The minimum rolling thickness in asymmetrical rolling was analyzed compared with that in symmetrical rolling. The differential equilibrium equations on forces were established to calculate the asymmetrical rolling for...The minimum rolling thickness in asymmetrical rolling was analyzed compared with that in symmetrical rolling. The differential equilibrium equations on forces were established to calculate the asymmetrical rolling force equation by slab method. An implicit expression of the minimum rolling thickness was then derived from the rolling force equation and Hitehcock equation. The results show that permissible minimum rolling thickness of asymmetrical rolling only exists within a specific range of cross-shear ratio, which is termed the cross-shear zone proportion of the whole de- formation zone. Numerical computation was carried out to obtain a discrete solution of the minimum rolling thick- ness. Experiments were designed to investigate the influence factors on cross-shear ratio. Finally, experimental re- sults prove the correctness of the improved formula given.展开更多
A novel approach is proposed for computing the minimum thickness of a metal foil that can be achieved by asymmetric rolling using rolls with identical diameter. This approach is based on simultaneously solving Tseliko...A novel approach is proposed for computing the minimum thickness of a metal foil that can be achieved by asymmetric rolling using rolls with identical diameter. This approach is based on simultaneously solving Tselikov equation for the rolling pressure and the modified Hitchcock equation for the roller flattening. To minimize the effect of the elastic deformation on the equal flow per second during the ultrathin foil rolling process, the law of conservation of mass was employed to compute the proportions of the forward slip, backward slip, and the cross shear zones in the contact arc, and then a formula was derived for computing the minimum thickness for asymmetric rolling. Experiment was conducted to find the foil minimum thickness for 304 steel by asymmetric rolling under the asymmetry ratios of 1.05, 1.15 and 1.30. The experimental results are in good agreement with the calculated ones. It was validated that the proposed formula can be used to calculate the foil minimum thickness under the asymmetric rolling condition.展开更多
High pressure and water-bearing caverns ahead of a karst tunnel face tend to cause geological disasters, such as water and mud bursts. So, the determination of safe thickness of the reserved rock plug is a key technic...High pressure and water-bearing caverns ahead of a karst tunnel face tend to cause geological disasters, such as water and mud bursts. So, the determination of safe thickness of the reserved rock plug is a key technical problem to be solved for karst tunnel construction. Based on the Hoek-Brown nonlinear failure criterion, the minimum safe thickness of rock plug was investigated in the light of the limit analysis theory. On the basis of the proposed failure mode, the expression of the minimum thickness for rock plug was obtained by means of upper bound theorem in combination with variational principle. The calculation results show the influence of each parameter on safe thickness and reveal the damage range of rock plug. The proposed method is verified by comparing the results with those of the drain cavern of Maluqing Tunnel. The research shows that with the increase of compressive strength and tensile strength as well as constant A of Hoek-Brown criterion, the safe thickness decreases, whereas with the increase of cavern pressure, tunnel diameter, and constant B from Hoek-Brown criterion, the safe thickness increases. Besides, the tensile strength, or constants A and B affect the shear failure angle of rock plug structure, but other parameters do not. In conclusion, the proposed method can predict the minimum safe thickness of rock plug, and is useful for water burst study and prevention measures of tunnels constructed in high-risk karst regions.展开更多
Monocrystalline Cu exhibits excellent electrical and signal-transmission properties due to its absence of grain boundaries,making it a critical material for the production of micro-machinery and micro-components;howev...Monocrystalline Cu exhibits excellent electrical and signal-transmission properties due to its absence of grain boundaries,making it a critical material for the production of micro-machinery and micro-components;however,achieving ultrahigh precision and ultralow damage machining of functional devices using traditional techniques such as grinding and polishing is extremely challenging.Consequently,nanocutting has emerged as an efficient means to fabricate monocrystalline materials with complex surface characteristics and high surface integrity.Nevertheless,the macroscopic cutting theory of metal materials cannot be applied to nanocutting.Accordingly,in this paper,both simulations and experiments were conducted to examine the chip deformation mechanisms of monocrystalline Cu.First,large-scale molecular