Low Torque Research Articles

A design study on 20 kW class axial flux motor with HTS field winding for 100 MPa liquid hydrogen pump

This paper presents a design study of a low-speed, high torque 20 kW class motor with a high-temperature superconductor (HTS) field coil for a liquid hydrogen centrifugal pump. The motor is designed based on three key concepts: 1) employing an axial-flux motor topology that can increase torque density by reducing the axial length together with a centrifugal pump; 2) using liquid hydrogen in a pump as a coolant for HTS coil; 3) adopting no-insulation (NI) YBCO solenoid coils as field coils of the motor to improve coil protection as well as mechanical stability. In the design process, first, an electromagnetic design of the axial type motor is obtained considering the required performance of previous commercial pumps. Considering the current and temperature margin to secure the HTS coils' stable operation, two types of HTS coils (solenoid type and triangle type) are designed and their performances are compared. Second, to evaluate validity of the electromagnetic designs, mechanical stresses in the HTS coils are estimated. By comparing the solenoid type and the triangle type, it is confirmed that the solenoid type has a distinct stress-reducing effect in terms of magnetic stress as well as rotational stress. Our design study results show the potential superior performance of the axial flux motor with HTS coils for several tens of kW applications with low speed and high torque loads such as liquid hydrogen pumps.

Comprehensive Characterization of Blue Wire NiTi File Failure: A Comparative Analysis of Cyclic Fatigue and Torsional Resistance Properties

This study compared the fatigue resistance and elemental composition of two blue heat-treated nickel–titanium (NiTi) files used in root canal preparation as follows: Tia Tornado Blue (TTB) and Race Evo (RE) file systems. For cyclic fatigue testing, the two systems were tested where each file was rotated inside an artificial metal canal submerged in either sodium hypochlorite or saline solution until fracture. Time to fracture was recorded. For torsional fatigue testing, the file tip was secured while the file was allowed to rotate at a fixed rate until fracture. Torque at failure was recorded. The two experiments were performed at simulated body temperature and the length of fractured segments was measured. Statistical analysis was carried out with a significance level (p-value) set at 5%. The mean cycles to fracture for RE were superior to that of TTB irrespective of the solution used (p < 0.05). TTB’s cyclic fatigue resistance decreased in NaOCl (p < 0.0001). RE demonstrated lower torque at failure (p = 0.002). All files were fractured at comparable lengths (p = 0.218). Although RE is considered more resistant to cyclic fatigue, it showed inferior torsional resistance compared with TTB. The NaOCl negatively affected the TTB’s cyclic fatigue resistance.

Implant Stability and Histomorphometric Analysis Comparing Two Different Implant Macrogeometries Placed in Fresh Sockets: An Experimental Study in Sheep.

The aim of the present animal study was to examine the impact of two implant designs that promote different insertion torque values on implant stability and evaluate, histomorphometrically, the bone healing for immediate implant placement in fresh sockets. Twelve female sheep (35.0±5.0kg) and 48 conical Morse-taper dental implants divided into two groups (n = 24 per group): G1 group, where the implants present a design that can provide high insertion torque values; and G2 group, where the implants present a design that can provide low insertion torque values. Both had the same surface treatment, and dimensions (4.0 mm in diameter and 10 mm in length). The first two posterior teeth (both sides) were extracted carefully. Sequentially, there were osteotomies in the mesial socket of each molar tooth. The final implant position was 2 mm below the buccal bone crest level. On the right side, implants of the G1 were placed anteriorly, followed by implants of the G2; and, on the left side, it was the reverse. A digital torquemeter was used to measure the maximum final insertion torque value (f-IT). The initial implant stability quotient (ISQ) was measured immediately after the implant insertion (T0) and immediately after the euthanasia and removing the mandibles with the implants. The animals were euthanized (n=6 animals/ time) at 21 days (T1) and 35 days (T2). The t-test was used to compare statistical differences for each intragroup parameter analyzed. Pearson's correlation was used to analyze possible correlations: f-IT and BIC%, f-IT and ISQ, and ISQ and %BIC. Regarding the insertion torque, the G1 presented higher values than the G2, with a statistically significant difference (p<0.0001). The ISQ mean values were higher in the B-L direction than those obtained for M-D for both groups. %BIC measurements showed higher values in samples from G2 than G1 at both times and in both directions. New bone, medullary spaces, and collagen matrix had statistical differences between the groups at each evaluation time. Using implants with a modified macrogeometry plays a significant role in implant stability and the healing process of bone tissue around the implant. It is important for clinicians to carefully consider implant macrogeometry when planning dental implant surgery to achieve optimal implant stability and successful osseointegration, mainly in cases of immediate implant placement.

