Edge Profile Research Articles

3D FEM Simulation of Titanium Alloy (Ti6Al4V) Machining with Harmonic Endmill Tools

AbstractUsually, end milling operations have been carried out using conventional uniform helix tools with fixed helix angles. Thus, many studies have been conducted to study the effects of these tools on the thermomechanical properties of a milling process. Recently, there have been works that point to the benefits of using harmonic endmills. Harmonic endmills consist of cutting edge profiles that have continuously harmonically varying helix angles. The variation is described using a harmonic function of axial position (elevation) of points on the cutting edge. In this work, a 3D finite element simulation using ABAQUS, is carried out for the complex milling process of Titanium alloy Ti6Al4V. The envelope of the harmonic tool is first generated using a set of MATLAB codes and stored in a Standard Triangle Language (.stl) format. The machine tool is introduced into an FEM program which has been designed to provide for dynamic effects, thermo‐mechanical coupling, material damage law and the criterion for contact associated with the milling process. A Johnson‐Cook material constitutive equation which combines the effects of strain hardening, strain softening, and temperature softening is used. To account for the chip separation criterion, the Johnson Cook damage evolution equation is used. The milling process simulation for Ti6Al4V is then carried out. In the end, the stress distribution and the cutting forces are obtained.

A SVM-based design method for cutting edge profile stability of large-pitch thread turning tool considering vibration

A SVM-based design method for cutting edge profile stability of large-pitch thread turning tool considering vibration

Influence of trailing edge curve on the performance of radial turbine in turbocharger

Abstract To combat climate change and promote sustainable engine development, the optimization of the turbocharger development process is necessary to decrease emissions and increase fuel economy. This article presents the influence of trailing edge curves on the performance of the significantly small radial turbine impeller of an automotive turbocharger used in a 0.8-l two-cylinder gasoline engine by comparing numerical analysis results under two boundary conditions: a constant pressure ratio and constant mass flow rate. The curve of a trailing edge depends on several parameters; however, in this study, the exponent ($n$) was selected to modify the turbine impeller trailing edge profile, as it exhibits a more significant influence on the curve than other parameters. Hence, computational fluid dynamics analyses were conducted on the radial turbine for various trailing edge curves under a constant pressure ratio and constant mass flow rate, and the results were compared. The results indicated that the efficiency improvement was negligible under the pressure ratio and mass flow rate conditions due to inadequate alterations. Nevertheless, a significant shaft power improvement was observed based on changes in the trailing edge curve under a constant pressure ratio. In contrast, the same changes caused a considerable decrease in the shaft power under a constant mass flow rate.

Role of edge-localized neoclassical tearing modes in quiescent H-mode plasmas in the DIII-D tokamak

The edge-harmonic oscillations (EHOs) in standard quiescent H-mode (QH-mode) plasmas in DIII-D are consistent with edge-localized neoclassical tearing modes (NTMs) based on nonlinear two-fluid MHD simulations. Using kinetic equilibria constrained by edge profile measurements, the MHD simulations show that the n = 1 NTM and its harmonics can be destabilized at the pedestal top of QH-mode plasma by the edge bootstrap current. The simulations further show that the unstable NTMs can saturate either at small (<2% ψN) or large (>4% ψN) island width depending on the magnitude of the edge bootstrap current, where ψN is the normalized radius in poloidal flux. The onset of the EHO also results in a prompt decrease in the pedestal width and height, consistent with simulation results for the onset of the NTM at the top of the QH-mode pedestal. This suggests that the avoidance of edge-localized modes (ELMs) in QH-mode can be attributed to the enhanced local transport induced by the NTM that is sufficient to prevent the expansion of the pedestal to an unstable width, analogous to the mechanism explored for ELM suppression by resonant magnetic perturbations. Nonlinear MHD simulations scanning the E × B frequency and the ratio of parallel and perpendicular thermal diffusivity (χǁ/χ⊥) at the pedestal top show that edge-localized NTMs are destabilized for conditions of high E × B frequency, high pedestal temperature, and low pedestal density, qualitatively consistent with experimental conditions required for observing the EHO.

