Near Net Forming Research for Fin-Typed LED Radiator.

Pure aluminum radiator is the best choice for heat dissipation of various LED products at present. Its forming methods include common extrusion, die casting, forging, etc. Compared with other forming technologies, the LED radiator formed by cold forging has good heat dissipation performance, but there are some disadvantages in the forming process, such as uneven deformation, large material consumption and low die life. The cold forging process of pure aluminum fin-typed LED radiator is analyzed by the finite element method. The calculation results show that equal fillet structure of concave die is improper, leading to serious uneven flow velocity distribution during aluminum forging, inconsistent fin length, and warpage tendency. The gradient fillet structure of concave die is adopted. Numerical simulation and production test show that the gradient fillet structure design can significantly reduce the uneven metal flow. The extruded fins have a uniform length, which is conducive to reducing subsequent machining and production cost.

Calculation and AFM Experimental Research on Slip Friction for Unlubricated Spherical Contact with Roughness Effect.

Previous research on friction calculation models has mainly focused on static friction, whereas sliding friction calculation models are rarely reported. In this paper, a novel sliding friction model for realizing a dry spherical flat contact with a roughness effect at the micro/nano scale is proposed. This model yields the sliding friction by the change in the periodic substrate potential, adopts the basic assumptions of the Greenwood-Williamson random contact model about asperities, and assumes that the contact area between a rigid sphere and a nominal rough flat satisfies the condition of interfacial friction. It subsequently employs a statistical method to determine the total sliding friction force, and finally, the feasibility of this model presented is verified by atomic force microscopy friction experiments. The comparison results show that the deviations of the sliding friction force and coefficient between the theoretical calculated values and the experimental values are in a relatively acceptable range for the samples with a small plasticity index (Ψ≤1).

A Static Friction Model for Unlubricated Contact of Random Rough Surfaces at Micro/Nano Scale.

A novel static friction model for the unlubricated contact of random rough surfaces at micro/nano scale is presented. This model is based on the energy dissipation mechanism that states that changes in the potential of the surfaces in contact lead to friction. Furthermore, it employs the statistical theory of two nominally flat rough surfaces in contact, which assumes that the contact between the equivalent rough peaks and the rigid flat plane satisfies the condition of interfacial friction. Additionally, it proposes a statistical coefficient of positional correlation that represents the contact situation between the equivalent rough surface and the rigid plane. Finally, this model is compared with the static friction model established by Kogut and Etsion (KE model). The results of the proposed model agree well with those of the KE model in the fully elastic contact zone. For the calculation of dry static friction of rough surfaces in contact, previous models have mainly been based on classical contact mechanics; however, this model introduces the potential barrier theory and statistics to address this and provides a new way to calculate unlubricated friction for rough surfaces in contact.