The shell composed of large-scale parts is the essential component of mechanical structures in the aerospace,shipping,and railway industries.These workpieces are characterized by thin walls and weak rigidity,thus requ...The shell composed of large-scale parts is the essential component of mechanical structures in the aerospace,shipping,and railway industries.These workpieces are characterized by thin walls and weak rigidity,thus requiring an effective technology for high-performance machining.Accordingly,an embedded locally resonant metamaterial with double resonators is proposed and combined with the magnetic follow-up support technology to attenuate the vibration of thin-walled parts for the first time.The band structures and parametric adjustment laws are systematically investigated and validated by analytical calculation and finite element method,which proves the proposed model is broadband,lightweight,and flexible in low frequencies.Its characteristics,as well as the relatively simple structure,are unique advantages for thin-walled structure milling.Finally,mirror milling experiments have been performed to assess the slave module with the proposed substructure.From the results,the root mean square amplitude of the thin-walled workpiece with the combined device decreases by nearly 9%,which means that the performance has been improved by the combined device.Furthermore,this work provides an integrated and efficient solution for vibration suppression in thin-walled parts milling,which extends locally resonant metamaterials to practical engineering fields and helps to improve the status quo of mirror milling from the perspective of metamaterials.展开更多
The measurement uncertainty analysis is carried out to investigate the measurable dimensions of cylindrical workpieces by the rotary-scan method in this paper.Due to the difficult alignment of the workpiece with a dia...The measurement uncertainty analysis is carried out to investigate the measurable dimensions of cylindrical workpieces by the rotary-scan method in this paper.Due to the difficult alignment of the workpiece with a diameter of less than 3 mm by the rotary scan method,the measurement uncertainty of the cylindrical workpiece with a diameter of 3 mm and length of 50 mm which is measured by a roundness measuring machine,is evaluated according to GUM(Guide to the Expression of Uncertainty in Measurement)as an example.Since the uncertainty caused by the eccentricity of the measured workpiece is different with the dimension changing,the measurement uncertainty of cylindrical workpieces with other dimensions can be evaluated the same as the diameter of 3 mm but with different eccentricity.Measurement uncertainty caused by different eccentricities concerning the dimension of the measured cylindrical workpiece is set to simulate the evaluations.Compared to the target value of the measurement uncertainty of 0.1μm,the measurable dimensions of the cylindrical workpiece can be obtained.Experiments and analysis are presented to quantitatively evaluate the reliability of the rotary-scan method for the roundness measurement of cylindrical workpieces.展开更多
To improve the milling surface quality of the Al-Li alloy thin-wall workpieces and reduce the cutting energy consumption.Experimental research on the milling processing of AA2195 Al-Li alloy thin-wall workpieces based...To improve the milling surface quality of the Al-Li alloy thin-wall workpieces and reduce the cutting energy consumption.Experimental research on the milling processing of AA2195 Al-Li alloy thin-wall workpieces based on Response Surface Methodology was carried out.The single factor and interaction of milling parameters on surface roughness and specific cutting energy were analyzed,and the multi-objective optimization model was constructed.The Multiobjective Particle Swarm Optimization algorithm introducing the Chaos Local Search algorithm and the adaptive inertial weight was applied to determine the optimal combination of milling parameters.It was observed that surface roughness was mainly influenced by feed per tooth,and specific cutting energy was negatively correlated with feed per tooth,radial cutting depth and axial cutting depth,while cutting speed has a non-significant influence on specific cutting energy.The optimal combination of milling parameters with different priorities was obtained.The experimental results showed that the maximum relative error of measured and predicted values was 8.05%,and the model had high reliability,which ensured the low surface roughness and cutting energy consumption.It was of great guiding significance for the success of Al-Li alloy thin-wall milling with a high precision and energy efficiency.展开更多
In this paper, the traditional empirical coefficient method and a novel loop material analytical method presented by the authors have been compared and discussed by analyzing several practical cylindrical workpieces’...In this paper, the traditional empirical coefficient method and a novel loop material analytical method presented by the authors have been compared and discussed by analyzing several practical cylindrical workpieces’ deep drawing projects. Also, some conclusions about how to modify the traditional analyzing method of cylindrical workpieces’ deep drawing process could be concluded and the necessity of this modification could be proved.展开更多
Laser surface hardening is a very promising hardening process for ferrous alloys where transformations occur during cooling after laser heating in the solid state. The characteristics of the hardened surface depend on...Laser surface hardening is a very promising hardening process for ferrous alloys where transformations occur during cooling after laser heating in the solid state. The characteristics of the hardened surface depend on the physicochemical properties of the material as well as the heating system parameters. To exploit the benefits presented by the laser hardening process, it is necessary to develop an integrated strategy to control the process parameters in order to produce desired hardened surface attributes without being forced to use the traditional and fastidious trial and error procedures. This study presents a comprehensive modelling approach for predicting the hardened surface physical and geometrical attributes. The laser surface transformation hardening of cylindrical AISI 4340 steel workpieces is modeled using the conventional regression equation method as well as artificial neural network method. The process parameters included in the study are laser power, beam scanning speed, and the workpiece rotational speed. The upper and the lower limits for each parameter are chosen considering the start of the transformation hardening and the maximum hardened zone without surface melting. The resulting models are able to predict the depths representing the maximum hardness zone, the hardness drop zone, and the overheated zone without martensite transformation. Because of its ability to model highly nonlinear problems, the ANN based model presents the best modelling results and can predict the hardness profile with good accuracy.展开更多
