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20 pages, 11753 KiB

Open AccessArticle

Research on Multiscale Modeling and Experiment of CFRP Milling

by Jing Ni, Haishan Liu, Zhi Hong, Aihua Meng and Mingfan Li

Materials 2023, 16(20), 6748; https://doi.org/10.3390/ma16206748 - 18 Oct 2023

Cited by 1 | Viewed by 815

High-quality milling of carbon fiber reinforced polymer (CFRP) composites is of great importance for the high-performance manufacturing of structures made of this hard-to-machine material. In this paper, a multiscale finite element (FE) model, considering the thermal–mechanical coupling effect, was developed to simulate the [...] Read more.

High-quality milling of carbon fiber reinforced polymer (CFRP) composites is of great importance for the high-performance manufacturing of structures made of this hard-to-machine material. In this paper, a multiscale finite element (FE) model, considering the thermal–mechanical coupling effect, was developed to simulate the milling process and reveal its material removal mechanism. The corresponding milling experiments were conducted to validate the simulated cutting forces and temperature, which were in good agreement with the experiment results. In the macroscale model, the Hashin failure criteria were used to estimate the failure of the composites. In the microscale model, the fibers, matrix, and the fiber–matrix interface were modeled separately, to investigate the mechanisms of material removal behavior during milling, among fiber breakage, matrix cracking, and fiber–matrix debonding. Based on the macroscale numerical and experimental results, the higher cutting speed was demonstrated to improve the surface quality of CFRP milling. According to the results from the microscale model, the material removal mechanism varies depending on the orientation of the fibers and can be divided into four stages. The outcome of this work provides guidelines to further investigate optimal manufacturing parameters for the milling of CFRP composites and their cutting mechanisms. Full article

(This article belongs to the Special Issue Smart Manufacturing: Materials and Technologies for Advanced Equipment)

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14 pages, 5403 KiB

Open AccessArticle

Experimental and Simulation Study on Welding Characteristics and Parameters of Gas Metal Arc Welding for Q345qD Thick-Plate Steel

by Hui Zhang, Rong Li, Shuxuan Yang, Liebang Zhan, Ming Xiong, Ban Wang and Juyong Zhang

Materials 2023, 16(17), 5944; https://doi.org/10.3390/ma16175944 - 30 Aug 2023

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Abstract

The welding and construction processes for H-type thick-plate bridge steel involve complex multi-pass welding processes, which make it difficult to ensure its welding performance. Accordingly, it is crucial to explore the inherent correlations between the welding process parameters and welding quality, and apply [...] Read more.

The welding and construction processes for H-type thick-plate bridge steel involve complex multi-pass welding processes, which make it difficult to ensure its welding performance. Accordingly, it is crucial to explore the inherent correlations between the welding process parameters and welding quality, and apply them to welding robots, eliminating the instability in manual welding. In order to improve welding quality, the GMAW (gas metal arc welding) welding process parameters are simulated, using the Q345qD bridge steel flat joint model. Four welds with X-shaped grooves are designed to optimize the parameters of the welding current, welding voltage, and welding speed. The optimal welding process parameters are investigated through thermal–elastic–plastic simulation analysis and experimental verification. The results indicate that, when the welding current is set to 230 A, the welding voltage to 32 V, and the welding speed to 0.003 m/s, the maximum deformation of the welded plate is 0.52 mm, with a maximum welding residual stress of 345 MPa. Both the simulation results of multi-pass welding, and the experimental tests meet the welding requirements, as they show no excessive stress or strain. These parameters can be applied to building large steel-frame bridges using welding robots, improving the quality of welded joints. Full article

(This article belongs to the Special Issue Smart Manufacturing: Materials and Technologies for Advanced Equipment)

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16 pages, 5316 KiB

Open AccessArticle

Intelligent Optimization Design of a Phononic Crystal Air-Coupled Ultrasound Transducer

by Jianghai Wang, Huawei Ji, Anqi Qi, Yu Liu, Liming Lin, Xin Wu and Jing Ni

Materials 2023, 16(17), 5812; https://doi.org/10.3390/ma16175812 - 24 Aug 2023

Cited by 1 | Viewed by 810

Abstract

To further improve the operational performance of a phononic crystal air-coupled ultrasonic transducer while reducing the number of simulations, an intelligent optimization design strategy is proposed by combining finite element simulation analysis and artificial intelligence (AI) methods. In the proposed strategy, the structural [...] Read more.

