Experimental analysis of interface contact behavior using a novel image processing method

The spatial and temporal evolution of real contact area of contact interface with loads is a challenge. It is generally believed that there is a positive linear correlation between real contact area and normal load. However, with the development of measuring instruments and methods, some scholars have found that the growth rate of real contact area will slow down with the increase of normal load under certain conditions, such as large-scale interface contact with small roughness surface,which is called the nonlinear phenomenon of real contact area. At present, there is no unified conclusion on the explanation of this phenomenon. We set up an experimental apparatus based on the total reflection principle to verify this phenomenon and analyze its mechanism. An image processing method is proposed, which can be used to quantitative analysis micro contact behaviors on macro contact phenomenon. The weighted superposition method is used to identify micro contact spots, to calculate the real contact area, and the color superimposed image is used to identify micro contact behaviors.Based on this method, the spatiotemporal evolution mechanism of real contact area nonlinear phenomena is quantitatively analyzed. Furthermore, the influence of nonlinear phenomenon of real contact area on the whole loading and unloading process is analyzed experimentally. It is found that the effects of fluid between contact interface, normal load amplitude and initial contact state on contact behavior cannot be ignored in large-scale interface contact with small roughness surface.     

Relationship between the real contact area and contact force in pre-sliding regime

The pre-sliding regime is typically neglected in the dynamic modelling of mechanical systems. However, the change in contact state caused by static friction may decrease positional accuracy and control precision. To investigate the relationship between contact status and contact force in pre-sliding friction, an optical experimental method is presented in this paper.With this method, the real contact state at the interface of a transparent material can be observed based on the total reflection principle of light by using an image processing technique. A novel setup, which includes a pair of rectangular trapezoidal blocks, is proposed to solve the challenging issue of accurately applying different tangential and normal forces to the contact interface. The improved Otsu's method is used for measurement. Through an experimental study performed on polymethyl methacrylate(PMMA), the quantity of contact asperities is proven to be the dominant factor that affects the real contact area. The relationship between the real contact area and the contact force in the pre-sliding regime is studied, and the distribution of static friction at the contact interface is qualitatively discussed. New phenomena in which the real contact area expands along with increasing static friction are identified. The aforementioned relationship is approximately linear at the contact interface under a constant normal pressure, and the distribution of friction stress decreases from the leading edge to the trailing edge.     

Measurement of dynamic characteristics of metal sheet under laser shock

A new approach is developed to measure the dynamic characteristics of metal sheet under laser shock,including deformation velocity,strain,and strain rate.The detecting laser beam is partially shaded by the target deformation induced by the laser action.A photodiode transforms the received beam intensity real time into an electrical signal which could record the process of the target deformation.The functional relation between the electrical signal and the deformation of the metal sheet is derived.The deformation curve of a thin aluminum and the velocity curve of its deformation are also obtained during the exper-iment.The results indicate that the average velocity of the elastic deformation of the target can reach 2.999×10 3 m/s in the central area.This new method provides an approach in the study of the effect of strain rate on deformation.     

The effect of laser patterning parameters on fluorine-doped tin oxide films deposited on glass substrates

The purpose of this study is to pattern the fluorine-doped tin oxide thin film deposited on the soda-lime glass substrates for touch screen applications by ultraviolet laser. The patterned film structures provide the electrical isolation and prevent the electrical contact from each region for various touch screens. The surface morphology, edge quality, three-dimensional topography, and profile of isolated lines and electrode structures after laser patterning were measured by a confocal laser scanning microscope. Moreover, a four-point probe instrument was used to measure the sheet resistance before and after laser patterning on film surfaces and also to discuss the electrical property at different laser spot overlaps. After laser patterning, a high overlapping area of laser spot was used to pattern the electrode layer on film surfaces that could obtain an excellent machined quality of edge profile. All sheet resistance values of film surfaces near the isolated line edge were larger than the original ones. Moreover, the sheet resistance values increased with increasing laser spot overlapping area.     

An experimental method for quantitative analysis of real contact area based on the total reflection optical principle

The simulation of real contact area between materials is foundationally important for the contact mechanics of mechanical structures. The Greenwood and Williamson(GW) model and the Majumdar(MB) model are the basic models in this field, which are widely accepted and proven to be valid in many experiments and engineering. Although the contact models have evolved considerably in recent years, the verifications of the models are most based on the indirect methods such as electrical conductivity and contact stiffness, because of the lack of effective methods to directly measure the variation of contact surface. In this paper, the total reflection(TR) method is introduced into the verification of contact models.An experiment system based on TR method is constructed to measure the real contact area of two PMMA specimens. The comparison analysis between the results of experiment and models suggests that the experiment result has the same trend with simulation, the MB model has better agreement with the experimental result because this method can take into account the variation of radius and the merging of asperities, while the GW model has a huge deviation because of the dependence on resolution and the lack of considering the variation of radius and asperity's merging process. Taking the interaction of asperities into account could give a better result that is closer to the experiment. Our results and analysis prove that the experimental methods in this paper could be used as a more direct and valid method to quantitatively measure the real contact area and to verify the contact models.     

