Viscosity behavior of magnetic suspensions in fluid-assisted finishing

Magnetic fluid-assisted finishing has been verified both theoretically and experimentally as an effective fabrication technology for optical mirrors and lenses. The purpose of this paper is to introduce a novel design of polishing tool and demonstrate the possible applications of this technology. The work includes studying the viscosity of the magnetic suspensions of micrometer-sized Carbonyl iron particles under the influence of a magnetic field. Both the cases of magnetizable suspension with and without abrasive cerium oxide particles are studied for their ensuing polishing effectiveness. Determination of material removal function is conducted using a Wyko Nat1100 interferometer. Experiments to reduce surface roughness with the proposed tool are also performed using a K9 mirror as the work-piece. Results show that the surface accuracy is improved over three times to less than 0.5 nm after two cycles of polishing.     

Characterization of composite particles responsive to electric and magnetic fields

The multilayer particles with responses to electric and magnetic fields are a prerequisite for particles assembled under external fields. Three routes to produce particles responsive to electric and magnetic fields are presented in this article. The size and morphology, properties as well as the electric-magnetic responses of three kinds of particles are comparatively discussed. This will provide a useful basis for the control of the behavior of the particles in suspensions by external electric and magnetic fields.     

Surface roughness and removal rate in magnetorheological finishing of a subsurface damage free surface

Based on computer-controlled optical surfacing, a new technique called magnetorheological finishing (MRF), is presented. The new technique combines the features of conventional loose abrasive machining with a wheel shaped polishing tool. The tool incorporates a host of features and has unprecedented fabricating versatility. The pre-polishing and fine polishing processes can be performed only by adjusting different parameters. The material removal function is studied theoretically and the results of simulation present a Gaussian distribution feature. Based on the established theoretical model, material removal rate experiments involving a parabolic mirror are designed and carried out to determine the effect of controllable parameters on size of the gap between the workpiece and the polishing wheel, rotating speed of the polishing wheel, concentration of volume fraction of non-magnetic particles and polishing time. Further experiments are carried out on the surface microstructure of the workpiece, the final surface roughness with an initial value of 10.98 nm reaches 1.22 nm root mean square (RMS) after 20 min of polishing. The subsurface damage experiment and the atomic force microscopy (AFM) measurement on the polished surface can also verify the feasibility of the MRF technique.     

Chemically Synthesised Pt Particles on Surface Oxidized Carbon Nanotubes as an Effective Catalyst for Direct Methanol Fuel Cell

1 Results The synthesis, physical characterization and electrochemical analysis of Pt particles prepared using the surface oxidized carbon nanotubes prepared by chemically anchoring Pt onto the surface of the CNTs with 2.0 mol/L HNO3 by refluxing for 10 h to introduce surface functional groups.The particles of Pt are synthesized by reduction with sodium borohydride of H2PtCl6. The electro-oxidation of liquid methanol of this catalyst as a thin layer on glassy carbon electrode is investigated at room temperature by cyclic voltammetry. The results demonstrate that the prepared catalyst is more active than ordinarily carbon-supported Pt as catalyst. The results show that surface oxidized carbon nanotubes support allows to obtain higher power density in comparision with carbon nanotubes based electrode.     

Remote intelligent identification system of structural damage

The focus of this paper is to build the damage identify system, which performs “system identification“ to detcct the positions and extents of structural damages. The identification of structural damage can be characterized as a nonlinear process which linear prediction models such as linear regression are not suitable. However. neural network techniques may provide an effective tool for system identification. The method of damage identification using the radial basis function neural network (P, BFNN) is presented in this paper. Using this method, a simple reinforced concrete structure has been tested both in the absence and presence of noise. The resuits show that the RBFNN identification technology can he used with related success for the solution of dynamic damage identification problems, even in the presence of a noisy identify data. Furthermore, a remote identification system based on that is set up with Java Technologies.     

Progress in material removal mechanisms of surface polishing with ultra precision

Chemical mechanical polishing (CMP) process is commonly regarded as the best method for achieving global planarization in the field of surface finishing with ultra-precision. The development of investigation on material removal mechanisms for different materials used in computer hard disk and ultra-large scale integration fabrication are reviewed here. The mechanisms underlying the interaction between the abrasive particles and polished surfaces during CMP are addressed, and some ways to investigate the polishing mechanisms are presented.     