Time course changes in in vivo muscle mechanical function and Ca2+ regulation of force following experimentally induced gradual ovarian failure in mice.

The abrupt cessation of ovarian hormone release is associated with declines in muscle contractile function, yet the impact of gradual ovarian failure on muscle contractility across peri-, early- and late-stage menopause remains unclear. In this study, a 4-vinylcyclohexene diepoxide (VCD)-induced ovarian failure mouse model was used to examine time course changes in muscle mechanical function. Plantar flexors of female mice (VCD: n=10; CON: n=8) were assessed at 40 (early perimenopause), 80 (late perimenopause), 120 (menopause onset) and 176 (late menopause) days post-initial VCD injection. A torque-frequency relationship was established across a range of frequencies (10-200Hz). Isotonic dynamic contractions were elicited against relative loads (10-80% maximal isometric torque) to determine the torque-velocity-power relationship. Mice then performed a fatigue task using intermittent 100Hz isometric contractions until torque dropped by 60%. Recovery of twitch, 10Hz and 100Hz torque were tracked for 10min post-task failure. Additionally, intact muscle fibres from the flexor digitorum brevis underwent a fatigue task (50 repetitions at 70Hz), and 10 and 100Hz tetanic [Ca2+] were monitored for 10min afterward. VCD mice exhibited 16% lower twitch torque than controls across all time points. Apart from twitch torque, 10Hz torque and 10Hz tetanic [Ca2+], where VCD showed greater values relative to pre-fatigue during recovery, no significant differences were observed between control and VCD mice during recovery. These results indicate that gradual ovarian failure has minimal detriments to in vivo muscle mechanical function, with minor alterations observed primarily for low-frequency stimulation during recovery from fatigue.

Comparative assessment of a novel 8/18 multi-teeth with conventional 8/10 in-wheel SRM for an E-Scooter

Electric scooters are increasingly gaining popularity in India owing to rising global crude oil prices and rising levels of vehicular pollution. Most of them are currently powered by expensive in-wheel (IW) permanent magnet (PM) brushless DC motors. Owing to their simplicity, and ruggedness while being cost-effective (since they do not employ PMs), switched reluctance motors (SRMs) are a viable alternative. Despite these benefits, SRMs possess drawbacks such as low torque density and inferior efficiency. Recently, a multi-teeth (MT) SRM with an improved performance was reported. However, the design of MTSRM topologies and their electromagnetic performance have not been explored sufficiently. In this paper, a design formula governing the selection of the number of MT and rotor poles for MTSRMs has been proposed. Using this, a novel four-phase 8/18 IW-MTSRM is derived and proposed for an E-scooter. The characteristics of the proposed SRM are numerically compared with a conventional 8/10 SRM based on magnetic characteristics, efficiencies and steady-state operation for the complete torque-speed range. Results indicate that the proposed 8/18 MTSRM has a higher peak torque capacity, torque density, superior drive cycle efficiency and reduced torque ripple. Further, the FEA model is validated experimentally on a downsized 8/18 MTSRM prototype.

RASP methods for achieving low torque pulsation in spoke-type PM motors

RASP methods for achieving low torque pulsation in spoke-type PM motors

Mechanical and Magnetic Properties Variation in Non-Oriented Electrical Steels with Different Cutting Technology: A Review.