High-resolution, respiratory-resolved coronary MRA using a Phyllotaxis-reordered variable-density 3D cones trajectory

PurposeTo develop a respiratory-resolved motion-compensation method for free-breathing, high-resolution coronary magnetic resonance angiography (CMRA) using a 3D cones trajectory. MethodsTo achieve respiratory-resolved 0.98 mm resolution images in a clinically relevant scan time, we undersample the imaging data with a variable-density 3D cones trajectory. For retrospective motion compensation, translational estimates from 3D image-based navigators (3D iNAVs) are used to bin the imaging data into four phases from end-expiration to end-inspiration. To ensure pseudo-random undersampling within each respiratory phase, we devise a phyllotaxis readout ordering scheme mindful of eddy current artifacts in steady state free precession imaging. Following binning, residual 3D translational motion within each phase is computed using the 3D iNAVs and corrected for in the imaging data. The noise-like aliasing characteristic of the combined phyllotaxis and cones sampling pattern is leveraged in a compressed sensing reconstruction with spatial and temporal regularization to reduce aliasing in each of the respiratory phases. ResultsIn initial studies of six subjects, respiratory motion compensation using the proposed method yields improved image quality compared to non-respiratory-resolved approaches with no motion correction and with 3D translational correction. Qualitative assessment by two cardiologists and quantitative evaluation with the image edge profile acutance metric indicate the superior sharpness of coronary segments reconstructed with the proposed method (P < 0.01). ConclusionWe have demonstrated a new method for free-breathing, high-resolution CMRA based on a variable-density 3D cones trajectory with modified phyllotaxis ordering and respiratory-resolved motion compensation with 3D iNAVs.

Inversion-based correction of Double-Torsion (DT) subcritical crack growth tests for crack profile geometry

Because of its simplicity and the ability to produce a stable, slow-propagating crack, the Double-Torsion (DT) method has been used widely for investigating the critical and subcritical propagation of a slow-propagating tensile (mode-I) crack. However, to determine the complex relationship between the crack velocity vc vs. the strain energy release rate G (or the stress intensity factor K) from laboratory measurements, several corrections must be made to account for the impact of sample and crack geometry. Particularly, DT test typically produces a crack with a curved edge profile instead of a straight line, causing the local vc and G vary along the crack front. The experimentally measured vc and G data merely reflect collective, averaged behavior of the crack. This makes inversion for the intrinsic, “true” crack growth kinetics necessary, based upon the knowledge of the crack geometry. Simple and effective correction methods have been proposed and validated for the slow, chemical-reaction-controlled part (Region I) of the vc−G curve. However, reliable methods for the highly nonlinear, transport-dominated part (Region II) and its sudden transition to the dynamic propagation part (Region III) are still lacking. In this paper, we propose a method for determining the intrinsic vc−G relationship across all three Regions based upon DT test data, using a simple model function and its numerical inversion. The performance of this approach is examined and demonstrated using both synthetic and laboratory data for subcritical crack growth in soda lime glass.

Simulation Analysis on the Performance of a Circular-Edge Technique in Measurements of the Modulation Transfer Function.

The modulation transfer function (MTF) plays an important role in characterizing medical imaging systems. For such characterization, the circular-edge technique has become a prevalent task-based methodology. When determining the MTF with complicated task-based measurements, error factors must be well understood to properly interpret the results. In this context, the aim of this work was to study the changes in measurement performance in the analysis of the MTF using a circular edge. To eliminate the systematic error related to the measurement and suitably manage the error factors, images were generated by Monte Carlo simulation. Further, a performance comparison with the conventional method was conducted; in addition, the influence of the edge size and contrast and the setting error of the center coordinates were investigated. The difference from the true value and the standard deviation relative to the average value were applied to the index as the accuracy and precision, respectively. The results demonstrated that the smaller the circular object used and the lower the contrast, the grater the deterioration in the measurement performance. Furthermore, this study clarified the underestimating of the MTF in proportion to the square of the distance with respect to the setting error of the center position, which is important for the synthesis of the edge profile. Evaluations in the backgrounds wherein there are multiple factors affecting the results are complex, and the system users must properly judge the validity of the characterization results. These findings provide meaningful insight in the context of MTF measurement techniques.

