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Electrochemical micromachining of micro-dimple arrays on cylindrical inner surfaces using a dry-film photoresist 总被引:1,自引:1,他引:0
The application of surface textures has been employed to improve the tribological performance of various mechanical components. Various techniques have been used for the application of surface textures such as micro-dimple arrays, but the fabrication of such arrays on cylindrical inner surfaces remains a challenge. In this study, a dry-film photoresist is used as a mask during through-mask electrochemical micromachining to successfully prepare micro-dimple arrays with dimples 94 lm in diameter and 22.7 lm deep on cylindrical inner surfaces, with a machining time of 9 s and an applied voltage of 8 V. The versatility of this method is demonstrated, as are its potential low cost and high efficiency. It is also shown that for a fixed dimple depth, a smaller dimple diameter can be obtained using a combination of lower current density and longer machining time in a passivating sodium nitrate electrolyte. 相似文献
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Invar alloy consisting of 64% iron and 36% nickel has been widely used for the production of shadow masks for organic light emitting diodes(OLEDs) because of its low thermal expansion coefficient(1.86 ? 10à6cm/°C).To fabricate micro-hole arrays on 30 lm invar alloy film,through-mask electrochemical micromachining(TMEMM) was developed and combined with a portion of the photolithography etching process.For precise hole shapes,patterned photoresist(PR) film was applied as an insulating mask.To investigate the relationship between the current density and the material removal rate,the principle of the electrochemical machining was studied with a focus on the equation.The finite element method(FEM) was used to verify the influence of each parameter on the current density on the invar alloy film surface.The parameters considered were the thickness of the PR mask,inter-electrode gap(IEG),and electrolyte concentration.Design of experiments(DOE) was used to figure out the contribution of each parameter.A simulation was conducted with varying parameters to figure out their relationships with the current density.Optimization was conducted to select the suitable conditions.An experiment was carried out to verify the simulation results.It was possible to fabricate micro-hole arrays on invar alloy film using TMEMM,which is a promising method that can be applied to fabrications of OLEDs shadow masks. 相似文献
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使用瞬态液晶(TLC)热像传热测试技术,对具有边缘倒圆的凹陷涡发生器局部传热特征和流动阻力进行了实验研究。凹陷边缘倒圆方案有2种:凹陷前边缘倒圆和凹陷边缘全部倒圆。凹陷的投影直径与通道高度比为1.0,凹陷深度与直径比为0.2,实验雷诺数范围为10 000~60 000。实验结果表明,在选取的雷诺数下,相比于光滑通道,边缘无倒圆的常规球型凹陷涡发生器阵列表面对流换热性能提升了约62.0%,相应的摩擦因子也增大了约73.0%。与无倒圆的常规球型凹陷涡发生器相比,边缘全倒圆的凹陷涡发生器换热性能提升了约3.6%,摩擦因子降低了约4.6%;前边缘倒圆的凹陷涡发生器换热性能提升了约11.0%,摩擦因子提高了约5.2%。综合看来,边缘倒圆使得凹陷涡发生器内部表面传热更加均匀;前边缘倒圆的凹陷涡发生器综合换热性能最高,比边缘无倒圆的常规凹陷涡发生器高出约9.6%;而边缘全部倒圆的凹陷涡发生器的综合换热性能比常规凹陷涡发生器高出近4.4%。 相似文献
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应用光干涉方法对周期间歇卷吸条件下的弹流油膜进行了测量,结果显示了三种不同的局部油膜凹陷。第一种油膜凹陷产生于固体表面周期性的运动和停止,纯滚动的凹陷封油量大于纯滑动的封油量。第二种凹陷产生于启动过程的速度振荡瞬时峰值,该类局部凹陷以卷吸速度通过赫兹接触区。纯滑动条件下,界面滑移作用产生第三种凹陷,该凹陷位于入口附近,与表面速度和运动时间有关。实验中观察到的现象可由油膜的挤压效应,卷吸效应和界面滑移效应进行解释。 相似文献
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Bao Huaiqian a b Xu Jiawen a Li Ying a c aJiangsu Key Laboratory of Precision Micro-Manufacturing Technology Nanjing University of Aeronautics Astronautics Nanjing China bCollege of Mechanical Electric Engineering Shandong University of Science Technology Qingdao China cSchool of Mechanical Electrical Engineering Jinling Institute of Technology Nanjing China 《中国航空学报》2008,(5)
为了寻求航空精密微细制造新技术并实现绿色制造和精密微细制造,对一种新型微细电解加工方法——纯水微细电解加工进行了研究。基于水解离机理,在新研制的试验装置上,采用不同的试验条件,进行了一系列工艺试验,探索并揭示了实现纯水微细电解加工的必要工艺条件和工艺规律,加工了圆孔和字母"PW-ECM";还研究了超声振动—纯水电解复合加工新方法,进而在不锈钢薄片上加工出三角、方形盲孔、三角通孔;试验研究结果证明了纯水微细电解加工的可行性。 相似文献