dynamics(MD)simulations were conducted to gain a comprehensive understanding of the deformation behavior during nanocutting.This included examining the influencing factors and the variation patterns of the chip deformation coefficient,cutting force,and minimum cutting thickness.Subsequently,nanocutting experiments were performed using a specially designed nanocutting platform with high-resolution online observation by scanning electron microscopy.The experimental results served to verify the accuracy and reliability of theMDmodeling,as they exhibited excellent consistency with the simulated results.Although this work considered monocrystalline Cu,it is believed that the elucidated chip deformation mechanisms could also be applied to other face-centered-cubic metals.These results are of great value for advancing the understanding of the mechanisms of ultraprecision cutting.展开更多
Titanium alloys are widely used in the aviation and aerospace industries due to their unique mechanical and physical properties.Specifically,thin-walled titanium(Ti)cylinders have received increasing attention for the...Titanium alloys are widely used in the aviation and aerospace industries due to their unique mechanical and physical properties.Specifically,thin-walled titanium(Ti)cylinders have received increasing attention for their applications as rocket engine casings,aircraft landing gear,and aero-engine hollow shaft due to their observed improvement in the thrust-to-weight ratio.However,the conventional cutting(CC)process is not appropriate for thin-walled Ti cylinders due to its low thermal conductivity,high strength,and low stiffness.Instead,high-speed ultrasonic vibration cutting(HUVC)assisted processing has recently proved highly effective for Ti-alloy machining.In this study,HUVC technology is employed to perform external turning of a thinwalled Ti cylinder,which represents a new application of HUVC.First,the kinematics,tool path,and dynamic cutting thickness of HUVC are evaluated.Second,the phenomenon of mode-coupling chatter is analyzed to determine the effects and mechanism of HUVC by establishing a critical cutting thickness model.HUVC can increase the critical cutting thickness and effectively reduce the average cutting force,thus reducing the energy intake of the system.Finally,comparison experiments are conducted between HUVC and CC processes.The results indicate that the diameter error rate is 10%or less for HUVC and 51%for the CC method due to a 40%reduction in the cutting force.In addition,higher machining precision and better surface roughness are achieved during thin-walled Ti cylinder manufacturing using HUVC.展开更多
The miniaturisation context leads to the rise of micro-machining processes. Micro-milling is one of the most flexible and fast of them. Although it is based on the same principles as macro-cutting, it is not a simple ...The miniaturisation context leads to the rise of micro-machining processes. Micro-milling is one of the most flexible and fast of them. Although it is based on the same principles as macro-cutting, it is not a simple scaling-down of it. This down-sizing involves new phenomena in the chip formation, such as the minimum chip thickness below which no chip is formed. This paper presents a review of the current state of the art in this field from an experimental and a numerical point of view. A 2D finite element model is then developed to study the influence of the depth of cut on the chip formation. After the model validation in macro-cutting, it highlights the phenomena reported in literature and allows to perform a minimum chip thickness estimation.展开更多
Alumina dispersion-strengthened copper (ADSC), as a representative particle-reinforced metal matrix composite (PRMMC), exhibits superior wear resistance and high strength. However, challenges arise in their processabi...Alumina dispersion-strengthened copper (ADSC), as a representative particle-reinforced metal matrix composite (PRMMC), exhibits superior wear resistance and high strength. However, challenges arise in their processability because of the non-uniform material properties of biphasic materials. In particular, limited research has been conducted on the reinforcement mechanism and behavior of particles during material cutting deformation of PRMMC with nanoscale particles. In this study, a cutting simulation model for ADSC was established, separating the nanoscale reinforcement particles from the matrix. This model was utilized to analyze the interactions among particles, matrix, and tool during the cutting process, providing insights into chip formation and fracture. Particles with high strength and hardness are more prone to storing stress concentrations, anchoring themselves at grain boundaries to resist grain fibration, thereby influencing the stress distribution in the cutting deformation zone. Stress concentration around the particles leads to the formation of discontinuous chips, indicating that ADSC with high-volume fractions of particle (VFP) exhibits low cutting continuity, which is consistent with the results of cutting