超声辅助滚压系统研究

鉴于风力发电机组主轴的复杂工作情况和疲劳断裂失效形式,提出一种基于表面强化技术的超声辅助滚压加工系统。首先基于运动合成原理,获得了滚轮接触线的运动轨迹特征,并应用ANSYS/LS-DYNA软件分析了加工过程的特点。之后,基于一维振动理论、等效波长理论与牛顿迭代理论,推导并求解了复合变幅杆的频率方程,实现了该复合变幅杆的纵向振动。通过对该变幅杆进行有限元仿真分析与振动特性测试,结果表明二者相对设计频率的偏差仅在0.817%以内。最后,通过对40Cr主轴进行超声辅助滚压测试,获得了粗糙度Ra 0.085μm和表面硬度32.2 HRC的加工表面,较普通滚压加工粗糙度降低了69.1%,显微硬度提高了60%。     

带有锥形孔的复合变幅杆设计及动态分析

在超声振动拉丝加工过程中,为了实现线材的顺利拉拔,需要应用带有锥形孔的复合变幅杆。为此,本文基于等效四端网络与传输矩阵法,建立了带锥形孔圆锥变幅杆的传输矩阵,推导出带锥形孔圆锥过渡复合变幅杆的频率方程的一般公式。根据推导出的频率方程,应用区间搜索法和牛顿迭代法获取了准确的数值解,实现了该复合变幅杆的纵向振动。之后,应用有限元软件Ansys对设计出的复合变幅杆分别进行模态分析和动力学特性分析,获得了各段不同长度下复合变幅杆谐振频率、放大系数以及最大应力值的变化规律。最后,对制造出的复合变幅杆进行阻抗与振动性能测试,结果表明其频率准确,且振幅比较稳定。     

超声辅助磨削杯形砂轮变幅器设计与试验*

超声辅助磨削在硬脆材料的加工中应用广泛。为研制以杯形砂轮为加工工具的超声辅助磨削主轴附件式工具系统,建立了杯形砂轮变幅器的理论模型,推导了其频率方程,并通过Matlab开发了杯形砂轮变幅器设计软件。利用该软件结合有限元分析对杯形砂轮变幅器进行了设计。将研制的杯形砂轮变幅器与BT40刀柄一体化外套筒、导电滑环装配组成了杯形砂轮超声辅助磨削主轴附件式工具系统。对该超声振动系统进行了阻抗分析试验及超声谐振试验,结果表明,该超声振动系统阻抗性能较好,能够使杯形砂轮产生稳定的超声振动,验证了所提出的设计方法的正确性,为主轴附件式超声磨削装置的设计提供了理论参考。     

超声滚压中的空化现象*

在超声滚压加工中引入切削液后可能会产生空化现象,由此产生的微射流和冲击波对超声表面强化将有积极作用。为研究超声滚压加工中空化现象是否存在及空化效应在超声滚压中的作用,本文首先分析了超声滚压中的空化阈值,然后进行了染色法试验和超声滚压后试样氧元素能谱分析,最后通过超声滚压加工对比试验研究了空化效应对加工后材料表面粗糙度和显微硬度的影响。研究发现,超声滚压加工中的声压幅值远大于空化阈值,满足空化存在的必要条件;超声滚压中发生了明显的卡纸染色现象,引入切削液后工件超声滚压加工表面氧元素含量显著提高,表明超声滚压中发生了空化现象。超声滚压加工中的空化效应能进一步降低工件表面粗糙度和提高表面显微硬度,有利于提高工件表面强化质量。本研究为空化效应在超声滚压中的积极利用提供了依据。     

微型轴承内滚道超声辅助超精研磨系统的设计研究*

为了提高5G基站中微型轴承的精度和使用寿命,基于微型轴承外套圈结构特征提出一种超声振动辅助研磨轴承外圈滚道的加工工艺。通过坐标变换及运动合成,获得了振动研磨轴承外圈滚道的工作面轨迹特点,阐明了振动高效研磨的本质特征;之后,分别采用等效电路法和有限分析法,建立了振动系统的等效电路图与频率方程,分析了该系统模型的固有模态与谐响应特性;最后,通过对自行研制的超声辅助研磨系统分别进行振动特性测试和加工效果测试。结果表明,加工系统振动频率相对设计频率的误差率为10‰,超声振幅为12.95μm,加工轴承滚道的粗糙度和轮廓度较传统研磨加工分别降低了27.17%和24.1%。     

纵-扭谐振超声滚压系统设计与试验

为实现6061铝合金高效优质表面强化,采用有限元仿真法优化设计了阶梯型纵-扭谐动变幅杆,设计、制造了一套纵-扭超声滚压试验装置。纵-扭谐动通过检测变幅杆输出端纵向、扭转两个方向的振幅间接验证。进行超声滚压试验,结果表明：相比普通滚压加工,纵-扭谐振超声滚压过试件表层显微硬度最高提高了41%;在所选参数范围内出现随着静压力增大表面显微硬度整体呈现局部变化整体增大趋势,随着转速增加呈现局部变化整体减小的趋势,随着进给量的增大先增大后减小的现象;相比普通滚压加工,纵-扭谐振超声滚压过的工件表面组织更细密光滑,滚痕由于扭振的高频反复挤压明显减少,形貌得到了较大改善,从而证明纵-扭超声滚压加工能更有效的实现6061铝合金的强化处理。     