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This article proposes a precise and ecofriendly micromachining technology for aerospace application called electrochemical machining in pure water (PW-ECM). On the basis of the principles of water dissociation, a series of test setups and tests are devised and performed under different conditions. These tests explain the need for technological conditions realizing PW-ECM, and further explore the technological principles. The results from the tests demonstrate a successful removal of electrolytic slime by means of ultrasonic vibration of the workpiece. To ensure the stability and reliability of PW-ECM process, a new combined machining method of PW-ECM assisted with ultrasonic vibration (PW-ECM/USV) is devised. Trilateral and square cavities and holes as well as a group of English alphabets are worked out on a stainless steel plate. It is confirmed that PW-ECM will be probably an efficient new aviation precision machining method. 相似文献
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Electrochemical micromachining (EMM) technology for fabricating micro structures is presented in this article. By applying ultra short pulses, dissolution of a workpiece can be restricted to the region very close to the electrode. First, an EMM system for meeting the requirements of the EMM process is established. Second, sets of experiments is carried out to investigate the influence of some of the predominant electrochemical process parameters such as electrical parameters, feed rate, electrode geometry features and electrolyte composition on machining quality, especially the influences of pulse on time on shape precision and working end shape of electrode on machined surface quality. Finally, after the preliminary experiments, a complex microstructure with good shape precision and surface quality is successfully obtained. 相似文献
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A high friction coefficient and a low wear rate of contacted surfaces are essential elements to friction pairs between the stator and the rotor in ultrasonic motors. It has been shown that surface textures have a significant effect on improving the tribological performance of friction pairs.In this paper, microgroove arrays are introduced to the stator surface for improving the tribological performance of friction pairs between the stator and the rotor in ultrasonic motors. Microgrooves were fabricated on a phosphor bronze surface by through-mask electrochemical micromachining(TMEMM). Parameters, namely, the electrolyte inlet pressure, applied voltage, pulse duty cycle,and frequency, were varied to investigate their influences on the dimensions and morphology of the microgrooves. Results showed that the width and depth of the microgrooves were strongly affected by the applied voltage and frequency, while the morphology of the microgrooves was dependent on the electrolyte inlet pressure and the pulse duty cycle. Compared with a smooth surface, the friction coefficient increased from 0.245 to 0.334 and less abrasion was obtained when a surface was textured with microgrooves of which the width and depth were 185.6 and 57.6 lm,respectively. Microgroove arrays might play an important role in enhancing the performance of ultrasonic motors. 相似文献
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The inter-electrode gap (IEG) is an essential parameter for the anode shaping process in electrochemical machining (ECM) and directly affects the machining accuracy. In this paper, the IEG during the leveling process of an oval anode workpiece in counter-rotating ECM (CRECM) is investigated. The variation of the minimum IEG is analyzed theoretically, and the results indicate that rather than reaching equilibrium, the minimum IEG in CRECM expands constantly when a constant feed speed is used for the cathode tool. This IEG expansion leads to a poor localization effect and has an adverse influence on the roundness of the machined workpiece. To maintain a small constant IEG in CRECM, a variable feed speed is used for the cathode based on a fitted equation. The theoretical results show that the minimum IEG can be controlled at a small value by using an accelerated feed speed. Experiments have been conducted using a specific experimental apparatus in which the cathode tool is designed as a combined structure of two sectors and a thin sheet. By detecting the machining currents flowing through the minimum IEG, how the latter varies is obtained indirectly. The results indicate that using an accelerated feed speed is effective for controlling the IEG, thereby improving the roundness of the machined workpiece. 相似文献
