The gears of new energy vehicles are required to withstand higher rotational speeds and greater loads,which puts forward higher precision essentials for gear manufacturing.However,machining process parameters can caus...The gears of new energy vehicles are required to withstand higher rotational speeds and greater loads,which puts forward higher precision essentials for gear manufacturing.However,machining process parameters can cause changes in cutting force/heat,resulting in affecting gear machining precision.Therefore,this paper studies the effect of different process parameters on gear machining precision.A multi-objective optimization model is established for the relationship between process parameters and tooth surface deviations,tooth profile deviations,and tooth lead deviations through the cutting speed,feed rate,and cutting depth of the worm wheel gear grinding machine.The response surface method(RSM)is used for experimental design,and the corresponding experimental results and optimal process parameters are obtained.Subsequently,gray relational analysis-principal component analysis(GRA-PCA),particle swarm optimization(PSO),and genetic algorithm-particle swarm optimization(GA-PSO)methods are used to analyze the experimental results and obtain different optimal process parameters.The results show that optimal process parameters obtained by the GRA-PCA,PSO,and GA-PSO methods improve the gear machining precision.Moreover,the gear machining precision obtained by GA-PSO is superior to other methods.展开更多
Ti-Zr-Cu alloy has garnered signifcant attention in the feld of dental implants due to its excellent biocompatibility,antibacterial properties,and potentially controllable mechanical properties.However,two critical ch...Ti-Zr-Cu alloy has garnered signifcant attention in the feld of dental implants due to its excellent biocompatibility,antibacterial properties,and potentially controllable mechanical properties.However,two critical challenges remain in the selective laser melting(SLM)fabrication of Ti-Zr-Cu alloy:First,the high thermal conductivity of the Cu element tends to destabilize the solidifcation behavior of the molten pool,leading to uncontrollable pore defect evolution;Second,the infuence of process parameters on the synergistic efects of zirconium solution strengthening and copper precipitation strengthening is not well understood,hindering precise control over the material's mechanical properties.To address these issues,this study systematically elucidates the quantitative impact of energy input on the defect formation mechanisms and strengthening efects in the SLM processing of Ti15Zr5Cu alloy.By optimizing laser power(120–200 W)and scanning speed(450–1200 mm/s)through a full-factor experimental design,we comprehensively analyze the efects of energy input on defect morphology,microstructure evolution,and mechanical performance.The results demonstrate that as energy density decreases,defect types transition from spherical pores to irregular pores,signifcantly infuencing mechanical properties.Based on the defect evolution trends,three distinct energy density regions are identifed:the high-energy region,the lowenergy region,and the transition region.Under the optimal processing conditions of a laser power of 180 W and a scanning speed of 1200 mm/s,the Ti15Zr5Cu alloy exhibits a relative density of 99.998%,a tensile strength of 1490±11 MPa,and an elongation at break of 6.0%±0.5%.These properties ensure that the material satisfes the stringent requirements for high strength in narrow-diameter implants used in the maxilloanterior region.This study provides theoretical and experimental support for the process-property optimization of Ti-Zr-Cu alloys in additive manufacturing and promotes their application in the fabrication of high-performance,antibacterial dental implants.展开更多
To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and l...To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and low energy consumption was proposed.But the unreasonable process parameters may lead to the inferior consistency of the forming quality of single-channel multilayer in Joule heat additive manufacturing process,and it is difficult to reach the condition for forming thinwalled parts.Orthogonal experiments were designed to fabricate single-channel multilayer samples with varying numbers of layers,and their forming quality was evaluated.The influence of printing current,forming speed,and contact pressure on the forming quality of the single-channel multilayer was analyzed.The optimal process parameters were obtained and the quality characterization of the experiment results was conducted.Results show that the printing current has the most significant influence on the forming quality of the single-channel multilayer.Under the optimal process parameters,the forming section is well fused and the surface is continuously smooth.The surface roughness of a single-channel 3-layer sample is 0.16μm,and the average Vickers hardness of cross section fusion zone is 317 HV,which lays a foundation for the subsequent use of Joule heat additive manufacturing technique to form thinwall parts.展开更多
The squeeze cast process parameters of AZ80 magnesium alloy were optimized by morphological matrix. Experiments were conducted by varying squeeze pressure, die pre-heat temperature and pressure duration using L9（33）...The squeeze cast process parameters of AZ80 magnesium alloy were optimized by morphological matrix. Experiments were conducted by varying squeeze pressure, die pre-heat temperature and pressure duration using L9（33） orthogonal array of Taguchi method. In Taguchi method, a 3-level orthogonal array was used to determine the signal/noise ratio. Analysis of variance was used to determine the most significant process parameters affecting the mechanical properties. Mechanical properties such as ultimate tensile strength, elongation and hardness of the components were ascertained using multi variable linear regression analysis. Optimal squeeze cast process parameters were obtained.展开更多
Additive manufacturing(AM)has revolutionized modern manufacturing,but the application of magnesium(Mg)alloys in laser-based AM remains underexplored due to challenges such as oxidation,low boiling point,and thermal ex...Additive manufacturing(AM)has revolutionized modern manufacturing,but the application of magnesium(Mg)alloys in laser-based AM remains underexplored due to challenges such as oxidation,low boiling point,and thermal expansion,which lead to defects like porosity and cracking.This study provides a comprehensive analysis of microstructure changes in WE43 magnesium(Mg)alloy after laser surface melting(LSM),examining grain morphology,orientation,size,microsegregation,and defects under various combinations of laser power,scan speed,and spot size.Ourfindings reveal that variations in laser power and spot size exert a more significant influence on the depth and aspect ratio of the keyhole melt pool compared to laser scan speed.Critically,we demonstrate that laser energy density,while widely used as a quantitative metric to describe the combined effects of process parameters,exhibits significant limitations.Notable variations in melt pool depth,normalized width,and microstructure with laser energy density were observed,as reflected by low R²values.Additionally,we underscore the importance of assessing the temperature gradient across the width of the melt pool,which determines whether conduction or keyhole melting modes dominate.These modes exhibit distinct heatflow mechanisms and yield fundamentally different microstructural outcomes.Furthermore,we show that the microstructure and grain size in conduction mode exhibit a good correlation with the temperature gradient(G)and solidification rate(R).This research provides a framework for achieving localized microstructural control in LSM,providing insights to optimize process parameters for laser-based 3D printing of Mg alloys,and advancing the integration of Mg alloys into AM technologies.展开更多
