A model- and simulation-based approach for tolerancing and verifying the functional capability of micro/nano-structured workpieces

The evaluation of functional features of manufactured workpieces is based on GO- and NO-GO-test results, which are obtained by comparing measured geometric characteristics with nominal dimensions and tolerances specified by the designer. These geometrical specifications are based on a tolerancing system, which was originally defined for the function mating capability. Against the background of upcoming lots of other new functions (like reduction of flow resistance, light absorption, reduction of friction, diffraction of light, self-cleaning or mass transmission) are to be realized with our products – particularly by micro- and nano scaled features. If the verification process will deliver the prediction of the achievable degree of functionality, the usability of a part can be assessed more accurately and in consequence quality and economics can be improved. So, a new principle for tolerancing and verifying turns out to be necessary. In this paper the fundamental deficit of the actual tolerancing and specification systems GPS and ASME Y14.5 is derived and the path for enlarging the system by preposing a functional model is shown. To verify the functional capability of the workpieces an approach based on simulations done with the parameterized mathematical–physical model of the function is suggested. Advantages of this approach will be discussed and demonstrated by examples with microstructured inking rolls, crankshafts and injection valves.     

Refractive index of soft contact lens materials measured in packaging solution and standard phosphate buffered saline and the effect on back vertex power calculation

PurposeTo measure the refractive index (RI) of commonly available soft contact lens (CL) materials, their packaging solutions and compare to the manufacturers’ nominal RI. The relationship between RI versus water content, and the effect of inaccurate RI when converting lens power measured in solution to in-air back vertex power were examined.MethodsThe RI of 18 single vision soft CL materials were measured using CLR 12–70 digital refractometer. Three lenses of each material were measured, in their packaging solution and then after soaking in standard phosphate buffered saline (PBS). The RIs of packaging solution were also measured. Accuracy requirements for correct wet to dry power conversion based on thick lens formula were projected.ResultsThe standard deviation between three samples was less than 0.005. The measured RI ranged from 1.3744 ± 0.001–1.4265 ± 0.0004 for PBS soaked and from 1.3739 ± 0.0003–1.4264 ± 0.0024 for packaging solution soaked materials. Comparing nominal with mean measured PBS and packaging solution RIs, 5 and 3 lens materials, respectively, fell outside ISO tolerance. The packaging solution RI of DailiesAquaComfortPlus had the largest difference of 0.0040, compared to RI of standard PBS. For converting lens power measured in PBS to in-air power, the difference between measured and nominal RI of 0.0104 would result in wrongly calculated in-air power 0.99 D for a -6.00 D lens.ConclusionThe CLR 12–70 is reliable and accurate refractometer for the measurement of soft CL materials. Accurate RI measurements are of relevance with increased use of wavefront sensors to measure lens power while they are immersed in solution. Even small errors in solution or material RI can lead to significant errors in converted in-air power. To obtain valid in-air lens power results, measurement conditions must match the material and solution RIs used for the conversion.     

Study and characterization of porous copper oxide produced by electrochemical anodization for radiometric heat absorber

The aim of this work is to optimize the different parameters for realization of an absorbing cavity to measure the incident absolute laser energy. Electrochemical oxidation is the background process that allowed the copper blackening. A study of the blackened surface quality was undertaken using atomic force microscopy (AFM) analysis and ultraviolet-visible-infrared spectrophotometry using a Shimadzu spectrophotometer. A two-dimensional and three-dimensional visualization by AFM of the formed oxide coating showed that the copper surfaces became porous after electrochemical etching with different roughness. This aspect is becoming more and more important with decreasing current density anodization. In a 2 mol L ^-1 of NaOH solution, at a temperature of 90°C, and using a 16 mA cm² constant density current, the copper oxide formed has a reflectivity of around 3% in the spectral range between 300 and 1,800 nm. Using the ‘mirage effect’ technique, the obtained Cu₂O diffusivity and thermal conductivity are respectively equal to (11.5 ± 0.5) 10 to 7 m² s^-1 and (370 ± 20) Wm^-1 K^-1. This allows us to consider that our Cu₂O coating is a good thermal conductor. The results of the optical and thermal studies dictate the choice of the cavity design. The absorbing cavity is a hollow cylinder machined to its base at an angle of 30°. If the included angle of the plane is 30° and the interior surface gives specular reflection, an incoming ray parallel to the axis will undergo five reflections before exit. So the absorption of the surface becomes closely near 0.999999.     