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以ELID 电解原理为基础,结合超声振动辅助磨削过程中单颗磨粒的运动学分析,建立了超声
ELID 复合磨削条件下的磨削力数学解析模型,并对模型进行了分析和仿真。对模型的分析表明:超声振动改
变了磨粒的运动轨迹,使同等条件下的未变形切屑厚度减小,砂轮的在线电解修整使磨粒始终处于锋锐状态,
而且影响砂轮的实际切削深度,进而对磨削力产生影响。磨削力随着超声振动频率、振幅、电解电压、脉冲比、
电解液电阻率的增大而减小;随着切削深度、工件速度的增大而增大。 相似文献
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滚动轴承振动的灰自助动态评估与诊断 总被引:4,自引:4,他引:0
以灰预报和自助再抽样方法为基础, 提出灰自助动态评估与诊断模型, 以评估和改进滚动轴承的振动.该模型用动态不确定度、估计区间、估计真值、平均不确定度、平均真值和系统误差测度等6个参数, 描述滚动轴承振动的基本特征.对HKRB轴承的试验表明, 该模型对随机误差的概率分布与系统误差的类型没有任何要求, 在平均不确定度为最小的条件下分离出系统误差.评估的可信度达到100%.根据灰自助动态评估结果, 还诊断出影响轴承振动的误差特征, 揭示了来自轴承零件制造的误差根源, 为实施滚动轴承振动的生产过程控制奠定了基础. 相似文献
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为了获得发动机进气道支板的热气防冰特性,采用热色液晶全表面瞬态测温技术对带凹坑楔形通道内表面开展冲击换热实验。研究了射流雷诺数,凹坑间距,射流入口到凹坑的距离和凹坑排数对壁面努塞尔数分布和大小的影响。结果表明:带凹坑壁面的平均换热效果要强于光滑壁面,两者的努塞尔数均随雷诺数的增加而增大。壁面的局部努塞尔数在凹坑尾缘出现一个峰值,凹坑间距越小,侧壁的平均换热效果越强。在小雷诺数时,凹坑的位置靠近出口缝,能够较大的增强侧壁的换热;在较大雷诺数时,凹坑位置越靠近前缘,则越能增强前缘的换热效果。当凹坑的排数增加,壁面的平均努塞尔数增大。 相似文献
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《中国航空学报》2021,34(9):247-260
As Ti-6Al-4V is a typical hard to machine material, especially in micro drilling aviation parts, chip breaking difficulty is of increasing interest to explore its further development. In this study, Longitudinal-Torsional Ultrasonic Assisted Drilling (LTUAD) was employed to machine Ti-6Al-4V, and its feasibility was evaluated by comparing with Conventional Drilling (CD). By combining periodical characteristics and vibration models (the separated or the unseparated ultrasonic elliptical vibration), the influence of ultrasonic frequency on the intersection characteristics of trajectories were analyzed. And the intersection characteristics were divided into four categories: even periodicity, odd periodicity, non-odd and even periodicity and composite periodicity, indicating different capability for chip breaking. By applying the longitudinal-torsional compound vibration horn, the micro-hole drilling experiment was carried out on machining center. The chip morphology, the thrust force, and the burr height were discussed. Experimental results showed that the morphology of chips presented as smaller and more fragmentary ones in LTUAD compared with continuous helical conical ones and fold-shaped ones in CD. Compared with CD, the average values of the thrust force in LTUAD reduced by 1.98% to 24.9%. According to the burr around the hole exit in both LTUAD and CD, the height of the latter was greatly affected by the drilling parameters. And the burr around the exit of the hole were distributed rather evenly with smaller extension in LTUAD. Consequently, the LTUAD employed in micro-hole drilling was effective. 相似文献
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气体静压轴承是气浮系统的重要组成元件,其气膜自激微振动会降低气浮系统的工作精度和刚度特性。为了进一步提高气体静压轴承的工作精度和稳定性,在分析轴承内部气膜波动形成机理的基础上,开展了数值计算及实验研究。不仅验证了气旋分布规律和气旋中心压降的存在可靠性,并且有力证明了气膜支撑区域内沿流动方向存在的分区现象。结合实验进一步分析了影响高压区气旋强度和分布位置的可能因素。结果表明:供气压力、供气孔径和气腔结构都分别对气旋的位置和强度有各自不同的影响规律;而主气旋的核心位置和内外压差造成的压力脉动又会直接决定气体静压轴承微振动的强度和频率特征。 相似文献
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TB6钛合金由于具有优越的性能,广泛地用于航空航天领域。然而从大余量的TB6钛合金锻铸件毛坯加工成复杂结构的零件,其加工效率低,刀具和机床成本高,造成了极大的浪费。为解决这一问题,提出了一种利用薄型中空电极进行快速大余量去除的电解加工(ECM)方法,即将零件与多余材料切割分离,有望较大程度提高加工效率,降低加工成本。为改善电解加工流场特性,提高加工精度,对电极施加振动,并对薄型中空电极的振动切割进行了建模分析和试验研究。试验结果表明,合适的振动幅值和频率(A=0.05mm,f=50Hz)可以使得各处电解液电导率趋于一致,从而提高加工的精度、稳定性和效率。复杂结构件的成功切割证明了薄型中空电极振动电解切割加工技术具有一定的适用性。 相似文献
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基于振动监测数据的航空发动机滚动轴承损伤大小识别,对于研究滚动轴承故障演化、故障预测和故障诊断具有重要意义。针对传统模型对先验知识依赖性高、特征提取不充分、故障尺寸训练类别有限等问题,提出了一种基于深度学习的滚动轴承损伤尺寸预计方法,能够对训练过程中未出现的中间尺寸进行准确识别。在经典模型的基础上,搭建了一种深度卷积网络与长短期记忆网络组合模型,该模型可对轴承振动信号的多维特征与时序特征进行充分提取,实现轴承故障的智能和高效诊断。最后,利用滚动轴承加速疲劳试验机,进行了多种转速与损伤尺寸下的滚动轴承故障试验,基于试验数据进行了方法的比较,结果表明,该组合网络的在正常和加噪的情况下预测精度分别达到99.94%和98.67%,较单独的深度卷积网络、长短期记忆网络及其他模型精度更高,比较结果充分表明了本文所提方法的优越性。 相似文献