Line-laser-based yarn shadow sensing break sensor

In this paper, a line-laser-based yarn break sensor is proposed. In the proposed sensor, yarns are illuminated by a line laser placed on one side of the yarn plane. A screen is placed on the other side and the image formed on the screen is detected by a camera. The total number of yarns is compared with the total number of shadows formed by the yarns or the total number of light spots formed due to the distances between yarns. If the total number of yarns to be detected is greater than the total number of shadows or light spots formed due to the distances between the yarns, the sensor warns of breaking. In the proposed method, evaluation is made using only light spots or shadows formed by the yarns. Consequently, the yarn type, structure, color, or dimensions do not affect the results.Design principles of the line-laser-based yarn break sensor, which consists of a screen and a Charged Coupled Device (CCD) camera, are presented. The screen displays the shadows formed by the yarns and the light spots formed due to the distances between them. The CCD camera detects the image on the screen. Formation of the shadows by the yarns is explained and an analytical formula that expresses the dimensions of the shadows is obtained. The detection area of the sensor is expressed relative to the total number of yarns, yarn thickness, and distances between the yarns. Line laser radiation angle and light spot intensity equations are obtained relative to the width of the detection area and the height of the line laser placement. The screen length is obtained relative to the number of yarns and the placement of the laser, the yarn plane, and the screen.Different placement situations of the line laser (transmitter), the screen, and the CCD camera (receiver) relative to the yarn plane are discussed. An experimental setup is developed to test the system. The image formed on the screen is studied.     

Evolution of real contact area during stick-slip movement observed by total reflection method

We build an experiment system based on total reflection(TR) method to observe the evolution of real contact area of polymethyl methacrylate(PMMA) in the continual stick-slip movement. The bilateral friction is adopted to overcome the bending moment in the lateral friction movement. Besides some classical phenomena of stick-slip movement such as periodical slow increase of frictional force in sticking phase and a sudden drop when slipping, a special phenomenon that the contact area increases with the tangential force is observed, which was called junction growth by Tabor in 1959.Image processing methods are developed to observe the variation of the junction area. The results show that the center of the strongest contact region will keep sticking under the tangential force until the whole slipping, the strongest point undergoes three stages in one cycle, which are named as sticking stage, fretting stage, and cracking stage, respectively. The combined analysis reveals a physical process of stick-slip movement: the tangential force causes the increase of the real contact area, which reduces the pressure between the contact spots and finally leads to the slipping. Once slipping occurs,the real contact area drops to the original level resulting in the pressure increase to the original level, which makes the sticking happen again.     

Elastic contact mechanics: Percolation of the contact area and fluid squeeze-out

The dynamics of fluid flow at the interface between elastic solids with rough surfaces depends sensitively on the area of real contact, in particular close to the percolation threshold, where an irregular network of narrow flow channels prevails. In this paper, numerical simulation and experimental results for the contact between elastic solids with isotropic and anisotropic surface roughness are compared with the predictions of a theory based on the Persson contact mechanics theory and the Bruggeman effective medium theory. The theory predictions are in good agreement with the experimental and numerical simulation results and the (small) deviation can be understood as a finite-size effect. The fluid squeeze-out at the interface between elastic solids with randomly rough surfaces is studied. We present results for such high contact pressures that the area of real contact percolates, giving rise to sealed-off domains with pressurized fluid at the interface. The theoretical predictions are compared to experimental data for a simple model system (a rubber block squeezed against a flat glass plate), and for prefilled syringes, where the rubber plunger stopper is lubricated by a high-viscosity silicon oil to ensure functionality of the delivery device. For the latter system we compare the breakloose (or static) friction, as a function of the time of stationary contact, to the theory prediction.     

Contact electrification between polymers and steel

Electrification occurs when metals are put into contact with polymers, and the mechanism is still not fully understood. In this paper, experimental study of contact electrification between a metal and polymers was conducted. Effects of contact cycle, load, and nominal area on electrification were investigated. Results showed that electrification charge increased with real contact area. However, experimental results showed that charge density increased with nominal area and decreased with load. The key factor that determined the charge density was contact stress. Charge density decreased with contact stress linearly. A quantitative relationship between charge density and contact stress was proposed.     

