Modelling and prevention of meshing interference in gear skiving of internal gears: Conference Proceedings [Modellierung und Vermeidung von Freiflächeninterferenz beim Wälzschälen von Innenverzahnungen]

Gear skiving is a highly productive process for machining of internal gears which are required in large quantity for electric mobility transmissions. Due to the complex kinematics of gear skiving, collisions of the tool and workpiece can occur during the process. Models exist to check for collisions of the tool shank or collisions in the tool run-out. While these models are sufficient for the process design of external gear skiving, at internal gears meshing interferences between tool and workpiece can appear outside the contact plane on the clearance face of the tool. To test for meshing interference requires comprehensive assessment of workpiece, tool and process kinematics. Currently, this is often done by time consuming CAD-simulation. In contrast, this paper presents an automated geometrical model for the analysis of meshing interference. The test for collisions is thereby performed along the whole height of the tool and especially includes constructive clearance angles and eccentric tool positions. The model is developed for user-friendly implementation and practical applications. The model for avoiding meshing interference in gear skiving is validated on two different process applications. In doing so, influences of the tool and process design on the interference situation are investigated, compared and discussed. Furthermore this new approach enables the prevention of meshing interference or tooth tip collisions in the early tool design by adjusting the process kinematics or the tool design itself. The maximal viable tool height can be quantified and recommendations for improving the clearance face situation are suggested

Influence of the atmosphere and temperature on the properties of the oxygen-affine bonding system titanium-diamond during sintering

Grinding tools can be manufactured from metal, vitrified, and resin bond materials. In combination with superabrasives like diamond grains, metal-bonded tools are used in a wide range of applications. The main advantages of metal over vitrified and resin bonds are high grain retention forces and high thermal conductivity. This paper investigates the influence of the atmosphere and manufacturing parameters such as sintering temperature on the properties of titanium-bonded grinding layers. Titanium is an active bond material, which can increase the retention of diamond grains in metal-bonded grinding layers. This can lead to higher bond stress and, consequently, decreased wear of grinding tools in use when compared to other commonly used bond materials like bronze. The reason for this is the adhesive bond between titanium and diamond due to the formation of carbides in the interface, whereas bronze can only form a mechanical cohesion with diamond grains. However, when using oxygen-affine metals such as titanium, oxidizing effects could limit the strength of the bond due to insufficient adhesion between Ti-powder particles and the prevention of carbide formation. The purpose of this paper is to show the influence of the sintering atmosphere and temperature on the properties of titanium-bonded diamond grinding layers using the mechanical and thermal characterization of specimens. A higher vacuum (Δpatm = − 75 mbar) reduces the oxidation of titanium particles during sintering, which leads to higher critical bond stress (+ 38% @ Ts = 900 °C) and higher thermal conductivity (+ 3.4% @Ts = 1000 °C, Ta = 25 °C). X-ray diffraction measurements could show the formation of carbides in the cross-section of specimens, which also has a positive effect on the critical bond stress due to an adhesive bond between titanium and diamond

Structurally constrained inversion by means of a Minimum Gradient Support regularizer: examples of FD-EMI data inversion constrained by GPR reflection data

Many geophysical inverse problems are known to be ill-posed and, thus, requiring some kind of regularization in order to provide a unique and stable solution. A possible approach to overcome the inversion ill-posedness consists in constraining the position of the model interfaces. For a grid-based parameterization, such a structurally-constrained inversion can be implemented by adopting the usual smooth regularization scheme in which the local weight of the regularization is reduced where an interface is expected. By doing so, sharp contrasts are promoted at interface locations while standard smoothness constraints keep affecting the other regions of the model. In this work, we present a structurally-constrained approach and test it on the inversion of frequency-domain electromagnetic induction (FD-EMI) data using a regularization approach based on the Minimum Gradient Support (MGS) stabilizer, which is capable to promote sharp transitions everywhere in the model, i.e., also in areas where no structural a priori information is available. Using 1D and 2D synthetic data examples, we compare the proposed approach to a structurally-constrained smooth inversion as well as to more standard (i.e., not structurally-constrained) smooth and sharp inversions. Our results demonstrate that the proposed approach helps in finding a better and more reliable reconstruction of the subsurface electrical conductivity distribution, including its structural characteristics. Furthermore, we demonstrate that it allows to promote sharp parameter variations in areas where no structural information are available. Lastly, we apply our structurally-constrained scheme to FD-EMI field data collected at a field site in Eastern Germany to image the thickness of peat deposits along two selected profiles. In this field example, we use collocated constant offset ground-penetrating radar (GPR) data to derive structural a priori information to constrain the inversion of the FD-EMI data. The results of this case study demonstrate the effectiveness and flexibility of the proposed approach