To further improve the operational performance of a phononic crystal air-coupled ultrasonic transducer while reducing the number of simulations, an intelligent optimization design strategy is proposed by combining finite element simulation analysis and artificial intelligence (AI) methods. In the proposed strategy, the structural design parameters of 1–3 piezoelectric composites and acoustic impedance gradient matching layer are sampled using the optimal Latin hypercube sampling (OLHS) method. Moreover, the COMSOL software is utilized to calculate the performance parameters of the transducer. Based on the simulation data, a radial basis function neural network (RBFNN) model is trained to establish the relationship between the design parameters and the performance parameters. The accuracy of the approximation model is verified through linear regression plots and statistical methods. Finally, the NSGA-II algorithm is used to determine the design parameters of the transducer. After optimization, the band gap widths of the piezoelectric composites and acoustic impedance gradient matching layer are increased by 16 kHz and 13.5 kHz, respectively. Additionally, the −6 dB bandwidth of the transducer is expanded by 11.5%. The simulation results and experimental results are consistent with the design objectives, which confirms the effectiveness of the design strategy. This work provides a feasible strategy for the design of high-performance air-coupled ultrasonic transducers, which is of great significance for the development of non-destructive testing technology. Full article

(This article belongs to the Special Issue Smart Manufacturing: Materials and Technologies for Advanced Equipment)

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14 pages, 6177 KiB

Open AccessArticle

Modeling and Analysis of Wave Energy Harvester with Symmetrically Distributed Galfenol Cantilever Beams

by Sunyangyang Jin, Aihua Meng, Mingfan Li, Zhenlong Xu, Shuaibing Wu and Yu Chen

Materials 2023, 16(16), 5585; https://doi.org/10.3390/ma16165585 - 11 Aug 2023

Viewed by 714

Abstract

In response to the challenges of difficult energy supply and high costs in ocean wireless sensor networks, as well as the limited working cycle of chemical batteries, a cylindrical wave energy harvester with symmetrically distributed multi-cantilever beams was designed with Galfenol sheet as [...] Read more.

In response to the challenges of difficult energy supply and high costs in ocean wireless sensor networks, as well as the limited working cycle of chemical batteries, a cylindrical wave energy harvester with symmetrically distributed multi-cantilever beams was designed with Galfenol sheet as the core component. The dynamic equation of the device was established, and ANSYS transient dynamic simulations and Jiles-Atherton hysteresis model analysis were conducted to develop a mathematical model of the induced electromotive force of the Galfenol cantilever beam as a function of deformation. Experimental validation demonstrated that the simulated results of the cantilever beam deformation had an average error of less than 7% compared to the experimental results, while the average error between the theoretical and experimental values of the induced electromotive force of the device was around 15%, which preliminarily verifies the validity of the mathematical model of the device, and should be subject to further research and improvement. Full article

(This article belongs to the Special Issue Smart Manufacturing: Materials and Technologies for Advanced Equipment)

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10 pages, 2899 KiB

Open AccessArticle

Fabrication of Silicon Nanowires by Metal-Assisted Chemical Etching Combined with Micro-Vibration

by Weiye Huang, Junyi Wu, Wenxin Li, Guojin Chen, Changyong Chu, Chao Li, Yucheng Zhu, Hui Yang and Yan Chao

Materials 2023, 16(15), 5483; https://doi.org/10.3390/ma16155483 - 05 Aug 2023

Cited by 1 | Viewed by 727

Abstract

In this work, we design a micro-vibration platform, which combined with the traditional metal-assisted chemical etching (MaCE) to etch silicon nanowires (SiNWs). The etching mechanism of SiNWs, including in the mass-transport (MT) and charge-transport (CT) processes, was explored through the characterization of SiNW’s [...] Read more.

In this work, we design a micro-vibration platform, which combined with the traditional metal-assisted chemical etching (MaCE) to etch silicon nanowires (SiNWs). The etching mechanism of SiNWs, including in the mass-transport (MT) and charge-transport (CT) processes, was explored through the characterization of SiNW’s length as a function of MaCE combined with micro-vibration conditions, such as vibration amplitude and frequency. The scanning electron microscope (SEM) experimental results indicated that the etching rate would be continuously improved with an increase in amplitude and reached its maximum at 4 μm. Further increasing amplitude reduced the etching rate and affected the morphology of the SiNWs. Adjusting the vibration frequency would result in a maximum etching rate at a frequency of 20 Hz, and increasing the frequency will not help to improve the etching effects. Full article

(This article belongs to the Special Issue Smart Manufacturing: Materials and Technologies for Advanced Equipment)

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13 pages, 7573 KiB

Open AccessArticle

Research on the Dynamic Characteristics of Perfluoroalkoxy Alkane Springs

by Jing Ni, Yujie Feng, Zhi Cui, Lihua He and Jingbo Sun

Materials 2023, 16(15), 5289; https://doi.org/10.3390/ma16155289 - 27 Jul 2023

Cited by 1 | Viewed by 830

Abstract

Semiconductor cleaning system ultra-clean flow control pumps are critical equipment in the semiconductor industry. Among them, the perfluoroalkoxy alkane (PFA) spring is a pivotal component to control the pump, and its dynamic performance is crucial to ensure the efficient operation of the system. [...] Read more.

