Functional Manufacturing Technologies and Ceeusro I

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Authors: Feng Xu, Jian Jun Zhu, Xin Wu, Xiao Jun Zang, Dun Wen Zuo
Abstract: The research was carried out on the parameter optimization of milling titanium alloy in this paper. The cutting models including cutting force, tool life and machined surface roughness are obtained by orthogonal array experiments. The maximum metal removal rate, MRR is selected as objective function. The constraints related to machine tool, workpiece, cutting tool and other machining situations are presented in details. Genetic algorithm is used to search for the optimum milling parameters for the maximum metal removal rate of titanium alloy. The optimization results show the optimization system can improve the productivity of milling Ti6Al4V obviously.
Authors: Hui Fan
Abstract: Laminated templates electro-deposition (LTE) is a small-sized metallic-structure fabrication technique based on template-patterned depositing. Avoiding locally excessive electroplating at the template edge area has been proved crucial to this method. To improve deposition uniformity, auxiliary cathode and modulated double-pulse current were tried individually and assessed on their effects and efficiencies. By applying assisting cathode the deposition uniformity in plannar pattern depositing was significantly improved with an increased thickness ratio of edge to center for the plating sample. Pulse application, especially double-pulse was studied mainly on the proportion between anodic duty circle and cathodic duty circle. Through a group of optimized parameters, including current density ranging 8-10A/dm2, anodic and cathodic duty circle of respectively 80% and 30%, frequency 300HZ, a bulk of copper parts, section size 20×20mm and 4-7mm thick were produced with a well depositing quality.
Authors: Pai Shan Pa
Abstract: The low yield rate of the transparent conducting oxide (TCO) is easily existent through the processes of semiconductor production. A nanotechnology system of the recycling process for removing the TCO-layer from displays’ color filter surface of computer display is presented. By establishing a recycling process for the ultra-precise removal of the thin film nanostructure, the semiconductor optoelectronic industry can effectively reclaim defective products, reducing both production costs and pollution for the technical application. In the current experiment, the major interest is the design mechanism features of the removal process for a thin layer of TCO and an effective design dumbbell-tool. For the recycling processes, a small diameter of the positive-electrode, a small gap-width between the negative-electrode and the positive-electrode corresponds to a higher removal rate for the TCO-layer. A high rotational speed of the dumbbell-tool, or a high flow velocity of the electrolyte increases the dreg discharge mobility and improves the removal effect. A higher working temperature or a higher concentration of the electrolyte corresponds to a higher removal rate for the TCO-layer. An enough electric power corresponds with a higher feed rate of the displays’ color filter produces a fast removal rate and reduces the production costs. An effective design of the system mechanism and the machining tool in the electroremoval processes requires quite a short time to make the TCO-layer remove easily and cleanly.
Authors: H.B. Wu, Yuan Wei Liu
Abstract: In this study, a method called “house-building frame modeling” based on the APDL language is introduced firstly, and the finite element model of the milling distortion analysis is established for a platform structure with 192 frames by the method, and the prediction analysis of the milling distortion under different milling conditions is carried out, by means of 3-D finite element simulation technology. Comparing the simulation results and the measurement ones of the milling distortion, the proposed model is modified; the modeling method and prediction method are proved to be effective.
Authors: Hun Guo, Dun Wen Zuo, Guo Xing Tang
Abstract: It is very difficult to predict the CNC milling process of monolithic components in aero-industry by either theoretical analysis or experimental research,because of their complicated structure. The machining distortion becomes one of the neck problems in the rapid development and the efficient production of our national defense weapons. The milling process of monolithic components web is simulated by 3D FEM, and the residual stress distribution and the variation tendency of the milling distortion are obtained, comparing the simulation results and the real measurement in the distortion,the proposed model is proved to be effective.
Authors: Jing Kang, Dun Wen Zuo, Yu Li Sun, Wen Zhuang Lu, Yu Fei Zhao
Abstract: The exchange of the heat of the IFA polishing system was analyzed at first in this paper. Then the three-dimensional temperature finite element model was set up. By changing the material of the elements, the ice-melting process was simulated. It was found that the obtained simulating results showed a good agreement with the experimental results. The temperature distribution and the melting rate were studied in the case of different technical parameters, which can be used to provide references for choosing better parameters.
Authors: X.J. Wu, Feng Xu, Dun Wen Zuo, Wen Zhuang Lu, M. Wang
Abstract: Chemical vapor deposited (CVD) diamond film has a series of outstanding properties. However, it can not be easily machined by conventional technologies available currently for its high hardness and stability. Laser processing diamond film method can be an efficient way to process diamond film because of its high energy density. The mechanisms of laser processing diamond film are thermal oxidation, graphitization and evaporative ablation of graphite. Temperature distribution is of great importance to understand these complex phenomena taking place during the process because different temperatures lead to different physical and chemical changes of diamond. In this paper, the finite element method (FEM) software ANSYS is applied to calculate the temperature distribution. The relation between etching depth and laser machining parameters (laser power and scanning speed) is presented. The proper parameter ranges of laser power and scanning speed for a certain etching depth is also investigated with this method.
Authors: Bing Kun Xiang, Dun Wen Zuo, Xiang Feng Li, Feng Xu, M. Wang
Abstract: Boron-doped micro-nanocrystalline diamond coating may be successfully prepared on Mo substrate with DC arc plasmas jet deposition device. Along with the increase of doped-boron concentration in the film, two-point resistance measurement indicates that film resistance presents exponential decrease; Raman spectrum test shows that, the characteristic peak value of diamond 1332cm-1 in the spectrum moves toward low frequency, the semi-height width of diamond peak, peak D and peak G, etc. in the spectrum is expanded, and the component of non-diamond bonds such as sp2, etc. in the film is increased; SEM and AFM observation shows that, increasing the doped-boron concentration could further subdivide the crystal grains in the film, and is beneficial for the growth of nano- or ultra-nano-crystalline diamond film; film annealing test shows that, micro-nanocrystalline diamond film with higher doped-boron concentration has better thermal stability than the micro-nanocrystalline diamond film without doped boron.
Authors: Yi Fang Wen, Yan Nian Rui, Jian Dong Cao
Abstract: Titanium alloys have good mechanical properties and organizational stability. However, due to the larger viscousity of titanium, a reasonable choice of the characteristic parameters of oilstone will directly affect the quality and efficiency of honing processing. This article solved multi-objective problem using artificial neural network with fast convergence and high precision. Based on a comprehensive analysis of the relationship between the workpiece material, materials status, surface hardness, the required surface quality and various parameters of oilstone, the improved artificial neural network algorithm-GCAQBP was adopted, through coding optimization of input and output parameters, model of intelligent choice of oilstone’s parameters was constructed about titanium alloy cylinder honing processing. Through experimental studies, it is shown that the intelligent model can choose quickly with high reliability compared with the traditional experience.

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