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Precision forging technology for aluminum alloy

Lei DENG, Xinyun WANG, Junsong JIN, Juchen XIA

《机械工程前沿（英文）》 2018年 第13卷 第1期   页码 25-36 doi: 10.1007/s11465-018-0477-y

摘要：

Aluminum alloy is a preferred metal material for lightweight part manufacturing in aerospace, automobile, and weapon industries due to its good physical properties, such as low density, high specific strength, and good corrosion resistance. However, during forging processes, underfilling, folding, broken streamline, crack, coarse grain, and other macro- or microdefects are easily generated because of the deformation characteristics of aluminum alloys, including narrow forgeable temperature region, fast heat dissipation to dies, strong adhesion, high strain rate sensitivity, and large flow resistance. Thus, it is seriously restricted for the forged part to obtain precision shape and enhanced property. In this paper, progresses in precision forging technologies of aluminum alloy parts were reviewed. Several advanced precision forging technologies have been developed, including closed die forging, isothermal die forging, local loading forging, metal flow forging with relief cavity, auxiliary force or vibration loading, casting-forging hybrid forming, and stamping-forging hybrid forming. High-precision aluminum alloy parts can be realized by controlling the forging processes and parameters or combining precision forging technologies with other forming technologies. The development of these technologies is beneficial to promote the application of aluminum alloys in manufacturing of lightweight parts.

关键词： precision forging     aluminum alloy     closed die forging     flow control forging     hybrid-forming technology    

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近β锻造推翻陈旧理论发展了三态组织

周义刚,曾卫东,俞汉清

《中国工程科学》 2001年 第3卷 第5期   页码 61-66

摘要：

将坯料置于相变的临界点附近10～15℃加热、锻造、锻后水冷，随后，不是采用时效处理，而是先进行高温韧化再低温强化处理。近β锻造的组织不再是等轴α量过多，或是为零的网篮条状α的结构模式；而是约含20%等轴α、50%～60%条状α构成的网篮和β转变基体组成的三态组织。这种结构不仅丰富和发展了国 际上钛合金已有的4种组织类塑（等轴、双态、网篮和并列），而且将等轴和网篮组织的性能优势集于一身，由此带来的力学性能超过了国内外相关技术的性能水平：能在不降低塑性，不丧失热稳定性的条件下，提高材料的高温性能、低周疲劳性能和断裂韧性，在改善性能的同时提高使用温度。近β锻造适用于（α+β)型合金， 还可应用于α、近α和近β型合金，其研究成果已用于制造了多种发动机盘件、飞机和导弹等重要结构件。

关键词： 钛合金     近β锻造     三态组织    

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Interfacial heat transfer coefficient between metal and die during high pressure die casting process

GUO Zhipeng, XIONG Shoumei, CHO SangHyun, CHOI JeongKil

《机械工程前沿（英文）》 2007年 第2卷 第3期   页码 283-287 doi: 10.1007/s11465-007-0049-z

摘要： The present work focused on the determination of the interfacial heat transfer coefficient (IHTC) between metal and die during the high pressure die casting (HPDC) process. Experiments were carried out on an aluminum alloy, ADC12Z, using step shape casting so-called because of its shape. The IHTC was successfully determined by solving one of the inverse heat problems using the nonlinear estimation method first used by Beck. The calculation results indicated that the IHTC immediately increased after liquid metal was brought into the cavity by the plunger and decreased as the solidification process of the liquid metal proceeded. The liquid metal eventually solidified completely, a condition when the IHTC tended to be stable. Casting thickness played an important role in affecting the IHTC between the metal and die not only in terms of its value but also in terms of its change tendency. Also, under the test conditions, different change tendencies of the metal solid fraction were found between castings with different thicknesses and the die.