Silicone material extrusion(MEX)is widely used for processing liquids and pastes.Owing to the uneven linewidth and elastic extrusion deformation caused by material accumulation,products may exhibit geometric errors an...Silicone material extrusion(MEX)is widely used for processing liquids and pastes.Owing to the uneven linewidth and elastic extrusion deformation caused by material accumulation,products may exhibit geometric errors and performance defects,leading to a decline in product quality and affecting its service life.This study proposes a process parameter optimization method that considers the mechanical properties of printed specimens and production costs.To improve the quality of silicone printing samples and reduce production costs,three machine learning models,kernel extreme learning machine(KELM),support vector regression(SVR),and random forest(RF),were developed to predict these three factors.Training data were obtained through a complete factorial experiment.A new dataset is obtained using the Euclidean distance method,which assigns the elimination factor.It is trained with Bayesian optimization algorithms for parameter optimization,the new dataset is input into the improved double Gaussian extreme learning machine,and finally obtains the improved KELM model.The results showed improved prediction accuracy over SVR and RF.Furthermore,a multi-objective optimization framework was proposed by combining genetic algorithm technology with the improved KELM model.The effectiveness and reasonableness of the model algorithm were verified by comparing the optimized results with the experimental results.展开更多
A series of tests were carried microstructures of 2124 aluminum alloy in increase of aging time, temperature and low-to-peak-to-low manner. No significant out to investigate the effects of process parameters on mechan...A series of tests were carried microstructures of 2124 aluminum alloy in increase of aging time, temperature and low-to-peak-to-low manner. No significant out to investigate the effects of process parameters on mechanical properties and creep aging process. The results show that creep strain and creep rate increase with the applied stress. The hardness of specimen varies with aging time and stress in a effect of temperature on hardness of material is seen in the range of 185-195 ℃. The optimum mechanical properties are obtained at the conditions of （200 MPa, 185 ℃, 8 h） as the result of the coexistence of strengthening S＂ and S＇ phases in the matrix by transmission electron microscopy （TEM）. TEM observation shows that applied stress promotes the formation and growth of precioitates and no obvious stress orientation effect is observed in the matrix.展开更多
In the present study,the effects of process parameters(output voltage x,nitrogen flux l and specific strengthening time s)on the microstructure and wear resistance properties of TiN coatings prepared by electrospark d...In the present study,the effects of process parameters(output voltage x,nitrogen flux l and specific strengthening time s)on the microstructure and wear resistance properties of TiN coatings prepared by electrospark deposition(ESD)were investigatedsystematically.The microstructure of the coatings was characterized for thickness(TOC),content of TiN(CON)and porosity(POC).A statistical model was developed to identify the significant factors affecting the microstructure and wear resistance of the coatings.The results show that the output voltage x and nitrogen flux l present significant effects on majority of the evaluation indexes such asTOC,friction coefficient(COF)and wear mass loss(Id),while the specific strengthening time s has a significant effect on POC and asmall effect on the other indexes.The optimal process parameters were obtained as follows:output voltage(x,60V),nitrogen flux(l,15L/min)and specific strengthening time(s,3min/cm2).The variation of wear mass loss(Id)by the variation of the outputvoltage(x)and nitrogen flux(l)is attributed to the change of wear mechanisms of TiN coatings.The main wear mechanism of TiNcoating prepared under optimal process parameters is micro-cutting wear accompanied by micro-fracture wear.展开更多
AA5083 friction stir welds were produced using systematic experimental design, the process forces and heat input with varying parameters were studied. Helpful empirical models were developed in designing friction stir...AA5083 friction stir welds were produced using systematic experimental design, the process forces and heat input with varying parameters were studied. Helpful empirical models were developed in designing friction stir welding （FSW） tools and FSW welders. These models may be further helpful for making process parameter choice for this sort of alloy, defining welding program and control of process parameters by using computer numerical control friction stir welding welders. The results show that tool rotational speed, welding speed and tool shoulder diameter are most significant parameters affecting axial force and heat input, while longitudinal force is significantly affected by welding speed and probe diameter.展开更多
Many studies have investigated the selective laser melting(SLM)of AlSi10Mg and AlSi7Mg alloys,but there are still lack of researches focused on Al-Si-Mg alloys specifically tailored for SLM.In this work,a novel high M...Many studies have investigated the selective laser melting(SLM)of AlSi10Mg and AlSi7Mg alloys,but there are still lack of researches focused on Al-Si-Mg alloys specifically tailored for SLM.In this work,a novel high Mg-content AlSi8Mg3 alloy was specifically designed for SLM.The results showed that this new alloy exhibited excellent SLM processability with a lowest porosity of 0.07%.Massive lattice distortion led to a high Vickers hardness in samples fabricated at a high laser power due to the precipitation of Mg_(2)Si nanoparticles from theα-Al matrix induced by high-intensity intrinsic heat treatment during SLM.The maximum microhardness and compressive yield strength of the alloy reached HV(211±4)and(526±12)MPa,respectively.After aging treatment at 150℃,the maximum microhardness and compressive yield strength of the samples were further improved to HV(221±4)and(577±5)MPa,respectively.These values are higher than those of most known aluminum alloys fabricated by SLM.This paper provides a new idea for optimizing the mechanical properties of Al-Si-Mg alloys fabricated using SLM.展开更多
In this paper,a progressive approach to predict the multiple shot peening process parameters for complex integral panel is proposed.Firstly,the invariable parameters in the forming process including shot size,mass flo...In this paper,a progressive approach to predict the multiple shot peening process parameters for complex integral panel is proposed.Firstly,the invariable parameters in the forming process including shot size,mass flow,peening distance and peening angle are determined according to the empirical and machine type.Then,the optimal value of air pressure for the whole shot peening is selected by the experimental data.Finally,the feeding speed for every shot peening path is predicted by regression equation.The integral panel part with thickness from 2 mm to 5 mm and curvature radius from 3200 mm to 16000 mm is taken as a research object,and four experiments are conducted.In order to design specimens for acquiring the forming data,one experiment is conducted to compare the curvature radius of the plate and stringer-structural specimens,which were peened along the middle of the two stringers.The most striking finding of this experiment is that the outer shape error range is below 3.9%,so the plate specimens can be used in predicting feeding speed of the integral panel.The second experiment is performed and results show that when the coverage reaches the limit of 80%,the minimum feeding speed is 50 mm/s.By this feeding speed,the forming curvature radius of the specimens with different thickness from the third experiment is measured and compared with the research object,and the optimal air pressure is 0.15 MPa.Then,the plate specimens with thickness from 2 mm to 5 mm are peened in the fourth experiment,and the measured curvature radius data are used to calculate the feeding speed of different shot peening path by regressive analysis method.The algorithm is validated by forming a test part and the average deviation is 0.496 mm.It is shown that the approach can realize the forming of the integral panel precisely.展开更多