In order to obtain the desired mechanical properties of quenching and tempering workpieces, as well as reduce the cracking tendency and distortion, a program of controllable quenching was established. Furthermore, a c...In order to obtain the desired mechanical properties of quenching and tempering workpieces, as well as reduce the cracking tendency and distortion, a program of controllable quenching was established. Furthermore, a computer-aided quenching system (CAQ) was also developed. The application samples of the CAQ system showed satisfactory results.展开更多
Grinding is an energy-intensive process in which the heat generated can cause various types of thermal damage to workpiece.Many theoretical,empirical or numerical models have been developed to predict grinding tempera...Grinding is an energy-intensive process in which the heat generated can cause various types of thermal damage to workpiece.Many theoretical,empirical or numerical models have been developed to predict grinding temperature.However,these models are not directly applicable for coated workpieces.Tools or other parts are coated with hard materials like tungsten carbide,ceramics or polycrystalline diamond to increase their surface hardness and prolong their life expectancy.In this paper,an empirical model is proposed to predict the maximum grinding temperature of coated workpieces.Experimental and numerical studies are carried out to validate the model.The results indicated that the new model is able to accurately predict grinding temperature.展开更多
In order to form large-diameter thin-wall cylindrical workpieces of TA15 titanium alloy,tube hot spinning experiments of the alloy were conducted on a CNC hot spinning machine.The causes of some forming defects occuri...In order to form large-diameter thin-wall cylindrical workpieces of TA15 titanium alloy,tube hot spinning experiments of the alloy were conducted on a CNC hot spinning machine.The causes of some forming defects occuring in hot spinning,such as crack,pileup,bulge and corrugation,were analyzed and the corresponding measures were put forward to avoid spinning defects,based on which a proper process scheme of hot spinning of TA15 alloy was obtained and the large-diameter and thin-walled cylindrical workpieces were formed with good quality.The results show that spinning temperature has distinct influence on forming quality of spun workpieces.The range of spinning temperature determines the spinnability of titanium alloy and the ununiformity of temperature distribution near the deformation zone leads to the formation of bulge.The reasonable heating method is that the deforming region is heated to the optimum temperature range of 600-700 ℃,the deformed region is heated continuously and a certain length of undeformed region is preheated.With the thickness-to-diameter ratio(t/D) of spun workpiece reducing to certain value(t/D<1%),surface bulge and corrugation is rather easier to come into being,which could be controlled through restraining diameter growth and employing smaller reduction rate and lower temperature in the optimum spinning temperature range.展开更多
To reduce the vibration and deformation of large thin-walled workpieces during the milling process,mirror milling is widely used due to its point-to-point support and strong applicability.The influence of the support ...To reduce the vibration and deformation of large thin-walled workpieces during the milling process,mirror milling is widely used due to its point-to-point support and strong applicability.The influence of the support head on the workpiece’s dynamic characteristics is crucial in determining whether the mirror milling process is reliable and effective.Therefore,this study establishes a time-varying dynamic model for mirror milling of thin-walled workpieces with various boundary conditions to accurately analyze and predict the dynamic characteristics and response of the workpiece.First,a new analytical method for material removal with extensive applicability and high precision is proposed.In this method,the Ritz mode shape is used to approximate the workpiece’s mode shape as it changes during material removal.Next,the Hertz contact theory is adopted to establish a tool-workpiece-support head coupling model,which considers the jump-off phenomenon between them.Subsequently,the dynamic model is solved using the Newmark-β numerical integration method to obtain the workpiece’s time-domain acceleration and displacement responses under the forced vibration.Finally,the measured frequency response function(FRF)and vibration signals of workpieces verify the correctness of the proposed mirror milling model for thin-walled workpieces considering material removal.In addition,this paper analyzes the dynamic characteristics and forced vibration law of workpieces in mirror milling,which lays the foundation for high precision mirror milling.展开更多
As critical components of aircraft skins and rocket fuel storage tank shells,large thin-walled workpieces are susceptible to vibration and deformation during machining due to their weak local stiffness.To address thes...As critical components of aircraft skins and rocket fuel storage tank shells,large thin-walled workpieces are susceptible to vibration and deformation during machining due to their weak local stiffness.To address these challenges,we propose a novel tunable electromagnetic semi-active dynamic vibration absorber(ESADVA),which integrates with a magnetic suction follower to form a followed ESADVA(follow-ESADVA)for mirror milling.This system combines a tunable magnet oscillator with a follower,enabling real-time vibration absorption and condition feedback throughout the milling process.Additionally,the device supports self-sensing and frequency adjustment by providing feedback to a linear actuator,which alters the distance between magnets.This resolves the traditional issue of being unable to directly monitor vibration at the machining point due to space constraints and tool interference.The frequency shift characteristics and vibration absorption performance are comprehensively investigated.Theoretical and experimental results demonstrate that the prototyped follow-ESADVA achieves frequency synchronization with the milling tool,resulting in a vibration suppression rate of approximately 47.57%.Moreover,the roughness of the machined surface decreases by18.95%,significantly enhancing the surface quality.The results of this work pave the way for higher-quality machined surfaces and a more stable mirror milling process.展开更多
