超声辅助滚压系统的设计与研究*

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,推导了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,结果获得了粗糙度Ra 0.085μm和表面硬度32.2HRC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％。     

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。     

大负载超声振动磨削系统的设计

设计了一种大负载超声振动磨削系统,超声系统由换能器、圆柱圆锥形变幅杆和轮辐式砂轮组成。首先将轮辐式砂轮等效成轮毂为圆柱杆、辐板与轮缘为中厚板的复合模型,利用各接触面边界连续的条件推导系统的频率方程,完成了超声磨削系统的设计,制作了实验装置并分析验证了其声学振动特性。实验结果表明:利用轮辐式砂轮复合模型求解系统频率方程,在解决大负载超声振动磨削系统设计难题上的有效性。该超声系统结构简单,声学振动特性稳定,可输出均匀的位移振幅,有望在大负载的超声磨削领域获得应用。     

超声辅助提取微藻油脂机理及工艺参数的研究*

对微藻细胞壁进行破碎是提高微藻油脂提取率的重要手段,超声振动破碎是一种有效的细胞破碎方法。建立基于声冲流、声辐射力、声空化的传质动力学的经验模型,运用传输矩阵法设计用于微藻细胞破碎的超声振动子,搭建了实验平台,并设置不同超声振动工艺参数对微藻细胞的破碎率进行了实验研究。结果表明:超声振动子,在工具头浸入微藻二分之一总溶液深度、工作时间30 min、功率225 W、纵振频率25 kHz的条件下,超声振动破碎的效果最佳,采用氯仿试剂对破碎液进行油脂提取,效果最好。     

微型光谱分析系统检测食品添加剂山梨酸的研究

基于对微型光谱仪的二次深度研发,构建了新型食品安全检测微型光谱分析系统,并采用标准加入法,对牛肉粒中的食品添加剂山梨酸进行快速定量检测。结果表明,采用标准加入法消除了样本基体成分的干扰,牛肉粒中山梨酸在0～10.0 mg·L-1质量浓度范围内有良好的线性关系(R2=0.998 9),山梨酸加标回收率为99.2%～99.5%,RSD(n=5)为0.14%。该微型光谱分析系统在食品添加剂检测应用方面表现出良好的实用化前景。     

一种微型光纤陀螺环境适应能力的提升设计

双折射效应、Shupe效应等与温度相关的效应和部分结构较脆弱的光学器件等因素,使某微型光纤陀螺不能在宽温度范围和高冲击环境条件下正常工作。通过有限元热仿真分析和隔冲理论计算进行结构优化设计保证某微型光纤陀螺在-45~65℃的温度范围和3 000g的半正弦冲击下正常工作。实验证明该优化设计方案在确保光纤陀螺测量精度指标的同时,大幅提高了该型号光纤陀螺的环境适应能力。     

超声辅助加工系统的刀具状态自感知算法

超声波振动台内含压电材料,可以拾取切削过程产生的振动信号,实现不借助外部传感器刀具工作状态的自感知。为了从刀具振动信号中获取有效信息,该文提出一种基于经验模态分解的时频域重构算法。首先,采用经验模态分解算法将原始信号分解,得到多个固有模态函数分量和残差分量;其次,计算原始信号与各分量之间的时频域互相关系数;再次,归一化时频域互相关系数作为权重值,将固有模态函数分量和残差进行重构;最后,通过数值仿真和超声辅助加工实验,验证了基于经验模态分解的时频域重构算法的去噪性能,提取了信噪比为5.03 dB的目标信号,从而实现了超声辅助加工系统的自感知功能。     

车轮轮辋缺陷的超声相控阵检测系统研究*

针对火车车轮检测中常规超声波探伤存在的检测灵敏度低、声束灵活性差、信噪比低等问题,研究了超声相控阵在火车车轮轮辋检测中的应用。本文介绍了超声相控阵检测技术的原理,并从超声相控阵换能器、硬件系统和软件系统三个方面阐述了火车车轮轮辋缺陷的超声相控阵检测系统的研究过程。最后通过人工模拟缺陷的相控阵检测实验,测试了该检测系统的性能,验证了相控阵检测设备具有灵敏度高、声束可控性好和可靠性高等优点。     

超声复合振动系统中局部共振现象的有限元分析

本文用有限元软件对超声复合振动系统中的局部共振现象进行了仿真计算.通过对仿真结果的分析,验证了“局部共振是耦合振动”的观点.在此基础上,用有限元方法进一步研究了截面直径比、工具杆长度等影响局部共振的因素,总结出了产生局部共振的条件.     