The problem of energy consumption reduction establishes important challenges for electric motor producers in the framework of new international regulations regarding the conditions that must be accomplished by motors in the near future. One of the most important topics is related to the core loss decrease directly linked to the effect of electrical steel degradation induced by the cutting technology. Understanding exactly how this phenomenon occurs by analyzing the chemical, mechanical, crystallographic, magnetic domain, and magnetic properties is of utmost importance when manufacturing processes must be changed and adapted to a new market characterized by high-efficiency motors. Today, mechanical and laser cutting technologies are the most used because of their reduced price and high-speed process. Still, unfortunately, these methods are not the best due to the fact that they lead, in most cases, to a high value of magnetic core losses, low electromagnetic torque, and hence reduced efficiency. This review paper shows that non-conventional technologies such as water jetting and electroerosion could be applied if proper modifications are added. This paper's main idea is to present a comprehensive study regarding the impact of cutting technologies on microhardness and residual stresses, crystallographic texture, magnetic domain structure, and magnetic properties of some non-oriented electrical steels used in motor production. It provides a detailed analysis of the abovementioned aspects by including the authors' research and findings in the wider context of other research group contributions. It also offers a general idea of the mechanisms present at the macro- and microscopic levels. The readers can find some of the most used analytical models, including the cutting process's damaged effect on the magnetic properties' variation based on a simple mathematical approach and examples of finite element modeling performed on real motor designs implemented in various programs. Last but not least, some practical implementations of the cutting procedure's influence on motor working conditions are presented in the last section of the paper. It provides an up-to-date analysis regarding how the cutting method should be included in high-efficiency motor production by emphasizing the importance of the topic and identifying where supplementary research must be undertaken. From the investigated literature, by analyzing specific sample geometries associated with different characterization methods, it can be concluded that all the cutting technologies have an important contribution to the mechanical and magnetic quantities. When the magnetic core of an electric motor is produced through non-conventional methods, the overall influence of the cutting procedure has a low percentage in the motor efficiency, as presented in this paper.

Design and Fabrication of Switched Reluctance Motor for Energy Efficient Operation by Minimizing Torque Ripple

Around the world, motor is consuming more than 40% of the total-generated electrical energy. Accordingly, energy efficient electrical drives are the needs of the hour. The Switched Reluctance Motor (SRM) is more energy efficient than other kinds. Since SRM has a rugged structure, it has inherent fault tolerance characteristics and is cost-effective than synchronous and induction machines. Nevertheless, the application of such a motor is limited due to low torque density, torque ripples and power losses because of control circuit. In this research work, the author proposed a novel-designed SRM, which is achieved by optimizing stator and rotor pole arc. Alongside, a novel control circuit, which has single transistor, is proposed. The modification of stator and rotor pole arcs assists in the reduction of the torque ripple. The stator pole arc is modified from 32 degree to 36 degree, and the rotor pole arc is modified from 30 degree to 28 degree. Thus, the torque ripple is reduced from 3.25 to 2.92 Nm, and thus, the useful torque is increased from 4.94 to 5.2 Nm. Furthermore, a single transistor switching device is used instead of the conventional one with four switches. Hence, energy loss on the control circuit is significantly reduced. From the experimental analysis, it is found that, with-pole-arc modified SRM has higher efficiency than the one without it.

Advance effect of magnetic field on the rheological properties of manganese zinc ferrite ferrofluid

The rheological characteristics of manganese zinc (Mn-Zn) ferrite magnetic nanofluid synthesized using co-precipitation technique were examined in the absence and presence of magnetic fields. The research formulates required conditions needed for the formation of a gelly-like structure. The impact of magnetic field and temperature on the rheological properties of Mn-Zn ferrite ferrofluid is investigated. When a magnetic field was applied, higher magnetoviscoelasticity and magnetoviscosity were formed. Analysis was also done on other rheological parameters, such as the damping factor, which is crucial for regulating and restricting vibrations in a system. A stiff, gel-like structure is produced when a magnetic field is applied, and the gel-like quality grows as the magnetic field increases; when the magnetic field is removed, the gel-like and rigidity of the structure is lost. At low temperatures, the liquid phase is dominated by solid-like particles, whereas at high temperatures, the liquid-like structure is dominant. This study reveals the conditions required for the creation of high viscous effect and the viscoelastic behavior induced by the field offers important insights for optimizing the Mn-Zn ferrite ferrofluid for a range of applications. Other criterial for gel-like structure formation such as low torque and deflection angle of the ferrofluid were also established.

