A novel approach to minimizing material loss for computer numerical control flank-regrinding of worn end mills

Flanks of end mills are prone to wear in a long machining process.Regrinding is widely used in workshops to restore the flank to an original-like state.However,the traditional method involves material waste by trial and error and dramatically decreases the potential regrinding.Moreover,over-cut would happen to the flutes of worn cutters in the regrinding processes because of improper wheel path.This study presented a new approach to planning the wheel path for regrinding worn end mills to minimize material loss and recover the over-cut.In planning,a scaling method was developed to determine the maximum size of the new cutter according to the similarity of cutter shapes before and after regrinding.Then,the wheel path is first generated by envelope theory to regrind the worn area with a four-axis computer numerical control grinder according to the new size of cutters.Moreover,a second regrinding strategy is applied to recover the flute shape over-cut in the first grinding.Finally,the proposed method is verified by an experiment.Results showed that the proposed approach could save 25%of cutter material compared with the traditional method and ensure at least three regrinding times.This work effectively provides a general regrinding solution for the worn flank with maximum material-saving and regrinding period.

Progress in hole-transporting materials for perovskite solar cells

In recent years the photovoltaic community has witnessed the unprecedented development of perovskite solar cells（PSCs） as they have taken the lead in emergent photovoltaic technologies. The power conversion efficiency of this new class of solar cells has been increased to a point where they are beginning to compete with more established technologies. Although PSCs have evolved a variety of structures, the use of hole-transporting materials（HTMs） remains indispensable. Here, an overview of the various types of available HTMs is presented. This includes organic and inorganic HTMs and is presented alongside recent progress in associated aspects of PSCs, including device architectures and fabrication techniques to produce high-quality perovskite films. The structure, electrochemistry, and physical properties of a variety of HTMs are discussed, highlighting considerations for those designing new HTMs. Finally, an outlook is presented to provide more concrete direction for the development and optimization of HTMs for highefficiency PSCs.

Improving resolution of superlens based on solid immersion mechanism

Super-resolution imaging with superlens has been one of the fundamental research topics. Unfortunately, the resolution of superlens is inevitably restrained by material loss. To address the problem, we introduce the solid immersion mechanism into the slab superlens and the cylindrical superlens. The proposed solid immersion slab superlens(SISSL) and the solid immersion cylindrical superlens(SICSL) can improve the resolution by converting evanescent wave to propagating wave using high refractive index materials. From the perspective of applications, the cylindrical superlens with finite cross section and the ability of magnification or demagnification has more advantages than the slab superlens. Therefore,we focus on demonstrating analytically the super-resolution imaging of SICSL. Due to the impedance mismatching caused by solid immersion mechanism, the whispering gallery modes(WGMs) are excited between SICSL and the air interface.We clarify the excitation conditions of WGMs and analyze their influence on the imaging quality of SICSL. The SISSL and SICSL may pave a way to apply in lithography technique and real-time biomolecular imaging in future.

Structural failure mechanism and strengthening method of fracture plugging zone for lost circulation control in deep naturally fractured reservoirs

Focused on the lost circulation control in deep naturally fractured reservoirs, the multiscale structure of fracture plugging zone is proposed based on the theory of granular matter mechanics, and the structural failure pattern of plugging zone is developed to reveal the plugging zone failure mechanisms in deep, high temperature, high pressure, and high in-situ stress environment. Based on the fracture plugging zone strength model, key performance parameters are determined for the optimal selection of loss control material(LCM). Laboratory fracture plugging experiments with new LCM are carried out to evaluate the effect of the key performance parameters of LCM on fracture plugging quality. LCM selection strategy for fractured reservoirs is developed. The results show that the force chain formed by LCMs determines the pressure stabilization of macro-scale fracture plugging zone. Friction failure and shear failure are the two major failure patterns of fracture plugging zone. The strength of force chain depends on the performance of micro-scale LCM, and the LCM key performance parameters include particle size distribution, fiber aspect ratio, friction coefficient, compressive strength, soluble ability and high temperature resistance. Results of lab experiments and field test show that lost circulation control quality can be effectively improved with the optimal material selection based on the extracted key performance parameters of LCMs.

Measurement of insertion loss for underwater acoustic passive materials with the time reversal technique

A method using the time reversal（TR） technique to measure the insertion loss（IL） of passive materials is presented.Firstly the received signals are focused according to the TR theory when there is not a sample between the source and the received array.Then,the sample is placed near the received array and the TR processing is again employed to realize the focus of the received signal.Finally,the IL of the sample is evaluated from these focusing signals.Because the TR processing can focus the energy in spatial domain and time domain,the method can be used to measure acoustic properties of passive materials in a waveguide tank with reflections induced by boundaries or with low source frequencies.Two samples with the same size of 1.1 m×1.0 m×5 mm are tested in the waveguide tank.The method is demonstrated by the comparison of the theoretical and the experimental results in the measured frequency range of 1-20 kHz.