用于铝板缺陷无损检测的激光超声有限元模拟研究

激光超声技术能够在材料表面形成超声波,是实现材料缺陷无损检测的重要环节。借助Abaqus有限元分析工具,基于激光超声热弹机制建立了轴对称铝板的表面缺陷模型,模拟了激光激发产生的表面波在材料中的传播特性及其与铝板缺陷的相互作用过程。数值模拟实验表明,铝板表面缺陷的分布深度值越大,反射波越强,并且当缺陷深度达到一定程度时,反射波的幅值趋于稳定;但缺陷的分布宽度对于反射波的影响则十分有限。所得结论为基于激光超声的材料缺陷的定量检测及识别提供有效的理论依据。     

Vibration characteristics of aluminum surface subjected to ultrasonic waves and their effect on wetting behavior of solder droplets

The vibration characteristics of an aluminum surface subjected to ultrasonic waves were investigated with a combination of numerical simulation and experimental testing. The wetting behavior of solder droplets on the vibrating aluminum surface was also examined. The results show that the vibration pattern of the aluminum surface is inhomogeneous. The amplitude of the aluminum surface exceeds the excitation amplitude in some zones, while the amplitude decreases nearly to zero in other zones. The distribution of the zero-amplitude zones is much less dependent on the strength of the vibration than on the location of the vibration source. The surface of the liquid solder vibrates at an ultrasonic frequency that is higher than the vibration source, and the amplitude of the liquid solder is almost twice that of the aluminum surface. The vibration of the surface of the base metal (liquid solder) correlates with the oxide film removal effect. Significant removal of the oxide film can be achieved within 2 s when the amplitude of the aluminum surface is higher than 5.4 μm or when the amplitude of the liquid solder surface is higher than 10.2 μm.     

Effects of high power ultrasonic vibration on temperature distribution of workpiece in dry creep feed up grinding

Temperature history and distribution of steel workpiece (X20Cr13) was measured by a high tech infrared camera under ultrasonic assisted dry creep feed up grinding. For this purpose, a special experimental setup was designed and fabricated to vibrate only workpiece along two directions by a high power ultrasonic transducer. In this study, ultrasonic effects with respect to grinding parameters including depth of cut (a_e), feed speed (v_w), and cutting speed (v_s) has been investigated. The results indicate that the ultrasonic vibration has considerable effect on reduction of temperature, depth of thermal damage of workpiece and width of temperature contours. Maximum temperature reduction of 25.91% was reported at condition of v_s = 15 m/s, v_w = 500 mm/min, a_e = 0.4 mm in the presence of ultrasonic vibration.     

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。     

微织构超声振动铣削系统的研究

为了在金属切削过程中在7075铝合金表面形成稳定的微织构以提高其服役性能,提出一种微织构超声铣削加工工艺。为此,该文首先基于运动合成原理获得了刀尖的运动轨迹特征和工件表面的织构形貌特征。然后,基于等效电路原理和传输矩阵法建立了超声铣削系统的频率方程,并应用牛顿迭代法获得了准确的数值解,通过有限元软件对建立的超声振动系统分别进行模态分析和谐响应分析,获得了具有微织构特征的纵扭复合超声铣削系统。最后,对加工制造出的微织构纵扭复合超声铣削系统进行振动测试、切削力测试和加工测试,结果表明:工件表面形成的"鱼鳞网纹"微观织构能够改变其润湿性能。     

使用Inventor软件的超声变幅杆模态分析

使用Inventor软件建立超声变幅杆三维实体模型,并利用软件中集成的ANSYS有限元分析模块对其进行了模态分析,得到变幅杆各阶振型和纵向振动固有频率。分析结果表明,固有频率的模态分析值与实测值接近。Inventor软件将形状设计与力学分析集为一体,方便了变幅杆的设计。     

Study on a novel omnidirectional ultrasonic cavitation removal system for Microcystis aeruginosa

Microcystis aeruginosa, as a typical alga, produces microcystin with strong liver toxicity, seriously endangering the liver health of human and animals. Inhibiting the bloom of the Microcystis aeruginosa in lakes becomes a significant and meaningful work. Ultrasonic cavitation is currently considered to be the most environmentally friendly and effective method for the removal of Microcystis aeruginosa. However, the commercialized ultrasonic algae removal systems require multi-Langevin transducers to achieve omnidirectional ultrasonic irradiation due to the single irradiation direction of the Langevin transducer, resulting in the complex design and high energy consumption. To achieve a low-cost, simple structure, and high-efficiency algae removal system, a novel omnidirectional ultrasonic cavitation removal system for Microcystis aeruginosa is proposed. The proposed system is major composed of a novel omnidirectional ultrasonic transducer, which generates the omnidirectional ultrasonic irradiation by its shaking-head motion coupled by two orthogonal bending vibration modes. Modal simulation, sound field simulation, and cavitation bubble radius simulation are first carried out to optimize the geometric sizes of the proposed transducer and verify the correctness of the omnidirectional ultrasonic irradiation principle. Then the vibration characteristics of the transducer prototype are measured by vibration tests and impedance tests. Finally, the feasibility and effectiveness of the proposed omnidirectional ultrasonic removal system for Microcystis aeruginosa are evaluated through the algae removal experiments. The experimental results exhibit that the algal cells damaged by ultrasonic irradiation from the proposed system do not have the ability to self-repair. In addition, the algal removal rates reached 55.41% and 72.97% after 30 min of ultrasonic treatment when the corresponding ultrasonic densities are 0.014 W/mL and 0.021 W/mL, respectively. The proposed omnidirectional ultrasonic algae removal system significantly simplifies the configuration and reduces energy consumption, presenting the potential promise of algae removal and environmental protection.