To improve the productivity,the resource utilization and reduce the production cost of flexible job shops,this paper designs an improved two-layer optimization algorithm for the dual-resource scheduling optimization p...To improve the productivity,the resource utilization and reduce the production cost of flexible job shops,this paper designs an improved two-layer optimization algorithm for the dual-resource scheduling optimization problem of flexible job shop considering workpiece batching.Firstly,a mathematical model is established to minimize the maximum completion time.Secondly,an improved two-layer optimization algorithm is designed:the outer layer algorithm uses an improved PSO(Particle Swarm Optimization)to solve the workpiece batching problem,and the inner layer algorithm uses an improved GA(Genetic Algorithm)to solve the dual-resource scheduling problem.Then,a rescheduling method is designed to solve the task disturbance problem,represented by machine failures,occurring in the workshop production process.Finally,the superiority and effectiveness of the improved two-layer optimization algorithm are verified by two typical cases.The case results show that the improved two-layer optimization algorithm increases the average productivity by 7.44% compared to the ordinary two-layer optimization algorithm.By setting the different numbers of AGVs(Automated Guided Vehicles)and analyzing the impact on the production cycle of the whole order,this paper uses two indicators,the maximum completion time decreasing rate and the average AGV load time,to obtain the optimal number of AGVs,which saves the cost of production while ensuring the production efficiency.This research combines the solved problem with the real production process,which improves the productivity and reduces the production cost of the flexible job shop,and provides new ideas for the subsequent research.展开更多
To investigate the workpiece curvature influence on groove deformation,numerical studies with curvature varying from negative to positive were conducted on copper material.Groove deformations were analyzed,including g...To investigate the workpiece curvature influence on groove deformation,numerical studies with curvature varying from negative to positive were conducted on copper material.Groove deformations were analyzed,including groove geometry,effective stress distribution and plough force.The curled groove shape whose workpiece curvature was 0.133 mm-1 was validated by experiments.Moreover,a series of geometry models with various curvatures were introduced to analyze the change of groove deformation.The results show that positive curvatures influence groove deformation more intensively than negative or zero curvature.It is mainly due to the action of the tool forming face during plough process.展开更多
A conventional non-computerized numerical control （CNC） machine is updated by mounting a six degree-of-free （DOF） parallel mechanism on it, thus obtaining a new CNC one. The structure of this CNC milling machine i...A conventional non-computerized numerical control （CNC） machine is updated by mounting a six degree-of-free （DOF） parallel mechanism on it, thus obtaining a new CNC one. The structure of this CNC milling machine is introduced, and the workpiece locating system and the post processing system of the cutter location （CL） data file are analyzed. The new machine has advantages of low costs, simple structure, good rigidity, and high precision. It is easy to be transformed and used to process the workpiece with a complex surface.展开更多
Milling of the thin-walled workpiece in the aerospace industry is a critical process due to the high flexibility of the workpiece. In this paper, a flexible fixture based on the magnetorheological (MR) fluids is desig...Milling of the thin-walled workpiece in the aerospace industry is a critical process due to the high flexibility of the workpiece. In this paper, a flexible fixture based on the magnetorheological (MR) fluids is designed to investigate the regenerative chatter suppression during the machining. Based on the analysis of typical structural components in the aerospace industry, a general complex thin-walled workpiece with fixture and damping constraint can be equivalent as a rectangular cantilever beam. On the basis of the equivalent models, natural frequency and mode shape function of the thin-walled workpiece is obtained according to the Euler-Bernoulli beam assumptions. Then, the displacement response function of the bending vibration of the beam is represented by the product of all the mode shape function and the generalized coordinate. Furthermore, a dynamic equation of the workpiece-fixture system considering the external damping factor is proposed using the Lagrangian method in terms of all the mode shape function and the generalized coordinate, and the response of system under the dynamic cutting force is calculated to evaluate the stability of the milling process under damping control. Finally, the feasibility and effectiveness of the proposed approach are validated by the impact hammer experiments and several machining tests. (C) 2016 Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics.展开更多
The milling stability of thin-walled components is an important issue in the aviation manufacturing industry,which greatly limits the removal rate of a workpiece.However,for a thin-walled workpiece,the dynamic charact...The milling stability of thin-walled components is an important issue in the aviation manufacturing industry,which greatly limits the removal rate of a workpiece.However,for a thin-walled workpiece,the dynamic characteristics vary at different positions.In addition,the removed part also has influence on determining the modal parameters of the workpiece.Thus,the milling stability is also time-variant.In this work,in order to investigate the time variation of a workpiece's dynamic characteristics,a new computational model is firstly derived by dividing the workpiece into a removed part and a remaining part with the Ritz method.Then,an updated frequency response function is obtained by Lagrange's equation and the corresponding modal parameters are extracted.Finally,multi-mode stability lobes are plotted by the different quadrature method and its accuracy is verified by experiments.The proposed method improves the computational efficiency to predict the time-varying characteristics of a thin-walled workpiece.展开更多