The large warping deformation at platform of turbine blade directly affects the forming precision. In the present research, equivalent warping deformation was firstly presented to describe the extent of deformation at...The large warping deformation at platform of turbine blade directly affects the forming precision. In the present research, equivalent warping deformation was firstly presented to describe the extent of deformation at platform. To optimize the process parameters during investment casting to minimize the warping deformation of the platform, based on simulation with Pro CAST, the single factor method, orthogonal test, neural network and genetic algorithm were subsequently used to analyze the influence of pouring temperature, shell mold preheating temperature, furnace temperature and withdrawal velocity on dimensional accuracy of the platform of superalloyDD6 turbine blade. The accuracy of investment casting simulation was verified by measurement of platform at blade casting. The simulation results with the optimal process parameters illustrate that the equivalent warping deformation was dramatically reduced by 21.8% from 0.232295 mm to 0.181698 mm.展开更多
This paper presents the effects of different process parameters in producing Al-STi-1B grain refiner,i.e.various sequences and reaction time,on grain refinement efficiency of aluminum castings.It was found that differ...This paper presents the effects of different process parameters in producing Al-STi-1B grain refiner,i.e.various sequences and reaction time,on grain refinement efficiency of aluminum castings.It was found that different process parameters resulted in different morphology and size distribution of TiAl-3 and TiB-2 in grain refiner. The experiment was carried out by adding KBF-4 and K-2TiF-6 to molten aluminum.The melting temperature was controlled at 800℃in an electric resistance furnace.Three different sequences of KBF-4 and K-2TiF-6 additions were applied,i.e.,adding KBF-4 before K-2TiF-6,adding K-2TiF-4 before KBF-4 and mixing both KBF-4 and K-2TiF-6 before adding to molten aluminum.Three different holding time at 1 min,30 min and 60 min were applied.The results showed that no significant difference of morphology and size distribution was found by varying three different sequences.Whereas,the different holding time provided major differences in both morphology and size distribution,which are technically expectable from diffusion and agglomeration between particles resulting in larger particle size and wider range of size distribution of TiAI3 and TiB2.If the reaction time was longer than 30 rain,morphology of both TiAl-3 and TiB-2 became too large.If the reaction time was too short,less reaction between TiAl-3 and TiB2 to form would be obtained.For grain refinement efficiency, it was found that mixing KBF-4 and K-2TiF-6 before adding to molten aluminum with a holding time of 30 min resulted in best grain refinement efficiency.展开更多
To study the influence of roll casting process parameters on temperature and thermal-stress fields for the AZ31 magnesium alloy sheets,three-dimensional geometric and 3D finite element models for roll casting were est...To study the influence of roll casting process parameters on temperature and thermal-stress fields for the AZ31 magnesium alloy sheets,three-dimensional geometric and 3D finite element models for roll casting were established based on the symmetry of roll casting by ANSYS software.Meshing method and smart-sizing algorithm were used to divide finite element mesh in ANSYS software.A series of researches on the temperature and stress distributions during solidification process with different process parameters were done by 3D finite element method.The temperatures of both the liquid-solid two-phase zone and liquid phase zone were elevated with increasing pouring temperature.With the heat transfer coefficient increasing,the two-phase region for liquid-solid becomes smaller.With the pouring temperature increasing and the increase of casting speed,the length of two-phase zone rises.The optimized of process parameters（casting speed 2 m/min,pouring temperature 640 ℃ and heat transfer coefficient 15 kW/（m2·℃） with the water pouring at roller exit was used to produce magnesium alloy AZ31 sheet,and equiaxed grains with the average grain size of 50 μm were achieved after roll casting.The simulation results give better understanding of the temperature variation in phase transformation zone and the formation mechanism of hot cracks in plates during roll casting and help to design the optimized process parameters of roll casting for Mg alloy.展开更多
The effects of process parameters in rapid heat cycle moulding （RHCM） on parts warpage were investigated. A vehicle-used blue-tooth front shell （consisting of ABS material） was considered as a part example manufac...The effects of process parameters in rapid heat cycle moulding （RHCM） on parts warpage were investigated. A vehicle-used blue-tooth front shell （consisting of ABS material） was considered as a part example manufactured by RHCM method. The corresponding rapid heat response mould with an innovational conformal heating/cooling channel system and a dynamic mould temperature control system based on the Jll-W-160 type precise temperature controller was proposed. During heating/cooling process, the mould was able to be heated from room temperature to 160 ~C in 6 s and then cooled to 80 ~C in 22 s. The effects of processing conditions in RHCM on part warpage were investigated based on the single factor experimental method and Taguchi theory. Results reveal that the elevated mould temperature reduces unwanted freezing during the injection stage, thus improving mouldability and enhancing part quality, whereas the overheated of mould temperature will lead to defective product. The feasible mould temperature scope in RHCM should be no higher than 140 ~C, and the efficient mould temperature scope should be around the polymer heat distortion temperature. Melt temperature as well as injection pressure effects on warpage can be divided into two stages The lower stage gives a no explicit effect on warpage whereas the higher stage leads to a quasi-linear downtrend. But others affect the warpage as a V-type fluctuation, reaching to the minimum around the heat distortion temperature. Under the same mould temperature condition, the effects of process parameters on warpage decrease according to the following order, packing time, packing pressure, melt temperature, injection pressure and cooling time, respectively.展开更多
The effects of Sr addition and pressure increase on the microstructure and casting defects of a low-pressure die cast （LPDC） AISi7Mg0.3 alloy have been studied. Metallographic and image analysis techniques have been...The effects of Sr addition and pressure increase on the microstructure and casting defects of a low-pressure die cast （LPDC） AISi7Mg0.3 alloy have been studied. Metallographic and image analysis techniques have been used to quantitatively examine the microstructural changes and the amount of porosity occurring at different Sr levels and pressure parameters. The results indicate that an increase in the filling pressure induces lower heat dissipation of the liquid close to the die/core surfaces, with the formation of slightly greater dendrite arms and coarser eutectic Si particles. On the other hand, the increase in the Sr level leads to finer microstructural scale and eutectic Si. The analysed variables, within the experimental conditions, do not affect the morphology of eutectic Si particles. Higher applied pressure and Sr content generate castings with lower amount of porosiW. However, as the filling pressure increases the flow of metal inside the die cavity is more turbulent, leading to the formation of oxide films and cold shots. In the analysed range of experimental conditions, the design of experiment methodology and the analysis of variance have been used to develop statistical models that accurately predict the average size of secondary dendrite arm spacing and the amount of porosity in the low-pressure die cast AISiTMg0.3 alloy.展开更多
