Bending fatigue behaviour of bearing ropes working around pulleys of different materials

Nondestructive quantitative detection and artificial detection were carried out to study bending fatigue behaviour and failure mechanisms of wire ropes. When working around nylon pulleys, wire ropes exhibit a slowly increasing of fracture rate and total damage in one lay length. The bending fatigue life of wire ropes is twice longer than that of ropes working around steel pulleys. The primary failure mode of wire ropes working around nylon pulleys is fatigue fracture and the fracture surfaces of wires exhibit a wide crack propagation zone and narrow tear zone.     

Mechanical properties of Si nanowires as revealed by in situ transmission electron microscopy and molecular dynamics simulations

Deformation and fracture mechanisms of ultrathin Si nanowires (NWs), with diameters of down to ~9 nm, under uniaxial tension and bending were investigated by using in situ transmission electron microscopy and molecular dynamics simulations. It was revealed that the mechanical behavior of Si NWs had been closely related to the wire diameter, loading conditions, and stress states. Under tension, Si NWs deformed elastically until abrupt brittle fracture. The tensile strength showed a clear size dependence, and the greatest strength was up to 11.3 GPa. In contrast, under bending, the Si NWs demonstrated considerable plasticity. Under a bending strain of <14%, they could repeatedly be bent without cracking along with a crystalline-to-amorphous phase transition. Under a larger strain of >20%, the cracks nucleated on the tensed side and propagated from the wire surface, whereas on the compressed side a plastic deformation took place because of dislocation activities and an amorphous transition.     

Failure analysis of a wire rope

Wire ropes, pulleys, counterweights, and connecting systems are used for auto tensioning of contact wires of electric railways. A wire rope in one such auto tensioning system suffered premature failure. Failure investigation revealed fatigue cracks initiating at nonmetallic inclusions near the surface of individual wire strands in the rope. The inclusions were identified as Al-Ca-Ti silicates in a large number of stringers, and some oxide and nitride inclusions were also found. The wire used in the rope did not conform to the composition specified for AISI 316 grade steel, nor did it satisfy the minimum tensile strength requirements. Failure of the wire rope was found to be due to fatigue; however, the ultimate fracture of the rope was the result of overload that occurred after fatigue failure had reduced the number of wire strands supporting the load.     

Comparative Analysis of Fracture Strength of Slurry and Diamond Wire Sawn Multicrystalline Silicon Solar Wafers

This paper presents an analysis of fracture strength of multicrystalline silicon (mc‐Si) solar wafers produced by slurry and diamond wire sawing. The wafers were bent in two orthogonal orientations relative to the saw marks. The fracture strength of slurry sawn wafers increases gradually from wire entry to wire exit whereas the strength variation in the wire feed direction is small. The fracture strength of diamond wire sawn wafers is bi‐directional, with a higher strength if bent perpendicular to the saw marks and a lower strength if bent parallel to the saw marks. The fracture strength variation is related to the microcracks generated in the vicinity of grit‐induced surface damage.     

The effect of metal wires on the fracture of a brittle-matrix composite

The behaviour of stainless steel, work-hardened nickel and annealed nickel wires bridging a crack in a brittle-matrix has been studied as a function of the length and orientation of the wire. The pull-out stress for stainless steel wire in epoxy resin increases less than linearly with wire length, following the behaviour predicted by Takaku and Arridge [6]. Wires inclined at 20° and 40° to the tensile axis gave pull-out stresses some 30% higher than wires parallel to the tensile axis, this increase being attributed mainly to enhanced friction on the bent wire near its point of exit from the matrix. Work-hardened nickel wires fractured when their length exceeded a critical value, and the critical length was significantly shorter for inclined wires than for wires parallel to the tensile axis. In contrast, annealed nickel wires, no matter how long, did not fracture but pulled out at a limiting stress which was slightly higher for inclined wires than for wires parallel to the tensile axis. The results show that, in some cases, there does not exist a critical length above which an embedded wire will fracture rather than pull out of the matrix.     

