Occurrence of particle debris field during focused Ga ion beam milling of glassy carbon

To explore the machining characteristics of glassy carbon by focused ion beam (FIB), particles induced by FIB milling on glassy carbon have been studied in the current work. Nano-sized particles in the range of tens of nanometers up to 400 nm can often be found around the area subject to FIB milling. Two ion beam scanning modes - slow single scan and fast repetitive scan - have been tested. Fewer particles are found in single patterns milled in fast repetitive scan mode. For a group of test patterns milled in a sequence, it was found that a greater number of particles were deposited around sites machined early in the sequence. In situ EDX analysis of the particles showed that they were composed of C and Ga. The formation of particles is related to the debris generated at the surrounding areas, the low melting point of gallium used as FIB ion source and the high contact angle of gallium on glassy carbon induces de-wetting of Ga and the subsequent formation of Ga particles. Ultrasonic cleaning can remove over 98% of visible particles. The surface roughness (Ra) of FIB milled areas after cleaning is less than 2 nm. © 2010.

Modelling and characterisation of an ortho-planar micro-valve

The main difficulties encountered in the development of microscale fluidic pumping systems stem from the fact that these systems tend to comprise highly three-dimensional parts, which are incompatible with traditional microproduction technologies. Regardless of the type of pumping principle, most of the hydraulic systems contain valves and in particular a one-way valve. This paper presents the design and modelling of an ortho-planar one-way microvalve. The main advantages of such a valve are that it is very compact and can be made from a single flat piece of material. An analytical model of the spring deflection has been developed and compared to FEM. A prototype with a bore of 1.5 mm has been build using a micro EDM (electro discharge machining) machine and also tested. © 2006 International Federation for Information Processing.

Manufacturing dish shaped rings on radial-axial ring rolling mills

Ring rolling is an established method to produce seamless rings of different cross-sectional geometries. For dish shaped rings, there are applications in different areas such as offshore, aeronautics or the energy sector. At the moment, dish shaped rings are produced by machining of rings with rectangular shaped cross section, by (open die) hollow forging on a conical mandrel or by using shaped ring rolling tools. These ways of manufacturing have the disadvantage of high material waste, additional costs for special tools, long process time and limited or inflexible geometries. Therefore, the manufacturing of dish shaped rings on conventional radial-axial ring rolling mills would expand the range of products for ring producers. The aim of this study is to investigate the feasibility of an alternative to the current manufacturing processes, without requiring additional tooling and material costs. Therefore, the intended formation of dish shaped rings-previously regarded as a form error-is investigated. Based on an analysis of geometrical requirements and metal flow mechanisms, a rolling strategy is presented, causing dishing and ring climbing by a large height reduction of the ring. Using this rolling strategy dish shaped rings with dishing angles up to 18° were achieved. In addition to the experiments finite element method (FEM)-simulations of the process have been successfully conducted, in order to analyze the local strain evolution. However, when the contact between ring and main roll is lost in the process the ring starts to oscillate around the mandrel and neither dishing nor ring climbing is observed. © 2013 German Academic Society for Production Engineering (WGP).

Developing ISO 14649-based conversational programming system for multi-channel complex machine tools

A multi-channel complex machine tool (MCCM) is a versatile machining system equipped with more than two spindles and turrets for both turning and milling operations. Despite the potential of such a tool, the value of the hardware is largely dependent on how the machine tools are effectively programmed for machining. In this paper we consider a shop-floor programming system based on ISO 14649 (called e-CAM), the international standard for the interface between computer-aided manufacture (CAM) and computer numerical control (CNC). To be deployed in practical industrial usage a great deal of research has to be carried out. In this paper we present: 1) Design consideration for an e-CAM system, 2) The architecture design of e-CAM, 3) Major algorithms to fulfill the modules defined in the architecture, and 4) Implementation details.

Characterizing the class of local metal sheet thickening processes

The need to create high-value products for specialist applications, and the search for efficient forming routes that obviate the need for some machining steps, is driving Interest In a novel class of forming processes aiming to create locally thickened features within sheet work- pieces. A number of novel forming processes have been proposed to meet this need, but it is as yet unclear which processes will be most effective in creating local thickening of various geometries, and many process configurations have yet to be tried. This paper aims to provide some basic principles for designing and characterising process behaviour. A simplified generic description of sheet thickening processes is provided, with two tools of variable operating on a sheet workpiece in plane strain, with different tool separations and motions parameterised. A comprehensive numerical study of the behaviour of this class of processes is conducted in Abaqus to predict the main characteristics of the material flow in each configuration. The results are used to classify the different basic behaviours that can be achieved by the sheet-bulk thickening processes and to give guidance on future process development, capability and applicability. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.

Magnetic characterisation of large grain, bulk Y-Ba-Cu-O superconductor-soft ferromagnetic alloy hybrid structures