A certain amount of Ti was added to the plasma cladding Fe-Cr-C coating in the early stage in order to improve the quality and properties of the coating.Ti-Fe-Cr-C composite powder was prepared by precursor carbonizat...A certain amount of Ti was added to the plasma cladding Fe-Cr-C coating in the early stage in order to improve the quality and properties of the coating.Ti-Fe-Cr-C composite powder was prepared by precursor carbonization-composition process.In situ synthesized TiC-Fe-Cr coatings were fabricated on substrate of Q235 steel by plasma cladding process with the composite powder.Microstructures of the coatings with different process parameters,including cladding current,cladding speed,number of overlapping cladding layers,were analyzed by scanning electron microscope.The results show that the structure of the TiC-Fe-Cr coating is greatly affected by the cladding current,the cladding speed and the overlapping cladding process.In this test,when the cladding current of 300 A and the cladding process parameter of the cladding speed of 50 mm/min are clad with three layers,a well-formed and well-structured TiC-Fe-Cr coating can be obtained in this test.TiC-Fe-Cr coating has good wear resistance and good load characteristics under dry sliding wear test conditions.展开更多
In order to overcome the problems of many pores,large deformation and unstable weld quality of traditional laser welded aluminumcopper alloy joints,a red-blue dual-beam laser source and a swinging laser were introduce...In order to overcome the problems of many pores,large deformation and unstable weld quality of traditional laser welded aluminumcopper alloy joints,a red-blue dual-beam laser source and a swinging laser were introduced for welding.T2 copper and 6063 aluminum thin plates were lap welded by coaxial dual-beam laser welding.The morphology of weld cross section was compared to explore the influence of process parameters on the formation of lap joints.The microstructure characteristics of the weld zone were observed and compared by optical microscope.The results show that the addition of laser beam swing can eliminate the internal pores of the weld.With the increase of the swing width,the weld depth decreases,and the weld width increases first and then decreases.The influence of welding speed on the weld cross section morphology is similar to that of swing width.With the increase of welding speed,the weld width increases first and then decreases,while the weld depth decreases all the time.This is because that the red laser is used as the main heat source to melt the base metals,with the increase of red laser power,the weld depth increases.As an auxiliary laser source,blue laser reduces the total energy consumption,consequently,the effective heat input increases and the spatter is restrained effectively.As a result,the increase of red laser power has an enhancement effect on the weld width and weld depth.When the swing width is 1.2 mm,the red laser power is 550 W,the blue laser power is 500 W,and the welding speed is 35 mm/s,the weld forming is the best.The lap joint of T2 copper and 6063 aluminum alloy thin plate can be connected stably with the hybrid of blue laser.The effect rules of laser beam swing on the weld formation were obtained,which improved the quality of the joints.展开更多
The isothermal compression test for Ti-6Al-7Nb alloy was conducted by using Gleeble-3800 thermal simulator.The hot deformation behavior of Ti-6Al-7Nb alloy was investigated in the deformation temperature ranges of 940...The isothermal compression test for Ti-6Al-7Nb alloy was conducted by using Gleeble-3800 thermal simulator.The hot deformation behavior of Ti-6Al-7Nb alloy was investigated in the deformation temperature ranges of 940-1030℃and the strain rate ranges of 0.001-10 s^(-1).Meanwhile,the activation energy of thermal deformation was computed.The results show that the flow stress of Ti-6Al-7Nb alloy increases with increasing the strain rate and decreasing the deformation temperature.The activation energy of thermal deformation for Ti-6Al-7Nb alloy is much greater than that for self-diffusion ofα-Ti andβ-Ti.Considering the influence of strain on flow stress,the strain-compensated Arrhenius constitutive model of Ti-6Al-7Nb alloy was established.The error analysis shows that the model has higher accuracy,and the correlation coefficient r and average absolute relative error are 0.9879 and 4.11%,respectively.The processing map(PM)of Ti-6Al-7Nb alloy was constructed by the dynamic materials model and Prasad instability criterion.According to PM and microstructural observation,it is found that the main form of instability zone is local flow,and the deformation mechanisms of the stable zone are mainly superplasticity and dynamic recrystallization.The optimal processing parameters of Ti-6Al-7Nb alloy are determined as follows:960-995℃/0.01-0.18 s^(-1)and 1000-1030℃/0.001-0.01 s^(-1).展开更多
To gain a deep insight into the hot drawing process of aluminum alloy sheet, simulations of cylindrical cup drawing at elevated temperatures were carried out with experimental validation. The influence of four importa...To gain a deep insight into the hot drawing process of aluminum alloy sheet, simulations of cylindrical cup drawing at elevated temperatures were carried out with experimental validation. The influence of four important process parameters, namely,punch velocity, blank holder force(BHF), friction coefficient and initial forming temperature of blank on drawing characteristics(i.e.minimum thickness and thickness deviation) was investigated with the help of design of experiments(DOE), analysis of variance(ANOVA) and analysis of mean(ANOM). Based on the results of ANOVA, it is shown that the blank holder force has the greatest influence on minimum thickness. The importance of punch velocity for thickness deviation is 44.35% followed by BHF of 24.88%,friction coefficient of 15.77% and initial forming temperature of blank of 14.995%. After determining the significance of each factor on forming characteristics, how the individual parameter affects characteristics was further analyzed by ANOM.展开更多
基金Projects(U22B2084,52275483,52075142)supported by the National Natural Science Foundation of ChinaProject(2023ZY01050)supported by the Ministry of Industry and Information Technology High Quality Development,China。
文摘The gears of new energy vehicles are required to withstand higher rotational speeds and greater loads,which puts forward higher precision essentials for gear manufacturing.However,machining process parameters can cause changes in cutting force/heat,resulting in affecting gear machining precision.Therefore,this paper studies the effect of different process parameters on gear machining precision.A multi-objective optimization model is established for the relationship between process parameters and tooth surface deviations,tooth profile deviations,and tooth lead deviations through the cutting speed,feed rate,and cutting depth of the worm wheel gear grinding machine.The response surface method(RSM)is used for experimental design,and the corresponding experimental results and optimal process parameters are obtained.Subsequently,gray relational analysis-principal component analysis(GRA-PCA),particle swarm optimization(PSO),and genetic algorithm-particle swarm optimization(GA-PSO)methods are used to analyze the experimental results and obtain different optimal process parameters.The results show that optimal process parameters obtained by the GRA-PCA,PSO,and GA-PSO methods improve the gear machining precision.Moreover,the gear machining precision obtained by GA-PSO is superior to other methods.