Biodiesel production from waste cooking oil using calcium oxide derived from scallop shell waste

Abstract Biodiesel is one of the alternative forms of diesel fuel and can be obtained using the transesterification process of waste cooking oil with a catalyst to accelerate the reaction. The heterogeneous catalyst from waste scallop shells is used due to its potential for being reused in the subsequent transesterification reactions. Heterogeneous catalysts can also be recycled, contributing to their environmentally friendly nature. This study aims to identify the performance of recycling a calcium oxide (CaO) catalyst from scallop shell waste on synthesis biodiesel. The method used is the transesterification method with the basic ingredients of waste cooking oil using a CaO catalyst. Then, after the transesterification process is complete, the catalyst is separated from the biodiesel and recycled to be reused in the transesterification process up to five times. The biodiesel samples obtained are identified for yield value, physico-chemical properties, thermal properties and performance. X-ray diffraction characterization results for the CaO catalyst show that it has a crystal size of 67.83 nm. Scanning electron microscope characterization shows that it has spherical particle shapes. Fourier transform infrared characterization shows the presence of Ca–O bonds. The highest biodiesel yield value of 74.23% is obtained in biodiesel Cycle 1. The flash point value of biodiesel samples ranges from 141.2°C to 149°C. Further, all of the biodiesel samples exhibit a cetane number of 75. The highest lower heating value of 38.22 MJ/kg is obtained in biodiesel Cycle 1 and the viscosity of the biodiesel samples ranges from 5.65 to 5.88 cSt. The density of the biodiesel samples ranges from 881.23 to 882.92 kg/m3. Besides, ester functional groups (C=O) and methyl functional groups have been successfully formed in all samples, with the methyl oleate compound observed as dominating the biodiesel samples. The cloud point value of the biodiesel samples ranges from 12°C to 13°C, and their pour point value ranges from 10°C to 12°C. The lead content in biodiesel is 0.8826 mg/kg. The lowest sulphur content is obtained from biodiesel Cycles 1 and 2 at 0.005%. Performance tests show that biodiesel has lower torque and brake power values than commercial diesel fuel and higher specific fuel consumption values than commercial diesel fuel.

A Fast Calibration Method for an sEMG-Based Lower Limb Joint Torque Estimation Model

The joint torque estimation model based on surface electromyography (sEMG) signals needs to recalibrate the model parameters when used for joint torque estimation at different volunteers. However, the feature transferability drops significantly in higher task-specific layers, which reduce the performance of the model. The generalization of joint torque estimation models among different volunteers has become a challenge. In this paper, a fast calibration method based on a deep adaptive regression network is proposed to reduce the frequency and time of model recalibration when volunteers change. The proposed method associates source domain (SD) data with target domain (TD) data through migration learning. The maximum mean difference (MMD) adaptive method is used to migrate the model trained in the SD dataset to the TD dataset, which avoids the recalibration required in the joint torque estimation model. The experimental results show that the proposed method can improve the migration ability of the model used for estimating joint torque and achieve the generalization application of the model on different volunteer datasets. Moreover, the proposed method can reduce the calibration operations and iterations of the model caused by volunteer changes and improve the speed of joint torque estimation. The optimal normalized root mean square error (NRMSE) and Pearson correlation coefficient (ρ) of knee extension/flexion joint torque estimation reached 0.02198/0.02565 and 0.9892/0.9839, respectively.

