Fast Generation of Micro-Channels on Cylindrical Surfaces by Elliptical Vibration Texturing

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Ping Guo ◽  
Yong Lu ◽  
Pucheng Pei ◽  
Kornel F. Ehmann
Keyword(s):  
Process Parameters ◽  
High Efficiency ◽  
Low Cost ◽  
Pattern Generation ◽  
Depth Of Cut ◽  
Channel Formation ◽  
Structured Surfaces ◽  
Elliptical Vibration ◽  
Micro Channels ◽  
Elliptical Vibration Texturing

Micro-structured surfaces are assuming an ever-increasing role since they define the ultimate performance of many industrial components and products. Micro-channels, in particular, have many potential applications in micro-fluidic devices, micro heat exchangers, and friction control. This paper proposes an innovative vibration-assisted machining method to generate micro-channels on the external surface of a cylinder. This method, referred to as elliptical vibration texturing, was originally developed by the authors to generate dimple patterns. It uses the modulation of the depth-of-cut by tool vibrations to create surface textures. The most promising features of the proposed method are its high efficiency, low cost, and scalability for mass production. It is shown that with proper combinations of the process parameters the created dimples start to overlap and form channels. An analytical model is established to predict channel formation with respect to the overlapping ratios of the dimples. Channel formation criteria and expressions for channel geometries are given along with a channel generation map that relates channel geometry to the process parameters. Experimental results are given to verify the model. A further example of micro-pattern generation is also given to showcase the flexibility of the process.

Fast Generation of Planar Micro-Structured Surfaces by Elliptical Vibration Texturing

2016 ◽  
Author(s):  
Yang Yang ◽  
Ping Guo
Keyword(s):  
Simulation Model ◽  
Functional Performance ◽  
Ultrasonic Frequency ◽  
Specific Class ◽  
Structured Surfaces ◽  
High Productivity ◽  
Elliptical Vibration ◽  
Elliptical Vibration Texturing ◽  
Cutting Velocity ◽  
Micro Dimples

Micro-structured surfaces have extensive applications in a wide array of fields, due to their improved functional performance. Existing manufacturing methods for these surfaces fall short of efficiency for volume production or are only applicable to a specific class of materials. In this paper, an innovative and highly-efficient machining method, elliptical vibration texturing (EVT), is proposed for rapid generation of micro-dimples on planar engineered surfaces. The cutting tool of the EVT process vibrates along an elliptical trajectory. The elliptical vibrations, when coupled with a high cutting velocity, impose micro-dimples onto workpiece surfaces while machining. The high productivity is achieved by adopting a newly designed tertiary motion generator which is able to deliver required elliptical vibrations at an ultrasonic frequency. The shape and distribution of the generated dimple patterns have been theoretically analyzed and predicted by a proposed simulation model. Preliminary texturing results using aluminum and brass as workpieces are given to validate the process principle and simulation model.

A Novel Desktop Device for Lapping Milled Micro Thin-Walled Structures

2011 ◽  
Vol 325 ◽  
pp. 508-513 ◽  
Author(s):  
Peng Zhang ◽  
Bo Wang ◽  
Mark J. Jackson ◽  
Xing Mao
Keyword(s):  
Surface Topography ◽  
High Efficiency ◽  
Low Cost ◽  
Three Dimensional ◽  
Structured Surfaces ◽  
Structured Surface ◽  
Thin Walled Structures ◽  
Key Points ◽  
Thin Walled ◽  
Small Parts

Current requirements for producing highly precise and ultra-smooth micro structured surfaces of small parts are proposed in certain situations. The following question arises: how to make a highly precise and ultra-smooth micro-structured surface with high efficiency and low cost? Novel desktop lapping and polishing devices should be developed to satisfy these requirements. In order to improve the surface topography and remove the surface damaged layer of a highly precise and ultra-smooth micro thin-walled structure after milling with the width of 150 μm and the depth of 10 μm, a novel lapping desktop device is designed and developed. There are two key points in the design of the lapping desktop device: one is the vertical coupled macro-micro movement axis; the other is the fixture with a thin and flexible hinge structure, which has the capability of measuring both force and displacement as a double-feedback sensor to control both the micro lapping force and the depth of lapping. The experimental results show that the surface topography of the micro thin-walled structured surface is much improved after lapping, and that the three-dimensional surface roughness decreased from 329 nm to 82.2 nm.

scholarly journals Effects of Electrospinning Parameters on the Microstructure of PVP/TiO2 Nanofibers

