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Vibration-assisted vat photopolymerization for pixelated-aliasing-free surface fabrication

International Journal of Extreme Manufacturing 2024年第3期6卷 440-456页

作者： Han Xu Renzhi Hu Shuai Chen Junhong Zhu Chi Zhou Yong Chen Center for Advanced Manufacturing University of Southern CaliforniaLos AngelesCA 90007United States of America Daniel J.Epstein Department of industrial and Systems engineering University of Southern CaliforniaLos AngelesCA 90089United States of America Department of Aerospace and mechanical engineering University of Southern CaliforniaLos AngelesCA 90089United States of America Department of industrial and Systems engineering University of BuffaloBuffaloNY 14260United States of America

Mask image projection-based vat photopolymerization(MIP-VPP)offers advantages like low cost,high resolution,and a wide material range,making it popular in industry and ***,MIP-VPP employing liquid crystal displays(LCDs)has gained traction,increasingly replacing digital micromirror devices,particularly among hobbyists and in educational settings,and is now beginning to be used in industrial ***,LCD-based MIP-VPPsuffers from pronounced pixelated aliasing arising from LCD’s discrete image pixels and itsdirect-contact configuration in MIP-VPP machines,leading to rough surfaces on the 3D-printed ***,we propose a vibration-assisted MIP-VPP method that utilizes a microscalevibration to uniformize the light intensity distribution of the LCD-based mask image on VPP’s building *** maintaining the same fabrication speed,our technique generates asmoother,non-pixelated mask image,reducing the roughness on flat surfaces and boundary segments of 3D-printed *** light intensity modeling and simulation,we derived an optimal vibration pattern for LCD mask images,subsequently validated by *** assessed the surface texture,boundary integrity,and dimensional accuracy of componentsproduced using the vibration-assisted *** notably smoother surfaces and improved boundary roughness enhance the printing quality of MIP-VPP,enabling its promisingapplications in sectors like the production of 3D-printed optical devices and others.

关键词： additive manufacturing vat photopolymerization piezo vibration sub-pixel resolution aliasing

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Two-stage dynamic recrystallization and texture evolution in Al-7Mg alloy during hot torsion

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International Journal of Minerals,Metallurgy and Materials 2024年第8期31卷 1900-1911页

作者： Kwang Tae Son Chang Hee Cho Myoung Gyun Kim Ji Woon Lee School of mechanical Industrialand Manufacturing EngineeringOregon State UniversityCorvallis OR 97331USA Department of Materials Science engineering Northwestern UniversityEvanston IL 60208USA Research Institute of industrial Science and Technology(RIST) Pohang 37673Rep.of Korea Division of Advanced Materials engineering Kongju National UniversityCheonan 31080Rep.of Korea Center for Advanced Materials and Parts of Powders Kongju National UniversityCheonan 31080Rep.of Korea

Hot torsion tests were performed on the Al-7Mg alloy at the temperature ranging from 300 to 500℃ and strain rates between 0.05 and 5 s^(-1) to explore the progressive dynamic recrystallization(DRX)and texture *** DRX behavior of the alloy manifested two distinct stages:Stage 1 at strain of≤2 and Stage 2 at strains of≥*** Stage 1,there was a slight increase in the DRXed grain fraction(X_(DRX))with predominance of discontinuous DRX(DDRX),followed by a modest change in X_(DRX) until the transition to Stage *** 2 was marked by an accelerated rate of DRX,culminating in a substantial final X_(DRX) of~*** backscattered diffraction(EBSD)analysis on a sample in Stage 2 revealed that continuous DRX(CDRX)predominantly occurred within the(121)[001]grains,whereas the(111)[110]grains underwent a geometric DRX(GDRX)evolution without a noticeable sub-grain ***,a modified Avrami’s DRX kinetics model was utilized to predict the microstructural refinement in the Al-7Mg alloy during the DRX *** this kinetics model did not accurately capture the DDRX behavior in Stage 1,it effectively simulated the DRX rate in Stage *** texture index was employed to assess the evolution of the texture isotropy during hot-torsion test,demonstrating significant improvement(>75%)in texture randomness before the commencement of Stage *** initial texture evolution is attributed to the rotation of parent grains and the substructure evolution,rather than to an increase in X_(DRX).