Geometrical metrology for metal additive manufacturing

The needs, requirements, and on-going and future research issues in geometrical metrology for metal additive manufacturing are addressed. The infrastructure under development for specification standards in AM is presented, and the research on geometrical dimensioning and tolerancing for AM is reviewed. Post-process metrology is covered, including the measurement of surface form, texture and internal features. In-process requirements and developments in AM are discussed along with the materials metrology that is pertinent to geometrical measurement. Issues of traceability, including benchmarking artefacts, are presented. The information in the review sections is summarized in a synthesis of current requirements and future research topics.     

钢丝绳缺陷的微磁无损检测技术研究

为了探讨微磁检测技术在钢丝绳无损探伤领域的应用,采用有限元法,分析了无外加磁场激励状态下利用钢丝绳自身剩余磁场实现断丝缺陷检测的可行性。计算了钢丝绳缺陷处及周围空气中的漏磁场强度、分布规律及可测性;论述了地磁场的影响,为微磁检测技术提供了理论依据。通过对钢丝绳微磁检测方法的实验研究,得出了不同断丝状态下漏磁场的检测结果及变化规律。给出了钢丝绳金属截面损失与检测系统输出量的函数关系,验证了微磁无损探伤技术的可行性与可靠性。     

维生素K_1冻干标准物质的研制

采用二甲基亚砜(DMSO)作为冻干标准物质的溶剂,以重量法准确配制维生素K_1/DMSO溶液,再进行分装、冷冻干燥,经定性分析、定值分析、均匀性检验、稳定性考察和不确定度评定,研制了维生素K_1冻干标准物质。以维生素K_1纯度标准物质溶液为校准品,对得到的冻干物质进行了高效液相色谱法定值分析,冻干标准物质的准确定值结果为0.96 mg/mL,相对扩展不确定度为7%。建立的维生素K_1冻干标准物质研制方法,对于临床检验中维生素K_1的准确测定和相关疾病的正确诊断治疗以及维生素K_1长期保存具有重要意义。     

基于双重逆极限空间液压系统泄漏特征提取方法

为了检测大型锻造液压机液压系统的泄漏问题,提出了一种基于双重逆极限空间的特征分析方法。将大型锻造液压机液压系统的泄漏作为原信息空间,并在此基础上建立与之拓扑同构的双重逆极限空间。在双重逆极限空间,并通过拓扑不变性来反映大型锻造液压机液压系统的泄漏情况。最后通过仿真实验验证了此理论方法的可行性。结果表明,基于双重逆极限空间的特征提取方法更适合提取泄漏的耦合特征,所提取的特征信息对泄漏具有很好的检测和定位能力。     

丁腈橡胶在燃气介质中的老化性能测试研究

基于烘箱热空气老化试验方法,建立了一种能让试验样品处于流通气氛冲刷的闭合试验装置,对橡胶材料进行燃气环境中老化性能测试。选用丁腈橡胶为试样,测试其在不同温度、不同气氛下的老化性能,预测其使用时间。测试结果显示,采用空气气氛方法进行丁腈橡胶加速老化试验,预测的使用时间结果与实际使用时间的偏差在80%以上;燃气气氛冲刷环境下,丁腈橡胶在老化速率是热空气老化的2倍左右,且燃气气氛下的加速老化使用时间的预测结果与实际的偏差在±20%之内。     

基于高斯光脉冲延迟技术的光纤长度精确测量方法

提出了一种基于高斯光脉冲延迟技术的无盲区、高精度光纤长度测量方法。借助光纤延迟环的作用,在高速示波器上可以观察两路具有相对时延的高斯脉冲序列。通过调节脉冲频率可使两路高斯脉冲完全重合,依据此时脉冲频率可计算出光纤长度。脉冲未完全重合则会引入频率测量的误差,而利用脉冲时延与幅度的转换关系,通过脉冲幅度极大值的测量可以精确判断脉冲是否重合。脉冲频率的分辨力达到0.1 Hz,从而提高光纤长度测量的精确度。实验中当光源波长为1296nm时,该方法测量2284.34m G.652单模光纤长度的不确定度为0.04m,测量12726.57m的不确定度为0.24m。     

100μL微量移液器国际关键比对的数学模型研究

为验证各国对微量移液器的校准能力,组织了国际关键比对。通过比对发现大气压力对移液器的校准结果有着较大影响,为此对数学模型进行了修正,经过修正后计算所得各参比实验室的校准结果有了较好的一致性。同时通过大量实验得出,微量移液器由于其自身结构存在不稳定性所带入的不确定度分量是不确定度分析中的一个主要来源。比对中研究所得的数学模型其算法准确、结果可靠,很好地解决了移液器在日常检定及校准中的数据处理问题。