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A Novel Approach Using Finite Element Modeling and Contact Area Parameter for Predicting Wire Bond Shear Strength Nondestructively

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IEEE TRANSACTIONS ON COMPONENTS PACKAGING AND MANUFACTURING TECHNOLOGY 2024年第9期14卷 1593-1600页

作者： Long, Yangtao He, Hu Cent South Univ Coll Mech & Elect Engn State Key Lab Precis Mfg Extreme Serv Performance Changsha 410083 Peoples R China

Wire bonding remains widely utilized in numerous products today due to its mature technology and costeffectiveness. However, improper bonding parameters can result in damage to the metal layer at the bonding interface, leading to the formation of "craters." Therefore, it is worthwhile for continuous optimization of the bonding process. The presented work employs finite element modeling to investigate the thermo-compression ultrasonic bonding process, focusing on the impact of bonding parameters on the stress at the bond pad interface. It was observed that the main determinant of bonding strength is the peripheral ring area, where the FAB adheres to the bond pad. Furthermore, excessive bonding pressure was found to result in over compression and subsequent separation at the bonding interface. In the experiment, it was discovered that bonding force had the most significant influence on shear strength, followed by ultrasonic current, whereas bonding time exhibited a less pronounced effect. However, there was no significant difference in pull strength under different bonding process parameters. The optimized process parameters were determined to be 110 mA for ultrasonic current, 25 ms for bonding time, and 20 gf for bonding force. Finally, the mapping relationship between the bonding ball size parameter (bonding ring area S : the inner ring represents the capillary's inner diameter, while the outer ring represents the capillary's contact with the outermost boundary) and shear strength was determined: as S increases, the shear strength decreases. This indicates that this dimensional parameter has the potential to serve as a nondestructive indicator for predicting shear strength.

关键词： optimization of process parameters reliability Bonding strength wire bonding wire bonding reliability wire bonding

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processability and Microstructural Evolution of W360 Hot Work Tool Steel by Directed Energy Deposition

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METALS AND MATERIALS INTERNATIONAL 2024年第2期30卷 501-516页

作者： Vincic, Josip Aversa, Alberta Lombardi, Mariangela Manfredi, Diego Politecn Torino Dept Appl Sci & Technol DISAT Corso Duca Abruzzi 24 I-10129 Turin Italy Ctr Sustainable Future Technol CSFT Polito Ist Italiano Tecnol IIT Via Livorno 60 I-10144 Turin Italy

Laser directed energy deposition (L-DED) was used to produce samples of the newly patented W360 hot work tool steel by Bohler. The process parameters were optimized to obtain nearly fully dense samples through the production and analysis of single deposited tracks and single layers. Subsequently, bulk samples underwent a hardening heat treatment, consisting of austenitizing, air quenching, and tempering. The samples were analysed in the as-built condition (AB), after quenching (Q) and following tempering cycles (HT) to observe the microstructural evolution. The microstructure was investigated using optical and scanning electron microscopes, energy dispersive X-ray analysis, and X-ray diffraction analysis. Furthermore, the microstructural evolution was analysed with differential scanning calorimetry, while the mechanical response was evaluated through microhardness test. It was found that the AB samples exhibited a dendritic-cellular microstructure with tempered martensite laths. The thermal history of the AB samples was completely modified by the austenitizing treatment followed by quenching, resulting in a fully martensitic Q sample that did not display the typical dendritic-cellular microstructure of the L-DED process. The completion of the heat treatment with tempering cycles revealed the presence of Mo-rich carbides dispersed in a martensitic matrix. The HT samples exhibited a mean microhardness of 634 HV, remaining constant along the entire building direction from the substrate to the last deposited layer, indicating a homogeneous microstructure. This high value, similar to other hot work tool steels such as H13, makes W360 a very promising candidate for tool build and repair purposes.