The workpiece frames relative to each robot base frame should be known in advance for the proper operation of twin-robot nondestructive testing system. However, when two robots are separated from the workpieces, the t...The workpiece frames relative to each robot base frame should be known in advance for the proper operation of twin-robot nondestructive testing system. However, when two robots are separated from the workpieces, the twin robots cannot reach the same point to complete the process of workpiece frame positioning. Thus, a new method is proposed to solve the problem of coincidence between workpiece frames. Transformation between two robot base frames is initiated by measuring the coordinate values of three non-collinear calibration points. The relationship between the workpiece frame and that of the slave robot base frame is then determined according to the known transformation of two robot base frames, as well as the relationship between the workpiece frame and that of the master robot base frame. Only one robot is required to actually measure the coordinate values of the calibration points on the workpiece. This requirement is beneficial when one of the robots cannot reach and measure the calibration points. The coordinate values of the calibration points are derived by driving the robot hand to the points and recording the values of top center point（TCP） coordinates. The translation and rotation matrices relate either the two robot base frames or the workpiece and master robot. The coordinated are solved using the measured values of the calibration points according to the Cartesian transformation principle. An optimal method is developed based on exponential mapping of Lie algebra to ensure that the rotation matrix is orthogonal. Experimental results show that this method involves fewer steps, offers significant advantages in terms of operation and time-saving. A method used to synchronize workpiece frames in twin-robot system automatically is presented.展开更多
A novel DLC film deposition method was proposed to realize the deposition of DLC film on the surface of complex shaped workpiece.Meanwhile,Si-DLC film was deposited on the surface of M2 high-speed steel(HSS M2)and 304...A novel DLC film deposition method was proposed to realize the deposition of DLC film on the surface of complex shaped workpiece.Meanwhile,Si-DLC film was deposited on the surface of M2 high-speed steel(HSS M2)and 304 stainless steel(304SS),and the microstructure,surface roughness,mechanical properties,corrosion resistance and tribological properties of Si-DLC films were characterized in detail.Results show that Si-DLC film at different axial positions of the auxiliary cathode possesses similar microstructure,film thickness and surface roughness,and the as-deposited Si-DLC film shows the low intrinsic stress of<0.3 GPa.Compared with the 304SS substrate,the Si-DLC film presents more noble corrosion potential,lower corrosion current density and higher polarization resistance,exhibiting higher corrosion resistance.Moreover,the Si-DLC film exhibits higher hardness,elastic factor and plastic factor than HSS M2 substrate and the corresponding adhesive strength is more than 10 N.The Si-DLC film sliding against GCr15 steel ball shows a lower friction coefficient than that of HSS M2 substrate and the wear rate of GCr15 steel ball sliding against the Si-DLC is lower than that of HSS M2 substrate.In addition,this novel method was used to deposit Si-DLC film on gears,drills and bearings without rotating sample racks.As a consequence,this method possesses great potential and can be generalized for the deposition of DLC film on the surface of complex shape workpiece.展开更多
The problem of chatter vibration is associated with adverse consequences that often lead to tool impairment and poor surface finished in a workpiece, and thus, controlling or suppressing chatter vibrations is of great...The problem of chatter vibration is associated with adverse consequences that often lead to tool impairment and poor surface finished in a workpiece, and thus, controlling or suppressing chatter vibrations is of great significance to improve machining quality. In this paper, a workpiece and an actuator dynamics are considered in modeling and controller design. A proportional-integral controller(PI) is presented to control and actively damp the chatter vibration of a workpiece in the milling process. The controller is chosen on the basis of its highly stable output and a smaller amount of steady-state error. The controller is realized using analog operational amplifier circuit. The work has contributed to planning a novel approach that addresses the problem of chatter vibration in spite of technical hitches in modeling and controller design. The method can also lead to considerable reduction in vibrations and can be beneficial in industries in term of cost reduction and energy saving. The application of this method is verified using active damping device actuator(ADD) in the milling of steel.展开更多
Microstructured roll workpieces have been widely used as functional components in the precision industries. Current researches on quality control have focused on surface profile measurement of microstructured roll wor...Microstructured roll workpieces have been widely used as functional components in the precision industries. Current researches on quality control have focused on surface profile measurement of microstructured roll workpieces, and types of measurement systems and measurement methods have been developed. However, low measurement efficiency and low measurement accuracy caused by setting errors are the common disadvantages for surface profile measurement of microstructured roll workpieces. In order to shorten the measurement time and enhance the measurement accuracy, a method for self-calibration and compensation of setting errors is proposed for surface profile measurement of microstructured roll workpieces. A measurement system is constructed for the measurement, in which a precision spindle is employed to rotate the roll workpiece and an air-bearing displacement sensor with a micro-stylus probe is employed to scan the microstructured surface of the roll workpiece. The resolution of the displacement sensor is 0.14 nm and that of the rotary encoder of the spindle was 0.15r~. Geometrical and mathematical models are established for analyzing the influences of the setting errors of the roll workpiece and the displacement sensor with respect to the axis of the spindle, including the eccentric error of the roll workpiece, the offset error of the sensor axis and the zero point error of the sensor output. Measurement experiments are carded out on a roll workpiece on which periodic microstructures are a period of 133 i^m along the circumferential direction. Experimental results demonstrate the feasibility of the self-compensation method. The proposed method can be used to detect and compensate the setting errors without using any additional accurate artifact.展开更多