Structural formation and evolution mechanisms of fracture plugging zone

A coupled CFD-DEM method is used to simulate the formation process of fracture plugging zone.A photo-elastic system characterizing mesoscale force chain network developed by our own is used to model the pressure evolution in fracture plugging zone to reveal the evolution mechanism of the structure of fracture plugging zone.A theoretical basis is provided for improving the lost circulation control effect in fractured reservoirs and novel methods are proposed for selecting loss control materials and designing loss control formula.CFD-DEM simulation results show that bridging probability is the key factor determining the formation of fracture plugging zone and fracture plugging efficiency.Critical and absolute bridging concentrations are proposed as the key indexes for loss control formula design.With the increase of absolute bridging concentration,the governing factor of bridging is changed from material grain size to the combination of material grain size and friction force.Results of photo-elastic experiments show that mesoscale force chain network is the intrinsic factor affecting the evolution of pressure exerting on the fracture plugging zone and determines the macroscopic strength of fracture plugging zone.Performance parameters of loss control material affect the force chain network structure and the ratio of stronger force chain,and further impact the stability and strength of fracture plugging zone.Based on the study results,the loss control formula is optimized and new-type loss control material is designed.Laboratory experiments results show that the fracture plugging efficiency and strength is effectively improved.

Rapid determination of lithium-ion battery degradation: High C-rate LAM and calculated limiting LLI

Herein,incremental capacity-differential voltage (IC-DV) at a high C-rate (HC) is used as a non-invasive diagnostic tool in lithium-ion batteries,which inevitably exhibit capacity fading caused by multiple mechanisms during charge/discharge cycling.Because battery degradation modes are complex,the simple output of capacity fading does not yield any useful data in that respect.Although IC and DV curves obtained under restricted conditions (<0.1C,25℃) were applied in non-invasive analysis for accurate observation of degradation symptoms,a facile,rapid diagnostic approach without intricate,complex calculations is critical in on-board applications.Herein,Li Ni_(0.5)Mn_(0.3)Co_(0.2)O_(2)(NMC532)/graphite pouch cells were cycled at 4 and 6C and the degradation characteristics,i.e.,loss of active materials (LAM) and loss of lithium inventory (LLI),were parameterized using the IC-DV curves.During the incremental current cycling,the initial steep LAM and LLI slopes underwent gradual transitions to gentle states and revealed the gap between low-and high-current measurements.A quantitative comparison of LAM at high and low C-rate showed that a IC;revealed the relative amount of available reaction region limited by cell polarization.However,this did not provide a direct relationship for estimating the LAM at a low C-rate.Conversely,the limiting LLI,which is calculated at a C-rate approaching 0,was obtained by extrapolating the LLI through more than two points measured at high C-rate,and therefore,the LLI at 0.1C was accurately determined using rapid cycling.

Performance evaluation of nanosilica derived from agro-waste as lost circulation agent in water-based mud

Seepage or loss of the mix-water from the drilling muds into the porous and permeable formations is a common problem during drilling operation.The drilling mud design requires a good knowledge of sealing integrity and all the factors influencing the mud to bridge through fractures or pore throat of exposed rocks.Loss circulation materials(LCMs)are commonly introduced into the drilling mud to prevent or minimize filtrate loss.This study investigates silica nanoparticle(SNP)derived from rice husk(RH)termed RH-SNP using the wet-milling method as an LCM inwater-based mud(WBM).The impact of the RH-SNP in the enhancement of rheology and filtrate loss control properties of WBM was studied.Subsequently,the sealing integrity of the RH-SNP in a 1 mm and 2 mm simulated fracture for 7 min was determined using a stainless-steel slotted filter disk.The performance of the developed RH-SNP was compared with the widely applied nutshell.The synthesized RH-SNP at amount of 2.0 wt% significantly enhanced the yield point and plastic viscosity of the WBM by 75% and 386%,respectively,and minimized the fluid loss of the WBM by 47% at 80°F.The enhancement is due to the particles ability to spread and interact efficiently with the WBM.With the use of 1 mm and 2 mm simulated fracture for 7 min,the mud loss volume of the base mud reduced by 50%,66.7%,86%,and 90%(for 1 mm)and 40%,65.7%,77.1%,and 80%(for 2 mm)with the inclusion of 0.5 wt%,1.0 wt%,1.5 wt%,and 2.0 wt% of RH-SNP,respectively.Overall,the results showed that RH-SNP enhanced the seal integrity of the drilling mud and was more resistant to deformation compared to the nutshell.The findings of this study can help for better understanding of the application of RH-SNP as a loss circulation agent owing to its superior ability to seal fractured formation compared with the often used nutshell.