关键词： Additive manufacturing Laser directed energy deposition (L-DED) Hot work tool steel W360 optimization of process parameters Heat treatment Microhardness

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Multi-objective optimization of laser welding parameters for steel/Al based on Kriging-MSSA

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WELDING IN THE WORLD 2024年第12期68卷 3229-3230页

作者： Zhu, Zhi-wei Guo, Yong-huan Zhang, Xin-ran Lu, Xiang-ning Hua, Jun-yi Jiangsu Normal Univ Sch Mechatron Engn Xuzhou Peoples R China

In the context of automotive lightweighting strategy, steel/aluminum hybrid structures are widely used in the automotive industry. To address the reliability of steel/aluminum dissimilar metal joints, this study conducted steel/aluminum dissimilar metal laser welding tests by Taguchi’s design of experiments method and obtained relevant data. Based on the test results, a Kriging model with laser power, welding speed, and defocusing amount as inputs, and base material deformation and welded joint tensile strength as outputs was established. In this paper, with the amount of deformation of base material and tensile strength of welded joints after welding as the optimization objectives, the optimization analysis is carried out by combining the Kriging model and the multi-objective bottled sea-sheath swarm optimization algorithm (MSSA). The results show that under the conditions of laser power of 450 W, welding speed of 11.88 mm/s, and defocusing amount of 5.3 mm, the optimization objective reaches the optimal level, the base material warpage deformation is reduced by 22.33% compared with the pre-optimization, and the tensile strength of the welded joints is improved by 18.01%.

关键词： Dissimilar metal welding Kriging model Laser welding MSSA optimization of process parameters

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Flow field and temperature field analysis of three-sided feed cathode for deep special-shaped hole in ECM

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INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 2023年第11-12期127卷 5897-5913页

作者： Jia, Jianli Xu, Jiang Ma, Baoji Li, Shengchen Xu, Tianci Zhou, Xueying Zhong, Ling Xian Technol Univ Sch Mechatron Engn Xian 710021 Peoples R China

Electrochemical machining has the characteristics of no loss of processing cathode, high processing efficiency and good accuracy, and can process complex deep special-shaped holes at one time with simple feed motion. This paper uses electrochemical machining technology to solve the problem of complex deep special-shaped holes that are difficult to machine and designs a three-sided feed-type cathode. Firstly, the gap electric field was simulated and analyzed using COMSOL simulation software. The simulation results show that the width of the insulating layer on both sides of the end and wall of the cathode key tooth slot tip is 0.5 mm, and the rounded angle formed by the deep special-shaped hole key tooth tip is reduced to 0.11 mm after machining. Secondly, a simulation analysis of the gap electrolyte flow field and temperature field was carried out. The simulation results show that the gap electrolyte flow velocity is higher and the flow uniformity is better for the cathode structure with 10 through-holes, and the temperature of the gap electrolyte can be controlled below 30 & DEG;C, which significantly improves the forming accuracy of the deep special-shaped hole. Finally, process tests were carried out and the best combination of process parameters was obtained by the S/N ratio and grey correlation method. The simulation effectively shortens the cathode development cycle and optimizes the cathode structure.

关键词： Electrochemical machining Simulation analysis Cathode structure design Deep special-shaped hole optimization of process parameters

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Viscosity reduction and stability study of Indian heavy crude oil/water emulsion using hydrogenated castor oil ethoxylate with 40 moles of ethylene oxide as surfactant

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RESULTS IN SURFACES AND INTERFACES 2025年 19卷

作者： Desai, Shreyas Chakraborty, Mousumi Jana, Arun Kumar Kohli, Himanshu P. Sardar Vallabhbhai Natl Inst Technol Dept Chem Engn Surat 395007 Gujarat India RNG Patel Inst Technol Dept Chem Engn Bardoli 394620 Gujarat India

Viscosity reduces when heavy crude oil forms oil-in-water (o/w) emulsion in water or brine and can be easily transported through the pipeline. In this study, an oil/water (o/w) emulsion was prepared using crude oil and water as continuous and dispersed phases using two different non-ionic surfactants, hydrogenated castor oil ethoxylate with 40 mol of ethylene oxide, and castor oil ethoxylate with 40 mol of ethylene oxide. The advantage of using non-ionic surfactants is that they are biodegradable, are not affected by the salinity of water and their emulsion can be easily separated. An interaction plot and Box-Behnken Design (BBD) approach were used to optimize oil: water ratio, pH, and surfactant concentration to minimize the consumption of chemicals. O/W emulsions were characterized by optical microscopy, drop size distribution, and Attenuated total reflectance (ATR)-Fourier transform infrared spectroscopy (FTIR). A stability study was performed by gravity separation and turbiscan analysis. 2-10 v/v % toluene and n-heptane were mixed with crude oil for dilution, and viscosities were compared with the result obtained from the emulsification of crude oil using two different 1 v/v % nonionic surfactants. Using COMSOL Multi-Physics software, a pressure drop calculation was performed, and a velocity profile was developed considering the transportation of crude oil as well as o/w emulsion (containing hydrogenated castor oil ethoxylate with 40 mol of ethylene oxide as surfactant) through the pipeline.

