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High-precision simulation and experimental verification of residual stress and surface topography of cylindrical surface shot peening

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CHINESE JOURNAL OF AERONAUTICS 2024年第9期37卷 535-559页

作者： Zhao, Jiuyue Tang, Jinyuan Liu, Huaming Zhang, Huiyun Li, Xin Ding, Han Cent South Univ State Key Lab Precis Mfg Extreme Serv Performance Changsha 410083 Peoples R China Cent South Univ Coll Mech & Elect Engn Changsha 410083 Peoples R China

Shot peening is commonly employed for surface deformation strengthening of cylindrical surface part. Therefore, it is critical to understand the effects of shot peening on residual stress and surface topography. Compared to flat surface, cylindrical surface shot peening has two significant features: (i) the curvature of the cylindrical surface and the scattering of the shot stream cause distributed impact velocities; (ii) the rotation of the part results in a periodic variation of the impact velocity component. Therefore, it is a challenge to quickly and accurately predict the shot peening residual stress and surface topography of cylindrical surface. This paper developed a high-precision model which considers the more realistic shot peening process. Firstly, a kinematic analysis model was developed to simulate the relative movement of numerous shots and cylindrical surface. Then, the spatial distribution and time-varying impact information was calculated. Subsequently, the impact information was used for finite element modeling to predict residual stress and surface topography. The proposed kinematic analysis method was validated by comparison with the discrete element method. Meanwhile, 9310 high strength steel rollers shot peening test verified the effectiveness of the model in predicting the residual stress and surface topography. In addition, the effects of air pressure and attack angle on the residual stress and surface topography were investigated. This work could provide a functional package for efficient prediction of the surface integrity and guide industrial application in cylindrical surface shot peening.

关键词： Shot peening Cylindrical surface 9310 high strength steel High-precision modeling Residual stress surface topography FATIGUE BEHAVIOR ROUGHNESS INTEGRITY STRENGTH HARDNESS STEEL

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Generating synthetic as-built additive manufacturing surface topography using progressive growing generative adversarial networks

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Friction 2024年第6期12卷 1283-1298页

作者： Junhyeon SEO Prahalada RAO Bart RAEYMAEKERS Department of Mechanical Engineering Virginia TechBlacksburgVA 24061USA Grado Department of Industrial and Systems Engineering Virginia TechBlacksburgVA 24061USA

Numerically generating synthetic surface topography that closely resembles the features and characteristics of experimental surface topography measurements reduces the need to perform these intricate and costly ***,existing algorithms to numerically generated surface topography are not well-suited to create the specific characteristics and geometric features of as-built surfaces that result from laser powder bed fusion(LPBF),such as partially melted metal particles,porosity,laser scan lines,and ***,we present a method to generate synthetic as-built LPBF surface topography maps using a progressively growing generative adversarial *** qualitatively and quantitatively demonstrate good agreement between synthetic and experimental as-built LPBF surface topography maps using areal and deterministic surface topography parameters,radially averaged power spectral density,and material ratio *** ability to accurately generate synthetic as-built LPBF surface topography maps reduces the experimental burden of performing a large number of surface topography ***,it facilitates combining experimental measurements with synthetic surface topography maps to create large data-sets that facilitate,*** as-built surface topography to LPBF process parameters,or implementing digital surface twins to monitor complex end-use LPBF parts,amongst other applications.

关键词： additive manufacturing surface topography synthetic surface topography generative adversarial networks

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surface topography and Roughness of High-speed Milled AlMn1Cu

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Chinese Journal of Mechanical Engineering 2016年第6期29卷 1200-1207页

作者： WANG Zhenhua YUAN Juntang YIN Zengbin HU Xiaoqiu School of Mechanical Engineering Nanjing University of Science and Technology Collaborative Innovation Center of High-End Equipment Manufacturing Technology Nanjing University of Science and Technology

The aluminum alloy AlMn1Cu has been broadly applied for functional parts production because of its good properties. But few researches about the machining mechanism and the surface roughness were reported. The high-speed milling experiments are carried out in order to improve the machining quality and reveal the machining mechanism. The typical topography features of machined surface are observed by scan electron microscope（SEM）. The results show that the milled surface topography is mainly characterized by the plastic shearing deformation surface and material piling zone. The material flows plastically along the end cutting edge of the flat-end milling tool and meanwhile is extruded by the end cutting edge, resulting in that materials partly adhere to the machined surface and form the material piling zone. As the depth of cut and the feed per tooth increase, the plastic flow of materials is strengthened and the machined surface becomes rougher. However, as the cutting speed increases, the plastic flow of materials is weakened and the milled surface becomes smoother. The cutting parameters （e.g. cutting speed, feed per tooth and depth of cut） influencing the surface roughness are analyzed. It can be concluded that the roughness of the machined surface formed by the end cutting edge is less than that by the cylindrical cutting edge when a cylindrical flat-end mill tool is used for milling. The proposed research provides the typical topography features of machined surface of the anti-rust aluminum alloy AlMn1Cu in high speed milling.