斜槽式单激励纵扭超声变幅杆设计*

为实现在纵向单激励超声振动输入条件下获得纵扭谐振输出,提出一种基于声波传播理论为基础设计阶梯型变幅杆,并在其小端增加沿中心轴均布6斜槽的圆环传振杆的方案：首先数值计算进行理论设计,然后使用有限元进行分析修正,最后确定变幅杆尺寸。结果表明：理论设计谐振频率20kHz,仿真分析在19457Hz时变幅杆能够实现纵扭谐振;根据仿真结果制作变幅杆,阻抗测试结果谐振频率为19884Hz,与理论值、仿真值误差较小;在输入端加载幅值为5μm的纵向单激励超声振动,测试输出端截面圆周上任意一点,其切向和纵向振幅分别为12.7μm和8.5μm,表明变幅杆实现了纵扭谐振且振幅增强。     

模式转换型超声塑焊振动系统的设计

基于弯曲振动理论和耦合振动理论,设计了一种新型大尺寸筒形超声塑焊振动系统。该振动系统由纵向振动换能器及变幅杆、弯曲振动金属圆盘和耦合振动圆筒四部分组成。换能器和变幅杆的纵向振动驱动圆盘的二次弯曲模式振动,圆盘的二次弯曲模式振动激励圆筒的纵向模式振动,实现了工具头在较高频率下谐振。实验结果表明,振动系统的测试频率与计算频率比较符合,在大信号下测试的纵-弯-纵振动模式转换效果很好。研究结果为高频大尺寸超声焊接系统的设计提供了思路。      

低温微量超声雾化声学系统

针对低温微量超声雾化声学系统中的关键部件单波长超声雾化喷嘴进行研究。首先基于等效电路原理和传输矩阵法分别建立了带中心孔换能器和带中心孔复合变幅杆的频率方程,并应用数学分析软件获得了准确的数值解,实现了超声雾化喷嘴的全谐振。然后,对其进行有限元动力学分析和振动特性测试,结果表明二者相对于设计频率25 kHz的偏差率在0.6%以内,且空载超声振幅达13.5μm。之后,应用流体仿真分析软件对砂轮-工件磨削区进行流场特性分析,结果表明低温微量超声雾化声学系统可以解决磨削区涡流现象的产生。最后,通过对该系统使用前后两种润滑方式的磨削结果进行测试发现：低温微量超声雾化润滑不仅切削液使用量少,而且可以避免工件表面出现烧伤和硬度降低。     

性能可调的纵向振动圆锥形超声变幅杆*

提出了一种基于压电效应的性能可调纵向振动圆锥形超声变幅杆,并对其振动性能进行了研究。该变幅杆由传统的圆锥形超声变幅杆和压电陶瓷材料组合而成。论文研究了圆锥变幅杆中压电陶瓷材料的厚度、位置以及电阻抗的改变对变幅杆性能参数的影响,并进行了数值模拟仿真及实验验证。结果表明,通过改变压电陶瓷材料的厚度、位置和电阻抗值,可以实现变幅杆共振频率和位移放大系数的改变。理论计算结果与数值模拟值和实验测试值符合得很好。     

Surface energy modification by electron beam

We observe a pronounced variation of wettability properties in solid state materials induced by a low-energy electron beam. The phenomenon occurs in several stages characterized by various mechanisms. We show that for low electron doses the irradiation leads to decrease in the wetting of a dielectric surface due to induced surface electric potential. The higher electron charge leads to formation of a chemical monolayer on material’s surface. It has been found that the electron irradiation strongly modifies the surface free energy of SiO₂ by decreasing its total surface free energy value, almost twice. However, electron-induced variations of dispersive and polar components of the surface free energy are quite different and depend of incident electron charge.     

Unique edge structure and stability of fabricated dimer islands on Si(001)

The edge structure and stability of monolayer-high islands fabricated on Si(001) surfaces by scanning tunneling microscopy have been analyzed theoretically. In contrast to the edges of similar islands grown by depositing Si, the properties of edges of fabricated islands are determined by the length of the trench of dimers that are removed to create the island. We demonstrate the possibility of controlling the edge structure, and thus the stability, through a selective process of atom removal.     

