Localized electrodeposition micro additive manufacturing of pure copper microstructures

The fabrication of pure copper microstructures with submicron resolution has found a host of applications such as 5G communications and highly sensitive detection. The tiny and complex features of these structures can enhance device performance during high-frequency operation. However, the easy manufacturing of microstructures is still a challenge. In this paper, we present localized electrochemical deposition micro additive manufacturing (LECD-μAM), combining localized electrochemical deposition (LECD) and closed-loop control of atomic force servo technology, which can print helical springs and hollow tubes very effectively. We further demonstrate an overall model based on pulsed microfluidics from a hollow cantilever LECD process and the closed-loop control of an atomic force servo. The printing state of the micro-helical springs could be assessed by simultaneously detecting the Z-axis displacement and the deflection of the atomic force probe (AFP) cantilever. The results showed that it took 361 s to print a helical spring with a wire length of 320.11 μm at a deposition rate of 0.887 μm/s, which could be changed on the fly by simply tuning the extrusion pressure and the applied voltage. Moreover, the in situ nanoindenter was used to measure the compressive mechanical properties of the helical spring. The shear modulus of the helical spring material was about 60.8 GPa, much higher than that of bulk copper (~44.2 GPa). Additionally, the microscopic morphology and chemical composition of the spring were characterized. These results delineated a new way of fabricating terahertz transmitter components and micro-helical antennas with LECD-μAM technology.

Dynamics control of powered hydraulic roof supports in the underground longwall mining complex

The study presents the dynamic analysis of the hydraulic cylinders operated in the powered roof support sections as an important part of the longwall underground mining complexes. This type of hydraulic unit is subjected to frequent shock impacts from the significant rock masses released on the top of mined caverns. Hydraulic props are equipped with safety valves with steel helical springs, which intend to reduce peak loads by the relief of internal pressure. These valves respond to shock with a time delay due to the limited velocity of the pressure wave inside the cylinder and an additional pipe of a small section, which restricts fluid flow in outer space. The new approach represented in this paper is based on mathematical modelling of the interaction of the hydraulic and mechanical parts and using additional signals to control safety valves. Detection of shock in advance (0.02-0.05 s) allows reducing pressure peaks by 30% and avoid failures. The challenges are the development of a “smart valve” with optimised control functions by the signals from additional sensors (vibration, deformation, piston position) and providing fast reaction time with a high flow rate under pressures up to 100 MPa.

Guidelines for 3D printed springs using material extrusion

Purpose Springs are an integral part of mechanisms and can benefit from additive manufacturing’s (AM) increased design freedom. Given the limited literature on the subject, the purpose of this paper is to develop guidelines for fabricating helical springs using three-dimensional (3D) printing. Design/methodology/approach Polylactic acid (PLA) is the main material investigated, with ULTEM™ 9085 used as a comparison. The experimental procedure is to vary the spring parameters, print the springs and test them in tension or compression using constant velocity. Plots of the force and displacement are used to measure the linear and post-deformation spring constants. Loading of the springs is done both to breakage and cyclically. Cyclic loading is also used to observe the plastic behaviour of the springs. Parameters that are varied include wire and coil diameters, pitch, wire cross-section, in-fill and layer height. Findings A square wire cross-section is used, instead of a circle because it produces more consistent coils. In-fills make no significant difference in the elastic stiffness of the springs but the mono in-fill breaks at a greater extension, so it is recommended. Tension and compression springs are confirmed to behave the same when in the elastic regime. ULTEM™ 9085 produces consistently weaker springs compared to PLA. Variation of layer height shows that thinner layers increase the stiffness of the springs. Originality/value This study investigates the behaviour of 3D printed helical springs in tension and compression. Three guidelines are created: square wire cross-section, mono-directional in-fill and thin layers are recommended.

Principles of design optimization for springs

The spring is the widespread resilient element which is used in the industrial machinery and automotive systems, as diesel fuel pumps, valvetrains, brakes, suspensions, seats, doors and control elements. For reducing impact events in some heavy trucks and railroad cars primarily, helical, or coil, springs are applied. In some vehicles torsion bars are used instead of the coil springs. The reduction of weight of the suspension springs causes the decrease of unsprung mass of the axle and has a positive influence on the comfort, traction and steering properties of the car. The development of modern passenger cars has highlighted a trend towards reduced package space for suspension components in order to maximize package space for occupants and loads. Such requirements lead to reduction in spring dimensions and wire cross-section. Springs can be found in high-precision testing devices, where springs play the role of energy harvesters. The efficient design procedures for spring elements are based on the modern simulation and optimization methods. The design formulas for linear helical springs with an inconstant wire diameter and with a variable mean diameter of spring are presented. Based on these formulas the optimization of spring for given spring rate and strength of the wire is per-formed.

Analysis and Synthesis of Conical Coil Springs

Springs are mechanical devices that are employed to resist forces, store energy, absorb shocks, mitigate vibrations, or maintain parts contacting each other. Spring wires are commonly coiled in the forms of helixes for either extension or compression. Helical springs usually have cylindrical shapes that have constant coil diameter, constant pitch and constant spring rate. Unlike conventional cylindrical coil springs, the coil diameter of conically coiled springs is variable. They have conical or tapered shapes that have a large coil diameter at the base and a small coil diameter at the top. The variable coil diameter enables conical coil springs generate desired load deflection relationships, have high lateral stability and low buckling liability. In addition, conical compression springs can have significantly larger compression or shorter compressed height than conventional helical compression springs. The compressed height of a conical compression spring can reach its limit that is the diameter of the spring wire if it is properly synthesized. The height of an undeformed conical coil spring can have its height of its spring wire if the spring pitch is chosen to be zero. The variable coil diameter of conical coil springs provides them with unique feature, but also raises their synthesis difficulties. Synthesizing conical coil springs that require large spring compression or small deformed spring height or constant spring rate is challenging. This research is motivated by surmounting the current challenges facing conical coil springs. In this research, independent parameters are introduced to control the diameter and pitch of a conical coil spring. Different conical coil springs are modeled. Their performances are simulated using the created models. The deflection-force relationships of conical coil springs are analyzed. The results from this research provide useful guidelines for developing conical coil springs.

Analysis of Test Method to Extract Material Properties From Candu Fuel Channel Spacers Made of Helical Springs

In a particular nuclear application, separation between two concentric tubes is supported by helical springs installed in the annular space. Evaluation of material degradation due to the unique operating environment requires testing of ex-service spring material. Testing is done by compressing short segments of the spring material between two surfaces as per the loading mode in operation. Nominally, the specimen behaves like multiple rings loaded uniformly in parallel, but analysis of test results based on this approximation neglects significant end effects. A detailed analysis addresses the transition from the free end boundary condition through to where the coils become confined by friction to behave like rings. The thin ring solution is compared with finite element results as well as test results. Trends from the detailed thin ring solution correspond closely to the finite element and test results. A more precise relationship between the total applied load and the maximum stress in the material is determined.

Helical springs as a color indicator for determining chirality and enantiomeric excess

Chirality plays a key role in the physiological system, because molecular functionalities may drastically alter due to a change in chirality. We report herein a unique color indicator with a static helicity memory, which exhibits visible color changes in response to the chirality of chiral amines. A difference of less than 2% in the enantiomeric excess (ee) values causes a change in the absorption that is visible to the naked eyes. This was further quantified by digital photography by converting to RGB values. This system relies on the change in the tunable helical pitch of the π-conjugated polymer backbone in specific solvents and allows rapid on-site monitoring of chirality of nonracemic amines, including drugs, and the simultaneous quantitative determination of their ee values.