A review on the effects of different parameters on contact heat transfer

In this paper, a complete literature review for thermal contact between fixed and periodic contacting surfaces and also thermal contact between exhaust valve and its seat in internal combustion engines is presented. Furthermore, the effects of some parameters such as contact pressure, contact frequency, the contacting surfaces topography and roughness, curvature radius of surfaces, loading–unloading cycles, gas gap conductance and properties, interface interstitial material properties, surfaces coatings and surfaces temperature on thermal contact conductance are investigated according to the papers presented in this field. The reviewed papers and studies included theoretical/ analytical/experimental and numerical studies on thermal contact conductance. In studying the thermal contact between exhaust valve and its seat, most of the experimental studies include two axial rods as the exhaust valve, and seat and the one ends of both rods are considered at constant and different temperatures. In the experimental methods, the temperatures of multi-points on rods are measured in different conditions, and thermal contact conductance is estimated using them.     

Experimental and theoretical study of harmonic generation at contacting interface

The second harmonic generation behavior of a contacting interface has been evaluated experimentally and discussed theoretically in the light of a nonlinear interface model. Two aluminum blocks were mated together to constitute a contact interface and subjected to normal compressive loading. A 5 MHz longitudinal toneburst wave was sent to the interface in the normal direction and the transmitted wave was recorded, from which the fundamental and the second harmonic components were extracted. A nonlinearity parameter was obtained as the ratio of the second harmonic amplitude to the squared fundamental amplitude. From the measured contact pressure dependence of the transmitted fundamental amplitude, the linear and the second-order interfacial stiffness parameters were identified, which enabled the evaluation of the nonlinearity parameter based on the theoretical model. The theoretical contact pressure dependence of the nonlinearity parameter was found to be in good qualitative agreement with the experimental results.     

Wavelength dependence of transient photovoltage polarity

Using pulsed laser with different wavelengths, transient photovoltage (TPV) is investigated for the sandwich device of indium tin oxide (ITO)/poly (2-methoxy-5-(2′-ethylhexyloxy)-1, 4-phenylenevinylene) (MEH-PPV) (500 nm)/Al. At laser wavelength of 500 nm, a 0.1 millisecond negative TPV signal appears followed by a positive one lasting 40-80 milliseconds. With increasing laser wavelength, the negative signal becomes weak and disappears when wavelengths λ?560 nm. This work demonstrates the process of exciton dissociation at the interface between ITO and MEH-PPV. A new method measuring the relative dissociation rate at the interface between polymer and electrode is introduced. It is estimated that the dissociation rate at Al interface is 4-8 times of that at the ITO interface.     

Contact ratio of rough surfaces with multiple asperities in mixed lubrication at high pressures

Relative optical intensity interference was used to measure the lubrication film thickness when four kinds of polyalphaolefin (PAO) were used as lubricants confined between a smooth sapphire disc surface and a rough steel ball surface. Maximum Hertz contact pressure up to 3 GPa was applied in the central part of the contact region in mixed lubrication. It was found that the contact ratio (the ratio of real contact region to the whole nominal contact region) is related to the film thickness, the applied pressure, the surface roughness and the rolling speed, and so on. Contact ratio evidently reduces as lubrication film thickness or rolling speed increases. Quantitative relationship between the contact ratio and the influence factors was summarized based on the nonlinear fitting of experimental measurements. A formula was put forward to calculate the contact ratio at high pressure conditions according to the current experimental results.     

粗糙接触界面超声非线性效应的概率模型

提出描述粗糙接触界面超声非线性效应的概率模型,利用分段均匀概率函数描述粗糙接触界面劲度系数变化,结合表面粗糙峰的几何分布特征,得到界面粗糙度和两侧表面相对运动对声波的非线性调制作用。实验观测了铝合金材料的粗糙接触界面的高次谐波现象和阈值现象,进一步分析了归一化非线性参数与界面加载压力、粗糙度之间的关系。实验测量结果与概率模型的理论预测一致,证明了该模型的正确性,为利用超声非线性效应评价粗糙接触界面提供了理论依据。     

低温固体界面间接触导热“hysteresis”现象的研究

文中以强化低温固体界面间的接触导热为出发点 ,实验测定了低温环境下两种金属界面在过度加载前后的接触热导值 ,指出过度加载是一种经济有效的强化导热方法 ,对卸载过程接触热导率大于同次加载过程接触热导的“hysteresis”现象产生机理进行了分析     