On the surface trapping parameters of polytetrafluoroethylene block

Surface flashover phenomena under high electric field are closely related to the surface characteristics of a solid insulating material between energized electrodes. Based on measuring the surface potential decaying curve of polytetrafluoroethylene (PTFE) block charged by a needle-plane corona discharge, its surface trapping parameters are calculated with the isothermal current theory, and the correlative curve between the surface trap density and its energy level is obtained. The maximum density of electron traps and hole traps in the surface layer of PTFE presents a similar value of ∼2.7 × 10¹⁷ eV⁻¹ m⁻³, and the energy level of its electron and hole traps is of about 0.85-1.0 eV and 0.80-0.90 eV, respectively. Via the X-ray photoelectron spectroscopy (XPS) technique, the F, C, K and O elements are detected on the surface of PTFE samples, and F shows a remarkable atom proportion of ∼73.3%, quite different from the intrinsic distribution corresponding to its chemical formula. The electron traps are attributed to quantities of F atoms existing on the surface of PTFE due to its molecular chain with C atoms surrounded by F atoms spirally. It is considered that the distortions of chemical and electronic structure on solid surface are responsible for the flashover phenomena occurring at a low applied voltage.     

Investigation of surface properties of liquid transition metals: Surface tension and surface entropy

In the present study, surface properties namely surface tension and surface entropy of liquid transition metals have been reported. The surface entropy of liquid Fe, Co and Ni metals has been investigated using the expression derived by Gosh et al. [R.C. Gosh, A.Z. Ziauddin Ahmed, G.M. Bhuiyan, Eur. Phys. J. B 56 (2007) 177]. To describe interionic interaction the pseudopotential approach has been used and radial distribution functions have been determined from the solution of Ornstein-Zernike integral equation. The calculated values of surface tension and surface entropy agree well with experiment. The present study shows that the expression derived by Gosh et al. leads to a good estimation for the surface entropy.     

Comments on ‘‘Effect of the surface free energy on the behaviour of surface and guided waves”, by V. Vlasie Belloncle,M. Rousseau,Ultrasonics, 45 (2006) 188–195

In this short communication, it is demonstrated that the main results obtained by the authors of the commented paper, ‘‘Effect of the surface free energy on the behaviour of surface and guided waves”, by V. Vlasie Belloncle, M. Rousseau Ultrasonics, 45 (2006) 188–195, have been well-established long before publication of this paper. Therefore, the claim to novelty asserted by the authors is incorrect.     

Surface diffusivity of thin polymer films measured by a curvature driven flow and Rouse dynamics

Nanodefects induced by nanoindentation on thin polystyrene (PS) films spin cast on silicon (Si) relax upon annealing at 110 °C. The relaxation process for low molecular weight PS is interpreted in terms of a curvature driven flow which leads to the measurement of a diffusion coefficient. The latter is compared with the expected Rouse predictions using (i) bulk and (ii) surface glass transition temperature data, found in the literature. Deviations from the Rouse predictions are observed when is used for the analysis of the data. On the contrary, excellent agreement with the Rouse model is reported when is used.     

Surface plasmon polariton scattering by small ellipsoid particles

Scattering of surface plasmon polaritons (SPP’s) by small ellipsoid particles placed near a dielectric–metal interface is theoretically considered. Using the Green’s function formalism and the dipole approximation, we consider the differential and total scattering cross-sections associated with the SPP-to-SPP scattering as well as with the SPP scattering into waves propagating away from the interface, analyzing the influence of system parameters. As an example, scattering cross-sections of differently shaped gold spheroid particles placed near an air–gold interface are evaluated at the light wavelength of 800 nm. It is shown that the differential and total cross-sections depend strongly upon the particle-to-surface distance, the ratio between the major and minor axes and their orientation with respect to both the interface and the direction of SPP incidence. Implications of the obtained results to the design of SPP micro-optical components are also discussed.     

Diffusion coefficients across polycarbonate microporous membranes

Summary Apparent ionic diffusion coefficients across polycarbonate membranes bathed by two electrolyte solutions have been studied from Nernst-Planck equation using the assumption of constant electric field. From these diffusion coefficients we have also determined the cation transport numbers across the membranes. Six different membranes and two electrolytes (LiCl and MgCl₂) have been considered, at the temperature of 20°C and for concentrations in the range (10⁻⁴÷10⁻¹) mol l⁻¹.

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Riassunto Sono stati studiati coefficienti apparenti di diffusione ionica attraverso membrane di policarbonato magnate da due soluzioni di elettroliti a partire dall’equazione di Nernst-Planck usando l’assunto di campo elettrico costante. Da questi coefficienti di diffusione abbiamo anche determinato il numero di trasporto di cationi attraverso le membrane. Si sono considerate sei diverse membrane e due elettroliti (LiCl e MgCl₂), alla temperatura di 20°C e per concentrazioni nell’intervallo (10⁻³÷10⁺¹) mol l⁻¹.

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Резюме Используя предположения о постоянном электрическом поле, на основе уравнения Нернста-Планка исследуются ионные коэффициенты диффузии через поликарбанатные мембраны, омываемые двумя электролитическими растворами. Из этих коэффициентов диффузии мы также определяем транспорт катионов через эти мембраны. Были рассмотрены шесть различных мембран и два электролита (LiCl и MgCl₂) при температуре 20°C и для концентраций в области (10⁻⁴÷ ÷10⁻¹) моль·л⁻¹.