Finish Roll Forming of Spur Gears for High Efficiency

2000 ◽  
Author(s):  
Seizo Uematsu ◽  
Masana Kato
Keyword(s):  
Plastic Deformation ◽  
High Speed ◽  
High Efficiency ◽  
Tooth Profile ◽  
Roll Forming ◽  
Spur Gears ◽  
Design Data ◽  
Constant Center ◽  
The Relationship ◽  
Center Distance

Abstract Finish roll forming under the constant center distance by forced feed of tool can be conceived as a method of eliminating errors in conventional form rolling under constant loads. This method generates a high-precision tooth profile by low-speed form rolling when a high rigid screw or cam is used as loading parts. In this study, the high-speed rolling conditions of this method for necessary to be applied in practical situations are discussed. The following conclusions are obtained. When the following design data are given (module, number of teeth, addendum modification coefficient, prescribed design precision, and material characteristics), the accuracy of rolled gear can be predicted from the relationship between the required feed for the tool and the theoretically calculated plastic deformation on the tooth profile. These conclusions are verified experimentally. For example, the tooth accuracy of rolled gears with module 5 can improve from JIS class 3 to JIS class 0 or 1 when the load Fmax is 4 to 5kN and the pitch line velocity is 7 m/min.

scholarly journals Experimental Verification and Analytical Approach for Electromagnetic Characteristics of a High-Speed Permanent Magnet Motor with Two Different Rotors and Winding Patterns

2021 ◽  
Vol 11 (19) ◽  
pp. 9060
Author(s):  
Jong-Hyeon Woo ◽  
Tae-Kyoung Bang ◽  
Jeong-In Lee ◽  
Hoon-Ki Lee ◽  
Jang-Young Choi
Keyword(s):  
Permanent Magnet ◽  
High Speed ◽  
Mechanical Characteristics ◽  
High Efficiency ◽  
Permanent Magnet Motor ◽  
Final Model ◽  
Stator Current ◽  
Electromagnetic Characteristics ◽  
Rotor Shape ◽  
The Relationship

In general, high-speed machines should be designed with high efficiency electromagnetic and mechanical characteristics. It is important to analyze the electromagnetic loss for a design with high efficiency. In this study, the effects of the magneto–motive force and time harmonics of the stator current according to the winding distribution of a high-speed permanent magnet motor on the electromagnetic characteristics were comparatively analyzed using analytical methods and FEM. In addition, the final model was proposed by analyzing the relationship between the magnet usage according to the rotor shape and the electromagnetic and mechanical properties according to the winding patterns. Finally, the optimal model was manufactured and the validity was experimentally verified.

Evaluation of the Effect of High Speed Machining on Tapping

1994 ◽  
Vol 116 (4) ◽  
pp. 457-462 ◽  
Author(s):  
J. S. Agapiou
Keyword(s):  
Shear Strength ◽  
Steady State ◽  
High Speed ◽  
Cutting Speed ◽  
Hole Diameter ◽  
Roll Forming ◽  
High Speed Machining ◽  
High Speeds ◽  
Spindle Rotation ◽  
The Relationship

This paper summarizes tapping characteristics at speeds as high as 9,000 rpm (180 m/min surface speed) as compared to traditional tapping done at speeds from 500 to 1,500 rpm (20–30 m/min). High speed tapping was achieved by synchronizing the spindle rotation and the feed motion of a specially built machine at extremely high speeds and acceleration/deceleration rates. This investigation analyzes the performance of roll and cut tap geometries in the high speed tapping of 319 aluminum. The torque required by the different tap geometries at several speeds and percent threads combination is evaluated. The relationship between pretapped hole diameter and minor diameter of the thread and the estimation of percent thread are analyzed. The thread quality generated at high speeds is also evaluated. It is shown that the cutting speed does not affect the steady state torque and the shear strength. The torque for roll forming taps is higher than that for cut taps. The shear strength of roll forming threads increased with percent thread.