experiments. The tool tip that is in contact with particles experiences stress concentration, thereby accelerating tool wear. Cutting ADSC with 1.1% VFP results in tool blunting, which increases the radius of cutting edge from 0.5 to 1.9 μm, accompanied with remarkable coating delamination and wear. Simulation results indicate that the minimum uncut chip thickness increases from 0.04 to 0.07 μm as VFP increases from 0.3% to 1.1%. In conjunction with scratch experiments, MUCT increases with the augmentation of VFP. Computational analysis of the specific cutting force indicates that particles contribute to the material’s size effect. The results of this study provide theoretical guidance for practical engineering machining of ADSC, indicating its great importance for the process design of components made from ADSC.展开更多
Thin film and elastohydrodynamic lubrication regimes are rather young domains of tribology and they are still facing unresolved issues.As they rely upon a full separation of the moving surfaces by a thin (or very thin...Thin film and elastohydrodynamic lubrication regimes are rather young domains of tribology and they are still facing unresolved issues.As they rely upon a full separation of the moving surfaces by a thin (or very thin) fluid film,the knowledge of its thickness is of paramount importance,as for instance to developing lubricated mechanisms with long lasting and efficient designs.As a consequence,a large collection of formulae for point contacts have been proposed in the last 40 years.However,their accuracy and validity have rarely been investigated.The purpose of this paper is to offer an evaluation of the most widespread analytical formulae and to define whether they can be used as qualitative or quantitative predictions.The methodology is based on comparisons with a numerical model for two configurations,circular and elliptical,considering both central and minimum film thicknesses.展开更多
To reveal nonlinear dynamic rules of low viscosity fluid-lubricated tilting-pad journal bearings(TPJBs),the effects of design parameters on journal center orbits and dynamic minimum film thicknesses of water-lubricate...To reveal nonlinear dynamic rules of low viscosity fluid-lubricated tilting-pad journal bearings(TPJBs),the effects of design parameters on journal center orbits and dynamic minimum film thicknesses of water-lubricated TPJBs with and without static loads are investigated.The hydrodynamic bearing force used in the nonlinear dynamic analysis is an approximate analytical solution including the turbulence effect.The results reveal the methods for vibration suppression and load capacity improvement and give an optimal pivot offset and clearance ratio that can maximize the minimum film thickness.The results also show that four-pad TPJBs with loads between pads are preferred due to good dynamic performance and load capacity.This study would provide some guidance for nonlinear design of low viscosity fluid-lubricated TPJBs under dynamic loads.展开更多
基金Sponsored by National Natural Science Foundation of China(50974039)
文摘The minimum rolling thickness in asymmetrical rolling was analyzed compared with that in symmetrical rolling. The differential equilibrium equations on forces were established to calculate the asymmetrical rolling force equation by slab method. An implicit expression of the minimum rolling thickness was then derived from the rolling force equation and Hitehcock equation. The results show that permissible minimum rolling thickness of asymmetrical rolling only exists within a specific range of cross-shear ratio, which is termed the cross-shear zone proportion of the whole de- formation zone. Numerical computation was carried out to obtain a discrete solution of the minimum rolling thick- ness. Experiments were designed to investigate the influence factors on cross-shear ratio. Finally, experimental re- sults prove the correctness of the improved formula given.
基金Projects(51374069U1460107)supported by the National Natural Science Foundation of China
文摘A novel approach is proposed for computing the minimum thickness of a metal foil that can be achieved by asymmetric rolling using rolls with identical diameter. This approach is based on simultaneously solving Tselikov equation for the rolling pressure and the modified Hitchcock equation for the roller flattening. To minimize the effect of the elastic deformation on the equal flow per second during the ultrathin foil rolling process, the law of conservation of mass was employed to compute the proportions of the forward slip, backward slip, and the cross shear zones in the contact arc, and then a formula was derived for computing the minimum thickness for asymmetric rolling. Experiment was conducted to find the foil minimum thickness for 304 steel by asymmetric rolling under the asymmetry ratios of 1.05, 1.15 and 1.30. The experimental results are in good agreement with the calculated ones. It was validated that the proposed formula can be used to calculate the foil minimum thickness under the asymmetric rolling condition.