关键词： so-called     calculation     inverse     interfacial     aluminum    

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An energy consumption prediction approach of die casting machines driven by product parameters

《机械工程前沿（英文）》 2021年 第16卷 第4期   页码 868-886 doi: 10.1007/s11465-021-0656-0

摘要： Die casting machines, which are the core equipment of the machinery manufacturing industry, consume great amounts of energy. The energy consumption prediction of die casting machines can support energy consumption quota, process parameter energy-saving optimization, energy-saving design, and energy efficiency evaluation; thus, it is of great significance for Industry 4.0 and green manufacturing. Nevertheless, due to the uncertainty and complexity of the energy consumption in die casting machines, there is still a lack of an approach for energy consumption prediction that can provide support for process parameter optimization and product design taking energy efficiency into consideration. To fill this gap, this paper proposes an energy consumption prediction approach for die casting machines driven by product parameters. Firstly, the system boundary of energy consumption prediction is defined, and subsequently, based on the energy consumption characteristics analysis, a theoretical energy consumption model is established. Consequently, a systematic energy consumption prediction approach for die casting machines, involving product, die, equipment, and process parameters, is proposed. Finally, the feasibility and reliability of the proposed energy consumption prediction approach are verified with the help of three die casting machines and six types of products. The results show that the prediction accuracy of production time and energy consumption reached 91.64% and 85.55%, respectively. Overall, the proposed approach can be used for the energy consumption prediction of different die casting machines with different products.

关键词： die casting machine     energy consumption prediction     product parameters    

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Ultrasonic measurement of tie-bar stress for die-casting machine

《机械工程前沿（英文）》 doi: 10.1007/s11465-021-0663-1

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Experimental investigations on operating characteristics of a closed loop pulsating heat pipe

Yu WANG

《能源前沿（英文）》 2015年 第9卷 第2期   页码 134-141 doi: 10.1007/s11708-015-0354-x

摘要： The operating mechanism of the pulsating heat pipe (PHP) is not well understood and the present technology cannot predict required design parameters for a given task. The aim of research work presented in this paper is to better understand the operation regimes of the PHP through experimental investigations. A series of experiments were conducted on a closed loop PHP with 5 turns made of copper capillary tube of 2 mm in inner diameter. Two different working fluids viz. ethanol and acetone were employed. The operating characteristics were studied for the variation of heat input, filling ratio (FR) and inclination angle of the tested device. The results strongly demonstrate the effect of the filling ratio of the working fluid on the operational stability and heat transfer capability of the device. Important insight into the operational characteristics of PHP has been obtained.

关键词： closed loop pulsating heat pipe     thermal performance     operation limit     thermography    

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Establishment of the Comprehensive Evaluation System of Cold Stamping Die Quality

LU Xiao-chun, GUO Sheng, RUAN Feng

《机械工程前沿（英文）》 2006年 第1卷 第1期   页码 80-84 doi: 10.1007/s11465-005-0021-8

摘要：

A comprehensive evaluation system of die quality, a multiplayer hierarchical amendment index system according to the characteristics of cold stamping die production, an evaluation standard referring to the technique and design rules of dies, and a scientific evaluation by using the multiplayer hierarchical and the fuzzy comprehensive evaluation methods are presented in this paper. The applications show that the system can be used to evaluate the die quality objectively, fairly, and reasonably.

关键词： scientific evaluation     stamping     multiplayer hierarchical     technique     evaluation standard    

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Improvement of the cascading closed loop cycle system

ZHANG Guoqiang, CAI Ruixian

《能源前沿（英文）》 2007年 第1卷 第3期   页码 341-346 doi: 10.1007/s11708-007-0051-5

摘要： Aspen Plus was used to simulate and get more information about the cascading closed loop cycle (CCLC) system [1–3]. Following evaluation of the variable temperature heat source (e.g. gas turbine flue gas) utilized by the CCLC, both qualitative and quantitive comparisons between the system and simple steam Rankine cycle, were made. The results indicate that CCLC has the advantage in recuperating exergy from flue gas, but it cannot sufficiently convert the recuperated exergy to useful work. To improve the utilization of low temperature flue gas heat, the properties and parameters of the working substance must match conditions of the low temperature heat source. A better cycle scheme and pressure distribution was proposed to raise the efficiency of the CCLC. In addition, the multifunction system concept was introduced to improve the performance of CCLC with solar energy.
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Dynamic simulation of a space gas-cooled reactor power system with a closed Brayton cycle