基金supported by the National Natural Science Foundation of China(Nos.52401178 and U24A20713)the IMR Innovation Fund(No.2024-PY06)the CAS-WEGO Research and Development Plan Project.
文摘Ti-Zr-Cu alloy has garnered signifcant attention in the feld of dental implants due to its excellent biocompatibility,antibacterial properties,and potentially controllable mechanical properties.However,two critical challenges remain in the selective laser melting(SLM)fabrication of Ti-Zr-Cu alloy:First,the high thermal conductivity of the Cu element tends to destabilize the solidifcation behavior of the molten pool,leading to uncontrollable pore defect evolution;Second,the infuence of process parameters on the synergistic efects of zirconium solution strengthening and copper precipitation strengthening is not well understood,hindering precise control over the material's mechanical properties.To address these issues,this study systematically elucidates the quantitative impact of energy input on the defect formation mechanisms and strengthening efects in the SLM processing of Ti15Zr5Cu alloy.By optimizing laser power(120–200 W)and scanning speed(450–1200 mm/s)through a full-factor experimental design,we comprehensively analyze the efects of energy input on defect morphology,microstructure evolution,and mechanical performance.The results demonstrate that as energy density decreases,defect types transition from spherical pores to irregular pores,signifcantly infuencing mechanical properties.Based on the defect evolution trends,three distinct energy density regions are identifed:the high-energy region,the lowenergy region,and the transition region.Under the optimal processing conditions of a laser power of 180 W and a scanning speed of 1200 mm/s,the Ti15Zr5Cu alloy exhibits a relative density of 99.998%,a tensile strength of 1490±11 MPa,and an elongation at break of 6.0%±0.5%.These properties ensure that the material satisfes the stringent requirements for high strength in narrow-diameter implants used in the maxilloanterior region.This study provides theoretical and experimental support for the process-property optimization of Ti-Zr-Cu alloys in additive manufacturing and promotes their application in the fabrication of high-performance,antibacterial dental implants.
基金Shaanxi Province Qin Chuangyuan“Scientist+Engineer”Team Construction Project(2022KXJ-071)2022 Qin Chuangyuan Achievement Transformation Incubation Capacity Improvement Project(2022JH-ZHFHTS-0012)+1 种基金Shaanxi Province Key Research and Development Plan-“Two Chains”Integration Key Project-Qin Chuangyuan General Window Industrial Cluster Project(2023QCY-LL-02)Xixian New Area Science and Technology Plan(2022-YXYJ-003,2022-XXCY-010)。
文摘To overcome the shortage of complex equipment,large volume,and high energy consumption in space capsule manufacturing,a novel sliding pressure Joule heat fuse additive manufacturing technique with reduced volume and low energy consumption was proposed.But the unreasonable process parameters may lead to the inferior consistency of the forming quality of single-channel multilayer in Joule heat additive manufacturing process,and it is difficult to reach the condition for forming thinwalled parts.Orthogonal experiments were designed to fabricate single-channel multilayer samples with varying numbers of layers,and their forming quality was evaluated.The influence of printing current,forming speed,and contact pressure on the forming quality of the single-channel multilayer was analyzed.The optimal process parameters were obtained and the quality characterization of the experiment results was conducted.Results show that the printing current has the most significant influence on the forming quality of the single-channel multilayer.Under the optimal process parameters,the forming section is well fused and the surface is continuously smooth.The surface roughness of a single-channel 3-layer sample is 0.16μm,and the average Vickers hardness of cross section fusion zone is 317 HV,which lays a foundation for the subsequent use of Joule heat additive manufacturing technique to form thinwall parts.
基金Project (50975263) supported by the National Natural Science Foundation of ChinaProject (2011DFA50520) supported by International Science Technology Cooperation Program of China
文摘The squeeze cast process parameters of AZ80 magnesium alloy were optimized by morphological matrix. Experiments were conducted by varying squeeze pressure, die pre-heat temperature and pressure duration using L9（33） orthogonal array of Taguchi method. In Taguchi method, a 3-level orthogonal array was used to determine the signal/noise ratio. Analysis of variance was used to determine the most significant process parameters affecting the mechanical properties. Mechanical properties such as ultimate tensile strength, elongation and hardness of the components were ascertained using multi variable linear regression analysis. Optimal squeeze cast process parameters were obtained.
文摘Additive manufacturing(AM)has revolutionized modern manufacturing,but the application of magnesium(Mg)alloys in laser-based AM remains underexplored due to challenges such as oxidation,low boiling point,and thermal expansion,which lead to defects like porosity and cracking.This study provides a comprehensive analysis of microstructure changes in WE43 magnesium(Mg)alloy after laser surface melting(LSM),examining grain morphology,orientation,size,microsegregation,and defects under various combinations of laser power,scan speed,and spot size.Ourfindings reveal that variations in laser power and spot size exert a more significant influence on the depth and aspect ratio of the keyhole melt pool compared to laser scan speed.Critically,we demonstrate that laser energy density,while widely used as a quantitative metric to describe the combined effects of process parameters,exhibits significant limitations.Notable variations in melt pool depth,normalized width,and microstructure with laser energy density were observed,as reflected by low R²values.Additionally,we underscore the importance of assessing the temperature gradient across the width of the melt pool,which determines whether conduction or keyhole melting modes dominate.These modes exhibit distinct heatflow mechanisms and yield fundamentally different microstructural outcomes.Furthermore,we show that the microstructure and grain size in conduction mode exhibit a good correlation with the temperature gradient(G)and solidification rate(R).This research provides a framework for achieving localized microstructural control in LSM,providing insights to optimize process parameters for laser-based 3D printing of Mg alloys,and advancing the integration of Mg alloys into AM technologies.