An X-ray Microscopy Study of the Microstructural Effects on Thermal Conductivity in Cast Aluminum-Copper Compounds

A metallurgical joint between aluminum and copper established by compound casting provides for high thermal conductivity, which is required for lightweight cooling solutions in applications such as high-power light-emitting diodes or computer processors. If casting is employed in a silane-doped inert gas atmosphere whose oxygen partial pressure is adequate to extreme high vacuum, reoxidation of the active surfaces of aluminum and copper is prevented, and thus a metallurgical bond can be created directly between aluminum and copper. With this approach, thermal conductivities as high as 88.3 W/m·K were realized. In addition, X-ray microscopy was used to shed light on the microstructure–thermal property relationship. It is demonstrated that both porosity and non-bonded areas have a substantial impact on the thermophysical properties of the compound zone. Based on the data obtained, casting parameters can be developed that provide for defect-free bonding zones and optimal heat transfer between the joining partners

Oxygen-Free Compound Casting of Aluminum and Copper in a Silane-Doped Inert Gas Atmosphere: A New Approach to Increase Thermal Conductivity

Novel aluminum-copper compound castings devoid of oxide layers at the interface between the joining partners were developed in order to increase the thermal conductivity of the hybrid component. Due to the natural oxide layers of both aluminum and copper, metallurgical bonds between such bi-metal castings cannot be easily achieved in conventional processes. However, in an atmosphere comparable to extreme high vacuum created by using silane-doped inert gas, metallurgical bonds between the active surfaces of both aluminum and copper can be realized without additional coatings or fluxes. An intermetallic was created between aluminum and copper. Thus, very high thermal conductivities could be obtained for these hybrid castings, exceeding those of conventionally joined samples considerably. The intermetallic phase seams emerging between the joining partners were investigated using scanning electron microscopy and X-ray diffraction. The reduction of casting temperatures resulted in narrower intermetallic phase seams and these in turn in a much lower contact resistance between the two joining partners. This effect can be utilized for increasing the heat transfer capabilities of compound casting components employed for cooling heat sources such as high-power light-emitting diodes

An investigation into the association of the physical fitness of equestrians and their riding performance : a cross-sectional study

Poor riding performance may be due to medical issues with the horse or a variety of other factors, such as inadequate equipment or deficiencies in training. The physical fitness of the equestrian is one of the most unexplained factors of current research. The aim of this study is to investigate the association between the physical fitness of the equestrian and riding performance. 115 equestrians were assessed for physical fitness and riding performance. Seven components of physical fitness (balance, endurance, flexibility, reaction, speed, strength, symmetry) were measured by a physiotherapist using equestrian-specific tests. Based on a video-recorded riding test, individual riding performance was rated by two equestrian judges. The riding test included the horse and rider performing a walk, sitting trot, rising trot and canter in both directions. A linear model for riding performance, including the domains of physical fitness and potential confounders (body-mass-index, riding experience, hours of riding per week, and test-motivation), was fitted to the data. Inter-rater reliability of the judges was investigated by calculating the intraclass correlation coefficient (ICC). Endurance, reaction and strength were positively associated with riding performance, whereas flexibility had a negative association. The final model could explain 16.7% of the variance in riding performance. The effects of endurance and strength were significant (P<0.05), but not that of reaction. No association with riding performance was found for the components of balance, speed and symmetry. The inter-rater reliability of judges was confirmed to be ‘good’ to ‘excellent’ (ICC=0.9, 95% confidence interval: 0.86-0.93). Findings suggest that physical fitness is positively associated with riding performance. Fitness-training for equestrians should be included in current training concepts. Future research should investigate whether similar associations exist for junior and elite athletes