Nanomaterials ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 1616
Author(s):  
Wan-Tae Kim ◽  
Dong-Cheol Park ◽  
Wan-Hee Yang ◽  
Churl-Hee Cho ◽  
Won-Youl Choi
Keyword(s):  
Process Parameters ◽  
Organic Solar Cells ◽  
High Efficiency ◽  
Low Cost ◽  
Fluid Velocity ◽  
Average Diameter ◽  
Electrospinning Process ◽  
Electrical And Optical Properties ◽  
Tio2 Nanofibers ◽  
The Many

Titanium dioxide has excellent chemical, electrical, and optical properties, as well as good chemical stability. For that reason, it is widely used in many fields of study and industry, such as photocatalysts, organic solar cells, sensors, dental implants, and other applications. Many nanostructures of TiO2 have been reported, and electrospinning is an efficient practical technique that has a low cost and high efficiency. In various studies on improving performance, the researchers created nanofibers with suitable microstructures by changing various properties and the many process parameters that can be controlled. In this study, PVP/TiO2 nanofibers were fabricated by the electrospinning process. The diameters of the nanofibers were controlled by various parameters. To understand the effects on the diameter of the nanofibers, various process parameters were controlled: the molecular weight and concentration of the polymers, deionized water, applied voltage, fluid velocity, and concentration of titanium precursor. The average diameter of the PVP nanofibers was controlled in a range of 42.3 nm to 633.0 nm. The average diameter of the PVP/TiO2 nanofibers was also controlled in a range of 63.5 nm to 186.0 nm after heat treatment.

Machinability Investigation of Reaction-Bonded Silicon Carbide by Single-Point Diamond Turning

2008 ◽  
Vol 389-390 ◽  
pp. 151-156 ◽  
Author(s):  
Zhi Yu Zhang ◽  
Ji Wang Yan ◽  
Tsunemoto Kuriyagawa
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Large Scale ◽  
High Efficiency ◽  
Low Cost ◽  
Single Point ◽  
Diamond Turning ◽  
Machining Process ◽  
Depth Of Cut ◽  
Material Microstructure

Reaction-bonded silicon carbide (RB-SiC) is a recently developed ceramic material with many merits such as low manufacturing temperature, dense structure, high purity and low cost. In the present paper, the precision machinability of RB-SiC was studied by microindentation and single-point diamond turning (SPDT) tests. The influence of depth of cut and tool feed rate on surface roughness and cutting force was investigated. Results showed that there was no clear ductile-brittle transition in machining behavior. The material removal mechanism involves falling of the SiC grains and intergranular microfractures of the bonding silicon, which prevents from large-scale cleavage fractures. The minimum surface roughness depends on the initial material microstructure in terms of sizes of the SiC grains and micro pores. This work preliminarily indicates that SPDT can be used as a high-efficiency machining process for RB-SiC.

High-Efficiency and Precision Grinding Technology of HIPSN All-Ceramic Bearing Race

2007 ◽  
Vol 359-360 ◽  
pp. 108-112 ◽  
Author(s):  
Song Hua Li ◽  
Yu Hou Wu
Keyword(s):  
High Speed ◽  
High Efficiency ◽  
Removal Rate ◽  
Low Cost ◽  
Depth Of Cut ◽  
Precision Grinding ◽  
Ceramic Bearing ◽  
Cnc Grinding ◽  
Bearing Race ◽  
Grinding Machine

This paper deals with the development of a high-efficiency and precision grinding technology for producing HIPSN ceramic bearing races. A new high-speed CNC grinding machine has been developed, which is equipped with a high-speed ceramic spindle with a built-in motor. Extensive experiments have been performed with this new machine to investigate the influence of various process parameters such as wheel speed, work speed, depth of cut, and wheel grit size on material removal rate, surface finish, grinding forces, and so on. The results of these investigations are presented in this paper. With the application of this technology, a low cost production of ceramic bearings race was realized with the most optimized process parameter.

scholarly journals Fabrication and Optical Characterization of Polymeric Aspherical Microlens Array Using Hot Embossing Technology

2021 ◽  
Vol 11 (2) ◽  
pp. 882
Author(s):  
Yanlong Li ◽  
Kangsen Li ◽  
Feng Gong
Keyword(s):  
Process Parameters ◽  
High Efficiency ◽  
Low Cost ◽  
Microlens Array ◽  
Hot Embossing ◽  
Molding Pressure ◽  
Microlens Arrays ◽  
Aspheric Lens ◽  
Molding Temperature ◽  
Holding Temperature