Pressure pulsation reduction in the draft tube of pump turbine in turbine mode based on optimization design of runner blade trailing edge profile

Reversible pump turbine plays an important role in pumped storage technology. Its pressure pulsation performance also directly affects the stability and efficiency of unit operation. In this paper, under the conditions of multiple guide vane openings and multiple heads for a pump-turbine unit, based on the reasonable runner blade geometric deconstruction, a parameter control method of runner blade trailing edge is proposed. The Genetic Algorithm combined with Fuzzy Logic (GA-FL) is used as the optimization strategy. After optimization iteration, the optimized runner blade trailing edge shape corresponding to minimum value of pressure pulsation intensity is obtained. In addition, numerical simulation calculation and test verification are carried out for the initial and optimized units, the results are all in good agreement. The results show that the unit efficiency is slightly improved and the relative pressure pulsation intensity in draft tube is significantly reduced. Especially in the case of small guide vane opening, the pressure pulsation performance of optimized unit meets the actual engineering standards.

The Effects of High Centrifugal Acceleration on Bluff-Body Stabilized Premixed Flames

Abstract An experimental study is conducted on bluff-body stabilized premixed flames in a curved, square cross section duct. High flow velocities coupled with a small radius of curvature of the duct induce high centrifugal acceleration normal to the flame sheet. A cylindrical flame holder spans the width of the square cross section and is positioned at the channel midheight. Flame shear layers are stabilized on the radially inward (upper) and outward (lower) edges of the flame holder. Side-view high-speed Schlieren images and high-speed pressure measurements are captured. Static stability, overall pressure loss, and statistics and velocimetry results from the Schlieren images are reported, and results are compared to a straight configuration with no centrifugal acceleration. Two bluff-body diameters are studied to show the effect of flame holder diameter on static stability. For the curved configuration, blowout velocities are higher for the smaller bluff-body diameter, likely due to flow acceleration effects. Blowout velocities are lower for the curved configuration compared to the straight configuration which may be due to the destabilizing Rayleigh–Taylor (RT) effect on the upper flame layer. Overall pressure loss is slightly higher for the curved configuration than the straight configuration. High-speed Schlieren results show centrifugal acceleration causes significant structural and velocimetric asymmetry in the bluff-body wake. In the curved configuration, the upper flame layer displays destabilizing RT instabilities, and the lower flame layer displays stabilizing RT effects. The upper flame shows vigorous RT instabilities which broaden the flame brush and sustain a flame leading edge independent of inlet Reynolds number or velocity. Conversely, the lower flame exhibits suppression of Kelvin–Helmholtz and flame-generated instabilities in the wake, which confines the flame brush and significantly reduces transverse flame velocities. The lower flame edge profile moves toward the channel centerline with increasing inlet Reynolds number. The upper flame in the curved configuration shows higher flame edge velocities than the straight configuration while the lower flame shows velocities closer to zero. The empirical constant to the power law relation for upper flame edge velocities agrees with RT-dominated flame growth theory for this experimental scale and agrees with other RT-dominated flame studies.

On the acoustic emission characteristics of airfoils with different trailing edge configurations

The present study experimentally and numerically investigates the flow past flat plates and NACA0012 airfoils with the different trailing edge (i.e., blunt, sharp, and rounded) and both end-rounded configurations on the far-field acoustic emissions and complex flow phenomena to determine the best edge geometry for low noise. The studies are conducted for various jet speeds of 20, 30, and 40 m/s (chordwise Reynolds numbers of 1.812 × 105, 2.72 ×105, and 3.62 ×105). It is observed that all the edge-modified flat plates show the highest directivity at an emission angle of 60° for all jet velocities studied. The comparison of power directivities between realistic and flat plate airfoils reveals that the realistic airfoils radiate lower acoustic emissions as compared to flat plate airfoils, albeit they show a common feature of downstream directivity. In general, the far-field acoustic emissions of both end-rounded plates are observed to be lower as compared to blunt, sharp, and rounded trailing edge geometries. The leading edge modification is also observed to reduce airfoil self-noise. The likely reason for the lower far-field acoustic emissions provided by both end-rounded trailing edged foils is due to the modification in the boundary layer characteristics owing to the presence of smooth flow around the rounded leading edge as well as reduced vortex strength as compared to the other foil geometries. Thus, the present study demonstrates that passive modifications of leading edge profiles are essential along with trailing edge for achieving lower acoustic emissions and higher noise reductions.