In order to achieve active grinding control, a novel numerical controlmicropositioning workpiece table with a resolution of 6 nm has been developed. The table is drivenby three piezoelectric actuators mounted on the b...In order to achieve active grinding control, a novel numerical controlmicropositioning workpiece table with a resolution of 6 nm has been developed. The table is drivenby three piezoelectric actuators mounted on the base. An elastic structure with three half-notchflexure hinges is designed to apply preload to the piezoelectric actuators. The position of flexurebinges is also elaborately designed with consideration to reduce the bending deformation of themoving part. Three capacitive sensors are used to form close loop control system. Considering thetable as a damped 3-DOF mass-spring system, the models of static and dynamic stiffness and errorowing to the action of external forces have been established. In order to make the table have highresolution and positioning accuracy, an error compensation algorithm is implemented by using theestablished models. The experimental testing has been carried out to verify the performance of theworkpiece table and the established models of the micropositioning workpiece table.展开更多
基金supported by the National Natural Science Foundation of China(Grant Nos.12172248,12021002,12302022,12132010)Tianjin Research Program of Application Foundation and Advanced Technology(Grant No.22JCQNJC00780)the IoT Standards and Application Key Laboratory of the Ministry of Industry and Information Technology(Grant No.202306).
文摘The shell composed of large-scale parts is the essential component of mechanical structures in the aerospace,shipping,and railway industries.These workpieces are characterized by thin walls and weak rigidity,thus requiring an effective technology for high-performance machining.Accordingly,an embedded locally resonant metamaterial with double resonators is proposed and combined with the magnetic follow-up support technology to attenuate the vibration of thin-walled parts for the first time.The band structures and parametric adjustment laws are systematically investigated and validated by analytical calculation and finite element method,which proves the proposed model is broadband,lightweight,and flexible in low frequencies.Its characteristics,as well as the relatively simple structure,are unique advantages for thin-walled structure milling.Finally,mirror milling experiments have been performed to assess the slave module with the proposed substructure.From the results,the root mean square amplitude of the thin-walled workpiece with the combined device decreases by nearly 9%,which means that the performance has been improved by the combined device.Furthermore,this work provides an integrated and efficient solution for vibration suppression in thin-walled parts milling,which extends locally resonant metamaterials to practical engineering fields and helps to improve the status quo of mirror milling from the perspective of metamaterials.
基金supported by the National Defense Basic Scientific Research Program of China(Grant numbers JCKY2019427D002)。
文摘The measurement uncertainty analysis is carried out to investigate the measurable dimensions of cylindrical workpieces by the rotary-scan method in this paper.Due to the difficult alignment of the workpiece with a diameter of less than 3 mm by the rotary scan method,the measurement uncertainty of the cylindrical workpiece with a diameter of 3 mm and length of 50 mm which is measured by a roundness measuring machine,is evaluated according to GUM(Guide to the Expression of Uncertainty in Measurement)as an example.Since the uncertainty caused by the eccentricity of the measured workpiece is different with the dimension changing,the measurement uncertainty of cylindrical workpieces with other dimensions can be evaluated the same as the diameter of 3 mm but with different eccentricity.Measurement uncertainty caused by different eccentricities concerning the dimension of the measured cylindrical workpiece is set to simulate the evaluations.Compared to the target value of the measurement uncertainty of 0.1μm,the measurable dimensions of the cylindrical workpiece can be obtained.Experiments and analysis are presented to quantitatively evaluate the reliability of the rotary-scan method for the roundness measurement of cylindrical workpieces.
基金This research is supported by the National Natural Science Foundation of China(Grant Nos.51475087 and 51304105)the Natural Science Foundation of Liaoning Province(Grant No.20180550167)+1 种基金the Key Projects of Liaoning Province(Grant Nos.LJ2019ZL005 and LJ2017ZL001)the Oversea Training Project of High Level Innovation Team of Liaoning Province(Grant No.2018LNGXGJWPY-ZD001).
文摘To improve the milling surface quality of the Al-Li alloy thin-wall workpieces and reduce the cutting energy consumption.Experimental research on the milling processing of AA2195 Al-Li alloy thin-wall workpieces based on Response Surface Methodology was carried out.The single factor and interaction of milling parameters on surface roughness and specific cutting energy were analyzed,and the multi-objective optimization model was constructed.The Multiobjective Particle Swarm Optimization algorithm introducing the Chaos Local Search algorithm and the adaptive inertial weight was applied to determine the optimal combination of milling parameters.It was observed that surface roughness was mainly influenced by feed per tooth,and specific cutting energy was negatively correlated with feed per tooth,radial cutting depth and axial cutting depth,while cutting speed has a non-significant influence on specific cutting energy.The optimal combination of milling parameters with different priorities was obtained.The experimental results showed that the maximum relative error of measured and predicted values was 8.05%,and the model had high reliability,which ensured the low surface roughness and cutting energy consumption.It was of great guiding significance for the success of Al-Li alloy thin-wall milling with a high precision and energy efficiency.
