京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第22438号 / 工博第4699号 / 新制||工||1734(附属図書館) / 京都大学大学院工学研究科マイクロエンジニアリング専攻 / (主査)教授 松原 厚, 教授 西脇 眞二, 教授 小森 雅晴 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

Testing and analysis has been performed on square steel thin-walled tubes fabricated using symmetrically-overlapping U-channels and foam. This research analyzes flange-to-flange attachment, effect of foam in the columns, effect of adhesive stiffness, and influence of steel thickness, as related to the local buckling loads, global buckling loads, and crippling loads. Four 14-foot (4.27 m) foam-filled, thin-walled, galvanized steel columns were manufactured by Novatek, Inc. and tested in axial compression with pinned boundary conditions. For three of the four configurations, the two-piece 4-in. (10.2-cm) square shell surrounded prefabricated polystyrene foam inserts; the fourth column had no foam insert. The column outer shells were composed of two 16-gauge galvanized steel channels with overlapping flanges and the webs on opposite sides of the column. The two adjacent flanges on each side of the columns were adhesively bonded together in all cases. In addition to the adhesive, two columns had either periodic screws or short welds spaced evenly along the length of the columns to delay the onset of flange buckling of the outer channel, and potentially increase the compression strength. The other two columns had adhesive only bonding the flanges, one of which had no foam filler. The various configurations all exhibited similar compression strengths. Failure for all columns initiated with local buckling, followed by global buckling and local crippling, which occurred simultaneously. The method of flange attachment, the effect of the foam in the columns, and flange thicknesses were isolated and analyzed using mechanics-based analysis, parametric studies, and finite element analysis. The results show the ideal spacing of screws or short-welds, if used, is less than or equal to 5 in (12.7 cm) for the given column length. This increases the local buckling load to the Euler buckling load and preserves the original shape of the cross-section. The adhesive needs only a tensile strength of approximately 1 ksi (6.4 kPa) to prevent local buckling for any spacing of screws or short-welds, but needs to be applied uniformly (much of the adhesive in the column tests had been scraped off of the flanges during assembly). The results also show that foam core does not increase the Euler buckling load, but does increase the crippling load by delaying inward buckling of the column webs and flanges. Using foam with the given stiffness and a yield strength of 50 psi (345 kPa), uniform foam-to-steel bonding could increase the crippling strength up to 21% even without adhesive between the flanges. Using adhesive with the given stiffness between the flanges could increase the crippling strength by up to 63% without foam. The crippling strength could increase up to 72% if both adhesive between the flanges and a foam insert are used.

In this project, the scan strategy of selective laser melting (SLM) for thin walled structures was investigated by changing laser parameters and tool path. Producing thin walled structures is difficult due to defects such as warpage and porosity. A layer on the SLM 125 consists of hatch volume, fill contours, and borders, however, for thin walls, hatch volume can become unavailable, resulting in a solely border/fill contour laser tool path. Three central composite designs (CCD) were created to optimize the laser parameters of borders to minimize leakage rate and porosity. The two factors changed were border laser power and scanning speed. The center points of the CCDs were 0.24 J/mm, 0.20 J/mm, and 0.16 J/mm, respectively. This border linear energy density value was calculated by (border laser power / border scanning speed). A machined aluminum fixture was designed and assembled with pneumatics to perform a pressure drop leakage test. Additionally, micrographs of 500μm and 200μm wall thicknesses were analyzed to study between and within layers as well as melt pool dimensions. In the 200μm thick samples, there was delamination and insufficient overlap in border only prints. For border only prints, a lower border linear energy density is recommended, similar to Cal Poly’s hatch volume optimized parameters of 0.15 J/mm.

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This thesis looks at the capabilities of cutting thin webs on Wire EDM machines that are difficult or impossible to machine using conventional methods. Covered is an investigation of how different material and web thickness affect the capability of machining thin-walled parts. Five different metals are used for the test; Aluminum 6061 T6, Yellow Brass SS360, 420 Stainless Steel, D2 unheat-treated tool steel 25-30 RC, and D2 heat-treated tool steel 60-65 RC. The small parts were cut to a 6mm (0.2362 inch) height with six different wall thicknesses: 0.30mm (0.0118 inch), 0.25mm (0.0098 inch), 0.20mm (0.0078 inch), 0.15mm (0.0059 inch), 0.10mm (0.0039 inch), and 0.05mm (0.0020 inch). A Sodick AQ325L Wire EDM machine was utilized for testing. The methods employed during the study include the following: • Machine settings and offsets were limited to the default setting selected from the Sodick AQ325L database. • Two different pre-test cuts were taken on the material to check for web bending during the cutting process. • Hardness was tested for comparison of the web heights. This thesis shows that bending increased as webs became thinner and that bending occurred toward the wire as the second side of the web was cut. Bending does affect the height of the web. Physical properties of materials also impacted the height of the web with the hardest material staying intact during the cutting process. This study shows that two factors, physical properties of materials and web thickness, significantly affect cutting results for thin web parts.