Novel Plastic Encapsulation Holding Method for Automobile Glass Using Injection Molding Process

Glass positioning and holding is difficult in the process of injection molding encapsulation of automobile glass. A suction cup or soft resin is always introduced in this process. However, these materials cannot hold glass tightly, thus resulting in the unsteady quality of toughened glass and encapsulated plastic. To solve this problem, a novel holding method called magnetic high-pressure holding with twin bags is proposed to address the features of toughened glass and the encapsulation injection process. Firstly, a pair of permanent magnets is introduced as energy source, followed by the magnetization of a couple of magnetic particle bags. Contact between the single bag and the glass surface will enable the couple of magnetic particle bags to hold glass tightly and to self-adapt the freeform of the glass. Secondly, an experimental system with mechanical and control systems is designed. This system is controlled by the opening and closing force of the mold, which turns the magnetic field on or off to hold or loosen the glass. The magnetic field distributions are measured at important positions of the permanent magnets and in the magnetized particles in the experiments to determine the holding performance. Finally, the process of determining the parameters of the magnet and its attenuation is analyzed, including the minimum friction force between the glass and the particle bag during injection molding, the magnetic energy product and the magnetized filed distributions, and the re-checklng method for these parameters. The theoretical analysis and the experimental result show that this flexible holding system may produce sufficient holding force, which not only protects glass but serf-adapts the glass freeform as well. The production practice meets the technical requirements of injection molding with a defect-free surface, with no scratches and cracks on the glass and no slight glass movements in the mold cavity.     

Realization of magnetic signal acquisition scheme for banknotes

In order to solve the problem of low signal-to-noise ratio(about 15 d B) in magnetic signal acquisition of banknotes, a new method of magnetic signal acquisition and processing is proposed taking RMB as an example. In this method, weak signa detection is performed to reduce the noise accompanied with the signal. Seven orders of Chebyshev(Ⅰ) filter and the anti-jamming technology are used in the PCB layout, and grounding modes are introduced to reduce the noise of the amplitude waveform. The proposed method reduce the final output noise by 2/3 and the sig nal-to-noise ratio is increased to 24 d B. The experimental results show that the magnetic signal of RMB banknotes are acquired by the circuit stability, which provides an important guarantee for the improvements of the anti-counterfeit and discrimination for banknotes performance.     

Compound machining of silicon carbide ceramics by high speed end electrical discharge milling and mechanical grinding

A compound process that integrates end electrical discharge (ED) milling and mechanical grinding to machine silicon carbide (SiC) ceramics is developed in this paper. The process employs a turntable with several uniformly-distributed cylindrical copper electrodes and abrasive sticks as the tool, and uses a water-based emulsion as the machining fluid. End electrical discharge milling and mechanical grinding happen alternately and are mutually beneficial, so the process is able to effectively machine a large surface area on SiC ceramic with a good surface quality. The machining principle and characteristics of the technique are introduced. The effects of polarity, pulse duration, pulse interval, open-circuit voltage, discharge current, diamond grit size, emulsion concentration, emulsion flux, milling depth and tool stick number on performance parameters such as the material removal rate, tool wear ratio, and surface roughness have been investigated. In addition, the microstructure of the machined surface under different machining conditions is examined with a scanning electron microscope and an energy dispersive spectrometer. The SiC ceramic was mainly removed by end ED milling during the initial rough machining mode, whereas it is mainly removed by mechanical grinding during the later finer machining mode; moreover, the tool material can transfer to the workpiece surface during the compound process.     

Study on the pre-treatment of oxidized zinc ore prior to flotation

The pre-treatment of zinc oxide bearing ores with high slime content is important to ensure that resources are utilized optimally. This paper reports an improved process using hydrocyclone de-sliming, dispersion reagents, and magnetic removal of iron minerals for the pre-treatment of zinc oxide ore with a high slime and iron content, and the benefits compared to traditional technologies are shown. In addition, this paper investigates the damage related to fine slime and iron during zinc oxide flotation, the necessity of using hydrocyclone de-sliming together with dispersion reagents to alleviate the influence of slime, and interactions among hydrocyclone de-sliming, reagent dispersion, and magnetic iron removal. Results show that under optimized operating conditions the entire beneficiation technology results in a flotation concentrate with a Zn grade of 34.66% and a recovery of 73.41%.     

Viscosity behavior of magnetic suspensions in fluid-assisted finishing

Magnetic fluid-assisted finishing has been verified both theoretically and experimentally as an effective fabrication technology for optical mirrors and lenses. The purpose of this paper is to introduce a novel design of polishing tool and demonstrate the possible applications of this technology. The work includes studying the viscosity of the magnetic suspensions of micrometer-sized Carbonyl iron particles under the influence of a magnetic field. Both the cases of magnetizable suspension with and without abrasive cerium oxide particles are studied for their ensuing polishing effectiveness. Determination of material removal function is conducted using a Wyko Nat1100 interferometer. Experiments to reduce surface roughness with the proposed tool are also performed using a K9 mirror as the work-piece. Results show that the surface accuracy is improved over three times to less than 0.5 nm after two cycles of polishing.     

磁流变抛光头形状对加工表面粗糙度的影响

设计了4种不同形状的抛光头,并使用自制的磁流变抛光液体在三轴数控铣床上对K9平面玻璃进行了磁流变抛光工艺试验.分析了在不同的磁场强度、磁极转速,加工间隙等多种情况下抛光头形状对加工表面粗糙度的影响.试验结果表明:槽型平面抛光头的抛光效果最好;同等条件下,在抛光头上开槽能有效地提高加工效率和加工质量.     