Hot embossing has been widely used in fabricating microlens arrays because of its low cost, high efficiency, and high quality. The process parameters such as molding temperature, molding pressure, and holding temperature affect the microlens array’s replication quality. This work selected the stainless steel S136H tool steel as the mold material to process an aspheric microlens array structure through ultra-precision milling. Polymethyl methacrylate (PMMA) microlens arrays with different surface replication were prepared by controlling the molding temperature, molding pressure, and holding temperature. By analyzing the surface quality, contour replication, and optical imaging of hot-embossed samples, the optimal molding temperature of PMMA for optimal replication of aspheric lens arrays was determined as 130 °C. Besides, the internal elastic recovery of PMMA affected the dimensional accuracy and optical performance of the lens. The results showed that, at the molding pressure of 400 N and the holding temperature of 60 °C, the surface defects were eliminated, and the aspheric lens array had perfect replication with a profile deviation of only 4 μm. The aspheric microlens array with good quality was eventually achieved by these optimal process parameters, which provides a foundation for producing aspheric microlens arrays in a low-cost and high-efficiency way.

Influence of MBE Growth Conditions on Dislocation Densities of GaAs/Ge Epilayers Grown on Silicon Substrates

1985 ◽  
Vol 43 ◽  
pp. 364-365
Author(s):  
K.M. Hones ◽  
P. Sheldon ◽  
B.G. Yacobi ◽  
A. Mason
Keyword(s):  
High Efficiency ◽  
Lattice Mismatch ◽  
Low Cost ◽  
Growth Conditions ◽  
Nonradiative Recombination ◽  
Device Structure ◽  
Si Substrates ◽  
Transmission Electron ◽  
Dislocation Densities ◽  
Dislocation Type

There is increasing interest in growing epitaxial GaAs on Si substrates. Such a device structure would allow low-cost substrates to be used for high-efficiency cascade- junction solar cells. However, high-defect densities may result from the large lattice mismatch (∼4%) between the GaAs epilayer and the silicon substrate. These defects can act as nonradiative recombination centers that can degrade the optical and electrical properties of the epitaxially grown GaAs. For this reason, it is important to optimize epilayer growth conditions in order to minimize resulting dislocation densities. The purpose of this paper is to provide an indication of the quality of the epitaxially grown GaAs layers by using transmission electron microscopy (TEM) to examine dislocation type and density as a function of various growth conditions. In this study an intermediate Ge layer was used to avoid nucleation difficulties observed for GaAs growth directly on Si substrates. GaAs/Ge epilayers were grown by molecular beam epitaxy (MBE) on Si substrates in a manner similar to that described previously.

Improvement of Ti/RuO2–IrO2 Anode Lifetime and Electrocatalytical Properties by Using an Eco-Friendly Thermal Decomposition Method Using Polyvinyl Alcohol as Solvent

2019 ◽  
Author(s):  
Charlys Bezerra ◽  
Géssica Santos ◽  
Marilia Pupo ◽  
Maria Gomes ◽  
Ronaldo Silva ◽  
...  
Keyword(s):  
Thermal Decomposition ◽  
Polyvinyl Alcohol ◽  
High Efficiency ◽  
Electrochemical Impedance ◽  
Pechini Method ◽  
Low Cost ◽  
Charge Transfer Resistance ◽  
Transfer Resistance ◽  
Calcination Temperatures ◽  
Service Lifetime

<p>Electrochemical oxidation processes are promising solutions for wastewater treatment due to their high efficiency, easy control and versatility. Mixed metal oxides (MMO) anodes are particularly attractive due to their low cost and specific catalytic properties. Here, we propose an innovative thermal decomposition methodology using <a>polyvinyl alcohol (PVA)</a> as a solvent to prepare Ti/RuO<sub>2</sub>–IrO<sub>2</sub> anodes. Comparative anodes were prepared by conventional method employing a polymeric precursor solvent (Pechini method). The calcination temperatures studied were 300, 400 and 500 °C. The physical characterisation of all materials was performed by X-ray diffraction and scanning electron microscopy coupled with energy dispersive spectroscopy, while electrochemical characterisation was done by cyclic voltammetry, accelerated service lifetime and electrochemical impedance spectroscopy. Both RuO<sub>2</sub> and IrO<sub>2</sub> have rutile-type structures for all anodes. Rougher and more compact surfaces are formed for the anodes prepared using PVA. Amongst temperatures studied, 300 °C using PVA as solvent is the most suitable one to produce anodes with expressive increase in voltammetric charge (250%) and accelerated service lifetime (4.3 times longer) besides reducing charge-transfer resistance (8 times lower). Moreover, the electrocatalytic activity of the anodes synthesised with PVA toward the Reactive Blue 21 dye removal in chloride medium (100 % in 30 min) is higher than that prepared by Pechini method (60 min). Additionally, the removal total organic carbon point out improved mineralisation potential of PVA anodes. Finally, this study reports a novel methodology using PVA as solvent to synthesise Ti/RuO<sub>2</sub>–IrO<sub>2</sub> anodes with improved properties that can be further extended to synthesise other MMO compositions.</p>