关键词： O/W emulsion optimization of process parameters Gravity separation Stability Pressure drop calculation and CFD-Based simulation

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Study on the mechanism of inhomogeneous microdamage in short-pulse laser processing of carbon fiber reinforced plastic

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JOURNAL OF REINFORCED PLASTICS AND COMPOSITES 2021年第15-16期40卷 568-576页

作者： Xu, Luyao Lu, Jiuru Li, Kangmei Hu, Jun Donghua Univ Sch Mech Engn Shanghai Peoples R China

In this article, a micro-heterogeneous material simulation model with carbon fiber and resin phase about laser ablation on carbon fiber reinforced plastic (CFRP) is established by Ansys. The ablation process of CFRP by nanosecond ultraviolet laser is simulated, and the mechanism of pulse energy and spot spacing on the heat-affected zone (HAZ) is studied, then the process parameters are optimized with the goal of HAZ size and processing efficiency, and finally the validity of the model is verified by experiments. It is found that the residual gradient and the width of the radial HAZ increase with the increase of the spot spacing, and the width of the axial HAZ decreases slightly with the increase of the spot spacing, which indicates the existence of the optimal spot spacing. Second, the ablation depth increases with the increase of the pulse energy, and the carbon fiber retains a relatively complete degree of exposure when the pulse energy is low, which has a certain guiding significance for the cleaning and bonding of CFRP.

关键词： carbon fiber reinforced plastic micro-simulation model heterogeneous materials heat-affected zone residual gradient optimization of process parameters

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optimization of the Morphology of the Removal Function for Rotating Abrasive Water Jet Polishing

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MICROMACHINES 2023年第10期14卷 1931-1931页

作者： Tie, Guipeng Zhang, Zhiqiang Wang, Bo Song, Ci Shi, Feng Zhang, Wanli Si, Hailun Natl Univ Def Technol Coll Intelligence Sci & Technol 109 Deya Rd Changsha 410073 Peoples R China Natl Univ Def Technol Coll Intelligence Sci & Technol Lab Sci & Technol Integrated Logist Support 109 Deya Rd Changsha 410073 Peoples R China Hunan Key Lab Ultraprecis Machining Technol Changsha 410073 Hunan Peoples R China Chinese Acad Sci Precis Opt Mfg & Testing Ctr Shanghai Inst Opt & Fine Mech Shanghai 201800 Peoples R China

Abrasive water jet polishing has significant advantages in the manufacturing of complex optical components (such as high-slope optical component cavities) that require high-precision manufacturing. This is due to its processing process, in which the polishing tool does not make direct contact with the surface of the workpiece, and instead maintains a considerable distance. However, the removal functions of most existing abrasive water-jet polishing technologies do not possess strict symmetry, which significantly impacts the ability to correct surface figure errors. Therefore, this study implements rotating abrasive water-jet polishing based on traditional abrasive water jet processing to optimize the removal function, which turns it into a Gaussian form;thus, obtaining a type of removal function more suitable for CCOS polishing. This paper derives an empirical formula between the distance s' from the peak removal point of the removal function to the stagnation point and the nozzle tilt angle alpha, based on geometric relationships and experimental results, analyzes the relationship between material removal efficiency, nozzle tilt angle, and standoff distance. Finally, this paper verifies through experiments the validity of this empirical formula under different process parameters. Therefore, this study obtains the process conditions that allow rotating abrasive water-jet polishing technology to achieve a stable Gaussian form removal function, and the appropriate process parameters to be selected in conjunction with polishing efficiency;thereby, effectively improving the removal function's corrective ability and manufacturing efficiency. It provides theoretical support for the processing capability and process parameter selection of abrasive water-jet polishing technology, solves the problem of limited shaping capability of existing abrasive water jet tools, and significantly improves the manufacturing capability of high-end optical components.

