Dynamic research and optimization design of clamping device for electroslag remelting furnace
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Electroslag Remelting (ESR) technology is a main method of special metallurgy. ESR ingot has high pure, structure dense and favorable mechanical character and becomes high-grade steel and special steel. In this paper, based on virtual machine technology, dynamic research of the working process of electroslag-remelting-furnace clamping device was proceeded; influence of the structure parameters and the motion parameters applied on the motion locus and spring force was researched. 3D solid model of the electroslag remelting furnace was established; mathematical model of the clamping device was established; main technical parameters were accomplished; and simulation research of the dynamic process was proceeded. It was found that, appropriately increasing of damping ratio and spring stiffness of the clamping device is beneficial for lowering overshot and enhancing system stabilization, while sacrificing response speed in some extent.Keywords:
Ingot
Working principle of two kinds of hydraulic clamping devices,which based on rod-less piston,is introduced,and the mechanics calculation formulas were also given.Compared with traditional ones,they are more simple,more convenient to manufacture,and have a broader prospect in the future.
Lever
Piston (optics)
Piston rod
Telescopic cylinder
Position-sensing hydraulic cylinder
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Accurate measurement of static and dynamic forces during machining operations is important in the process monitoring, optimization and prediction of machining quality. Cutting and clamping forces are typically measured separately, for example, through hydraulic clamping force devices and piezoelectric table dynamometers. Since cutting and clamping forces interact throughout machining, both forces need to be measured simultaneously to accurately predict machining quality. This paper proposes a novel force measuring device in the form of a vise with built-in piezoelectric sensors and strain gauges to measure multi-axial clamping and cutting forces simultaneously. A strain concentrating design based on a cross-shaped groove was utilized to attach three strain gauges to measure clamping forces. These locations were chosen for their ability to measure clamping forces in real-time and minimize cross-talks. Piezoelectric sensors were embedded between layers in the vise jaw to measure cutting forces. A prototype of the proposed apparatus was fabricated and used to experimentally investigate sensitivities, bandwidth, clamping forces and cutting forces. The results showed that the proposed device has good performance in measuring clamping and cutting forces in milling operations.
Strain gauge
Dynamometer
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The efficacy of ingot level lifetime testing has been limited due to historically poor correlation between ingot lifetime and cell performance. Studies have shown that the DC photoconductance decay is capable of determining differences in average ingot lifetime as a function of starting material, but those studies showed the effects to be a small portion of the total variation. This work looks at a new attempt to correlate ingot lifetimes and cell performance given a more stable starting material supply, and an overall accounting of the sources of variation contributing to ingot lifetime. Finally, ingots whose lifetime was particularly low relative to the predicted performance were studied leading to an indication of additional root causes. The work, as a whole, provides a perspective on the practical impact of various factors on ingot lifetime.
Ingot
Carrier lifetime
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In order to improve ingot structure and to refine grain size of Cu Al Ni shape memory alloys by means of electropulse modification, the effect of voltage, frequency and time of the pulse as well as the type of cooling mold on the macrostructure of ingot have been systematically studied. The results show that the above four parameters are important influencing factors on the ingot macrostructure. By appropriately adjusting the parameters, the macrostructure of polycrystalline Cu Al Ni ingot can be significantly improved and nearly fully equiaxied region of the ingot is obtained; the corresponding grain size of the ingot can be dramatically reduced to less than 1/20 of that of unmodified.
