Materials Science Forum Vols. 532-533

Abstract: Stepping tapping is a new tapping mode for Nickel-based superalloy GH4169. Longer life of tap and higher machining efficiency can be obtained. But chipping of tap is very prevalent. In this paper, the mechanism of chipping in step tapping is investigated. Based on the wavelet analysis of the signals of tapping torque, the load applied to the tap in every stage of the period of motion is studied. It is found that chipping is prone to occur at the moment when the rotating direction of tap shifts from forward to backward, which is caused by the too large and rapidly changed tensile stress on cutting edge. The excessive wear of cutting edge results in the too large tensile stress. To reduce the wear, the backward rotating angle of tap should be selected to be smaller than 100°.

Abstract: In this paper, the wear behavior of the ID (inner diameter) saw blade in the cutting process of silicon ingot was observed with SEM. Its wear mechanism was discussed and the relation between the blade wear and vibration, deflection was analyzed. The results show that the blade worn manners include flatted diamond, micro-fractured diamond, macro-fractured diamond, pulled-out hole, tortoise-fractured bond, and polished bond. In the abnormal working stage of a blade, however, the working surface of the blade is displayed mainly with pulled out diamond, flatted diamond, macro-fractured diamond grains. Abnormal initial tension condition will induce severe vibration and deflection, and so then lots of diamond grits fractured or pulled out too early.

Abstract: As a “bottom-up” approach to nanostructures for nanofabrication, self-assembled block copolymer thin films have received much attention not only thanks to the scale of the microdomains but also due to the convenient shape tunability. In order to realize applications of self-assembled block copolymer thin films in nanotechnologies, control over microdomain spatial and orientational order is paramount. In this paper, using atomic force microscopy (AFM), we studied systemically nanostructure transitions induced by post-solvent annealing in self-assembled block copolymer thin films. Furthermore, a variety of thin films with well-ordered nanostructures, which can be employed as templates for nanotechnologies, have been realized simply and at low cost.

Abstract: The influence of the ultrasonic vibrated diamond tool on the transition of ductile cutting to brittle cutting of the glasses is investigated by facing turning. It is understood that the critical depth of cut for the ductile cutting of the brittle materials is increased obviously by the ultrasonic vibrated diamond tool. The optical quality surface of the glasses is obtained, the surface roughness of which is less than0.03m. Finally, the relation between the roughness of machined surface and the cutting distance is studied experimentally.

Abstract: Electrode materials are important factors affecting machining performances (MP) of electrical discharge machining (EDM). Experiments using different electrode materials were carried out in compressed air aim to realize MP of electrical discharge machining in gas (dry EDM). Experimental results show that a minimum pulse interval exists for given parameters and tool material. Calorific performances of tool materials are main influencing factors of MP on the condition of thorough deionization. Copper achieves the best MP in the experimental tool materials. Experimental results of different workpiece materials depict that material remove rate (MRR) and surface roughness (SR) value increase with increases of discharge energy. SKD61 steel achieves the highest MRR and SR value in the experimental materials. Material holding better performance of heat resistant, such as titanium alloy (TC4), achieves the lowest MRR.

Abstract: As environmental problems have become more serious, a sustainable society is necessary. To realize the inverse manufacturing system the prime problem is how to improve the rate of reusing the product modules. Therefore analyzing the life-time of the disassembled modules is very important before reassembling process. In this paper, a cumulative damage model is proposed to discuss the quality of the product that is assembled by reuse modules. It is supposed that modules suffer damages due to shocks and fails when the cumulative damage level exceeds the failure level. Then maintenance cost will be analyzed in order to minimize the expected maintenance cost-rate by optimal maintenance time T and optimal number of damages N in this cumulative damage model. The probable safe life-time of module reuse will be explored. Finally numerical examples are given to confirm the validity of the proposed model.

Abstract: Micro-Electromechanical Systems (MEMS) has been regarded as one of the most promising technologies for the 21st Century. Recently, some highlight areas attract great attention including Inertial MEMS, Optic MEMS, RF MEMS, BioMEMS, Power MEMS, and NEMS. The state of arts on MEMS research in China is briefly introduced and research activities in Northwestern Polytechnical University such as MEMS CAD tool, inertial MEMS devices, flexible substrate for MEMS integration, micro mirror, micro battery and three dimension measurement are demonstrated.

Abstract: This contribution aims at the mechanism of electrochemical mechanical finishing (ECMF). The change in surface micro-profile of workpiece and its influence on anodic electrochemical dissolution (ECD) as well as the action of the mechanical role were investigated. The results show that the peak-like micro-profile of surface is in favor of improving the ability of ECD. The mechanical role not only scratches the passive film resulted from ECD, but also changes the surface micro-profile of the workpiece. The action of the mechanical role influences the final finished surface quality of the workpiece.

Abstract: An arc envelope grinding method for non-axisymmetric aspheric surface was proposed in order to achieve the mould core used for the precision injection molding of optic reflector. In grinding, the arc-shaped diamond grinding wheel trued on CNC grinder was used to envelope workpiece and generate curve surface, and the spacing distance between tool paths is controlled by the equal-envelope height between wheel and workpiece. In this paper, arc envelope grinding principle was investigated in connection with wheel coordinate calculation and tool path number. The theoretical analysis and grinding experiment showed that arc envelope grinding may improve form grinding efficiency especially for large curvature and smoothness of ground surface and a smooth curve surface can be produced when the equal-envelope height is less than a certain value.