Measurements of Forces and Temperature Fields in High-Speed Machining of 6061-T6 Aluminum Alloy

This study focuses on experimental modeling of dry high-speed machining at 30 m/s cutting velocity using 6061-T6 aluminum alloy. A modified Hopkinson bar apparatus is employed to simulate orthogonal machining, a focused array of mercury–cadmium–tellurium infrared detectors is used to measure the temperature distribution around the tool tip, and a three-component quartz force transducer is utilized in measuring the cutting and feed forces. The resulting measurements confirm the assumption of steady-state cutting and allow for estimation of the partition of cutting work into heating, shear, and momentum changes in the chip. In an earlier study, measurements of temperature distributions showed little heating of the finished surface. Therefore, a study of the temperature fields generated during machining with a cutting tool that has a wear-land was performed. The wear-land contributes significantly to the heating of the workpiece and, at this speed, is the most likely mechanism for the generation of residual stresses and a temperature rise on the finished surface.     

基于Christopherson迭代的超精密加工流场分析方法

随着特种超精密加工技术的发展,复杂流体被越来越多地用于超精密加工工艺中。超精密加工流场分析具有几何特征复杂、流体本构特性多样、流体边界为自有边界等特点,传统流体数值分析方法难以实现可靠分析。从流体的一般特性出发,将D. G. Christopherson提出的非负二阶偏微分系统的超松弛迭代方法用于超精密加工流场分析,建立了适应性与可靠性兼顾的流场分析方法。以磁流变抛光为例,开展了抛光区域压力场数值计算,结果表明所得压力分布形态正确,且分布从x轴正半轴延伸到负半轴,与郑立功等人的实验测定结果一致。另外,基于Kistler力传感器对磁流变抛光过程的法向压力在0.1~0.3 mm浸深段进行了在位测量,发现计算与实验结果偏差均小于20%。表明了该方法的有效性与准确性。     

低密度PMP聚合物泡沫成型控制

为了进一步提高低密度聚-4-甲基-1-戊烯（PMP）聚合物泡沫的成型性能,满足惯性约束聚变物理实验的需求,采用热诱导倒相法结合原位成型和机械加工来进行低密度PMP聚合物泡沫的成型控制研究。 研究结果表明：在热诱导倒相法制备过程中,聚合物溶液形成凝胶后施加气压,再将其在加压状态下在液氮中淬火,可以大大减少得到的PMP/溶剂混合体中大的孔洞,提高其强度,并且在溶剂脱除后PMP泡沫收缩变小,微观结构更加均匀, 孔径更加细小。采用原位成型和机械加工的方法,可以实现低密度PMP聚合物泡沫的精密成型控制。     

光学零件加工主要难点的分析

本文根据光学零件在当今科学技术中的重要作用,阐述了球面及非球面光学零件的各种加工方法及其难点,讨论解决加工难点的方向和可行方法。     

Design and fabrication of low-cost X-ray mirrors

Traditional X-ray mirrors made from Zerodur and silicon carbide are quite expensive because of the fabrication cost involved in achieving a very high surface finish of the order of 15 Å or better. The cost of X-ray mirrors can be greatly reduced by using replication methods for producing the grazing-incidence type mirrors. This paper presents the optical and optomechanical design for a Wolter type I mirror and its mount, and the fabrication method used to produce a low-cost replicated nickel mirror. The finite element analysis results for this mirror are also presented. The design and fabrication steps for the aluminium master mandrel used for replication are also discussed. A surface finish of better than 15 Å was achieved for a such an electroformed mirror with a wall thickness of only 1 mm.     

Roughness measurement of metallic surfaces based on the laser speckle contrast method

A method of measuring surface roughness of flat lapped, ground and polished metallic surfaces, by the far-field speckle contrast method is presented in this paper. The laser speckle contrast technique depends on the existence of an approximately linear relationship between the speckle contrast and the roughness of the illuminated surface. Initially it was shown that the linear relationship existed up to 0.1 μm Ra (centre-line average) roughness using Helium–Neon light, after which a saturation effect was observed. The effect of varying the incident angle of illumination was investigated with a view to extending the measurement range. The use of high incident angles of illumination has been found to increase the surface roughness range up to 0.4 μm measurement Ra.     

Intensity profile distortion at the processing image plane of a focused femtosecond laser below the critical power: Analysis and counteraction

Femtosecond laser surface processing of materials allows for precise micro or sub-micrometer machining with restricted detrimental side effects. Thus, fine control of the laser intensity distribution (repeatability) in the processing plane is of outmost importance for industrial implementation. In this paper, we study the influence on non-linear effects on the machining quality. We experimentally study the profiles of cavities machined at the image plane of a focused femtosecond laser for a large set of fluences on stainless steel below the critical power. A strong distortion of the cavities is observed for high energetic levels. A beam analysis performed in the machining conditions reveals that the cavity profile follows the laser beam profile even at high fluences where the beam undergoes an increasing distortion. Numerical calculations of the laser beam distribution taking a Kerr effect into account are presented showing a good agreement with the experimental laser profile. To counteract the beam distortion at high fluences, we propose and successfully employ a robust solution consisting in geometrically forming the image processing plane before the laser focusing point. This ensures a beam profile free of distortion even at high fluences. Experimental evidence is made, showing a significant quality increase of the cavity profiles with an image plane placed before the focus point.     

Study of the parameters in electrical discharge machining through response surface methodology approach

Whereas the efficiency of traditional cutting processes is limited by the mechanical properties of the processed material and the complexity of the workpiece geometry, electrical discharge machining (EDM) being a thermal erosion process, is subject to no such constraints. The lack of correlations between the cutting rate, the surface finish and the physical material parameters of this process made it difficult to use. This paper highlights the development of a comprehensive mathematical model for correlating the interactive and higher order influences of various electrical discharge machining parameters through response surface methodology (RSM), utilizing relevant experimental data as obtained through experimentation. The adequacy of the above the proposed models have been tested through the analysis of variance (ANOVA). Optimal combination of these parameters was obtained for achieving controlled EDM of the workpieces.     

Computer simulation of two-dimensional electrolyte flow in electrochemical machining

A mathematical model and a method for numerical modeling of two-dimensional electrolyte flow in the interelectrode gap during electrochemical machining (ECM) are presented. Programs for modeling electrolyte flow and observing the distribution of ECM parameters are designed. The modeling results are compared with experimental data on continuous ECM and ECM with a vibrating tool.Translated from Elektrokhimiya, Vol. 41, No. 1, 2005, pp. 102–110.Original Russian Text Copyright © 2005 by Dabrowski, Paczkowski.