关键词： surface topography surface roughness Aluminum alloy AlMn1Cu high-speed milling

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surface topography of Fine-grained ZrO_2 Ceramic by Two-dimensional Ultrasonic Vibration Grinding

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Journal of Wuhan University of Technology(Materials Science) 2011年第6期26卷 1162-1165页

作者：丁爱玲 School of Mechanical and Automation Engineering North University of China

The surface quality of fine-grained ZrO2 engineering ceramic were researched using 270# diamond wheel both with and without work-piece two-dimension ultrasonic vibration grinding（WTDUVG）. By AFM images, the surface topography and the micro structure of the two-dimensional ultrasonic vibration grinding ceramics were especially analyzed. The experimental results indicate that the surface roughness is related to grinding vibration mode and the material removal mechanism. surface quality of WTDUVG is superior to that of conventional grinding, and it is easy for two-dimensional ultrasonic vibration grinding that material removal mechanism is ductile mode grinding.

关键词： two-dimension ultrasonic vibration grinding surface topography ductile grinding

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Experimental and modeling study of surface topography generation considering tool-workpiece vibration in high-precision turning

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Chinese Journal of Aeronautics 2023年第7期36卷 194-212页

作者： Xingying ZHOU Henan LIU Tianyu YU Ruiyang GUO Guangzhou WANG Yazhou SUN Mingjun CHEN State Key Laboratory of Robotics and System Harbin Institute of TechnologyHarbin 150001China School of Mechatronics Engineering Harbin Institute of TechnologyHarbin 150001China

High-precision turning(HPT)is a main processing method for manufacturing rotary high-precision components,especially for metallic ***,the generated vibration between tool tip and workpiece during turning may seriously deteriorate the surface ***,exploring the effect of vibration on turning surface morphology and quality of copper parts using 3D surface topography regeneration model is crucial for predicting HPT *** developed model can update the machined surface topology in real *** this study,the effects of tool arc radius,feed rate,radial vibration,axial vibration and tangential vibration on the surface topography and surface roughness were *** results show that the effect of radial vibration on surface topography is greater than that of axial vibration and tangential *** radial vibration frequency is also *** vibration frequency changes,the surface topography profile presents three different types:the standard sinusoidal curve,the sinusoidal curve whose lowfrequency signal envelopes high-frequency signal,and the oscillation curve whose low-frequency signal superimposes high-frequency *** addition,HPT experiment was carried out to validate the developed *** surface roughness obtained in the experiment was Ra=53 nm,while the roughness obtained by the simulation was Ra=46 nm,achieving a prediction accuracy of 86.7%.Received 4 September 2022;revised 3 October 2022;accepted 17 October 2022.

关键词： High-precision turning Machining vibration Modeling surface roughness surface topography

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Elliptical model for surface topography prediction in five-axis flank milling

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Chinese Journal of Aeronautics 2020年第4期33卷 1361-1374页

作者： Liping WANG Shuyi GE Hao SIa Liwen GUAN Feiyu DUAN Yuzhe LIU Department of Mechanical Engineering Tsinghua UniversityBeijing 100084China School of Mechanical and Electrical Engineering University of Electronic Science and Technology of ChinaChengdu 611731China Beijing Institute of Astronautical Systems Engineering Beijing 100076China

In five-axis flank milling operations,the intersecting surfaces of different cutting edges create roughness on the milled surfaces that cannot be ignored in situations with strict requirements,especially in aeronautical *** focus on motion problems in milling operations,this paper presents a new model that utilizes elliptical paths as cutting edge trajectories on 3D surface topography machined by peripheral ***,the cutter parallel axis offset and location angle are considered,which change the location of the ellipse center and intersection point of the cutting ***,through the proposed model,the predicted surface topography is obtained,and the factors that affect the development tendency of roughness are ***,the effects of the cutter location position(CLP)geometric parameters,cutter parallel axis offset and curvature on the roughness are evaluated by a numerical ***,machining tests are carried out to validate the model predictions,and the results show that the surface topography predictions correspond well with the experimental results.