Large grain, bulk Y-Ba-Cu-O (YBCO) high temperature superconductors (HTS) have significant potential for use in a variety of practical applications that incorporate powerful quasi-permanent magnets. In the present work, we investigate how the trapped field of such magnets can be improved by combining bulk YBCO with a soft FeNi, ferromagnetic alloy. This involves machining the alloy into components of various shapes, such as cylinders and rings, which are attached subsequently to the top surface of a solid, bulk HTS cylinder. The effect of these modifications on the magnetic hysteresis curve and trapped field of the bulk superconductor at 77 K are then studied using pick-up coil and Hall probe measurements. The experimental data are compared to finite element modelling of the magnetic flux distribution using Campbell's algorithm. Initially we establish the validity of the technique involving pick-up coils wrapped around the bulk superconductor to obtain its magnetic hysteresis curve in a non-destructive way and highlight the difference between the measured signal and the true magnetization of the sample. We then consider the properties of hybrid ferromagnet/superconductor (F/S) structures. Hall probe measurements, together with the results of the model, establish that flux lines curve outwards through the ferromagnet, which acts, effectively, like a magnetic short circuit. Magnetic hysteresis curves show that the effects of the superconductor and the ferromagnet simply add when the ferromagnet is saturated fully by the applied field. The trapped field of the hybrid structure is always larger than that of the superconductor alone below this saturation level, and especially when the applied field is removed. The results of the study show further that the beneficial effects on the trapped field are enhanced when the ferromagnet covers the entire surface of the superconductor for different ferromagnetic components of various shapes and fixed volume. © 2014 Elsevier B.V. All rights reserved.

Latest progress of the RFQ cooler and buncher RFQ1L

The RFQ cooler and buncher RFQ1L is a key device of the SHANS (Spectrometer for Heavy Atoms and Nucleax Structure). The status of the machining and assembly of the central part is introduced, and the structure of the whole RFQ1L system and the preliminary plan for the testing are discussed also.

A Particle-in-cell scheme of the RFQ in the SSC-Linac

A 52 MHz Radio Frequency Quadrupole (RFQ) linear accelerator (linac) is designed to serve as an initial structure for the SSC-Linac system (injector into Separated Sector Cyclotron). The designed injection and output energy are 3.5 keV/u and 143 keV/u, respectively. The beam dynamics in this RFQ have been studied using a three-dimensional Particle-In-Cell (PIC) code BEAMPATH. Simulation results show that this R,FQ structure is characterized by stable values of beam transmission efficiency (at least 95%) for both zero-current mode and the space charge dominated regime. The beam accelerated in the RFQ has good quality in both transverse and longitudinal directions, and could easily be accepted by Drift Tube Linac (DTL). The effect of the vane error and that of the space charge on the beam parameters have been studied as well to define the engineering tolerance for RFQ vane machining and alignment.

Fractal roughness characterization of super-ground Mn-Zn ferrite single crystals

The surface of superground Mn-Zn ferrite single crystal may be identified as a self-affine fractal in the stochastic sense. The rms roughness increased as a power of the scale from 10(2) nm to 10(6) nm with the roughness exponent alpha = 0.17 +/- 0.04, and 0.11 +/- 0.06, for grinding feed rate of 15 and 10 mu m/rev, respectively. The scaling behavior coincided with the theory prediction well used for growing self-affine surfaces in the interested region for magnetic heads performance. The rms roughnesses increased with increase in the feed rate, implying that the feed rate is a crucial grinding parameter affecting the supersmooth surface roughness in the machining process.

机器人研磨抛光工艺研究与实现

机器人研磨抛光工艺研究建立在大量机器人磨抛试验的基础上。本文针对加工对象——有机玻璃,在满足被加工工件质量的前提下,确定了机器人研磨抛光加工时磨片的合理使用顺序、规划加工路径和安排正交试验,以获得机器人磨抛加工的最优工艺参数组合,并制定机器人磨抛的加工策略。最后通过机器人研磨抛光加工实例,进一步验证了机器人的研磨抛光工艺知识有其合理性。

基于CAN总线的力传感器与机器人控制器通讯设计

研磨机器人系统中,研磨头与工件的接触力是保证加工精度,进行机器人力控制的一个重要因 素。采用 CAN 通讯可以确保力传感器准确、及时地把力信息传送给控制器进行力控制。本文 给出了6维腕力传感器与机器人控制器通讯的硬件结构,制定了可靠的通讯协议,实现了力信 息的正确读取,为研磨机器人控制系统获得可靠的力信息提供了一种新的解决方案。

一种基于遗传算法的机器人加工路径规划方法

针对传统机器人加工路径规划采用示教再现方法很难适应复杂变化任务的问题 ,提出了基于遗传算法的路径规划方法 ,研究了遗传算法中的编码方式、交叉算子和变异算子的改进方法 .仿真实验表明 ,采用遗传算法进行机器人加工路径规划是可行的和有效的 .

激光加工机器人通信协议及其实现

介绍激光加工机器人系统的通信协议以及实现方法，其中涉及到实时多任务系统VRTXsa、串口通信控件编制。该通信协议和通信系统在应用中取得了满意的效果。

并联刨床刚度分析及实验研究

为了提高刨削加工能力,而采用考虑到并联机构的特点而提出了并联刨床的概念并对其进行了简单说明.采用对机床进行分解的方法对机床的各功能模块分别建立刚度模型,并利用变形线性叠加的原理对机床的并联部分刚度进行分析.采用有限元软件对机床的床身框架及平面约束机构部分的刚度进行分析.并以仿真和实验加工的方式进行了刚度特性研究.

基于agent及holon的可重构生产线实现技术

以大批量制造的生产线制造系统为背景,研究基于agent与holon智能制造思想体系的可重构生产线制造系统实现技术,以提高生产线柔性与可重构能力为目标·深入分析了多agent制造及holonic制造模式体系下智能单元自主决策、协商合作在制造系统环境中的实现与运行机制,在以机械加工线和装配线为代表的不同的工程实际背景与应用环境下该思想体系目前的具体应用情况与实现技术·指出该思想体系面向具体工程背景的有效实施应用是理论研究的关键·最后以某汽车变速器装配生产线制造系统为应用实例,从其规划设计与运行角度,分析了可重构生产线系统的框架设计及具体实现技术与方法·