基金Project(2013CB036004)supported by the National Basic Research Program of ChinaProject(51378510)supported by the National Natural Science Foundation of ChinaProject(CX2014B069)supported by Hunan Provincial Innovation Foundation for Postgraduate,China
文摘High pressure and water-bearing caverns ahead of a karst tunnel face tend to cause geological disasters, such as water and mud bursts. So, the determination of safe thickness of the reserved rock plug is a key technical problem to be solved for karst tunnel construction. Based on the Hoek-Brown nonlinear failure criterion, the minimum safe thickness of rock plug was investigated in the light of the limit analysis theory. On the basis of the proposed failure mode, the expression of the minimum thickness for rock plug was obtained by means of upper bound theorem in combination with variational principle. The calculation results show the influence of each parameter on safe thickness and reveal the damage range of rock plug. The proposed method is verified by comparing the results with those of the drain cavern of Maluqing Tunnel. The research shows that with the increase of compressive strength and tensile strength as well as constant A of Hoek-Brown criterion, the safe thickness decreases, whereas with the increase of cavern pressure, tunnel diameter, and constant B from Hoek-Brown criterion, the safe thickness increases. Besides, the tensile strength, or constants A and B affect the shear failure angle of rock plug structure, but other parameters do not. In conclusion, the proposed method can predict the minimum safe thickness of rock plug, and is useful for water burst study and prevention measures of tunnels constructed in high-risk karst regions.
基金support of the National Natural Science Foundation of China(Grant No.51805371)the Innovation and Entrepreneurship Training Program of Tianjin University of Commerce(Grant No.202310069067).
文摘Monocrystalline Cu exhibits excellent electrical and signal-transmission properties due to its absence of grain boundaries,making it a critical material for the production of micro-machinery and micro-components;however,achieving ultrahigh precision and ultralow damage machining of functional devices using traditional techniques such as grinding and polishing is extremely challenging.Consequently,nanocutting has emerged as an efficient means to fabricate monocrystalline materials with complex surface characteristics and high surface integrity.Nevertheless,the macroscopic cutting theory of metal materials cannot be applied to nanocutting.Accordingly,in this paper,both simulations and experiments were conducted to examine the chip deformation mechanisms of monocrystalline Cu.First,large-scale molecular dynamics(MD)simulations were conducted to gain a comprehensive understanding of the deformation behavior during nanocutting.This included examining the influencing factors and the variation patterns of the chip deformation coefficient,cutting force,and minimum cutting thickness.Subsequently,nanocutting experiments were performed using a specially designed nanocutting platform with high-resolution online observation by scanning electron microscopy.The experimental results served to verify the accuracy and reliability of theMDmodeling,as they exhibited excellent consistency with the simulated results.Although this work considered monocrystalline Cu,it is believed that the elucidated chip deformation mechanisms could also be applied to other face-centered-cubic metals.These results are of great value for advancing the understanding of the mechanisms of ultraprecision cutting.
基金supported by the Defense Industrial Technology Development Program of China(No.JCKY2018601C209)。
文摘Titanium alloys are widely used in the aviation and aerospace industries due to their unique mechanical and physical properties.Specifically,thin-walled titanium(Ti)cylinders have received increasing attention for their applications as rocket engine casings,aircraft landing gear,and aero-engine hollow shaft due to their observed improvement in the thrust-to-weight ratio.However,the conventional cutting(CC)process is not appropriate for thin-walled Ti cylinders due to its low thermal conductivity,high strength,and low stiffness.Instead,high-speed ultrasonic vibration cutting(HUVC)assisted processing has recently proved highly effective for Ti-alloy machining.In this study,HUVC technology is employed to perform external turning of a thinwalled Ti cylinder,which represents a new application of HUVC.First,the kinematics,tool path,and dynamic cutting thickness of HUVC are evaluated.Second,the phenomenon of mode-coupling chatter is analyzed to determine the effects and mechanism of HUVC by establishing a critical cutting thickness model.HUVC can increase the critical cutting thickness and effectively reduce the average cutting force,thus reducing the energy intake of the system.Finally,comparison experiments are conducted between HUVC and CC processes.The results indicate that the diameter error rate is 10%or less for HUVC and 51%for the CC method due to a 40%reduction in the cutting force.In addition,higher machining precision and better surface roughness are achieved during thin-walled Ti cylinder manufacturing using HUVC.