磁性复合流体的深孔抛光工艺试验研究

针对深孔零件光整加工技术的难题,提出了基于针式抛光头的磁性复合流体（MCF）深孔抛光的加工方法。首先利用COMSOL Multiphysics有限元软件建立不同的永磁铁磁场组合模型,根据仿真结果设计磁场分布均匀且强度较强的针式抛光头;再建立MCF深孔抛光的磁流场耦合模型,分析MCF的流动特性;以黄铜H62的深孔零件为加工对象,进行磁性复合流体的深孔抛光工艺试验研究。仿真结果与试验结果吻合,结果表明,当针式抛光头采用纵向单列磁芯结构,转速为800 r/min,抛光间隙为3 mm,羟基铁粉粒径为48 μm时,表面粗糙度为0.13 μm,材料去除率为0.025 mg/min,从而获得了最理想的MCF深孔抛光效果。     

磁性复合抛光体配制及其抛光性能试验研究

介绍一种新的磁性复合抛光体（MPT）的配制及检测方法．新的磁性抛光体是将磁性复合流体和磨粒、植物纤维素均匀混合，通过外加磁场压缩制成的，在磁场作用下为半固态．MPT的主要成分及规格：煤油基纳米直径Fe3O4的磁流体（MF）、微米级直径的铁粉、微米级直径的纯Al2O3磨粒．对几种混合比例的MPT分别进行了SEM的显微观察和抛光作用力的三维检测，在给定压力下对MPT的剪切力和抛光性能进行了试验．结果表明：磁性复合抛光体的配比影响着MPT最大剪切力，具有承受剪切力大的磁性抛光体的抛光效果较好．该研究为复杂曲面的高效、高质量抛光提供了应用依据．     

具有公自转运动形式的可更新磁流变抛光工具

在光学自由曲面的成形抛光加工当中,加工去除的稳定性对工件加工质量具有重要的影响,而抛光液的更新是保证去除稳定的关键。该文提出了一种具有公自转运动形式的可更新磁流变抛光工具,能够完成磁流变抛光液内部磁链的重组更新,使得加工去除稳定。针对此抛光工具,使用刚体润滑理论获得理论去除轮廓,通过实验获得其在单自转状态下的去除轮廓,与理论分析吻合。峰值去除量时间的实验表明,该抛光头的去除效果受时间的影响很小,抛光去除稳定。     

微沟槽周期结构表面的磁性复合流体微纳光整研究及实验教学装置应用

针对磁性复合流体黏度可控的特性,研究一种微纳沟槽表面可控抛光加工方法及工艺,实现低成本、可控微纳结构表面加工技术,并将其应用于微纳加工实验教学。采用磁性复合流体作为抛光液,设计端面式和圆周面式两种磁性复合流体抛光机构;根据周期性微米级沟槽表面结构特点,采用圆周面式磁性复合流体抛光机构进行微结构表面抛光加工实验;设计加工工艺,通过实验对比微沟槽周期结构表面加工效果,验证了实验装置及微结构可控抛光加工方法的有效性,实现微沟槽周期结构表面材料可控去除加工。该装置结构紧凑,使用与维护成本低,有效填补面向机械专业制造类课程的微纳加工实验教学装置技术空白。     

TC4钛合金磁流变抛光的磁感应强度分布及参数

使用磁流变抛光技术对钛合金进行抛光,为了获得更好的表面质量,分别对磁感应强度分布、磁流变液和抛光参数进行了研究。首先,优化了加工区域的磁感应强度分布,通过在加工区域添加两块铁板,磁感应强度分布变得均匀,从而提高抛光后钛合金工件的表面质量。其次,分析了磁流变液的组成,即基液、磨粒类型以及磁性粒子和磨粒的质量占比对工件表面粗糙度的影响。随后,研究了四个基本抛光参数,即磨粒目数、工件转速、磁感应强度和抛光时间,找出这些参数对表面质量的影响规律。采用响应面法获得了工件表面粗糙度变化率的模型,并进行了方差分析以检查模型的显著性。最后,找出最优的抛光参数并对其进行了实验验证。     

超声振动辅助抛光BK7过程中聚氨酯抛光垫磨损行为

抛光光学玻璃等硬脆材料时常选用聚氨酯抛光垫,其微观形貌和磨损直接影响抛光精度和效率.本文对不同抛光时长下聚氨酯抛光垫微观形貌和磨损行为及其对材料去除率和表面粗糙度的影响进行了实验研究.结果表明：当主轴转速为8 000 r/min,进给速度为0.015 0 mm/s,轴向超声振幅为5μm时,材料去除率和表面粗糙度分别为0.977μm/min和153.67 nm.聚氨酯抛光垫在30 min内磨损量较小,随着抛光时长的增加,抛光垫表面孔隙逐渐被磨粒和玻璃碎屑填充,破坏抛光垫表面的疏松多孔结构,导致抛光垫表面硬化,失去弹性.同时,侵入抛光垫表面的磨粒会阻止抛光接触区域内的磨粒更新,导致抛光质量降低.