关键词： Al-7Mg alloys hot deformation hot torsion tests dynamic recrystazlliation microstructure texture

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Damage Diagnosis of Bleacher Based on an Enhanced Convolutional Neural Network with Training Interference

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Structural Durability & Health Monitoring 2024年第3期18卷 321-339页

作者： Chaozhi Cai Xiaoyu Guo Yingfang Xue Jianhua Ren School of mechanical and Equipment engineering Hebei University of EngineeringHandan056038China

Bleachers play a crucial role in practical engineering applications, and any damage incurred during their operationposes a significant threat to the safety of both life and property. Consequently, it becomes imperative to conductdamage diagnosis and health monitoring of bleachers. The intricate structure of bleachers, the varied types ofpotential damage, and the presence of similar vibration data in adjacent locations make it challenging to achievesatisfactory diagnosis accuracy through traditional time-frequency analysis methods. Furthermore, field environmentalnoise can adversely impact the accuracy of bleacher damage diagnosis. To enhance the accuracy and antinoisecapabilities of bleacher damage diagnosis, this paper proposes improvements to the existing ConvolutionalNeural Network with Training Interference (TICNN). The result is an advanced Convolutional Neural Networkmodel with superior accuracy and robust anti-noise capabilities, referred to as Enhanced TICNN (ETICNN).ETICNN autonomously extracts optimal damage-sensitive features from the original vibration data. To validatethe superiority of the proposed ETICNN, experiments are conducted using the bleacher model from Qatar Universityas the subject. Comparative studies under identical experimental conditions involve TICNN, Deep ConvolutionalNeural Networks with wide first-layer kernels (WDCNN), and One-Dimensional ConvolutionalNeural Network (1DCNN). The experimental findings demonstrate that the ETICNN model achieves the highestaccuracy, approximately 99%, and exhibits robust classification abilities in both Phases I and II of the damagediagnosis experiments. Simultaneously, the ETICNN model demonstrates strong anti-noise capabilities, outperformingTICNN by 3% to 4% and surpassing other models in performance.

关键词： Bleacher vibration signal damage diagnosis convolutional neural network anti-noise ability

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Comparison of electrochemical behaviors of Ti-5Al-2Sn-4Zr-4Mo-2Cr-1Fe and Ti-6Al-4V titanium alloys in NaNO_(3) solution

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International Journal of Minerals,Metallurgy and Materials 2024年第4期31卷 750-763页

作者： Jia Liu Shuanglu Duan Xiaokang Yue Ningsong Qu College of mechanical and Electrical engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China

The Ti-5Al-2Sn-4Zr-4Mo-2Cr-1Fe(β-CEZ)alloy is considered as a potential structural material in the aviation industry due to its outstanding strength and corrosion *** machining(ECM)is an efficient and low-cost technology for manufacturing theβ-CEZ *** ECM,the machining parameter selection and tool design are based on the electrochemical dissolution behavior of the *** this study,the electrochemical dissolution behaviors of theβ-CEZ and Ti-6Al-4V(TC4)alloys in NaNO3solution are *** open circuit potential(OCP),Tafel polarization,potentiodynamic polarization,electrochemical impedance spectroscopy(EIS),and current efficiency curves of theβ-CEZ and TC4 alloys are *** results show that,compared to the TC4 alloy,the passivation film structure is denser and the charge transfer resistance in the dissolution process is greater for theβ-CEZ ***,the dissolved surface morphology of the two titanium-based alloys under different current densities are *** low current densities,theβ-CEZ alloy surface comprises dissolution pits and dissolved products,while the TC4 alloy surface comprises a porous honeycomb *** high current densities,the surface waviness of both the alloys improves and the TC4 alloy surface is flatter and smoother than theβ-CEZ alloy ***,the electrochemical dissolution models ofβ-CEZ and TC4 alloys are proposed.

关键词： electrochemical machining dissolution behavior β-CEZ titanium alloy polarization curve current efficiency

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Design method and experimental study of a cathode tool with an extremely high leveling ratio for electrochemical machining of blisk

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Chinese Journal of Aeronautics 2024年第4期37卷 593-608页

作者： Moqi SHEN Jia LIU Jingtao WANG Di ZHU College of mechanical and Electrical engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China