Comparative Analysis of Consequent-Pole PM Vernier Machines With Different Rotor Types

Taking advantage of flux modulation effects, consequent-pole PM vernier (CPMV) machines have been widely investigated recently, featuring high torque density and PM utilization ratio. However, the low-order harmonics of modulated flux fields additionally cause high iron saturation, which results in relatively low average torque under overload conditions, especially for the CPMV machines with an interior CPM (ICPM) rotor. Therefore, this paper proposes two hybrid CPM (HCPM) rotors of PMV machines to improve the overload performance by adding SPMs into the conventional ICPM rotor. First, the topologies of the proposed HCPM rotors are presented, named HCPM1 and HCPM2 rotors, respectively. Then the HCPM rotors and a conventional ICPM rotor with the V-shaped PM arrangement are designed and optimized to find out the optimal design parameters. Moreover, the electromagnetic performances including back-EMF, torque performance, efficiency, flux-weakening capability, and end effect are comprehensively investigated and compared. It indicates that the two proposed HCPM rotors both can generate equivalently high average torque, efficiency, and flux-weakening capability, compared to the conventional ICPM rotor. Furthermore, the proposed HCPM2 rotor can produce ≥22.9% higher torque at overload conditions. In addition, due to the bipolar PM arrangement, the unipolar flux leakage of the HCPM2 rotor is significantly reduced and lower than 0.05T. Finally, the prototype of a 12-stator-slot/ 20-rotor-pole CPMV machine with the HCPM2 rotor is manufactured to validate the finite element (FE) results.

A C-Core Connected Two-Phase Switched Reluctance Motor With Embedded Permanent Magnets for Developed Torque Enhancement

Conventional switched reluctance motors (SRMs) face challenges like low torque density and high noise. To overcome these challenges, the structure of SRMs can be modified. This paper introduces a new hybrid-excited 16/18 two-phase SRM with a C-core structure. Each pole of the C-core has two teeth, which develop a positive torque during the rotor rotation; this enhances the torque and torque density of the motor. To show the merits of the proposed SRM with PMs, its static and dynamic characteristics, including flux density, flux-linkage, and torque, are obtained and compared with the SRM with no PMs, the 8/12 two-phase conventional SRM, and other motors with the same volume; a significant match was achieved. Finally, both proposed SRMs were prototyped and tested. Comparing the simulation and test results elucidates that the proposed SRM with PMs has unique high output power, torque, and efficiency.

Modeling of thrust force and torque in drilling aluminum 7050

Abstract The aluminum AA7050 alloy has high toughness and high strength. Despite the high machinability of the AA7050 alloy, hole quality can vary according to tool geometry and drilling parameters. This study investigated the effects of different cutting parameters and three different drill point angles on thrust force and torque. Numerical analyses for thrust force and torque were performed using the finite element method. The lowest thrust force and the highest torque were obtained with the drill at 130° drill point angle, while the highest cutting force and lowest torque were obtained with the drill at 118° drill point angle. There is an average difference of 5.37 and 6.9 % between the experimental and analysis values for thrust forces and torque, respectively, and the applicability of the finite element model has been proven. In the last part of the study, thrust force and torque are modeled with artificial neural networks. The statistical accuracy (R 2) values for the learning and testing values in the thrust force of the equation are 0.997797 and 0.995739, respectively. Torque’s learning and testing accuracy values are 0.987247 and 0.937909, respectively. The obtained equations have a high accuracy rate.

Development and Analysis of an On-Road Torque Measurement Device for Trucks

BackgroundRolling resistance and aerodynamic losses cause a significant part of a truck’s energy consumption. Therefore there is an interest from both vehicle manufacturers and regulators to measure these losses to understand, quantify and reduce the energy consumption of vehicles. On-road measurements are particularly interesting because it enables testing in various ambient conditions and road surfaces with vehicles in service.ObjectiveCommon driving loss measurement devices require unique instrumented measurement wheels, which hinders effective measurements of multiple tyre sets or measurements of vehicles in service. For this purpose, the objective is to develop a novel load-sensing device for measuring braking or driving torque.MethodsThe strength of the measurement device is calculated using finite element methods, and the output signal is simulated using virtual strain gauge simulations. In addition to the signal simulation, the device is calibrated using a torsional test rig.ResultsThe simulation results confirm that the device fulfils the strength requirements and is able to resolve low torque levels. The output signal is simulated for the novel cascaded multi-Wheatstone bridge using the strains extracted from the finite element analysis. The simulations and measurements show that the measurement signal is linear and not sensitive to other load directions. The device is tested on a truck, and the effort of mounting the device is comparable to a regular tyre change.ConclusionsA novel driving loss measurement device design is presented with an innovative positioning of strain gauges decoupling the parasitic loads from the driving loss measurements. The design allows on-road testing using conventional wheels without requiring special measurement wheels or instrumentation of drive shafts, enabling more affordable and accurate measurements.