Expansive soils are a worldwide problem that possesses various challenges for civil engineers. With increasing water content, they exhibit excessive volume changes, resulting in large horizontal and vertical stresses to the structures located or buried in these regions. The most common method to minimize this effect is to replace these types of clays around the proposed structure with nonexpansive soils. For the cases needing larger volume of replacement, either sidewalls or the foundations must be designed to cater for the anticipated pressures or a suitable improvement technique shall be applied in place. In this experimental study, it is intended to investigate the possible positive effects of trenches backfilled with granular material such as crushed stone or rock on the improvement of swell parameters of expansive soils. Thin-wall oedometer tests, conventional oedometer tests and larger size tests with moulds were performed on artificially compacted untreated and granular fill treated samples for this purpose. The trenches were modeled by opening a hole with a diameter that satisfies the predicted percent trench content at the center of the soil samples, which was then backfilled with granular material. Modified thin-wall oedometer tests were performed to measure the lateral swell pressures of both untreated and treated samples, whereas the conventional oedometer tests and tests on samples placed in moulds were performed to measure the vertical swell parameters of soils. It was observed that both the vertical swell percentages as well as the lateral swell pressures reduced considerably as the volume of granular material filled trench was increased. The treatment was observed to be more remarkable under the surcharge effect of a light weight structure or a fill placed on top.

Factors such as environmental requirements and fuel efficiency have pushed aerospace industry to develop reduced-weight engine designs and thereby light-weight and thin-walled components. As component wall thickness gets thinner and the mechanical structures weaker, the structure becomes more sensitive for vibrations during milling operations. Demands on cost efficiency increase and new ways of improving milling operations must follow. Historically, there have been two “schools” explaining vibrations in milling. One states that the entry angle in which the cutting insert hits the work piece is of greater importance than the exit angle. The other states that the way the cutter leaves the work piece is of greater importance than the cutter entry. In an effort to shed some light over this issue, a substantial amount of experiments were conducted. Evaluations were carried out using different tools, different tool-to-workpiece offset positions, and varying workpiece wall overhang. The resultant force, the force components, and system vibrations have been analyzed. The first part of this work shows the differences in force behavior for three tool-to-workpiece geometries while varying the wall overhang of the workpiece. The second part studies the force behavior during the exit phase for five different tool-to-workpiece offset positions while the overhang is held constant. The workpiece alloy throughout this work is Inconel 718. As a result of the project a spread sheet milling stability prediction model is developed and presented. It is based on available research in chatter theory and predicts the stability for a given set of variable input parameters. / <p>QC 20121206</p>

In the work is used the processing of metallic material by the method of Selective Laser Melting. The main objective is to verify and describe the influence of the individual process parameters entering the production process when processing the alloy Cu7.2Ni1.8Si1Cr with SLM. This alloy contains 90 % copper. The first theoretical part of the thesis describes so far processed copper alloys with a high content of copper using the method of Selective Laser Melting. The practical part then deals with the specification of the main process parameters, which are optimized in the next part of the work solution. On the basis of the information obtained experimental bodies have been created, which will be tested and analyzed in several steps. The work focuses on thin-walled samples, which have a perspective use in the creation of highefficiency heat exchangers. The main results that the work deals with are the relative density and mechanical properties of the material. Also, great emphasis is placed on the resulting surface quality

Wire Electric Discharge Machining (wire-EDM) is a non-traditional machining process. Controlled electric sparks are successively used to vaporize part of a workpiece along a programmed path in order to machine a desired part. Because there is no tool that comes in direct contact with the workpiece, it is possible to machine thin, delicate parts. This thesis was designed to observe and analyze the differences in cutting capabilities for a conventional wire-EDM machine when cutting thin-walled sections from five commonly used metals utilizing a variation of roughing and finishing passes. The five metals that were used in this study are: Aluminum 6061 T6, Yellow Brass SS360, 420 Stainless Steel, D2 Tool Steel at 25 to 30 RC, and D2 Tool Steel at 60 to 65 RC. The thin-walled sections were constrained on each end by the parent material to which they remained attached, and they ranged in thickness from 0.05 millimeters (0.002 inches) increasing incrementally by 0.05 millimeters (0.002 inches) until they reached a thickness of 0.30 millimeters (0.012 inches). A Sodick AQ325L wire-EDM machine was employed to perform the machining. It was observed that differences exist in the capabilities of cutting thin-walled sections from the five different metals. This could be both observed visually through inspection and statistically through the analysis of each data set obtained by measuring the resultant thickness of each section. It was also observed that differences exist for the same material while utilizing the variations of cutting parameters: a roughing with no finishing passes, a roughing with one finishing pass, and a roughing with three finishing passes. Thus both the material properties and the cutting parameters play a significant role in determining the capability of cutting thin-walled sections with a wire-EDM machine.