To obtain final parts with the desired dimensional accuracy and repeatability via electrochemical machining(ECM), the machining process must enter an ECM balanced state. However,for the ECM processing of blisk, a key component of aerospace engines, the surface of the blade blank often has an uneven allowance distribution due to the narrow passage of the cascade. It is difficult to remedy this issue in subsequent processing steps, which is necessary to ensure the dimensional accuracy and repeatability of the final blade profile. To solve this problem, electrolytic machining must be preceded by electrolytic shaping, which requires cathode tools with large leveling ratios to quickly homogenize the blank surface of the blade. In this study, to obtain a cathode tool with an extremely high leveling ratio, a design method based on the variation in the electrode gap in the non-equilibrium electrolytic state is proposed, and a dissolution model based on the nonequilibrium state is established. In this design method, the allowance on the blank to be machined is first divided into many discrete allowances with the normal direction. The initial machining clearance, feed rate, and total machining time are then calculated using classical ECM equilibrium state theory based on the maximum allowance. Meanwhile, the point coordinates of the cathode tool at maximum allowance can be determined. The non-equilibrium model can then be used to calculate the relative coordinate positions corresponding to the remaining discrete allowances. Finally, the entire cathode tool profile is designed. Simulations, fundamental experiments, and blisk unit workpiece experiments were carried out to validate the design approach. In the simulated processing of the plane workpiece, the leveling ratio of the cathode tool designed by the proposed method(0.77)was 83% higher than that of the cathode tool designed using the traditional method. The simulation results were confirmed by processing experiments. In t

关键词： Electrochemical machining(ECM) Non-equilibrium machining Large leveling ratios Cathode design Finite element simulation Blisk

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Flat jet electrochemical milling of TC4 alloy with tailoring backward parallel flow

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Chinese Journal of Aeronautics 2024年第4期37卷 574-592页

作者： Huanghai KONG Ningsong QU College of mechanical and Electrical engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China

In flat jet electrochemical milling, the electrolyte forms a backward parallel flow after impacting the workpiece, resulting in a weak current density distribution on the workpiece. Poor surface quality usually occurs on the machined titanium alloy surface because it inevitably suffers from the weak current density. In this study, a method of flat jet electrochemical milling with tailoring the backward parallel flow was proposed to eliminate the negative effects caused by the weak current density. Multiphysics simulations are carried out to comprehend the mechanism of flat jetEC milling with tailoring backward parallel flow and better construct the novel tool *** on flat jet electrochemical milling of TC4 alloy with and without tailoring backward parallel flow are conducted. The results reveal that, compared with flat jet electrochemical milling without tailoring backward parallel flow, the recommended tool reduces the surface roughness by86% to 93%, and improves the material removal rate by 93% to 163% with different feed ***, the recommended tool is more conducive to maintaining the inherent hardness of the material. Finally, a surface with low Sa of 0.37 μm is obtained.

关键词： Flat jet electrochemical milling TC4 alloy Surface roughness Micro-hardness Material removal rate

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Compression properties of cost-efficient porous expanded clay reinforced AA7075 syntactic foams fabricated by industrial-oriented die casting technology

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China Foundry 2024年第1期21卷 60-70页

作者： İsmail Cem Akgün Çağın Bolat Ali Gökşenli Faculty of mechanical engineering Istanbul Technical University34437İstanbulTurkey Faculty of engineering Samsun University55420SamsunTurkey

In today’s manufacturing industries,hard competition between rival firms makes it compulsory for researchers to design lighter and cheaper machine components due to the megatrends of cost-effectiveness and *** this point,aluminum syntactic foams(ASFs)are new-generation engineering composites and come into the upfront as a *** to their features like low density,sufficient elongation,and perfect energy absorption ability,these advanced foams have been considerably seductive for many industrial sectors *** this study,an industrial-oriented automatic die casting technology was used for the first time to manufacture the combination of AA7075/porous expanded clay(PEC).Micro evaluations(optical and FESEM)reveal that there is a homogenous particle distribution in the foam samples,and inspections are compatible with the other ASF ***,T6 aging heat treatment was operated on one half of the produced foams to explore the probable impact of aging on the compressive *** results show that PEC particles can be an alternative to expensive hollow spheres used in the previous ***,a favorable relationship is ascertained between the aging treatment and mechanical properties such as compression strength and plateau strength.