Combustion kinetic model development using surrogate model similarity method

An ideal combustion kinetic model needs to be validated by different experimental targets over a wide range of temperatures and pressures that represent operating conditions in real engines. However, conditions of laboratory experiments for model validation are often limited by the constraint of experimental techniques. In order to improve model predictions under certain conditions (for example, at a relatively higher pressure), it is often needed to use the experimental data obtained under other conditions. In this work, the surrogate model similarity (SMS) method is proposed to find the experimental conditions or targets for model optimisation under certain conditions where the experiments are hard to be conducted. The similarity coefficient is calculated by the cosine similarity between the characteristic coefficients (vectors) of the High Dimensional Model Representation (HDMR) models for different model predictions. A larger similarity coefficient represents a closer relationship between two model predictions. The experimental data with larger similarity coefficients could be more effective to model uncertainty reduction under the concerned conditions. To demonstrate this method, simulations were conducted for two selected combustion systems with hydrogen or methanol as the fuel. In addition to its strength in available experimental data selection for model optimization, this method can be used to screen out experimental targets with strong constraint effect beforehand, thus providing an effective way to maximise utilisation of experimental resources.     

Effect of laser energy on the deformation behavior in microscale laser bulge forming

Microscale laser bulge forming is a high strain rate microforming method using high-amplitude shock wave pressure induced by pulsed laser irradiation. The process can serve as a rapidly established and high precision technique to impress microfeatures on thin sheet metals and holds promise of manufacturing complex miniaturized devices. The present paper investigated the forming process using both numerical and experimental methods. The effect of laser energy on microformability of pure copper was discussed in detail. A 3D measuring laser microscope was adopted to measure deformed regions under different laser energy levels. The deformation measurements showed that the experimental and numerical results were in good agreement. With the verified simulation model, the residual stress distribution at different laser energy was predicted and analyzed. The springback was found as a key factor to determine the distribution and magnitude of the compressive residual stress. In addition, the absorbent coating and the surface morphology of the formed samples were observed through the scanning electron microscope. The observation confirmed that the shock forming process was non-thermal attributed to the protection of the absorbent coating.     

Quantification of patellofemoral joint contact area using magnetic resonance imaging

To describe a method for quantifying patellofemoral joint contact area using magnetic resonance imaging (MRI), we used a repeated measures design using cadaver specimens. The use of contact area obtained from cadaveric specimens for biomechanical modeling does not permit investigators to assess the inter-subject variability in contact area as a result of patellofemoral pathology or malalignment. Therefore, a method for measuring patellofemoral joint contact area in-vivo is necessary. Six fresh frozen unmatched human cadaver knees were thawed at room temperature and minimally dissected to permit insertion of a pressure sensitive film packet into the suprapatellar pouch. A custom loading apparatus was designed to apply a compressive load to the patellofemoral joint at 30 degrees of flexion. Simultaneous measurement of contact area was made using both the pressure sensitive film technique and MRI. The intraclass correlation coefficient (ICC) and coefficient of variation were used to compare the agreement between the two methods and to assess the repeatability of the MRI method. Good agreement was found between the MRI and pressure sensitive film techniques (ICC 0.91; CV 13%). The MRI technique also was found to be highly reproducible (ICC 0.98; CV 2.3%). MRI assessment of patellofemoral joint contact area was found to be comparable to the established pressure sensitive film technique. These results suggest that this method may be a valuable tool in quantifying patellofemoral joint contact area in-vivo. Quantification of the patellofemoral joint stress has been dependent on patellofemoral joint contact area obtained from cadaver specimens, thereby negating the potential influence of subject specific variability. Developing a non-invasive technique to evaluate contact area will assist researchers and/or clinicians in obtaining patient-specific contact area data to be used in biomechanical analyses and clinical decision making.     

激光加载下金属锡材料微喷颗粒与低密度泡沫混合实验研究

金属材料的微喷是冲击加载下金属表面发生的一种动态破碎现象,微喷研究在很多领域都具有重要意义,包括惯性约束聚变(ICF)和烟火制造等.由于激光实验特有的优势,近几年国内外开展了很多利用强激光驱动冲击加载研究材料微喷过程的实验.利用泡沫材料对微喷颗粒进行静态软回收虽然可以获得颗粒的形态分布、颗粒尺寸及颗粒质量等定量结果,但并不能反演微喷颗粒从进入泡沫到停滞过程中的动态混合过程.为此,在神光Ⅱ升级装置上利用皮秒脉冲激光照射金丝产生高能X射线,实现了对锡微喷颗粒与低密度泡沫混合过程的高时间分辨和高空间分辨背光照相.背光图像面密度结果证实微喷颗粒在泡沫中并没有发生二次破碎.静态回收结果表明,在锡材料与泡沫紧贴放置的情况下,微喷颗粒在泡沫中的穿透深度随着加载压强升高呈现先增大后减小的规律,与非紧贴放置的实验结果有明显的差别.     

Study of High-Order Harmonic at VUV/XUV

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