applications to high-speed trains in Chinawill be presented.Design/methodology/approach–First,the structural integrity and dynamical integrity of high-speed trains are defined,and their relationship is introduced.Then,the principles for assessing the structural integrity of structural and dynamical components are presented and practical examples of gearboxes and dampers are provided.Finally,the principles and approaches for assessing the dynamical integrity of highspeed trains are presented and a novel operational assessment method is further presented.Findings–Vehicle system dynamics is the core of the proposed framework that provides the loads and vibrations on train components and the dynamic performance of the entire vehicle system.For assessing the structural integrity of structural components,an open-loop analysis considering both normal and abnormal vehicle conditions is needed.For assessing the structural integrity of dynamical components,a closed-loop analysis involving the influence of wear and degradation on vehicle system dynamics is needed.The analysis of vehicle system dynamics should follow the principles of complete objects,conditions and indices.Numerical,experimental and operational approaches should be combined to achieve effective assessments.Originality/value–The practical applications demonstrate that assessing the structural integrity and dynamical integrity of high-speed trains can support better control of critical defects,better lifespan management of train components and better maintenance decision-making for high-speed trains.

Human intrusion detection for high-speed railway perimeter under all-weather condition

Purpose – The paper aims to solve the problem of personnel intrusion identification within the limits of highspeed railways. It adopts the fusion method of millimeter wave radar and camera to improve the accuracy ofobject recognition in dark and harsh weather conditions.Design/methodology/approach – This paper adopts the fusion strategy of radar and camera linkage toachieve focus amplification of long-distance targets and solves the problem of low illumination by laser lightfilling of the focus point. In order to improve the recognition effect, this paper adopts the YOLOv8 algorithm formulti-scale target recognition. In addition, for the image distortion caused by bad weather, this paper proposesa linkage and tracking fusion strategy to output the correct alarm results.Findings – Simulated intrusion tests show that the proposed method can effectively detect human intrusionwithin 0–200 m during the day and night in sunny weather and can achieve more than 80% recognitionaccuracy for extreme severe weather conditions.Originality/value – (1) The authors propose a personnel intrusion monitoring scheme based on the fusion ofmillimeter wave radar and camera, achieving all-weather intrusion monitoring;(2) The authors propose a newmulti-level fusion algorithm based on linkage and tracking to achieve intrusion target monitoring underadverse weather conditions;(3) The authors have conducted a large number of innovative simulationexperiments to verify the effectiveness of the method proposed in this article.

Calculation of high-speed abrasion forces for ceramic coatings based on the Hertzian contact model

Aero engine seal coatings can effectively improve the air tightness of aircraft engines and increase fuel efficiency.However,due to the frictional forces between the blades and the coating,the coating often flakes off,resulting in damage to the blades and causing eco-nomic losses.Therefore,it is necessary to analyze the friction between the blades and the coating.In this paper,three ceramic-based high-temperature seal coatings with different polyphenylene ester contents and a pure Yttria-stabilised zirconia coating were prepared by atmo-spheric plasma spraying(APS).The hardness and modulus of elasticity of the coated surfaces were obtained by hardness and modulus of elasticity tests,and the coatings were subjected to high-speed touch abrasion tests.The Hertzian contact model was used to calculate the maximum normal contact load on the coating during the process.The test values were compared with the theoretical values and it was found that the calculated values were always greater than the test values.In order to make the Hertzian contact model more accurate in calculating the touching and abrasion forces,the contact coefficients in the Hertzian contact model were optimized.Substituting the optimized coeffi-cients into the Hertzian contact model,the results show that the calculated results after optimizing the coefficients are much closer to the test values,with deviations from the test values ranging from 1%to 38%.

High-speed railway track components inspection framework based on YOLOv8 with high-performance model deployment

Railway inspection poses significant challenges due to the extensive use of various components in vast railway networks,especially in the case of high-speed railways.These networks demand high maintenance but offer only limited inspection windows.In response,this study focuses on developing a high-performance rail inspection system tailored for high-speed railways and railroads with constrained inspection timeframes.This system leverages the latest artificial intelligence advancements,incorporating YOLOv8 for detection.Our research introduces an efficient model inference pipeline based on a producer-consumer model,effectively utilizing parallel processing and concurrent computing to enhance performance.The deployment of this pipeline,implemented using C++,TensorRT,float16 quantization,and oneTBB,represents a significant departure from traditional sequential processing methods.The results are remarkable,showcasing a substantial increase in processing speed:from 38.93 Frames Per Second(FPS)to 281.06 FPS on a desktop system equipped with an Nvidia RTX A6000 GPU and from 19.50 FPS to 200.26 FPS on the Nvidia Jetson AGX Orin edge computing platform.This proposed framework has the potential to meet the real-time inspection requirements of high-speed railways.