Effects of Blade Suction Side Modification on Internal Flow Characteristics and Hydraulic Performance in a PIV Experimental Centrifugal Pump

In this paper, the effects of blade trailing edge (TE) profile modification of the suction side on the internal flow and hydraulic performance in a low-specific speed centrifugal pump are investigated through particle image velocimetry (PIV) analysis. Three impellers with different blade trailing edge profiles named original trailing edge (OTE), arc trailing edge 1 (ATE1), and arc trailing edge 2 (ATE2) are designed for PIV experiments. Results show that blade trailing edge modification of the suction side can significantly change the flow pattern, affecting the hydraulic performance of the model pumps. There is a definite counterclockwise backflow vortex near the suction side of OTE at deep-low flow rate, resulting in a decrease in the uniformity of the flow field at the outlet and the hydraulic performance. ATE1 with a reasonable larger blade outlet angle has the best flow field, and the head and efficiency are increased by about 1.2% and 8%, respectively under the same working condition. The hydraulic performance of ATE2 with the blade outlet angle of 59° is better than that of OTE under low flow rate, but it is less than that of OTE under high flow rate due to the streamline deviation generated on the pressure side. Meanwhile, the energy conversion abilities of the modified model pumps are evaluated by slip factor and the deviation degree of the nominalized local Euler head distribution (NLEHD). Since there is no definite counterclockwise backflow vortex at the outlet after modification, the slip factor of ATEs increases and the energy conversion ability is enhanced. Moreover, the jet-wake phenomenon of ATEs is weakened, and the local Euler head (LEH) increases near the outlet, decreasing the deviation degree of the NLEHD to obtain better energy conversion ability.

Effects of cutting speed and fiber orientation on tool wear and machining quality in milling CFRP with PCD cutter

Milling carbon fiber reinforced polymer (CFRP) composites faces significant challenges, such as rapid tool wear leading to machining damage, even for a polycrystalline diamond (PCD) cutter. However, the effects of the milling conditions on the tool wear of PCD cutters remain unclear. This study investigated the effects of the cutting speed and fiber orientation on the tool wear of a PCD cutter and the corresponding machining quality in milling CFRP. These effects were analyzed by considering fiber and cutter interactions, and milling experiments with a PCD cutter were conducted for validation based on the analyses of cutting-edge profiles, cutting forces, burr area, and machined surface of CFRP. The worn cutting edge profiles were found to be elliptical in shape for cutting CFRP in different fiber orientations owing to the more severe wear on the flank face and cutting edge. Tool wear decreased with increasing cutting speed under a consistent feed per tooth, which further led to a reduction in the cutting force, burr area, and surface roughness. In addition, the maximum and minimum variations of worn cutting edge profiles were found in the cutting of 45° and 135° CFRP, respectively, suggesting that frequently changing the tool working position at 45° could suppress burr damage and increase tool life.

P‐1.4: Analysis of the Hump Characteristics in Poly‐Si Thin Film Transistor &amp; Process a method to suppress hump effect

In this study, we investigate the transfer characteristics of low‐temperature polycrystalline silicon(LTPS) thin film transistors(TFTs) often show a “hump” in subthreshold region. This effect can be attributed to the presence of an enhanced electrical field at edges of the active layer. To reduce the hump effect which is one of the critical issues in ploy‐Si TFT, we focus on crowding of gate fringing field at channel edge and suggest a modified structure of channel edge. Using dry etching process, change the polysilicon layer at the edge of the channel from a steep profile to a slightly flat profile. And we confirmed that the severity of the hump effect is directly related to the edge profile of the polysilicon.