Modelling of Truck Tire–Rim Slip on Sandy Loam Using Advanced Computational Techniques

Vehicles often experience low tire pressures and high torques in off-road operations, making tire–rim slip likely. Tire–rim slip is undesirable relative rotation between the tire and rim, which, in this study, is measured by the relative tire–rim slip rate. There is little research on the effect of different terrains on tire–rim slip despite its significance for off-road driving; therefore, this topic was explored through Finite Element Analysis (FEA) simulations. An upland sandy loam soil was modelled and calibrated using Smoothed-Particle Hydrodynamics (SPH), and then a Regional Haul Drive (RHD) truck tire was simulated driving over this terrain, with a drawbar load added to increase drive torque. To examine their effects, five parameters were changed: tire–rim friction coefficient, longitudinal wheel speed, drawbar load, vertical load, and inflation pressure. The simulations showed that increasing the tire–rim friction coefficient and the inflation pressure decreased the tire–rim slip while increasing the vertical and drawbar loads increased the tire–rim slip. Varying the longitudinal wheel speed had no significant effect. Tire–rim slip was more likely to occur on the soil because it happened at lower drawbar loads on the soil than on the hard surface. These research results increased knowledge of tire–rim slip mechanics and provided a foundation for exploring tire–rim slip on other terrains, such as clays or sands.

Avoiding fusion plasma tearing instability with deep reinforcement learning

For stable and efficient fusion energy production using a tokamak reactor, it is essential to maintain a high-pressure hydrogenic plasma without plasma disruption. Therefore, it is necessary to actively control the tokamak based on the observed plasma state, to manoeuvre high-pressure plasma while avoiding tearing instability, the leading cause of disruptions. This presents an obstacle-avoidance problem for which artificial intelligence based on reinforcement learning has recently shown remarkable performance1–4. However, the obstacle here, the tearing instability, is difficult to forecast and is highly prone to terminating plasma operations, especially in the ITER baseline scenario. Previously, we developed a multimodal dynamic model that estimates the likelihood of future tearing instability based on signals from multiple diagnostics and actuators5. Here we harness this dynamic model as a training environment for reinforcement-learning artificial intelligence, facilitating automated instability prevention. We demonstrate artificial intelligence control to lower the possibility of disruptive tearing instabilities in DIII-D6, the largest magnetic fusion facility in the United States. The controller maintained the tearing likelihood under a given threshold, even under relatively unfavourable conditions of low safety factor and low torque. In particular, it allowed the plasma to actively track the stable path within the time-varying operational space while maintaining H-mode performance, which was challenging with traditional preprogrammed control. This controller paves the path to developing stable high-performance operational scenarios for future use in ITER.

Multimethod analysis of large- and low-tapered single file reciprocating instruments: Design, metallurgy, mechanical performance, and irrigation flow.