Ingot
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Clamping tool has an ability to hold an object securely through inward pressure to prevent movement or separation. Therefore, this tool is significant in cutting process. Conventional clamping methods in machine are universal angle milling vise and plain milling machine vise. Limitations occur in conventional method such as restriction in clamping complex shape, time consuming and provide non-uniform pressure or force towards work piece. Therefore, vacuum clamping method has been introduced to overcome this problem. This project is to propose a new design and develop of portable vacuum clamping for tool room. Mild steel has been chosen to be the main material for the vacuum clamping because it is harder and cheaper than other material in the market. CATIA V5 software has been used to design the overall product. This vacuum clamping device consists of two parts. Part 1 is vacuum clamping with dimension is 132mm (width) x 132mm (length) x 25mm (height) and part 2 is the vacuum pump. The vacuum pump in this project is single-staged vacuum pump VE115N with 0.47 bar suction force. Which combination of both parts makes it portable to be attached in any machine in example drilling, milling and grinding machine. To evaluate the product reliability, experiments have been conducted to measure surface roughness after cutting process using vacuum clamping and conventional vise. The result shows that vacuum clamping has almost 50% lower roughness average (Ra) than conventional vise. For that reason, the proposed design method for overcoming the limitations of conventional clamping method has been achieved.
Machine tool
Vacuum pump
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In order to improve ingot structure and to refine grain-size of Cu-Al-Ni shape memory alloys by means of electropulse modification, the effect of voltage, frequency and time of the pulse as well as the type of cooling mold on the macrostructure of ingot have been systematically studied. The results show that the above four parameters are important influencing factors on the ingot macrostructure. By appropriately adjusting the parameters, the macrostructure of polycrystalline Cu-Al-Ni ingot can be significantly improved and nearly fully equiaxied region of the ingot is obtained; the corresponding grain-size of the ingot can be dramatically reduced to less than 1/20 of that of unmodified.
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To study the response of the metal helical spring stiffness to the frequency,the present researcher adopted the dynamic stiffness matrix method to calculate the stiffness under the load of different frequency.And the result shows that the variety of the stiffness of spring is caused by the resonance itself mostly,and with the frequency increasing,the effect on the stiffness becomes more obvious.With the distribution mass of spring considered,the system of series spring-mass of multi-mass was used to substitute the helical spring.The result shows that the equivalent algorithm used in time domain calculation in multi-body system can accurately reflect the nature of the frequency variety of heliacal spring.
Direct stiffness method
Coil spring
Spring system
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AbstractAbstractMacrosegregation in heavy steel ingots was studied through numerical and experimental studies of a 500 kg ingot. The numerical model used heat conduction coupled with thermal convection. Simulation results confirm that a small 500 kg ingot poured in a sand mould has a solidification time that is equal to that of a 10 000 kg industrial ingot cast in an iron mould. Accordingly, the sand moulded ingot exhibits more severe macrosegregation compared to the iron moulded ingot, indicating the possibility that a relatively small ingot in sand can simulate conditions in a much heavier steel ingot in a conventional iron mould. Experiment demonstrated that a 500 kg ingot exhibited all the types of macrosegregation, including A- and V-segregates and negative and positive segregation commonly found in a 65 000 kg steel ingot.Keywords: MACROSEGREGATIONHEAVY STEEL INGOTNUMERICAL SIMULATION
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Carbon fiber reinforced composites (CFRP) are mostly manufactured near net shape. Nevertheless, a final milling step at the edges of the cured components is still necessary. Damages which occur during milling or drilling of CFRP lower the durability of the components and increase the production costs. Requirements concerning the clamping system for milling or drilling CFRP are rising simultaneously with increasing complexity of the components. This stresses the need for complex clamping systems like linear clamping jaws around the whole workpiece. However such types of clamping systems induce poor accessibility to the component being worked on and hence longer machining time. As a result to the need for complex clamping systems, the production costs are increased. Therefore, several benefits can be achieved by increasing the distances between the clamping points of the clamping system to reduce machining time and production costs. This paper discusses investigations of milling tests with variable clamping conditions of the workpieces. In the experiments a linear milling operation the edge of the workpiece is examined. The clamping of the planar specimens was realized with a clamping system which enables the adjustment of different distances between the clamping points of the specimen. The process forces and the resulting damage at the workpiece surfaces were measured during the experiments. These results are compared with a linear clamping system to examine the influence of rising clamping distances. The results demonstrate that the distance of the clamping points while milling the edge of the workpiece has a significant influence on the process forces.
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