《能源前沿（英文）》 2021年 第15卷 第4期   页码 916-929 doi: 10.1007/s11708-021-0757-9

摘要： Space nuclear reactor power (SNRP) using a gas-cooled reactor (GCR) and a closed Brayton cycle (CBC) is the ideal choice for future high-power space missions. To investigate the safety characteristics and develop the control strategies for gas-cooled SNRP, transient models for GCR, energy conversion unit, pipes, heat exchangers, pump and heat pipe radiator are established and a system analysis code is developed in this paper. Then, analyses of several operation conditions are performed using this code. In full-power steady-state operation, the core hot spot of 1293 K occurs near the upper part of the core. If 0.4 $ reactivity is introduced into the core, the maximum temperature that the fuel can reach is 2059 K, which is 914 K lower than the fuel melting point. The system finally has the ability to achieve a new steady-state with a higher reactor power. When the GCR is shut down in an emergency, the residual heat of the reactor can be removed through the conduction of the core and radiation heat transfer. The results indicate that the designed GCR is inherently safe owing to its negative reactivity feedback and passive decay heat removal. This paper may provide valuable references for safety design and analysis of the gas-cooled SNRP coupled with CBC.

关键词： gas-cooled space nuclear reactor power     closed Brayton cycle     system startup and shutdown     positive reactivity insertion accident    

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General closed-form inverse kinematics for arbitrary three-joint subproblems based on the product of

《机械工程前沿（英文）》 2022年 第17卷 第2期 doi: 10.1007/s11465-022-0681-7

摘要： The inverse kinematics problems of robots are usually decomposed into several Paden–Kahan subproblems based on the product of exponential model. However, the simple combination of subproblems cannot solve all the inverse kinematics problems, and there is no common approach to solve arbitrary three-joint subproblems in an arbitrary postural relationship. The novel algebraic geometric (NAG) methods that obtain the general closed-form inverse kinematics for all types of three-joint subproblems are presented in this paper. The geometric and algebraic constraints are used as the conditions precedent to solve the inverse kinematics of three-joint subproblems. The NAG methods can be applied in the inverse kinematics of three-joint subproblems in an arbitrary postural relationship. The inverse kinematics simulations of all three-joint subproblems are implemented, and simulation results indicating that the inverse solutions are consistent with the given joint angles validate the general closed-form inverse kinematics. Huaque III minimally invasive surgical robot is used as the experimental platform for the simulation, and a master–slave tracking experiment is conducted to verify the NAG methods. The simulation result shows the inverse solutions and six sets given joint angles are consistent. Additionally, the mean and maximum of the master–slave tracking experiment for the closed-form solution are 0.1486 and 0.4777 mm, respectively, while the mean and maximum of the master–slave tracking experiment for the compensation method are 0.3188 and 0.6394 mm, respectively. The experiments results demonstrate that the closed-form solution is superior to the compensation method. The results verify the proposed general closed-form inverse kinematics based on the NAG methods.