Study of rotor–stator interaction phenomenon in a double-suction centrifugal pump with impeller vane trailing edge as a design parameter

Various geometrical parameters, such as cut-water clearance, volute tongue location, tongue radius, vane trailing edge profile, and flow parameters like speed and operating point, affect the rotor–stator interaction in a centrifugal pump. In the present investigation, vane trailing edge is selected as a design parameter for profile modifications to study and reduce the rotor–stator interaction intensity and hence the pressure pulsations. A double-suction centrifugal pump with tangential discharge volute (M1) and specific speed (ns) 19 has been selected for the numerical experiments. Transient analysis using detached eddy simulation is used for predicting flow parameter behavior at impeller periphery (primary source) and volute tongue locations (secondary source). The impeller periphery probes in the rotor–stator interaction zone are used to identify the intensity of the jet-wake flow phenomenon and its interaction with the volute tongue. Similar strategy has been applied by modifying the trailing-edge profile of the original geometry with vane underfiling (M2) and the M2 vane geometry with novel trailing-edge profile (M3). The pressure pulsation behavior along the impeller periphery (primary source) shows the strong reduction of pressure amplitude near volute tongue by 42% in M3 compared to M1 aligning with the reduction of jet-wake flow intensity. The pressure fluctuation (rms) near volute tongue (secondary source) shows an average reduction of 11% in modified trailing edge (M3) relative to M1. The intensified rotor–stator interaction due to vortex shedding in M2 causes relatively higher pressure fluctuations (rms) near volute tongue compared to M1 and M3.

Combined ultraviolet- and electron-beam lithography with Micro-Resist-Technology GmbH ma-N1400 resist

We present a “mix-and-match” process to create large structures with submicrometer features by combining UV contact lithography and 100 kV electron-beam lithography in a single layer of negative-tone resist: Micro-Resist-Technology ma-N1405. The resist is successfully applied for the fabrication of an on-chip terahertz spectrometer, where the design requires 450 nm wide lines and 300 nm wide trenches in a 150 nm thick niobium-titanium-nitride layer, tolerating errors of ±30 nm. We use a resist thickness of 500 nm, optimized to allow reliable SF6/O2-based reactive ion etching of structures with 30 nm accuracy. We find that resist requires an electron-beam cross-linking dose of 1100 μC/cm2 for an acceleration voltage of 100 kV in combination with a 180 s 100 °C bake on a hot plate and 45 s development. The smallest resist bars made with our dedicated recipe are 100 nm wide, with the smallest gaps about 300 nm. The difference between the designed and realized feature size is between 2 and 30 nm for structures up to 700 nm wide. The optical exposure dose is 300 mJ/cm2 for the same development time and is optimized to produce a positive sloped edge profile allowing good step coverage for subsequent layers. The resist can be applied, shipped, and processed in a time span of a couple of days without notable deterioration of patterning quality.

Feature Extraction of Color Symbol Elements in Interior Design Based on Extension Data Mining

In order to improve the indoor color symbol elements in the design of visual communication ability, the interior design color symbol element feature extraction process is needed. We need to put forward a kind of extension data mining based on the interior design color symbol element feature extraction methods, build the visualization visual expression and big data characteristics of the distribution of the interior design of texture color symbol elements in intelligent information collection model, indoor color symbol elements in the design of the texture image and character segmentation, and extraction of texture and color symbol element in interior design edge feature point, based on the texture and edge profile characteristics of the distribution in the design of indoor color symbol elements of texture segmentation and matching, and extract the edge of the color symbol elements in interior design outline feature points. The extracted edge contour feature points of color image in interior design are used as the extended data feature components for texture matching, and the color symbol element feature extraction is realized according to the prior data distribution and extension data mining results. Simulation results show that this method has good adaptive performance in texture matching and feature extraction of color symbol elements in interior design and has a strong texture discrimination ability, which improves the visual communication ability of color symbol elements in interior design.

3D flexible displacement sensor for highly sensitive movement measurement assisted by the terahertz imaging system

Aiming at the difficulty of accurately calibrating the sample position in the terahertz (THz) imaging process, especially in the defect imaging detection and the precise characterization of the edge profile, a flexible and highly sensitive 3D terahertz displacement sensor with a resolution of up to 1 μm was proposed by the artificial electromagnetic metamaterials. The high resolution of the flexible sensor can be attributed to the used artificial electromagnetic metamaterials with the enhancing sensitivity of THz sensors as well as the flexible substrate with the high fitting to the target. Unlike the laser displacement sensor with a complex and large volume of the generating device, the proposed flexible sensor with a simple structural design is composed of only a fixed layer and a displacement indicating layer. The fixed layer is composed of the Mylar flexible substrate layer and the metal split resonator ring on it, and the displacement indicating layer is composed of the Mylar flexible substrate layer and the metal indicator lines on it. By using this unique double-layer structure, high-sensitivity measurement of displacement can be achieved by measuring the moving amount of the metal indicator line corresponding to the valley change in the THz transmission of the displacement sensor. The results demonstrate that the sensitivity of the displacement sensor can reach 145 GHz/μm, the quality factor Q can reach 194.67, and the quality factor figure of merit can reach 6.25 μm−1. Compared with the mature commercial displacement sensors and laser displacement sensors, the proposed sensor can have the characteristics of compact structure, simple preparation process, high-sensitivity, and flexibility, which can offer certain advantages for the realization of high-precision, miniaturization, and distributed sensing systems in the future.