文摘In this paper, the traditional empirical coefficient method and a novel loop material analytical method presented by the authors have been compared and discussed by analyzing several practical cylindrical workpieces’ deep drawing projects. Also, some conclusions about how to modify the traditional analyzing method of cylindrical workpieces’ deep drawing process could be concluded and the necessity of this modification could be proved.
文摘Laser surface hardening is a very promising hardening process for ferrous alloys where transformations occur during cooling after laser heating in the solid state. The characteristics of the hardened surface depend on the physicochemical properties of the material as well as the heating system parameters. To exploit the benefits presented by the laser hardening process, it is necessary to develop an integrated strategy to control the process parameters in order to produce desired hardened surface attributes without being forced to use the traditional and fastidious trial and error procedures. This study presents a comprehensive modelling approach for predicting the hardened surface physical and geometrical attributes. The laser surface transformation hardening of cylindrical AISI 4340 steel workpieces is modeled using the conventional regression equation method as well as artificial neural network method. The process parameters included in the study are laser power, beam scanning speed, and the workpiece rotational speed. The upper and the lower limits for each parameter are chosen considering the start of the transformation hardening and the maximum hardened zone without surface melting. The resulting models are able to predict the depths representing the maximum hardness zone, the hardness drop zone, and the overheated zone without martensite transformation. Because of its ability to model highly nonlinear problems, the ANN based model presents the best modelling results and can predict the hardness profile with good accuracy.
文摘In order to obtain the desired mechanical properties of quenching and tempering workpieces, as well as reduce the cracking tendency and distortion, a program of controllable quenching was established. Furthermore, a computer-aided quenching system (CAQ) was also developed. The application samples of the CAQ system showed satisfactory results.
基金the Shanghai Special Development Project of Major Equipment Technologies(No. 0706014)the Key Scientific Research Project of Shanghai Ministry of Science and Technology(No. 021111125)
文摘Grinding is an energy-intensive process in which the heat generated can cause various types of thermal damage to workpiece.Many theoretical,empirical or numerical models have been developed to predict grinding temperature.However,these models are not directly applicable for coated workpieces.Tools or other parts are coated with hard materials like tungsten carbide,ceramics or polycrystalline diamond to increase their surface hardness and prolong their life expectancy.In this paper,an empirical model is proposed to predict the maximum grinding temperature of coated workpieces.Experimental and numerical studies are carried out to validate the model.The results indicated that the new model is able to accurately predict grinding temperature.
文摘In order to form large-diameter thin-wall cylindrical workpieces of TA15 titanium alloy,tube hot spinning experiments of the alloy were conducted on a CNC hot spinning machine.The causes of some forming defects occuring in hot spinning,such as crack,pileup,bulge and corrugation,were analyzed and the corresponding measures were put forward to avoid spinning defects,based on which a proper process scheme of hot spinning of TA15 alloy was obtained and the large-diameter and thin-walled cylindrical workpieces were formed with good quality.The results show that spinning temperature has distinct influence on forming quality of spun workpieces.The range of spinning temperature determines the spinnability of titanium alloy and the ununiformity of temperature distribution near the deformation zone leads to the formation of bulge.The reasonable heating method is that the deforming region is heated to the optimum temperature range of 600-700 ℃,the deformed region is heated continuously and a certain length of undeformed region is preheated.With the thickness-to-diameter ratio(t/D) of spun workpiece reducing to certain value(t/D<1%),surface bulge and corrugation is rather easier to come into being,which could be controlled through restraining diameter growth and employing smaller reduction rate and lower temperature in the optimum spinning temperature range.
基金supported by the National Natural Science Foundation of China (Grant No.52175025)。
文摘To reduce the vibration and deformation of large thin-walled workpieces during the milling process,mirror milling is widely used due to its point-to-point support and strong applicability.The influence of the support head on the workpiece’s dynamic characteristics is crucial in determining whether the mirror milling process is reliable and effective.Therefore,this study establishes a time-varying dynamic model for mirror milling of thin-walled workpieces with various boundary conditions to accurately analyze and predict the dynamic characteristics and response of the workpiece.First,a new analytical method for material removal with extensive applicability and high precision is proposed.In this method,the Ritz mode shape is used to approximate the workpiece’s mode shape as it changes during material removal.Next,the Hertz contact theory is adopted to establish a tool-workpiece-support head coupling model,which considers the jump-off phenomenon between them.Subsequently,the dynamic model is solved using the Newmark-β numerical integration method to obtain the workpiece’s time-domain acceleration and displacement responses under the forced vibration.Finally,the measured frequency response function(FRF)and vibration signals of workpieces verify the correctness of the proposed mirror milling model for thin-walled workpieces considering material removal.In addition,this paper analyzes the dynamic characteristics and forced vibration law of workpieces in mirror milling,which lays the foundation for high precision mirror milling.