关键词： inverse kinematics     Paden–Kahan subproblems     three-joint subproblems     product of exponential     closed-form solution    

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Determining casting defects in near-net shape casting aluminum parts by computed tomography

Jiehua LI, Bernd OBERDORFER, Daniel HABE, Peter SCHUMACHER

《机械工程前沿（英文）》 2018年 第13卷 第1期   页码 48-52 doi: 10.1007/s11465-018-0493-y

摘要：

Three types of near-net shape casting aluminum parts were investigated by computed tomography to determine casting defects and evaluate quality. The first, second, and third parts were produced by low-pressure die casting (Al-12Si-0.8Cu-0.5Fe-0.9Mg-0.7Ni-0.2Zn alloy), die casting (A356, Al-7Si-0.3Mg), and semi-solid casting (A356, Al-7Si-0.3Mg), respectively. Unlike die casting (second part), low-pressure die casting (first part) significantly reduced the formation of casting defects (i.e., porosity) due to its smooth filling and solidification under pressure. No significant casting defect was observed in the third part, and this absence of defects indicates that semi-solid casting could produce high-quality near-net shape casting aluminum parts. Moreover, casting defects were mostly distributed along the eutectic grain boundaries. This finding reveals that refinement of eutectic grains is necessary to optimize the distribution of casting defects and reduce their size. This investigation demonstrated that computed tomography is an efficient method to determine casting defects in near-net shape casting aluminum parts.

关键词： near-net shape casting     aluminum parts     casting defects     low pressure die casting     die casting     semi-solid casting     computed tomography    

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Effect of Joule heating on electro-osmotic flow in a closed-end micro-channel with isothermal and convective

Liang ZHAO, Linhua LIU,

《能源前沿（英文）》 2009年 第3卷 第4期   页码 381-388 doi: 10.1007/s11708-009-0057-2

摘要： The effect of Joule heating on the steady state electro-osmotic flow in a closed-end micro-channel is studied through numerical simulation with the finite volume method. The velocity field and the temperature field are described by a rigorous mathematical model. Thermophysical properties including viscosity and thermal conductivity are considered to be temperature-dependent. The simulations show that the presence of Joule heating causes an increase in temperature and a decrease in viscosity in the whole micro-channel, which, thereafter, induce a large velocity near the wall and an increase in fluid velocity at the central region in order to maintain a zero flow rate at the cross section of the micro-channel. The effect of Joule heating on the induced pressure gradient is also studied, which is very important for the application of the closed-end micro-channel as a micro-actuator. The results reveal that the induced pressure gradient, taking into consideration Joule heating, is significantly smaller than that without considering Joule heating when the wall temperature of the micro-channel is constant. The induced pressure gradient difference between considering Joule heating and without considering Joule heating is small under the convective boundary condition.

关键词： closed-end micro-channel     electrical double layer     electro-osmotic flow     induced pressure gradient     Joule heating    

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Analysis of stress and failure in rock specimens with closed and open flaws on the surface

《结构与土木工程前沿（英文）》 2021年 第15卷 第5期   页码 1222-1237 doi: 10.1007/s11709-021-0773-1

摘要： The influence of closed and open surface flaws on the stress distribution and failure in rock specimens is investigated. Heterogeneous finite element models are developed to simulate the compression tests on flawed rock specimens. The simulated specimens include those with closed flaws and those with open flaws on the surface. Systematic analyses are conducted to investigate the influences of the flaw inclination, friction coefficient and the confining stress on failure behavior. Numerical results show significant differences in the stress, displacement, and failure behavior of the closed and open flaws when they are subjected to pure compression; however, their behaviors under shear and tensile loads are similar. According to the results, when compression is the dominant mode of stress applied to the flaw surface, an open flaw may play a destressing role in the rock and relocate the stress concentration and failure zones. The presented results in this article suggest that failure at the rock surface may be managed in a favorable manner by fabricating open flaws on the rock surface. The insights gained from this research can be helpful in managing failure at the boundaries of rock structures.