关键词： Cutter runout Elliptical paths Five-axis flank milling surface topography Workpiece curvature

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Regulation of substrate surface topography on differentiation of mesenchymal stem cells

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Acta Mechanica Sinica 2020年第5期36卷 1158-1169,I0004页

作者： Bo Huo Yang Zhao Xue Bai Qing Sun Fei Jiao Biomechanics Lab Department of MechanicsSchool of Aerospace EngineeringBeijing Institute of TechnologyBeijing 100081China

Mesenchymal stem pells(MSCs)have been extensively used in the field of tissue engineering and regenerative *** effect of surface properties on the differentiation of MSCs is a very important issue for the design and fabrication of scaffolds or *** review is mainly focused on the morphological or topographic characteristics of cell adhesion substrate,*** area and shape for individual cell,cell density and cell-cell contact for multiple cells,substrate roughnessridge width,micropillar height,nanoparticle diameter and aspect ratio of *** results from different studies were quantitativcly analyzed using comparable or unified parameters and definitions under the specific experimental conditions such as cell source,culture time,induction medium,matrix material and differentiation *** interesting phenomena and properties were discovered by this integrated and systematic analysis,which might give insights into the regulatory mechanism of surface morphology or topography on MSCs differentiation.

关键词： Mesenchymal stem cell Adhesion morphology surface topography Differentiation Biomaterial

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Effect of surface topography on Stress Concentration Factor

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Chinese Journal of Mechanical Engineering 2015年第6期28卷 1141-1148页

作者： CHENG Zhengkun LIAO Ridong School of Mechanical Engineering Beijing Institute of Technology

Neuber rule and Arola-Ramulu model are widely used to predict the stress concentration factor of rough specimens. However, the height parameters and effective valley radius used in these two models depend strongly on the resolution of the roughness-measuring instruments and are easily introduce measuring errors. Besides, it is difficult to find a suitable parameter to characterize surface topography to quantitatively describe its effect on stress concentration factor. In order to overcome these disadvantages, profile moments are carried out to characterize surface topography, surface topography is simulated by superposing series of cosine components, the stress concentration factors of different micro cosine-shaped surface topographies are investigated by finite element analysis. In terms of micro cosine-shaped surface topography, an equation using the second profile moment to estimate the stress concentration factor is proposed, predictions for the stress concentration factor using the proposed expression are within 10% error compared with the results of finite element analysis, which are more accurate than other models. Moreover, the proposed equation is applied to the real surface topography machined by turning. Predictions for the stress concentration factor using the proposed expression are within 10% of the maximum stress concentration factors and about 5% of the effective stress concentration factors estimated from the finite element analysis for three levels of turning surface topographies under different simulated scales. The proposed model is feasible in predicting the stress concentration factors of real machined surface topographies.

关键词： surface topography profile moments stress concentration factor finite element method

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Nature-inspired surface topography: design and function

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Science China(Physics,Mechanics & Astronomy) 2020年第2期63卷 32-46页

作者： XianTong Yan YuanKai Jin XueMei Chen Chao Zhang ChongLei Hao ZuanKai Wang Department of Mechanical Engineering City University of Hong KongHong Kong 999077China MIIT Key Laboratory of Thermal Control of Electronic Equipment School of Energy and Power EngineeringNanjing University of Science and TechnologyNanjing 210094China

Learning from nature has traditionally and continuously provided important insights to drive a paradigm shift in *** particular,recent studies show that many biological organisms exhibit spectacular surface topography such as shape,size,spatial organization,periodicity,interconnectivity,and hierarchy to endow them with the capability to adapt dynamically and responsively to a wide range of *** excitingly,in a broader perspective,these normally neglected topological features have the potential to fundamentally change the way of how engineering surface works,such as how fluid flows,how heat is transported,and how energy is generated,saved,and converted,to name a ***,the design of nature-inspired surface topography for unique functions will spur new thinking and provide paradigm shift in the development of the new engineering *** this review,we first present a brief introduction to some insights extracted from ***,we highlight recent progress in designing new surface topographies and demonstrate their applications in emerging areas including thermal-fluid transport,anti-icing,water harvesting,power generation,adhesive control,and soft ***,we offer our perspectives on this emerging field,with the aim to stimulate new thinking on the development of next-generation of new materials and devices,and dramatically extend the boundaries of traditional engineering.

关键词： natural inspiration biomimetic surface topography surface engineering unique functions interfacial interaction mechanisms

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Effect of electrochemical polishing time on surface topography of mild steel

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Journal of University of Science and Technology Beijing 2007年第3期14卷 236-239页

作者： Baocheng Wang Jinhua Zhu State Key Laboratory for Mechanical Behavior of Metal Materials Xi＇an Jiaotong University Xi＇an 710049 China College of Material Science and Engineering Taiyuan University of Technology Taiyuan 030024 China

The variation in altitude density function （ADF） of the surface topography of mild steel during electrochemical polishing （ECP） was investigated, and the mechanism of the variation of surface roughness with polishing time was analyzed. The results show that the variation trend of ADF with polishing time is flat-steep-flat; the variation of surface roughness results in the different distri- butions of surface current density, and there is a fine surface smoothness in the special period of ECP from 4 to 8 s.

关键词： mild steel electrochemical polishing altitude density function surface topography

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