Surface feature and material removal in ultrasonic vibration-assisted slot-milling of Ti–6Al–4 V titanium alloy

The continuous optimization of processing technology and evaluation methods is an important way to achieve high processing quality and processing efficiency for difficult-to-process materials. To solve the problem of frequent defects in the slot, the ultrasonic vibration-assisted slot-milling (UVASM) technology was developed for processing titanium alloy. Simultaneously, comparative experiments were carried out between UVASM and conventional slot milling (CSM), in terms of surface features of slot bottom and slot sidewall, cutting force, tool trajectory, chip morphology, and micro-hardness. The results show that uniform vibration micro-texture could significantly improve surface topography of slot bottom in UVASM, while numerous tool feed trajectories and observable machining defects detract from the surface quality in CSM. The UVASM can greatly reduce material spalling and edge breakage, thereby maintaining a smooth and regular edge profile of the slot sidewall. The tool tip trajectories of the two machining methods are highly corresponding to the machining textures of the slot sidewall surface. There is a high-frequency and small-amplitude force fluctuation signal on the axial force waveform in UVASM, which can reduce the instantaneous maximum milling force and milling force in the stable stage by 8.7 and 12.2%, respectively. The UVASM has a better chip breaking effect and surface anti-scratch effect, and the UVASM can obtain higher surface micro-hardness and deeper plastic deformation layer than those CSM. In summary, the multi-dimensional evaluation of slot processing status has been completed, and the processing quality of the slot has been improved.

Tool Wear Monitoring Using Improved Dragonfly Optimization Algorithm and Deep Belief Network

In recent decades, tool wear monitoring has played a crucial role in the improvement of industrial production quality and efficiency. In the machining process, it is important to predict both tool cost and life, and to reduce the equipment downtime. The conventional methods need enormous quantities of human resources and expert skills to achieve precise tool wear information. To automatically identify the tool wear types, deep learning models are extensively used in the existing studies. In this manuscript, a new model is proposed for the effective classification of both serviceable and worn cutting edges. Initially, a dataset is chosen for experimental analysis that includes 254 images of edge profile cutting heads; then, circular Hough transform, canny edge detector, and standard Hough transform are used to segment 577 cutting edge images, where 276 images are disposable and 301 are functional. Furthermore, feature extraction is carried out on the segmented images utilizing Local Binary Pattern (LBPs) and Speeded up Robust Features (SURF), Harris Corner Detection (HCD), Histogram of Oriented Gradients (HOG), and Grey-Level Co-occurrence Matrix (GLCM) feature descriptors for extracting the texture feature vectors. Next, the dimension of the extracted features is reduced by an Improved Dragonfly Optimization Algorithm (IDOA) that lowers the computational complexity and running time of the Deep Belief Network (DBN), while classifying the serviceable and worn cutting edges. The experimental evaluations showed that the IDOA-DBN model attained 98.83% accuracy on the patch configuration of full edge division, which is superior to the existing deep learning models.

An edge identification method for gap in-line measurement based on fillet assumption

The optical measurement technology could reduce manual work and improve quality in assembly. The confocal scanning scheme is proposed to measure the narrow gap in-line but it is hard to identify the edges of a gap. This paper proposed an edge definition and presented an edge identification method for gap measurement. The edge profile is defined as a part of a circle, which could be identified by the shutter time feature. The defined edge point could be calculated by fitting the edge profile, and then the width of a gap section is calculated by two edge points. The width of a gap can be evaluated by the average of several gap section. The experimental results indicate that the repeatability of the method is less than 2 µm and the precision of the measurement is higher than ±2.5 µm. The proposed method is feasible for in-line measurement application in assembly.