关键词： surface flaw     heterogeneity     circular hole     numerical modeling     relative displacement    

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Multiobjective image recognition algorithm in the fully automatic die bonder

JIANG Kai, CHEN Hai-xia, YUAN Sen-miao

《机械工程前沿（英文）》 2006年 第1卷 第3期   页码 313-316 doi: 10.1007/s11465-006-0026-y

摘要： It is a very important task to automatically fix the number of die in the image recognition system of a fully automatic die bonder. A multiobjective image recognition algorithm based on clustering Genetic Algorithm (GA), is proposed in this paper. In the evolutionary process of GA, a clustering method is provided that utilizes information from the template and the fitness landscape of the current population. The whole population is grouped into different niches by the clustering method. Experimental results demonstrated that the number of target images could be determined by the algorithm automatically, and multiple targets could be recognized at a time. As a result, time consumed by one image recognition is shortened, the performance of the image recognition system is improved, and the atomization of the system is fulfilled.

关键词： clustering     different     recognition algorithm     Algorithm     multiobjective    

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PWR-FBR with closed fuel cycle for a sustainable nuclear energy supply in China

XU Mi

《能源前沿（英文）》 2007年 第1卷 第2期   页码 129-134 doi: 10.1007/s11708-007-0016-8

摘要： From the thermal reactor to the fast reactor and then to the fusion reactor; this is the three-step strategy that has been decided for a sustainable nuclear energy supply in China. As the main thermal reactor type, the commercialized development phase of the pressurized water reactor (PWR) has been stepped up. The development of the fast reactor (FBR) is still in the early stage, marked by China experimental fast reactor (CEFR), which is currently under construction. According to the strategy study on the fast reactor development in China, its engineering development will be divided into three steps: the CEFR with a power of 65 MWt/20 MWe; the China prototype fast reactor (CPFR) with a power of 1 500 MWt/600 MWe; and the China demonstration fast reactor (CDFR) with a power of 2 500 3 750 MWt/1 000 1 500 MWe. With regards to the fuel cycle, a 100 t/a PWR spent fuel reprocessing pilot plant and a 500 kg/ a MOX fabrication plant are under construction. A project involving the construction of an industrial reprocessing plant and an MOX fabrication plant are also under application phase.

关键词： reactor development     reprocessing     MWt/600     demonstration     three-step strategy    

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标题 作者 时间 类型 操作

Precision forging technology for aluminum alloy

Lei DENG, Xinyun WANG, Junsong JIN, Juchen XIA

期刊论文

近β锻造推翻陈旧理论发展了三态组织

周义刚,曾卫东,俞汉清

期刊论文

Interfacial heat transfer coefficient between metal and die during high pressure die casting process

GUO Zhipeng, XIONG Shoumei, CHO SangHyun, CHOI JeongKil

期刊论文

An energy consumption prediction approach of die casting machines driven by product parameters

期刊论文

Ultrasonic measurement of tie-bar stress for die-casting machine

期刊论文

Experimental investigations on operating characteristics of a closed loop pulsating heat pipe

Yu WANG

期刊论文

Establishment of the Comprehensive Evaluation System of Cold Stamping Die Quality

LU Xiao-chun, GUO Sheng, RUAN Feng

期刊论文

Improvement of the cascading closed loop cycle system

ZHANG Guoqiang, CAI Ruixian

期刊论文

Dynamic simulation of a space gas-cooled reactor power system with a closed Brayton cycle

期刊论文

General closed-form inverse kinematics for arbitrary three-joint subproblems based on the product of

期刊论文

Determining casting defects in near-net shape casting aluminum parts by computed tomography

Jiehua LI, Bernd OBERDORFER, Daniel HABE, Peter SCHUMACHER

期刊论文

Effect of Joule heating on electro-osmotic flow in a closed-end micro-channel with isothermal and convective

Liang ZHAO, Linhua LIU,

期刊论文

Analysis of stress and failure in rock specimens with closed and open flaws on the surface

期刊论文

Multiobjective image recognition algorithm in the fully automatic die bonder

JIANG Kai, CHEN Hai-xia, YUAN Sen-miao

期刊论文

PWR-FBR with closed fuel cycle for a sustainable nuclear energy supply in China

XU Mi

期刊论文