Contradiction Analysis and Solution in the R&D of High-Power Solar LED Street Lamp Controller

2019 ◽  
Vol 12 (1) ◽  
pp. 12-19
Author(s):  
Zhengwang Xu ◽  
Wei Mei ◽  
Jiaqi Yu ◽  
Jiarui Zhang ◽  
Yuchun Yi ◽  
...  
Keyword(s):  
Power Supply ◽  
High Efficiency ◽  
Low Cost ◽  
Solar Panel ◽  
Battery Voltage ◽  
Supply Circuit ◽  
Led Light ◽  
Power Supply Circuit ◽  
Side Mode ◽  
Dual Power

As being restricted by factors such as cost, efficiency and size, the development of high-power solar LED street light controller is faced with plenty of difficulties. In case that a structure of two independent DC/DC is applied as the main circuit, it has to face problems such as large size and high cost; in case of applying the bidirectional BUCK/BOOST circuit, it requires change-over switches to control the solar panel and LED light. As being restricted by withstanding voltage, on-resistance and cost, a PMOS device cannot be used as the change-over switch of solar panel and LED light. However, when being used as a change-over switch, an NMOS device must apply the low-side mode under which the negative ends of the mentioned three parts are cut off. In the condition of applying the low-side mode, a differential circuit must be used to detect the voltage of the solar panel. Furthermore, in order to make sure batteries can still be regularly charged after wearing out in daylight, the controller must be supplied with power through a dual power supply circuit that can obtain power from both the solar panel and the battery. The demander has a requirement on extremely low standby power consumption of the product, and thus it is necessary to minimize the circuit that is live while working in standby mode. Methods: The bidirectional BUCK/BOOST circuit structure is applied to the main circuit to realize a higher change-over efficiency while giving considerations to both cost and size. The NMOS device, model IRFB4410ZPBF, with a price of about three yuan, is used as the switching device, and the low-side mode is applied, that is the switches inserted in between negative end of the solar panel or LED light and that of the DC/DC circuit. The low-cost rail-to-rail operational amplifier LM358 is used to form a differential amplification circuit for detecting the voltage of the solar panel. A XL1509-12E1 chip that only costs 0.88 yuan/pc is selected as the main change-over chip for the power supply, which has realized the highly-efficient and low-cost change-over of the power supply. A dual power supply circuit and a step-down protective circuit are designed for the XL1509-12E1 change-over chip. By comparing solar panel voltage with battery voltage, the solar panel booting circuit is realized. Only when solar panel voltage is higher than battery voltage, does the system program start to power it up for running, so that the outage of most of the circuits of the system under standby mode does not consume energy. Furthermore, the solar panel voltage detecting circuit, the solar panel booting circuit and several return difference functions are corrected during system debugging. Results: The circuit board of the entire controller features small size, low cost and high efficiency. It measures about 100*62*18mm in size, costs about 60 yuan, and the charge/discharge change-over efficiency reaches up to over 95%. The controller has many functions: it is capable of operating within a large scope, in which, solar panel voltage is subject to 15~50V, LED light voltage is subject to 15~60V, battery voltage is subject to 10~35V and battery-end charge/discharge current is 10A; it is capable of adapting to monocrystalline silicon/multicrystalline silicon/thin-film and many other kinds of solar panels, as well as lithium/lead-acid and many other kinds of batteries; it is capable of detecting the conversion of day and night, automatically controlling charging and discharging and automatically making adaptive adjustment according to seasonal variations; the current to be consumed during standby will be maintained below 3mA, and thus the power consumption is extremely low. Conclusion: By selecting the bidirectional BUCK/BOOST circuit structure, applying low-side mode for switching of solar panel and LED light, using a differential circuit to detect solar panel voltage, using a low-cost DC/DC chip to realize power supply change-over, designing a dual power supply circuit, introducing solar panel booting circuit and other hardware design, as well as MPPT algorithm, state recognition and control, return difference control and other software design, a solar LED street light control product featuring small size, low cost, high efficiency and multiple functions is successfully developed.

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