In clinical practice, cam-out failure at the recess-screwdriver interfaces may occur when tightening or removing a bone screw. For titanium-based periarticular fixation, the literature reports have revealed that cold welding at the plate-screw interfaces makes the screw recess especially prone to cam-out failure during screw removal. In this study, the effects of the four recess shapes (cross, hexagon, star, and crest), three torque value (0.8, 1.0, and 1.2N-m), and the three interfacial misfits (0.00, 0.05, and 0.10mm) on the cam-out failure were numerically evaluated. The free-rotation angle, torque-recess angle, slippage-resisting length, and interfacial stress distribution were defined and chosen as comparison indices for the twelve recess-misfit variations. The results revealed that the interfacial slippage, torque transfer, and stress distribution are highly related to both recess shape and interfacial misfit. The stresses of all recesses and screwdrivers consistently initiate at the contact sites. However, the recess profile significantly affects the stress propagation. The stress patterns of the recess and screwdriver are quite different between the cross-star and hexagon-crest groups. The cross-star group is superior to the hexagon-crest group in terms of the torque-recess angle and slippage-resisting length over. This makes the recess of the cross-star group less stressed than its counterpart. However, the volumes of the cross and the star screwdriver are more highly stressed than the hexagon due to the irregular shape and the thinner flange, respectively. The greater torque and misfit increase the performance difference between the four recess designs. In conclusion, the geometry of the cross and star groups provide the better performance of the screw recess in terms of torque-transferring efficiency and slippage-resisting ability. If the screwdriver material is properly strengthened and the stress-concentrating corners are modified, the cross and star groups would be the optimal designs that protects and extends the lifetime of both recess and reused screwdriver.
2 As the demand for optical glasses has increased, precision requirements for specific shapes, forms, surface textures, and sizes (miniaturization) have also increased. The standards and surface finishes applied to the reference mirrors used in measuring appliances are crucial. Hence, enhancements in figuring and surface finishing are indispensable to manufacturing industries. In this article, a novel self-propelled multi-jet abrasive fluid polishing technique is proposed for an ultra-precision polishing process in which a blade-less Tesla turbine was used as a prime mover. The turbine was characterized by high swirling velocity at the outlet; therefore, high levels of kinetic energy moving away from the turbine were used as polishing energy. Computational fluid dynamics (CFD) was also used to simulate the flow on the turbine blades. With a newly designed and manufactured polishing tool, the optimal polishing parameters for improving the surface roughness of crown optical glasses (N-BK7) were investigated. Taguchi's experimental approach, an L 18 orthogonal array, was employed to obtain the optimal process parameters. An analysis of variance (ANOVA) was also conducted to determine the significant factors. The surface roughness has been improved by approximately 94.44% from (R a ) 0.36 μm to (R a ) 0.02 μm. This study also presents a discussion on the influence of significant factors on improving surface roughness.
Ultraprecision freeform polishing using a bonnet or a felt ball mounted on a polishing head plays an important role in the mold and lens production industries. The volumetric wear of a bonnet or a felt polishing ball is still a problem to be solved. The objective of this study was to develop an ultrasonic-vibration-assisted ball polishing process on a CNC machining center to improve the surface roughness of a STAVAX mold steel and to reduce the volumetric wear of the polishing ball. The optimal combination of the ultrasonic-vibration-assisted ball polishing parameters for a plane surface was determined by conducting the Taguchi L18 matrix experiments, ANOVA analysis, and verification experiments. The surface roughness of the polished specimens was improved from the burnished surface roughness of Ra 0.122 μm to Ra 0.022 μm. In applying the optimal plane surface ball burnishing and vibration-assisted spherical polishing parameters sequentially to a fine-milled and burnished aspherical lens surface carrier on a five-axis machining center, the surface roughness of Ra 0.014 μm was obtainable. The improvement in the volumetric wear of the polishing ball was about 62% using the vibration-assisted polishing process compared with the nonvibrated polishing process.
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