基金supported by the National Key R&D Program of China(No.2022YFA1005204l)。
文摘Silicone material extrusion(MEX)is widely used for processing liquids and pastes.Owing to the uneven linewidth and elastic extrusion deformation caused by material accumulation,products may exhibit geometric errors and performance defects,leading to a decline in product quality and affecting its service life.This study proposes a process parameter optimization method that considers the mechanical properties of printed specimens and production costs.To improve the quality of silicone printing samples and reduce production costs,three machine learning models,kernel extreme learning machine(KELM),support vector regression(SVR),and random forest(RF),were developed to predict these three factors.Training data were obtained through a complete factorial experiment.A new dataset is obtained using the Euclidean distance method,which assigns the elimination factor.It is trained with Bayesian optimization algorithms for parameter optimization,the new dataset is input into the improved double Gaussian extreme learning machine,and finally obtains the improved KELM model.The results showed improved prediction accuracy over SVR and RF.Furthermore,a multi-objective optimization framework was proposed by combining genetic algorithm technology with the improved KELM model.The effectiveness and reasonableness of the model algorithm were verified by comparing the optimized results with the experimental results.
基金Project(51235010)supported by the National Natural Science Foundation of ChinaProject(2010CB731700)supported by the National Basic Research Program of ChinaProject(20120162110003)supported by PhD Programs Foundation of Ministry of Education of China
文摘A series of tests were carried microstructures of 2124 aluminum alloy in increase of aging time, temperature and low-to-peak-to-low manner. No significant out to investigate the effects of process parameters on mechanical properties and creep aging process. The results show that creep strain and creep rate increase with the applied stress. The hardness of specimen varies with aging time and stress in a effect of temperature on hardness of material is seen in the range of 185-195 ℃. The optimum mechanical properties are obtained at the conditions of （200 MPa, 185 ℃, 8 h） as the result of the coexistence of strengthening S＂ and S＇ phases in the matrix by transmission electron microscopy （TEM）. TEM observation shows that applied stress promotes the formation and growth of precioitates and no obvious stress orientation effect is observed in the matrix.
文摘In the present study,the effects of process parameters(output voltage x,nitrogen flux l and specific strengthening time s)on the microstructure and wear resistance properties of TiN coatings prepared by electrospark deposition(ESD)were investigatedsystematically.The microstructure of the coatings was characterized for thickness(TOC),content of TiN(CON)and porosity(POC).A statistical model was developed to identify the significant factors affecting the microstructure and wear resistance of the coatings.The results show that the output voltage x and nitrogen flux l present significant effects on majority of the evaluation indexes such asTOC,friction coefficient(COF)and wear mass loss(Id),while the specific strengthening time s has a significant effect on POC and asmall effect on the other indexes.The optimal process parameters were obtained as follows:output voltage(x,60V),nitrogen flux(l,15L/min)and specific strengthening time(s,3min/cm2).The variation of wear mass loss(Id)by the variation of the outputvoltage(x)and nitrogen flux(l)is attributed to the change of wear mechanisms of TiN coatings.The main wear mechanism of TiNcoating prepared under optimal process parameters is micro-cutting wear accompanied by micro-fracture wear.
文摘AA5083 friction stir welds were produced using systematic experimental design, the process forces and heat input with varying parameters were studied. Helpful empirical models were developed in designing friction stir welding （FSW） tools and FSW welders. These models may be further helpful for making process parameter choice for this sort of alloy, defining welding program and control of process parameters by using computer numerical control friction stir welding welders. The results show that tool rotational speed, welding speed and tool shoulder diameter are most significant parameters affecting axial force and heat input, while longitudinal force is significantly affected by welding speed and probe diameter.
基金financially supported by the the National Natural Science Foundation of China(Nos.51801079 and 52001140)the Natural Science Foundation for Young Scientists of Jiangsu,China(Nos.BK20180985 and BK20180987)the Open Foundation of Zhenjiang Key Laboratory for High Technology Research on Marine Functional Films(No.ZHZ2019001)。
文摘Many studies have investigated the selective laser melting(SLM)of AlSi10Mg and AlSi7Mg alloys,but there are still lack of researches focused on Al-Si-Mg alloys specifically tailored for SLM.In this work,a novel high Mg-content AlSi8Mg3 alloy was specifically designed for SLM.The results showed that this new alloy exhibited excellent SLM processability with a lowest porosity of 0.07%.Massive lattice distortion led to a high Vickers hardness in samples fabricated at a high laser power due to the precipitation of Mg_(2)Si nanoparticles from theα-Al matrix induced by high-intensity intrinsic heat treatment during SLM.The maximum microhardness and compressive yield strength of the alloy reached HV(211±4)and(526±12)MPa,respectively.After aging treatment at 150℃,the maximum microhardness and compressive yield strength of the samples were further improved to HV(221±4)and(577±5)MPa,respectively.These values are higher than those of most known aluminum alloys fabricated by SLM.This paper provides a new idea for optimizing the mechanical properties of Al-Si-Mg alloys fabricated using SLM.