关键词： rotating abrasive water jet removal function morphology optimization optimization of process parameters

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Capacity Consistency Prediction and process Parameter optimization of Lithium-Ion Battery based on Neural Network and Particle Swarm optimization Algorithm

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ADVANCED THEORY AND SIMULATIONS 2023年第8期6卷

作者： Han, Youjun Yuan, Hongyuan Shao, Ying Li, Jin Huang, Xuejie South China Univ Technol Sch Automat Sci & Engn Guangzhou 510640 Peoples R China Guangzhou Inst Ind Technol Guangzhou 511458 Peoples R China Chinese Acad Sci Inst Phys Beijing 100190 Peoples R China

The grading capacity of lithium-ion battery is an important basis for evaluating battery quality. Aiming at the difficulty of determining the critical control factors and the threshold of the control parameters in the lithium-ion battery manufacturing process, a capacity prediction and process parameter optimization model of lithium-ion battery is proposed by combining the back propagation (BP) and particle swarm optimization (PSO) algorithms. First, the BP method is applied to establish the nonlinear mapping relationship between process data and grading capacity, which is regarded as the capacity consistency prediction model. Second, using the prediction model as fitness function and combining with PSO algorithm, the optimization model of process parameters is established. Finally, under the given initial process parameters from the lithium-ion battery pilot line, it is carried out to obtain the best process parameter formula. The results show that the BP method has an accurate capacity consistency prediction effect. Combined with PSO algorithm, the optimized process parameters are obtained, which significantly improves the capacity consistency of lithium-ion batteries. The results serve as an engineering application method to guide the selection and confirmation of process parameters at the battery design stage.

关键词： battery manufacturing process consistency prediction lithium-ion battery consistency optimization of process parameters

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Simulation and experimental research based on carrier gas flow rate on the influence of four-channel coaxial nozzle flow field

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MEASUREMENT & CONTROL 2020年第9-10期53卷 1571-1578页

作者： Guo, Shi Rui Yin, Qian Qian Cui, Lu Jun Li, Xiao Lei Cui, Ying Hao Zheng, Bo Cao, Yan Long Zeng, Wen Han Zhongyuan Univ Technol Sch Mech & Elect Engn Zhengzhou 450007 Peoples R China

This paper investigates the influence of carrier gas flow on the external flow field of coaxial powder feeding nozzle. FLUENT software was adopted to establish gas-solid two-phase flow. The simulation of powder stream field under different carrier gas flow was also carried out. Results show that the larger the flow of carrier gas is, the higher the gas flow field velocity at the nozzle outlet is. At the same time, the concentration at the convergence point is lower, and the convergent point is maintained at 0.015 m. Under the condition of 4 L/min, the powder flow convergence is good. When it exceeds 4 L/min, powder spot diameter increases. The experiment of powder aggregation and laser cladding forming were completed, which shows that the forming effect is the best one under the condition of 4 L/min. It is consistent with the simulation analysis results and has a high reference to the optimization of the process parameters of coaxial nozzle.

关键词： Numerical simulation gas flow with particle convergent properties optimization of process parameters

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optimization of investment casting process parameters to reduce warpage of turbine blade platform in DD6 alloy

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China Foundry 2017年第6期14卷 469-477页

作者： Jia-wei Tian Kun Bu Jin-hui Song Guo-liang Tian Fei Qiu Dan-qing Zhao Zong-li Jin Yang Li Key Laboratory of Contemporary Design and Integrated Manufacturing Technology Northwestern Polytechnical University Xi 'an 710072 Shannxi China

The large warping deformation at platform of turbine blade directly affects the forming precision. In the present research, equivalent warping deformation was firstly presented to describe the extent of deformation at platform. To optimize the process parameters during investment casting to minimize the warping deformation of the platform, based on simulation with Pro CAST, the single factor method, orthogonal test, neural network and genetic algorithm were subsequently used to analyze the influence of pouring temperature, shell mold preheating temperature, furnace temperature and withdrawal velocity on dimensional accuracy of the platform of superalloyDD6 turbine blade. The accuracy of investment casting simulation was verified by measurement of platform at blade casting. The simulation results with the optimal process parameters illustrate that the equivalent warping deformation was dramatically reduced by 21.8% from 0.232295 mm to 0.181698 mm.

关键词： ProCAST optimization of process parameters warping deformation of platform orthogonal test genetic algorithm BP-neural network

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