A Study on a Wire Tension Adaptive Control System of a Multi-wire Saw in Computer Simulation

Based on the analysis of the mechanism of wire tension control by using torque motors in the multi-wire saw machining process,some mathematical models of a tension control system are studied,and an adaptive algorithm is designed for controlling the wire tension.In this algorithm of tension control,the rotation speeds and waving angle of motors are measured and fed back to the controller,and the NLMS(normalized least mean squares) algorithm is used to calculate the adaptive correction value and control the w...     

Processing of duplex stainless steel by WEDM

This study investigates the manufacturing process of 2205 duplex stainless steel by wire electrical discharge machining where the effects of pulse-on time (PONT), wire tension and pulse-off time (POFT) on surface finish, kerf width, and material removal rate (MRR). It was found that the kerf width was unchanged with the change of PONT at long pulse-of time and higher wire tension. However, it decreased initially and then increased due to the rise of PONT at low values of wire tension and POFT. Low wire tension and PONT, POFT and contributed towards widest kerf. Longer PONT increased MRR due to higher machining/processing speed. Lower wire tension and shorter POFT increased MRR more than that of higher wire tension and POFT. Craters and recast layer were on the machined surfaces at all machining conditions. Increased PONT raised surface roughness at the lower POFT and tension in the wire. The surface finish at high wire tension and longer PONT is always better than that at smaller PONT and lower tension in the wire. The microstructure underneath the recast layer remains unchanged and the failure of wire electrode occurred at higher wire tension, longer PONT and shorter POFT.     

绳索牵引骨盆康复机器人的骨盆刚度分析及骨盆运动轨迹规划研究

针对绳索牵引骨盆康复机器人的骨盆刚度控制以及骨盆运动轨迹规划进行了研究. 通过建立欠约束1R3T绳索牵引骨盆康复机器人的力学模型,解出了绳索拉力的表达式,并分析拉力解中零空间拉力部分对骨盆刚度的影响,得出控制绳索拉力能够实现对骨盆的刚度控制 ,为以后实现柔顺性控制提供了理论依据;基于凸集理论分析了骨盆不同位姿所属空间性质的不同,依此对牵引绳索进行合理布置,以保证骨盆在规划运动空间内的刚度完全可控,并基于矢量封闭原理和绳索拉力平衡对工作空间进行分析;通过MATLAB仿真证明了骨盆规划轨迹中绳索牵引的可控性,得出了骨盆位姿及绳索长度的变化规律,分析了骨盆位姿对绳索长度影响的原因.其规划结果可为该机器人运动控制的研究提供依据.     

A magnetic shift register employing controlled domain wall motion

A shift register based on controlled domain wall propagation in a magnetic wire with an axial easy direction has been developed. The operational characteristics of an experimental model are discussed. Some hard drawn magnetic materials have been shown to have at least a 3-to-1 nucleation-to-propagation threshold field window over several hundred foot lengths of wire which guarantees operation, This is accomplished without putting the wire under tension. One such promising material is a modified 79-percent Ni, 17- percent Fe, 3-percent Nb, 1-percent Ag, permalloy. An experimental5 times 10^{3}-bit shift register has been constructed with 0.8-mil hard drawn Nb, Ag permalloy and operated at speeds of5 times 10^{3}bps with 12-percent drive current margins. The input power at this rate is approximately 1 mW/bit.     

Dynamics of curved vortex lines in superfluids: Precession of a partially trapped line

We consider the precession of an isolated curved solitary vortex line around a thin wire inside a coaxial cylindrical container, an experiment which has recently been done in superfluid³He-B. The analysis is performed in the localized induction approximation, based on the vortex-line tension concept, as well as in a model, in which some non-local corrections from interactions between distant parts of the vortex line have been taken into account. By minimization of the energy in the rotating frame, where the vortex configuration corresponds to the ground state, the boundary condition has been derived for the point where the vortex line disconnects from the wire. Accuracies of the local and the nonlocal approaches are compared.     