Semiconductor cleaning system ultra-clean flow control pumps are critical equipment in the semiconductor industry. Among them, the perfluoroalkoxy alkane (PFA) spring is a pivotal component to control the pump, and its dynamic performance is crucial to ensure the efficient operation of the system. However, the dynamic performance of the spring is often affected by the operating frequency. This paper studied the effect of different working frequencies on the dynamic property of the spring through compression-cycle experiments under uniaxial sinusoidal excitation. The force–displacement curves under different compression frequencies were fitted to obtain the dynamic stiffness of the PFA spring under different cyclic loading frequencies. The variation in the spring’s hysteresis coefficient was evaluated using the hysteresis curves of different cyclic loading conditions. After 2 million compression experiments, the changes in dynamic stiffness, hysteresis coefficient, and spring height were investigated. The obtained results revealed that, as the frequency increases, the dynamic stiffness of the spring increases. The hysteresis coefficient of the PFA spring is the largest at 10 Hz and the smallest at 6 Hz. Upon conducting 2 million compression tests, it was discovered that the dynamic stiffness experiences the greatest attenuation rate of 4.19% at a frequency of 8 Hz, whereas the hysteresis coefficient undergoes the largest attenuation of 42.1% at a frequency of 6 Hz. The results will help to improve the design and application level of PFA springs. Full article

(This article belongs to the Special Issue Smart Manufacturing: Materials and Technologies for Advanced Equipment)

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18 pages, 9052 KiB

Open AccessArticle

Analysis of the Rolling Interface Contact Characteristics in Mixed Lubrication Based on Gaussian Distribution Theory

by Laihua Tao, Qiaoyi Wang, Ziwei Qi, Huajie Wu, Hanbin Zhu and Junbo Huang

Materials 2023, 16(15), 5220; https://doi.org/10.3390/ma16155220 - 25 Jul 2023

Viewed by 877

Abstract

To reveal the influence of surface morphology characteristics in mixed lubrication on the contact characteristics of the rolling interface, a random three-dimensional rough surface model based on Gaussian distribution theory was established. The model utilizes the finite element method (FEM) to simulate the [...] Read more.

To reveal the influence of surface morphology characteristics in mixed lubrication on the contact characteristics of the rolling interface, a random three-dimensional rough surface model based on Gaussian distribution theory was established. The model utilizes the finite element method (FEM) to simulate the regular contact and tangential sliding behavior of micro-asperities at the rolling interface in mixed lubrication conditions. The connection bearing capacity of models with varied roughness in mixed lubrication was studied. Furthermore, the effect of various sliding and normal indentation amounts on the normal and friction stress was investigated. The simulation result reveals that the roughness of the surface influences the distribution of the lubricating oil film. The lubricating oil layer between the interfaces with a lower roughness has a higher bearing capacity due to its more uniform distribution of peaks and valleys. An increase in the normal indentation amount raises the friction stress and normal stress. In contrast, an increase in sliding lowers the normal pressure, substantially impacting the fluctuation of the friction coefficient dramatically. Finally, the random three-dimensional rough surface model is verified by comparing it with the experimental data in the related literature. Full article

(This article belongs to the Special Issue Smart Manufacturing: Materials and Technologies for Advanced Equipment)

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14 pages, 4764 KiB

Open AccessArticle

Study of the Friction Behavior of Embedded Fibers in YG8 Surface Grooves

by Zhiping Huang, Haohan Zhang, Jing Ni, Lingqi Yang and Kai Feng

Materials 2023, 16(14), 5074; https://doi.org/10.3390/ma16145074 - 18 Jul 2023

Viewed by 785

Abstract

YG8 is a common cemented carbide material with excellent mechanical properties and mechanical properties, so it is widely used in the actual industry. However, due to the active chemical properties and strong affinity of tungsten alloy steel, it is easy to produce bonding [...] Read more.

YG8 is a common cemented carbide material with excellent mechanical properties and mechanical properties, so it is widely used in the actual industry. However, due to the active chemical properties and strong affinity of tungsten alloy steel, it is easy to produce bonding and peeling in application, resulting in an unstable process and short service life. In order to control and reduce the surface wear of YG8 cemented carbide, groove-textured surface (GS) and flocking surface (FS) were prepared on smooth surface (SS). The friction characteristics of the samples were studied under different applied load conditions. The results show that the average friction coefficient of SS, GS and FS is inversely proportional to the load in dry/oil environment. Compared with SS, FS exhibits the lowest friction coefficient, which is reduced by 30.78% (dry friction) and 13.13% (oil lubrication). FS effectively improves the tooth jump phenomenon of the sample and the amplitude of the friction coefficient, friction force and load, and has the best anti-friction characteristics. At the same time, the FS with the fastest contact angle drop at any time also showed excellent wetting ability, and the wear rate decreased by an order of magnitude. The implantation of fibers in the groove inhibits the spalling and furrow of wear track, which is attributed to the effect of fibers on damage repair. In the friction process, FS increases the content of the O element and induces the formation of oxides. The friction mechanism is mainly chemical wear. The excellent tribological properties of FS have a good guiding significance and theoretical support for improving the tribological properties of high hardness material surfaces. Full article

(This article belongs to the Special Issue Smart Manufacturing: Materials and Technologies for Advanced Equipment)

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