The Development of Auxiliary Sets in Novel Cold Roll Forming Line - Continuous Mini Stretching-Bending Straighter and Roller Punching System

2011 ◽  
Vol 291-294 ◽  
pp. 1178-1182
Author(s):  
Yan Bing Du ◽  
Jing Tao Han ◽  
Yong Jun Zhang
Keyword(s):  
High Speed ◽  
High Efficiency ◽  
Thin Strip ◽  
Roll Forming ◽  
Cold Roll Forming ◽  
High Quality ◽  
Cold Bending ◽  
Cold Roll ◽  
High Efficient

Cold roll forming thin strip products occupy a rather large proportion of novel cold bending manufacturing. Conventional roller straightening could not obtain perfect straightening effects when the thickness of strip less than 1mm. On the basis of continuous roller stretcher straightening theory, we developed an area saved, high efficient strip straightening facility. At the same time, punching is also requested during the cold roll forming of strips. High quality productions can be achieved at high speed through the roller punching system, so the device is adaptive for high efficiency cold roll forming production.

scholarly journals Investigation on a No Trial Weight Spray Online Dynamic Balancer

2018 ◽  
Vol 2018 ◽  
pp. 1-15 ◽  
Author(s):  
Xialun Yun ◽  
Xuesong Mei ◽  
Gedong Jiang ◽  
Zhenbang Hu ◽  
Zunhao Zhang
Keyword(s):  
High Precision ◽  
High Speed ◽  
High Efficiency ◽  
Vibration Suppression ◽  
Influence Coefficient ◽  
Analysis Model ◽  
Dynamic Balancing ◽  
Element Analysis ◽  
Balance Test ◽  
The Relationship

In order to suppress the spindle vibration with high efficiency and high precision, a no without trial weight spray online balance method is proposed in this paper. By analyzing the relationship between the unbalanced excitation and the unbalanced response of the spindle, the relationship between the dynamic influence coefficient and the system model is studied. A high-speed spindle finite element analysis model was established, and the dynamic influence coefficient matrix was identified. A no trial weight spray online dynamic balancing system was developed, which has the advantages of without trial weight and high-precision loading. A new type of integrated balancing terminal that was formed using 3D printing technology was first proposed by our research group, and its advantages in various aspects are significantly higher than traditional assembly balanced terminals. The experimental verification of the without trial weight spray online dynamic balancing system was performed on a high-speed spindle test stand. Experiments show that the no trial weight spray online balancing method proposed in this paper can achieve high-efficiency and high-precision vibration suppression, greatly reducing balance time and cost of the spindle. At the same time, the online balance test also verified the reliability of the integrated balanced terminal.

Predictive Failure Analysis of Solder Joints with Simultaneous High Speed EBSD and EDS

2018 ◽  
Author(s):  
J. Lindsay ◽  
P. Trimby ◽  
J. Goulden ◽  
S. McCracken ◽  
R. Andrews
Keyword(s):  
High Speed ◽  
Solder Joints ◽  
Phase Distribution ◽  
Bond Failure ◽  
Microstructural Parameters ◽  
Snpb Solder ◽  
Grain Orientations ◽  
Accelerated Thermal Cycling ◽  
The Relationship ◽  
Opening Up

Abstract The results presented here show how high-speed simultaneous EBSD and EDS can be used to characterize the essential microstructural parameters in SnPb solder joints with high resolution and precision. Analyses of both intact and failed solder joints have been carried out. Regions of strain localization that are not apparent from the Sn and Pb phase distribution are identified in the intact bond, providing key insights into the mechanism of potential bond failure. In addition, EBSD provides a wealth of quantitative detail such as the relationship between parent Sn grain orientations and Pb coarsening, the morphology and distribution of IMCs on a sub-micron scale and accurate grain size information for all phases within the joint. Such analyses enable a better understanding of the microstructural developments leading up to failure, opening up the possibility of improved accelerated thermal cycling (ATC) testing and better quality control.

One-step Separation and Purification of Four Phenolic Acids from Stenoloma chusanum (L.) Ching by Medium-pressure Liquid Chromatography and High-speed Counter-current Chromatography

2019 ◽  
Vol 9 (2) ◽  
pp. 138-143
Author(s):  
Tianyun Li ◽  
Xiling Dai ◽  
Yichen Li ◽  
Guozheng Huang ◽  
Jianguo Cao
Keyword(s):  
Natural Products ◽  
Liquid Chromatography ◽  
Phenolic Acids ◽  
High Speed ◽  
High Efficiency ◽  
Total Phenolic ◽  
Medium Pressure ◽  
Medium Pressure Liquid Chromatography ◽  
One Step ◽  
Counter Current