基金supported by the National Level Project of China。
文摘In this paper,a progressive approach to predict the multiple shot peening process parameters for complex integral panel is proposed.Firstly,the invariable parameters in the forming process including shot size,mass flow,peening distance and peening angle are determined according to the empirical and machine type.Then,the optimal value of air pressure for the whole shot peening is selected by the experimental data.Finally,the feeding speed for every shot peening path is predicted by regression equation.The integral panel part with thickness from 2 mm to 5 mm and curvature radius from 3200 mm to 16000 mm is taken as a research object,and four experiments are conducted.In order to design specimens for acquiring the forming data,one experiment is conducted to compare the curvature radius of the plate and stringer-structural specimens,which were peened along the middle of the two stringers.The most striking finding of this experiment is that the outer shape error range is below 3.9%,so the plate specimens can be used in predicting feeding speed of the integral panel.The second experiment is performed and results show that when the coverage reaches the limit of 80%,the minimum feeding speed is 50 mm/s.By this feeding speed,the forming curvature radius of the specimens with different thickness from the third experiment is measured and compared with the research object,and the optimal air pressure is 0.15 MPa.Then,the plate specimens with thickness from 2 mm to 5 mm are peened in the fourth experiment,and the measured curvature radius data are used to calculate the feeding speed of different shot peening path by regressive analysis method.The algorithm is validated by forming a test part and the average deviation is 0.496 mm.It is shown that the approach can realize the forming of the integral panel precisely.
基金financially supported by the National Natural Science Foundation of China(No.51371152)
文摘The large warping deformation at platform of turbine blade directly affects the forming precision. In the present research, equivalent warping deformation was firstly presented to describe the extent of deformation at platform. To optimize the process parameters during investment casting to minimize the warping deformation of the platform, based on simulation with Pro CAST, the single factor method, orthogonal test, neural network and genetic algorithm were subsequently used to analyze the influence of pouring temperature, shell mold preheating temperature, furnace temperature and withdrawal velocity on dimensional accuracy of the platform of superalloyDD6 turbine blade. The accuracy of investment casting simulation was verified by measurement of platform at blade casting. The simulation results with the optimal process parameters illustrate that the equivalent warping deformation was dramatically reduced by 21.8% from 0.232295 mm to 0.181698 mm.
文摘This paper presents the effects of different process parameters in producing Al-STi-1B grain refiner,i.e.various sequences and reaction time,on grain refinement efficiency of aluminum castings.It was found that different process parameters resulted in different morphology and size distribution of TiAl-3 and TiB-2 in grain refiner. The experiment was carried out by adding KBF-4 and K-2TiF-6 to molten aluminum.The melting temperature was controlled at 800℃in an electric resistance furnace.Three different sequences of KBF-4 and K-2TiF-6 additions were applied,i.e.,adding KBF-4 before K-2TiF-6,adding K-2TiF-4 before KBF-4 and mixing both KBF-4 and K-2TiF-6 before adding to molten aluminum.Three different holding time at 1 min,30 min and 60 min were applied.The results showed that no significant difference of morphology and size distribution was found by varying three different sequences.Whereas,the different holding time provided major differences in both morphology and size distribution,which are technically expectable from diffusion and agglomeration between particles resulting in larger particle size and wider range of size distribution of TiAI3 and TiB2.If the reaction time was longer than 30 rain,morphology of both TiAl-3 and TiB-2 became too large.If the reaction time was too short,less reaction between TiAl-3 and TiB2 to form would be obtained.For grain refinement efficiency, it was found that mixing KBF-4 and K-2TiF-6 before adding to molten aluminum with a holding time of 30 min resulted in best grain refinement efficiency.
基金Project(CSTC 2010BB4301) supported by Natural Science Foundation Project of Chongqing,ChinaProject supported by the Open Fund for Key Laboratory of Manufacture and Test Techniques for Automobile Parts of Ministry of Education Chongqing University of Technology,2003,China
文摘To study the influence of roll casting process parameters on temperature and thermal-stress fields for the AZ31 magnesium alloy sheets,three-dimensional geometric and 3D finite element models for roll casting were established based on the symmetry of roll casting by ANSYS software.Meshing method and smart-sizing algorithm were used to divide finite element mesh in ANSYS software.A series of researches on the temperature and stress distributions during solidification process with different process parameters were done by 3D finite element method.The temperatures of both the liquid-solid two-phase zone and liquid phase zone were elevated with increasing pouring temperature.With the heat transfer coefficient increasing,the two-phase region for liquid-solid becomes smaller.With the pouring temperature increasing and the increase of casting speed,the length of two-phase zone rises.The optimized of process parameters（casting speed 2 m/min,pouring temperature 640 ℃ and heat transfer coefficient 15 kW/（m2·℃） with the water pouring at roller exit was used to produce magnesium alloy AZ31 sheet,and equiaxed grains with the average grain size of 50 μm were achieved after roll casting.The simulation results give better understanding of the temperature variation in phase transformation zone and the formation mechanism of hot cracks in plates during roll casting and help to design the optimized process parameters of roll casting for Mg alloy.
基金Project(20122BAB206014)supported by National Natural Science Foundation of ChinaProject(51365038)supported by the Natural Science Foundation of Jiangxi Province,ChinaProject(GJJ13068)supported by the Science and Technology Program of Educational Committee of Jiangxi Province,China
文摘The effects of process parameters in rapid heat cycle moulding （RHCM） on parts warpage were investigated. A vehicle-used blue-tooth front shell （consisting of ABS material） was considered as a part example manufactured by RHCM method. The corresponding rapid heat response mould with an innovational conformal heating/cooling channel system and a dynamic mould temperature control system based on the Jll-W-160 type precise temperature controller was proposed. During heating/cooling process, the mould was able to be heated from room temperature to 160 ~C in 6 s and then cooled to 80 ~C in 22 s. The effects of processing conditions in RHCM on part warpage were investigated based on the single factor experimental method and Taguchi theory. Results reveal that the elevated mould temperature reduces unwanted freezing during the injection stage, thus improving mouldability and enhancing part quality, whereas the overheated of mould temperature will lead to defective product. The feasible mould temperature scope in RHCM should be no higher than 140 ~C, and the efficient mould temperature scope should be around the polymer heat distortion temperature. Melt temperature as well as injection pressure effects on warpage can be divided into two stages The lower stage gives a no explicit effect on warpage whereas the higher stage leads to a quasi-linear downtrend. But others affect the warpage as a V-type fluctuation, reaching to the minimum around the heat distortion temperature. Under the same mould temperature condition, the effects of process parameters on warpage decrease according to the following order, packing time, packing pressure, melt temperature, injection pressure and cooling time, respectively.