Bending rotation HCF testing of pseudoelastic Ni‐Ti shape memory alloys

In the present work, a computer‐controlled test rig for simultaneous fatigue testing of several pseudoelastic NiTi wires through bending rotation is described. Bending rotation fatigue (BRF) testing represents a displacement‐controlled experiment where a straight wire is bent into a semi‐circle und forced to rotate around its axis. Thus, each point on the wire surface is subjected to alternating tension and compression. A test rig, which allows to control loading amplitudes, rotation frequencies and temperatures is described. We report preliminary results of an experimental program, which aims for a better understanding of fatigue lives, crack initiation, and crack growth in pseudoelastic NiTi wires. It was found that a good surface quality is of utmost importance to avoid early crack initiation. Wöhler curves of pseudoelastic NiTi wires typically show two different regimes depending on the maximum imposed surface strain during bending rotation fatigue testing. Larger strain amplitudes, which are associated with macroscopic formation of stress‐induced martensite, result in relatively low fatigue lives (LCF regime). In contrast, cycle numbers exceeding 10⁷ were obtained for strain amplitudes where no large scale stress‐induced formation of martensite occurred (HCF regime).     

Optimizing dimensional accuracy of titanium alloy features produced by wire electrical discharge machining

This study investigates geometrical errors such as cylindricity, circularity and diametral errors of a feature (a hole) produced from wire electrical discharge machining of Ti6Al4V alloy where tension in wire, pulse on time, and flushing pressure are varied. Pareto analysis of variance (ANOVA), Taguchi design of experiment (DoE), and traditional analysis estimate the influence of variables on errors of holes. It was noted that flushing pressure is the most significant factor with individual contributions of 31.02%, 49.5% and 37.84% to circularity, cylindricity, and diametral errors, respectively. The circularity error of holes decreases as the flushing pressure and tension in wire rise, but decreases with the rise of pulse on time. The cylindricity error decreased with the increase of wire tension, flushing pressure and pulse on time. The absolute diametral error reduced as the pulse on time and tension in wire raised, but it raised with the rise of pulse on time. All these trends are associated with the influence of tension in wire on the flexibility of wire, the dependence of heat generation and dissipation on pulse on time, and ability of the flushing pressure to control the cooling, as well as debris removal from the machining zone.     

全自动引线键合机送丝系统受力模型及实验

丝线传输的阻力控制和张紧力控制是引线键合机送丝系统的关键技术之一,对键合质量有着重要的影响．为了解决当前全自动引线键合机送丝系统中的传输阻力大、传输张力不稳定等问题,根据引线键合工艺过程和系统的技术要求,设计了由气体导轨和真空张紧装置组成的低摩擦送丝系统,来实现金丝的低阻传输．建立了金线在气体导轨和真空张紧装置内的受力模型,得出了二者的控制参数与金线作用力的关系;分别对金丝在气体导轨和真空张紧装置内的受力模型进行了实验验证,实验结果表明达到了所要求的低摩擦力要求．     

Asymmetrical Bending Model for NiTi Shape Memory Wires: Numerical Simulations and Experimental Analysis

Abstract: A detailed numerical and experimental study of a NiTi Shape Memory Alloy (SMA) wire subjected to bending is presented in order to provide a complete characterisation of the material under this load case. The beam model presented is based on the classic Euler‐Bernoulli theory and uses De la Flor one‐dimensional constitutive equations modified to take into account different material responses to tension and compression as well as the different elastic properties of austenite and martensite. All the necessary experimental techniques were designed to determine the bending behaviour of NiTi SMA wire over the entire range of transformation temperatures. These experimental bending results were then compared with the numerical results. The numerical model proposed agrees quantitatively and qualitatively with the experimental bending results obtained for NiTi wire, representing an effective tool for the analysis of one‐dimensional structural devices. A comparison of the numerical results that assume symmetrical behaviour between tension and compression with the results that assume asymmetrical behaviour has shown that the tension/compression asymmetry is more pronounced in the martensitic range and has little influence on the response of the SMA wire subjected to bending at temperatures above A_f. These results are analyzed and discussed.     