关键词： die casting porous materials metal matrix sytanctic foams expanded clay compressive deformation

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Spark Plasma Sintering of Mg-based Alloys:Microstructure,mechanical Properties,Corrosion Behavior,and Tribological Performance

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Journal of Magnesium and Alloys 2024年第2期12卷 405-442页

作者： Alessandro M.Ralls Mohammadreza Daroonparvar Pradeep L.Menezes Department of mechanical engineering University of Nevada RenoRenoNV89557United States

Within the past ten years,spark plasma sintering(SPS)has become an increasingly popular process for Mg *** the SPS process,interparticle diffusion of compressed particles is rapidly achieved due to the concept of Joule *** to traditional and additive manufacturing(AM)techniques,SPS gives unique control of the structural and microstructural features of Mg *** doing so,their mechanical,tribological,and corrosion properties can be *** great advancements in this field have been made,these pieces of knowledge are scattered and have not been contextualized into a single *** motivation of this work is to address this scientific gap and to provide a groundwork for understanding the basics of SPS manufacturing for *** do so,the existing body of SPS Mg literature was first surveyed,with a focus on their structural formation and degradation *** was found that successful Mg SPS fabrication highly depended on the processing temperature,particle size,and particle *** addition of metal and ceramic composites also affected their microstructural features due to the Zener pinning *** degradative environments,their performance depends on their structural features and whether they have secondary phased *** industrial applications,SPS'd Mg was found to have great potential in biomedical,hydrogen storage,battery,automotive,and recycling *** prospects to advance the field include using Mg as a doping agent for crystallite size refinement and using bulk metallic Mg-based glass powders for amorphous SPS *** these findings,the interactions of multi-composites on the processing-structure-property relationships of SPS Mg is not well *** total,this work will provide a useful direction in the SPS field and serve as a milestone for future Mg-based SPS manufacturing.

关键词： Spark plasma sintering Magnesium alloys Nanocrystalline Tribology mechanical properties Corrosion

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Critical assessment of R410A alternatives for mini-split air conditioners in the Egyptian market

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Energy and Built Environment 2024年第3期5卷 426-445页

作者： Omar M.Zaki Omar Abdelaziz mechanical Power engineering Department Faculty of EngineeringCairo UniversityGiza 12613Egypt Department of mechanical engineering The American University in CairoAUC AvenueNew Cairo 11835Egypt

In this study,the potential implementation of three different low-GWP refrigerants(R32,R452B,and R454B)as replacements for R410A was *** study was performed using a simulation tool developed by the authors called RACHP-Lab,which is a vapor compression system simulation tool developed based on physics-based simulation for typical mini-split air *** simulation study was carried out and validated using experimental performance data of 10 different air conditioning units available in the Egyptian *** units included fixed-speed or variable-speed compressors and operated in cooling or heating ***-in replace-ment with the new refrigerants was carried *** R32,the capacity increased between 4.9%and 13%for cooling cases,and 6.3%and 12.4%for heating ***,COP did not improve in all *** R452B and R454B with direct replacement,the capacity nearly remained the same,with an increase of COP between 1.6%and 8.0%.Soft optimization was also conducted on cooling cases where compressor suction superheat,condenser subcooling,and compressor volumetric speed were optimized to maximize COP while maintaining the original capacity of R410A.R32 showed an improvement of COP over R410A between 4.6%and 15.5%,while for R452B and R454B between 2.2%and 13.2%.

关键词： Air conditioner Heat pump Alternative refrigerants Vapor compression cycle modeling

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Non-contact and full-field online monitoring of curing temperature during the in-situ heating process based on deep learning

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Advances in Manufacturing 2024年第1期12卷 167-176页

作者： Qiang-Qiang Liu Shu-Ting Liu Ying-Guang Li Xu Liu Xiao-Zhong Hao College of mechanical and Electrical engineering Nanjing University of Aeronautics and AstronauticsNanjing210016People’s Republic of China School of mechanical and Power engineering Nanjing Tech UniversityNanjing211816People’s Republic of China

Online monitoring of the curing temperature field is essential to improving the quality and efficiency of the manufacturing process of composite *** embedded sensor-based technologies have difficulty monitoring the full temperature field or have to introduce heterogeneous items that could have an undesired impact on the *** this paper,a non-contact,full-field monitoring method based on deep learning that predicts the internal temperature field of composite parts in real time using surface temperature measurements of auxiliary materials is *** the proposed method,an average temperature monitoring accuracy of 97%is achieved in various heating *** addition,this method also demonstrates satisfying feasibility when a stronger thermal barrier covers the *** method was experimentally validated during the self-resistance electric heating process,in which the monitoring accuracy reached 93.1%.This method can potentially be applied to automated manufacturing and process control in the composites industry.

关键词： Online monitoring Curing temperature field Deep learning(DL) In-situ heating

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