基金Project supported by the National Natural Science Foundation of China(Nos.12172248,12021002,12302022,and 12132010)the Tianjin Research Program of Application Foundation and Advanced Technology of China(No.22JCQNJC00780)IoT Standards and Application Key Laboratory of the Ministry of Industry and Information Technology of China(No.202306)。
文摘As critical components of aircraft skins and rocket fuel storage tank shells,large thin-walled workpieces are susceptible to vibration and deformation during machining due to their weak local stiffness.To address these challenges,we propose a novel tunable electromagnetic semi-active dynamic vibration absorber(ESADVA),which integrates with a magnetic suction follower to form a followed ESADVA(follow-ESADVA)for mirror milling.This system combines a tunable magnet oscillator with a follower,enabling real-time vibration absorption and condition feedback throughout the milling process.Additionally,the device supports self-sensing and frequency adjustment by providing feedback to a linear actuator,which alters the distance between magnets.This resolves the traditional issue of being unable to directly monitor vibration at the machining point due to space constraints and tool interference.The frequency shift characteristics and vibration absorption performance are comprehensively investigated.Theoretical and experimental results demonstrate that the prototyped follow-ESADVA achieves frequency synchronization with the milling tool,resulting in a vibration suppression rate of approximately 47.57%.Moreover,the roughness of the machined surface decreases by18.95%,significantly enhancing the surface quality.The results of this work pave the way for higher-quality machined surfaces and a more stable mirror milling process.
文摘To improve the productivity,the resource utilization and reduce the production cost of flexible job shops,this paper designs an improved two-layer optimization algorithm for the dual-resource scheduling optimization problem of flexible job shop considering workpiece batching.Firstly,a mathematical model is established to minimize the maximum completion time.Secondly,an improved two-layer optimization algorithm is designed:the outer layer algorithm uses an improved PSO(Particle Swarm Optimization)to solve the workpiece batching problem,and the inner layer algorithm uses an improved GA(Genetic Algorithm)to solve the dual-resource scheduling problem.Then,a rescheduling method is designed to solve the task disturbance problem,represented by machine failures,occurring in the workshop production process.Finally,the superiority and effectiveness of the improved two-layer optimization algorithm are verified by two typical cases.The case results show that the improved two-layer optimization algorithm increases the average productivity by 7.44% compared to the ordinary two-layer optimization algorithm.By setting the different numbers of AGVs(Automated Guided Vehicles)and analyzing the impact on the production cycle of the whole order,this paper uses two indicators,the maximum completion time decreasing rate and the average AGV load time,to obtain the optimal number of AGVs,which saves the cost of production while ensuring the production efficiency.This research combines the solved problem with the real production process,which improves the productivity and reduces the production cost of the flexible job shop,and provides new ideas for the subsequent research.
基金Project (U0834002) supported by the Key Program of NSFC-Guangdong Joint Funds of ChinaProject (51005079) supported by the National Natural Science Foundation of China+1 种基金Project (20100172120001) supported by Specialized Research Fund for the Doctoral Program of Higher Education, ChinaProject (10451064101005146) supported by the Natural Science Foundation of Guangdong Province,China
文摘To investigate the workpiece curvature influence on groove deformation,numerical studies with curvature varying from negative to positive were conducted on copper material.Groove deformations were analyzed,including groove geometry,effective stress distribution and plough force.The curled groove shape whose workpiece curvature was 0.133 mm-1 was validated by experiments.Moreover,a series of geometry models with various curvatures were introduced to analyze the change of groove deformation.The results show that positive curvatures influence groove deformation more intensively than negative or zero curvature.It is mainly due to the action of the tool forming face during plough process.
文摘A conventional non-computerized numerical control （CNC） machine is updated by mounting a six degree-of-free （DOF） parallel mechanism on it, thus obtaining a new CNC one. The structure of this CNC milling machine is introduced, and the workpiece locating system and the post processing system of the cutter location （CL） data file are analyzed. The new machine has advantages of low costs, simple structure, good rigidity, and high precision. It is easy to be transformed and used to process the workpiece with a complex surface.
基金supported by the National Basic Research Program of China (Grant No. 2013CB035802)the 111 Project of China (Grant No. B13044)
文摘Milling of the thin-walled workpiece in the aerospace industry is a critical process due to the high flexibility of the workpiece. In this paper, a flexible fixture based on the magnetorheological (MR) fluids is designed to investigate the regenerative chatter suppression during the machining. Based on the analysis of typical structural components in the aerospace industry, a general complex thin-walled workpiece with fixture and damping constraint can be equivalent as a rectangular cantilever beam. On the basis of the equivalent models, natural frequency and mode shape function of the thin-walled workpiece is obtained according to the Euler-Bernoulli beam assumptions. Then, the displacement response function of the bending vibration of the beam is represented by the product of all the mode shape function and the generalized coordinate. Furthermore, a dynamic equation of the workpiece-fixture system considering the external damping factor is proposed using the Lagrangian method in terms of all the mode shape function and the generalized coordinate, and the response of system under the dynamic cutting force is calculated to evaluate the stability of the milling process under damping control. Finally, the feasibility and effectiveness of the proposed approach are validated by the impact hammer experiments and several machining tests. (C) 2016 Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics.