To compare eight large- and low-tapered heat-treated reciprocating instruments regarding their design, metallurgy, mechanical properties, and irrigation flow through an in silico model. A total of 472 new 25-mm E-Flex Rex (25/.04 and 25/.06), Excalibur (25/.05), Procodile (25/.06), Reciproc Blue R25 (25/.08v), WaveOne Gold Primary (25/.07v), and Univy Sense (25/.04 and 25/.06) instruments were evaluated regarding their design (stereomicroscopy, scanning electron microscopy, and 3D surface scanning), metallurgy (energy-dispersive X-ray spectroscopy and differential scanning calorimetry), and mechanical performance (cyclic fatigue, torsional resistance, cutting ability, bending and buckling resistance). Computational fluid dynamics assessment was also conducted to determine the irrigation flow pattern, apical pressure, and wall shear stress in simulated canal preparations. Kruskal-Wallis and one-way anova post hoc Tukey tests were used for statistical comparisons (α = 5%). Instruments presented variations in blade numbers, helical angles, and tip designs, with all featuring non-active tips, symmetrical blades, and equiatomic nickel-titanium ratios. Cross-sectional designs exhibited an S-shaped geometry, except for WaveOne Gold. Univy 25/.04 and Reciproc Blue displayed the smallest and largest core diameters at D3. Univy 25/.04 and E-Flex Rec 25/.04 demonstrated the longest time to fracture (p < .05). Reciproc Blue and Univy 25/.04 exhibited the highest and lowest torque to fracture, respectively (p < .05). Univy 25/.04 and Reciproc Blue had the highest rotation angles, whilst E-Flex Rec 25/.06 showed the lowest angle (p < .05). The better cutting ability was observed with E-Flex Rec 25/.06, Procodile, Excalibur, and Reciproc Blue (p > .05). Reciproc R25 and E-Flex Rec showed the highest buckling resistance values (p < .05), with WaveOne Gold being the least flexible instrument. The impact of instruments' size and taper on wall shear stress and apical pressure did not follow a distinct pattern, although Univy 25/.04 and E-Flex Rec 25/.06 yielded the highest and lowest values for both parameters, respectively. Low-tapered reciprocating instruments exhibit increased flexibility, higher time to fracture, and greater angles of rotation, coupled with reduced maximum bending loads and buckling strength compared to large-tapered instruments. Nevertheless, low-tapered systems also exhibit lower maximum torque to fracture and inferior cutting ability, contributing to a narrower apical canal enlargement that may compromise the penetration of irrigants in that region.

Performance evaluation of a novel ball screw raceway profile based on geometric close contact theory

The raceway profile greatly influences the performance of a ball screw. Although the traditional circular raceway profile is simple in structure, it can be a limitation to the load carrying capacity of ball screws. In this paper, a novel type of ball screw raceway profile is proposed based on geometrical close contact theory. Firstly, the second-order approximation curve of the ball is derived using the McLaughlin formula in the normal plane of the raceway helix, which serves as the basis for constructing the close raceway profile. The mathematical expression of the contact stress distribution of the close raceway is then obtained using Chebyshev polynomials. A comparison and analysis of the contact stress distribution between the close raceway and the conventional raceway is carried out. Furthermore, simulation models of ball screws with the close raceway profile are established and the contact behavior of the ball with both types of raceways is statically simulated using ANSYS software. The dynamic performance of both ball screws is compared and analyzed using ADAMS software. The analysis results show that compared with the conventional raceway ball screw, the close raceway ball screw has lower stress, strain, and friction torque under the same load conditions. These research results have significant implications for the structural optimization of ball screws.

Thermal Error Measurement and Compensation with Torque Limit Skip in Swiss-type Lathe Manufacturing

This paper presents a new methodology for the measurement of thermal errors of Swiss-type lathes. The basis of the proposed method is the torque limit skip function integrated in the lathe’s control which stops the motion of a linear axis if the torque on the corresponding axis servo is exceeded. The skip signal is triggered via a slow contact between a bar in the lathe’s spindle and an artefact in the lathe’s tool holder. Experimental results indicate that when a sufficiently low torque override limit is applied, the axis positioning repeatability under the repeated application of the torque limit skip is within ±1μm. The relative change in position of the axis after the skip measured over several hours is the thermal error which can be compensated. The proposed measurement technique offers significant advantages over conventional thermal error measurement with a touch-trigger probe or linear displacement sensors: if available on the machine’s control, it does not require any specialized installation, can be used during production, and delivers comparable results without high additional equipment costs.