Background:Stenoloma chusanum (L.) Ching is a Chinese traditional medicinal fern with high total flavonoid and total phenolic content. Traditionally, phenolic compounds were separated by using column chromatography, which is relatively inefficient. </P><P> Objective: This study aims to use an efficient method to separate natural products from S. chusanum by Medium-Pressure Liquid Chromatography (MPLC) and High-Speed Counter-Current Chromatography (HSCCC).Methods:In the present research, firstly, a sample (2.5 g) from the dichloromethane extract of S. chusanum was separated by MPLC. Next, fraction P5 was purified by HSCCC with a two-phase solvent system composed of hexane-ethyl acetate-methanol-water (HEMWat) at a volume ratio of 2:4:1:4 (v/v/v/v). </P><P> Result: Four phenolic acids were obtained and their structures were identified by means of NMR and ESI-mass analysis. They were identified as: 1) protocatechuic acid (34 mg, purity 90.1%), 2) syringic acid (66 mg, purity 99.0%), 3) p-hydroxybenzoic acid (5 mg, purity 91.2%) and 4) vanillic acid (6 mg, purity 99.3%).Conclusion:The combination of MPLC and HSCCC is a high-efficiency separation method for natural products. This is the first report with regard to the separation of four phenolic acids in one step by MPLC and HSCCC from S. chusanum (L.) Ching.

scholarly journals Research on the Ignition Height and Reaction Flame Temperature of PTFE/Al/Si/CuO with Different Mass Ratios of PTFE/Si

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3464
Author(s):  
Xuan Zou ◽  
Jingyuan Zhou ◽  
Xianwen Ran ◽  
Yiting Wu ◽  
Ping Liu ◽  
...  
Keyword(s):  
Energy Release ◽  
High Speed ◽  
Flame Temperature ◽  
Sintering Process ◽  
Release Process ◽  
Reactive Material ◽  
Temperature Changes ◽  
Release Capacity ◽  
Mass Ratios ◽  
The Relationship

Recent studies have shown that the energy release capacity of Polytetrafluoroethylene (PTFE)/Al with Si, and CuO, respectively, is higher than that of PTFE/Al. PTFE/Al/Si/CuO reactive materials with four proportions of PTFE/Si were designed by the molding–sintering process to study the influence of different PTFE/Si mass ratios on energy release. A drop hammer was selected for igniting the specimens, and the high-speed camera and spectrometer systems were used to record the energy release process and the flame spectrum, respectively. The ignition height of the reactive material was obtained by fitting the relationship between the flame duration and the drop height. It was found that the ignition height of PTFE/Al/Si/CuO containing 20% PTFE/Si is 48.27 cm, which is the lowest compared to the ignition height of other Si/PTFE ratios of PTFE/Al/Si/CuO; the flame temperature was calculated from the flame spectrum. It was found that flame temperature changes little for the same reactive material at different drop heights. Compared with the flame temperature of PTFE/Al/Si/CuO with four mass ratios, it was found that the flame temperature of PTFE/Al/Si/CuO with 20% PTFE/Si is the highest, which is 2589 K. The results show that PTFE/Al/Si/CuO containing 20% PTFE/Si is easier to be ignited and has a stronger temperature destruction effect.

scholarly journals On-chip trans-dimensional plasmonic router

Nanophotonics ◽  
2020 ◽  
Vol 9 (10) ◽  
pp. 3357-3365 ◽  
Author(s):  
Shaohua Dong ◽  
Qing Zhang ◽  
Guangtao Cao ◽  
Jincheng Ni ◽  
Ting Shi ◽  
...  
Keyword(s):  
High Speed ◽  
High Efficiency ◽  
Incident Angle ◽  
Reciprocal Lattice ◽  
Plasmonic Waveguide ◽  
Optical Diffraction ◽  
Local Dynamic ◽  
Phase Gradient ◽  
On Chip ◽  
Plasmon Polaritons

AbstractPlasmons, as emerging optical diffraction-unlimited information carriers, promise the high-capacity, high-speed, and integrated photonic chips. The on-chip precise manipulations of plasmon in an arbitrary platform, whether two-dimensional (2D) or one-dimensional (1D), appears demanding but non-trivial. Here, we proposed a meta-wall, consisting of specifically designed meta-atoms, that allows the high-efficiency transformation of propagating plasmon polaritons from 2D platforms to 1D plasmonic waveguides, forming the trans-dimensional plasmonic routers. The mechanism to compensate the momentum transformation in the router can be traced via a local dynamic phase gradient of the meta-atom and reciprocal lattice vector. To demonstrate such a scheme, a directional router based on phase-gradient meta-wall is designed to couple 2D SPP to a 1D plasmonic waveguide, while a unidirectional router based on grating metawall is designed to route 2D SPP to the arbitrarily desired direction along the 1D plasmonic waveguide by changing the incident angle of 2D SPP. The on-chip routers of trans-dimensional SPP demonstrated here provide a flexible tool to manipulate propagation of surface plasmon polaritons (SPPs) and may pave the way for designing integrated plasmonic network and devices.