输电塔线体系断线非线性动力分析

以某500 k V高压输电线路为研究对象,建立三塔四线输电塔-线体系精细化有限元模型,在考虑跌落导(地)线与地面碰撞接触基础上,对其进行了不同断线位置以及不同断线根数的隐式非线性动力分析。结果表明:断线点位置对断线瞬间的冲击作用影响较小;断线后断线一侧张力衰减系数随着导线挂点位置增高而单调递减;未断线一侧张力衰减系数随着挂点位置增高先减小后增大;耐张塔张拉作用系数远大于直线塔;耐张塔的断线动力放大系数在1.1~1.5。在断多根线的最不利工况下研究了耐张塔的扭转破坏和弯曲破坏两种失效模式。     

输电线断线振荡研究

针对采用拟静力法不能计算输电线路断线动态张力的缺点,利用显式动力有限元方法研究了输电系统线路断线的振荡响应。研究表明:在邻近断线档绝缘串下端的动、静位移以及不平衡力响应较大,远离断线档迅速衰减;线路的动态张力峰值是初张力的1.5倍―2.5倍,且离断线档越远,放大作用越大;线路的静态张力是初张力的0.26倍―0.95倍,且离断线档越远,卸载作用越小。该文还研究了初张力、档距和绝缘串长度对断线响应的影响。     

CO2气体保护焊短路过渡液相桥自由液面分析

针对短路过渡液相桥在焊丝回抽至不同高度时的液面形态，进行了二维数值的分析和三维有限元分析。试验验证并考察了不同焊丝直径，表面张力系数及焊缝堆高对液相桥失效高度的。为焊线停送，回抽促进液相桥平稳拉断的控制方法奠定了理论基础。     

Cover Picture: Texture Evolution During Bending of a Single Crystal Copper Nanowire Studied by EBSD and Crystal Plasticity Finite Element Simulations (Adv. Eng. Mater. 8/2008)

The cover shows a bending test on a Cu single crystal nanowire. The distribution of the geometrically necessry dislocations in the bent wire was determined using high resolution electron back scatter diffraction and predicted using a crystal plasticity finite element method which uses a dislocation based constitutive law. More details can be found in the article of F. Weber, I. Schestakow, F. Roters, D. Raabe on page 737.     

Electrical Discharge Machining of MMCs Reinforced with Very Small Particles

This paper investigates material removal rate (MRR), kerf width, surface finish, and electrode wire wear for different pule-on-times as well as wire tensions during EDM of 6061 aluminum alloy reinforced with 10 vol % 700 nm SiCp MMC. Effects of pulse-on-time on output variables at lower and higher wire tensions were investigated. Similarly, effects of the wire tensions on output variables at shorter and longer pulse-on-times were also investigated. Longer pule-on-time increases the MRR though the higher wire tension reduces the MMR. The effect of wire tension on MRR is much more significant at longer pule-on-time compare to that at shorter pule-on-time. There is an optimum pule-on-time for which best surface finish is achieved. The surface finish deteriorates when the pulse-on-time is higher or lower than the optimum pule-on-time. With the rise of tension in wire, the surface roughness increases and decreases at shorter and longer pule-on-times, respectively. The machined surface contains solidified molten material, splash of materials, and blisters. Generation of the tapered slot with higher kerf width at the top indicates the wear of wire electrode. Significant variation of the electrode wire diameter was due to coating of the matrix, wear, and clogging of small reinforced particles in the electrode gap.     

The coupling influence of UV illumination and strain on the surface potential distribution of a single ZnO micro/nano wire

Interface/surface properties play an important role in the development of most electronic devices. In particular, nanowires possess large surface areas that create new challenges for their optoelectronic applications. Here, we demonstrated that the piezoelectric field and UV laser illumination modulate the surface potential distribution of a bent ZnO wire by the Kelvin probe force microscopy technology. Experiments showed that the surface potential distribution was changed by strain. The difference of surface potential between the outer/inner sides of the ZnO wire increased with increasing strain. Under UV laser illumination, the difference of surface potential between the outer/inner sides of the ZnO wire increased with increasing strain and illumination time. The origin of the observed phenomenon was discussed in terms of the energy band diagram of the bent wire and adsorption/desorption theory. It is suggested that the change of surface potential can be attributed to the uneven distribution of the carrier density across the wire deduced by the piezoelectric effect and surface adsorption/desorption of oxygen ions. This study provides an important insight into the surface and piezoelectric effects on the surface potential and can help optimize the performance of electronic and optoelectronic devices.

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