文摘The effects of Sr addition and pressure increase on the microstructure and casting defects of a low-pressure die cast （LPDC） AISi7Mg0.3 alloy have been studied. Metallographic and image analysis techniques have been used to quantitatively examine the microstructural changes and the amount of porosity occurring at different Sr levels and pressure parameters. The results indicate that an increase in the filling pressure induces lower heat dissipation of the liquid close to the die/core surfaces, with the formation of slightly greater dendrite arms and coarser eutectic Si particles. On the other hand, the increase in the Sr level leads to finer microstructural scale and eutectic Si. The analysed variables, within the experimental conditions, do not affect the morphology of eutectic Si particles. Higher applied pressure and Sr content generate castings with lower amount of porosiW. However, as the filling pressure increases the flow of metal inside the die cavity is more turbulent, leading to the formation of oxide films and cold shots. In the analysed range of experimental conditions, the design of experiment methodology and the analysis of variance have been used to develop statistical models that accurately predict the average size of secondary dendrite arm spacing and the amount of porosity in the low-pressure die cast AISiTMg0.3 alloy.
基金National Natural Science Foundation of China (Grant No. 51905382)the Cooperation in Production and Education by Ministry of Education (Grant No. 201802252016)Weifang University Distinguished Professor Support Programme
文摘A certain amount of Ti was added to the plasma cladding Fe-Cr-C coating in the early stage in order to improve the quality and properties of the coating.Ti-Fe-Cr-C composite powder was prepared by precursor carbonization-composition process.In situ synthesized TiC-Fe-Cr coatings were fabricated on substrate of Q235 steel by plasma cladding process with the composite powder.Microstructures of the coatings with different process parameters,including cladding current,cladding speed,number of overlapping cladding layers,were analyzed by scanning electron microscope.The results show that the structure of the TiC-Fe-Cr coating is greatly affected by the cladding current,the cladding speed and the overlapping cladding process.In this test,when the cladding current of 300 A and the cladding process parameter of the cladding speed of 50 mm/min are clad with three layers,a well-formed and well-structured TiC-Fe-Cr coating can be obtained in this test.TiC-Fe-Cr coating has good wear resistance and good load characteristics under dry sliding wear test conditions.
基金supported by Guangdong Science and Technology Plan Project(Grant No.20170902,No.20180902)Yangjiang Science and Technology Plan Project(Grant No.SDZX2020063)+1 种基金Shenzhen Key Projects of Innovation and Entrepreneurship Plan Technology(JSGG20210420091802007)Yunfu 2023 Science and Technology Plan Project(S2023020201).
文摘In order to overcome the problems of many pores,large deformation and unstable weld quality of traditional laser welded aluminumcopper alloy joints,a red-blue dual-beam laser source and a swinging laser were introduced for welding.T2 copper and 6063 aluminum thin plates were lap welded by coaxial dual-beam laser welding.The morphology of weld cross section was compared to explore the influence of process parameters on the formation of lap joints.The microstructure characteristics of the weld zone were observed and compared by optical microscope.The results show that the addition of laser beam swing can eliminate the internal pores of the weld.With the increase of the swing width,the weld depth decreases,and the weld width increases first and then decreases.The influence of welding speed on the weld cross section morphology is similar to that of swing width.With the increase of welding speed,the weld width increases first and then decreases,while the weld depth decreases all the time.This is because that the red laser is used as the main heat source to melt the base metals,with the increase of red laser power,the weld depth increases.As an auxiliary laser source,blue laser reduces the total energy consumption,consequently,the effective heat input increases and the spatter is restrained effectively.As a result,the increase of red laser power has an enhancement effect on the weld width and weld depth.When the swing width is 1.2 mm,the red laser power is 550 W,the blue laser power is 500 W,and the welding speed is 35 mm/s,the weld forming is the best.The lap joint of T2 copper and 6063 aluminum alloy thin plate can be connected stably with the hybrid of blue laser.The effect rules of laser beam swing on the weld formation were obtained,which improved the quality of the joints.
基金the National Natural Science Foundation of China(Grant No.51464035).
文摘The isothermal compression test for Ti-6Al-7Nb alloy was conducted by using Gleeble-3800 thermal simulator.The hot deformation behavior of Ti-6Al-7Nb alloy was investigated in the deformation temperature ranges of 940-1030℃and the strain rate ranges of 0.001-10 s^(-1).Meanwhile,the activation energy of thermal deformation was computed.The results show that the flow stress of Ti-6Al-7Nb alloy increases with increasing the strain rate and decreasing the deformation temperature.The activation energy of thermal deformation for Ti-6Al-7Nb alloy is much greater than that for self-diffusion ofα-Ti andβ-Ti.Considering the influence of strain on flow stress,the strain-compensated Arrhenius constitutive model of Ti-6Al-7Nb alloy was established.The error analysis shows that the model has higher accuracy,and the correlation coefficient r and average absolute relative error are 0.9879 and 4.11%,respectively.The processing map(PM)of Ti-6Al-7Nb alloy was constructed by the dynamic materials model and Prasad instability criterion.According to PM and microstructural observation,it is found that the main form of instability zone is local flow,and the deformation mechanisms of the stable zone are mainly superplasticity and dynamic recrystallization.The optimal processing parameters of Ti-6Al-7Nb alloy are determined as follows:960-995℃/0.01-0.18 s^(-1)and 1000-1030℃/0.001-0.01 s^(-1).
基金Project(2009ZX04014-074)supported by the National High Technology Research and Development Program of ChinaProject(20120006110017)supported by Doctoral Fund Program of Ministry of Education of ChinaProject(P2014-15)supported by State Key Laboratory of Materials Processing and Die & Mould Technology(Huazhong University of Science and Technology),China
文摘To gain a deep insight into the hot drawing process of aluminum alloy sheet, simulations of cylindrical cup drawing at elevated temperatures were carried out with experimental validation. The influence of four important process parameters, namely,punch velocity, blank holder force(BHF), friction coefficient and initial forming temperature of blank on drawing characteristics(i.e.minimum thickness and thickness deviation) was investigated with the help of design of experiments(DOE), analysis of variance(ANOVA) and analysis of mean(ANOM). Based on the results of ANOVA, it is shown that the blank holder force has the greatest influence on minimum thickness. The importance of punch velocity for thickness deviation is 44.35% followed by BHF of 24.88%,friction coefficient of 15.77% and initial forming temperature of blank of 14.995%. After determining the significance of each factor on forming characteristics, how the individual parameter affects characteristics was further analyzed by ANOM.