scholarly journals Verification of electric steel punching simulation results using microhardness

2021 ◽  
Author(s):  
Sampsa Vili Antero Laakso ◽  
Ugur Aydin ◽  
Peter Krajnik
Keyword(s):  
Plastic Deformation ◽  
High Speed ◽  
Steel Sheet ◽  
Electrical Steel ◽  
High Speed Steel ◽  
Experimental Methods ◽  
Fem Simulations ◽  
Iron Losses ◽  
Simulation Results ◽  
Electrical Steel Sheet

AbstractOne of the most dominant manufacturing methods in the production of electromechanical devices from sheet metal is punching. In punching, the material undergoes plastic deformation and finally fracture. Punching of an electrical steel sheet causes plastic deformation on the edges of the part, which affects the magnetic properties of the material, i.e., increases iron losses in the material, which in turn has a negative effect on the performance of the electromagnetic devices in the final product. Therefore, punching-induced iron losses decrease the energy efficiency of the device. FEM simulations of punching have shown significantly increased plastic deformation on the workpiece edges with increasing tool wear. In order to identify the critical tool wear, after which the iron losses have increased beyond acceptable limits, the simulation results must be verified with experimental methods. The acceptable limits are pushed further in the standards by the International Electrotechnical Commission (IEC). The new standard (IEC TS 60034-30-2:2016) has much stricter limits regarding the energy efficiency of electromechanical machines, with an IE5 class efficiency that exceeds the previous IE4 class (IEC 60034-30-1:2014) requirements by 30%. The simulations are done using Scientific Forming Technologies Corporation Deform, a finite element software for material processing simulations. The electrical steel used is M400-50A, and the tool material is Vanadis 23, a powder-based high-speed steel. Vanadis 23 is a high alloyed powder metallurgical high-speed steel with a high abrasive wear resistance and a high compressive strength. It is suitable for cold work processing like punching. In the existing literature, FEM simulations and experimental methods have been incorporated for investigating the edge deformation properties of sheared surfaces, but there is a research gap in verifying the simulation results with the experimental methods. In this paper, FEM simulation of the punching process is verified using an electrical steel sheet from real production environment and measuring the deformation of the edges using microhardness measurements. The simulations show high plastic deformation 50 μm into the workpiece edge, a result that is shown to be in good agreement with the experimental results.

scholarly journals Optimization of Air Gap Length and Capacitive Auxiliary Winding in Three-Phase Induction Motors Based on a Genetic Algorithm

Energies ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4407
Author(s):  
Mbika Muteba
Keyword(s):  
Genetic Algorithm ◽  
Design Process ◽  
Power Factor ◽  
High Speed ◽  
High Efficiency ◽  
Air Gap ◽  
Element Analysis ◽  
Three Phase ◽  
High Torque ◽  
Cage Induction Motor

There is a necessity to design a three-phase squirrel cage induction motor (SCIM) for high-speed applications with a larger air gap length in order to limit the distortion of air gap flux density, the thermal expansion of stator and rotor teeth, centrifugal forces, and the magnetic pull. To that effect, a larger air gap length lowers the power factor, efficiency, and torque density of a three-phase SCIM. This should inform motor design engineers to take special care during the design process of a three-phase SCIM by selecting an air gap length that will provide optimal performance. This paper presents an approach that would assist with the selection of an optimal air gap length (OAL) and optimal capacitive auxiliary stator winding (OCASW) configuration for a high torque per ampere (TPA) three-phase SCIM. A genetic algorithm (GA) assisted by finite element analysis (FEA) is used in the design process to determine the OAL and OCASW required to obtain a high torque per ampere without compromising the merit of achieving an excellent power factor and high efficiency for a three-phase SCIM. The performance of the optimized three-phase SCIM is compared to unoptimized machines. The results obtained from FEA are validated through experimental measurements. Owing to the penalty functions related to the value of objective and constraint functions introduced in the genetic algorithm model, both the FEA and experimental results provide evidence that an enhanced torque per ampere three-phase SCIM can be realized for a large OAL and OCASW with high efficiency and an excellent power factor in different working conditions.

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