文摘The miniaturisation context leads to the rise of micro-machining processes. Micro-milling is one of the most flexible and fast of them. Although it is based on the same principles as macro-cutting, it is not a simple scaling-down of it. This down-sizing involves new phenomena in the chip formation, such as the minimum chip thickness below which no chip is formed. This paper presents a review of the current state of the art in this field from an experimental and a numerical point of view. A 2D finite element model is then developed to study the influence of the depth of cut on the chip formation. After the model validation in macro-cutting, it highlights the phenomena reported in literature and allows to perform a minimum chip thickness estimation.
基金supported by the National Key R&D Program of China(Grant No.2023YFC2413303)the National Natural Science Foundation of China(Grant No.52075128)the Natural Science Foundation of Heilongjiang Province,China(Grant No.YQ2020E013).
文摘Alumina dispersion-strengthened copper (ADSC), as a representative particle-reinforced metal matrix composite (PRMMC), exhibits superior wear resistance and high strength. However, challenges arise in their processability because of the non-uniform material properties of biphasic materials. In particular, limited research has been conducted on the reinforcement mechanism and behavior of particles during material cutting deformation of PRMMC with nanoscale particles. In this study, a cutting simulation model for ADSC was established, separating the nanoscale reinforcement particles from the matrix. This model was utilized to analyze the interactions among particles, matrix, and tool during the cutting process, providing insights into chip formation and fracture. Particles with high strength and hardness are more prone to storing stress concentrations, anchoring themselves at grain boundaries to resist grain fibration, thereby influencing the stress distribution in the cutting deformation zone. Stress concentration around the particles leads to the formation of discontinuous chips, indicating that ADSC with high-volume fractions of particle (VFP) exhibits low cutting continuity, which is consistent with the results of cutting experiments. The tool tip that is in contact with particles experiences stress concentration, thereby accelerating tool wear. Cutting ADSC with 1.1% VFP results in tool blunting, which increases the radius of cutting edge from 0.5 to 1.9 μm, accompanied with remarkable coating delamination and wear. Simulation results indicate that the minimum uncut chip thickness increases from 0.04 to 0.07 μm as VFP increases from 0.3% to 1.1%. In conjunction with scratch experiments, MUCT increases with the augmentation of VFP. Computational analysis of the specific cutting force indicates that particles contribute to the material’s size effect. The results of this study provide theoretical guidance for practical engineering machining of ADSC, indicating its great importance for the process design of components made from ADSC.
文摘Thin film and elastohydrodynamic lubrication regimes are rather young domains of tribology and they are still facing unresolved issues.As they rely upon a full separation of the moving surfaces by a thin (or very thin) fluid film,the knowledge of its thickness is of paramount importance,as for instance to developing lubricated mechanisms with long lasting and efficient designs.As a consequence,a large collection of formulae for point contacts have been proposed in the last 40 years.However,their accuracy and validity have rarely been investigated.The purpose of this paper is to offer an evaluation of the most widespread analytical formulae and to define whether they can be used as qualitative or quantitative predictions.The methodology is based on comparisons with a numerical model for two configurations,circular and elliptical,considering both central and minimum film thicknesses.
基金This work is supported by National Basic Research Program of China(Grant No.2015CB057303)National Natural Science Foundation of China(Grant No.51775412).
文摘To reveal nonlinear dynamic rules of low viscosity fluid-lubricated tilting-pad journal bearings(TPJBs),the effects of design parameters on journal center orbits and dynamic minimum film thicknesses of water-lubricated TPJBs with and without static loads are investigated.The hydrodynamic bearing force used in the nonlinear dynamic analysis is an approximate analytical solution including the turbulence effect.The results reveal the methods for vibration suppression and load capacity improvement and give an optimal pivot offset and clearance ratio that can maximize the minimum film thickness.The results also show that four-pad TPJBs with loads between pads are preferred due to good dynamic performance and load capacity.This study would provide some guidance for nonlinear design of low viscosity fluid-lubricated TPJBs under dynamic loads.