基金the National Natural Science Foundation of China(No.51575319)the Young Scholars Program of Shandong University(No.2015WLJH31)+1 种基金the Major National Science and Technology Project(No.2014ZX04012-014)the Tai Shan Scholar Foundation(No.TS20130922)
文摘The milling stability of thin-walled components is an important issue in the aviation manufacturing industry,which greatly limits the removal rate of a workpiece.However,for a thin-walled workpiece,the dynamic characteristics vary at different positions.In addition,the removed part also has influence on determining the modal parameters of the workpiece.Thus,the milling stability is also time-variant.In this work,in order to investigate the time variation of a workpiece's dynamic characteristics,a new computational model is firstly derived by dividing the workpiece into a removed part and a remaining part with the Ritz method.Then,an updated frequency response function is obtained by Lagrange's equation and the corresponding modal parameters are extracted.Finally,multi-mode stability lobes are plotted by the different quadrature method and its accuracy is verified by experiments.The proposed method improves the computational efficiency to predict the time-varying characteristics of a thin-walled workpiece.
基金Supported by International S&T Cooperation Program of China(Grant No.2012DFA70260)High-end CNC Machine and Basic Manufacturing Equipment of Chinese Key National Science and Technology(Grant No.2011ZX04014-081)
文摘The workpiece frames relative to each robot base frame should be known in advance for the proper operation of twin-robot nondestructive testing system. However, when two robots are separated from the workpieces, the twin robots cannot reach the same point to complete the process of workpiece frame positioning. Thus, a new method is proposed to solve the problem of coincidence between workpiece frames. Transformation between two robot base frames is initiated by measuring the coordinate values of three non-collinear calibration points. The relationship between the workpiece frame and that of the slave robot base frame is then determined according to the known transformation of two robot base frames, as well as the relationship between the workpiece frame and that of the master robot base frame. Only one robot is required to actually measure the coordinate values of the calibration points on the workpiece. This requirement is beneficial when one of the robots cannot reach and measure the calibration points. The coordinate values of the calibration points are derived by driving the robot hand to the points and recording the values of top center point（TCP） coordinates. The translation and rotation matrices relate either the two robot base frames or the workpiece and master robot. The coordinated are solved using the measured values of the calibration points according to the Cartesian transformation principle. An optimal method is developed based on exponential mapping of Lie algebra to ensure that the rotation matrix is orthogonal. Experimental results show that this method involves fewer steps, offers significant advantages in terms of operation and time-saving. A method used to synchronize workpiece frames in twin-robot system automatically is presented.
基金financially supported by the National Key R&D Program of China(No.2018YFB0703801)the Sichuan Science and Technology Program(No.2019YFSY0012)the CAS"Light of West China"Program。
文摘A novel DLC film deposition method was proposed to realize the deposition of DLC film on the surface of complex shaped workpiece.Meanwhile,Si-DLC film was deposited on the surface of M2 high-speed steel(HSS M2)and 304 stainless steel(304SS),and the microstructure,surface roughness,mechanical properties,corrosion resistance and tribological properties of Si-DLC films were characterized in detail.Results show that Si-DLC film at different axial positions of the auxiliary cathode possesses similar microstructure,film thickness and surface roughness,and the as-deposited Si-DLC film shows the low intrinsic stress of<0.3 GPa.Compared with the 304SS substrate,the Si-DLC film presents more noble corrosion potential,lower corrosion current density and higher polarization resistance,exhibiting higher corrosion resistance.Moreover,the Si-DLC film exhibits higher hardness,elastic factor and plastic factor than HSS M2 substrate and the corresponding adhesive strength is more than 10 N.The Si-DLC film sliding against GCr15 steel ball shows a lower friction coefficient than that of HSS M2 substrate and the wear rate of GCr15 steel ball sliding against the Si-DLC is lower than that of HSS M2 substrate.In addition,this novel method was used to deposit Si-DLC film on gears,drills and bearings without rotating sample racks.As a consequence,this method possesses great potential and can be generalized for the deposition of DLC film on the surface of complex shape workpiece.
基金supported by National Natural Science Foundation of China(Grant No.51675440)Fundamental Research Funds for the Central Universities of China(Grant no.3102018gxc025)
文摘The problem of chatter vibration is associated with adverse consequences that often lead to tool impairment and poor surface finished in a workpiece, and thus, controlling or suppressing chatter vibrations is of great significance to improve machining quality. In this paper, a workpiece and an actuator dynamics are considered in modeling and controller design. A proportional-integral controller(PI) is presented to control and actively damp the chatter vibration of a workpiece in the milling process. The controller is chosen on the basis of its highly stable output and a smaller amount of steady-state error. The controller is realized using analog operational amplifier circuit. The work has contributed to planning a novel approach that addresses the problem of chatter vibration in spite of technical hitches in modeling and controller design. The method can also lead to considerable reduction in vibrations and can be beneficial in industries in term of cost reduction and energy saving. The application of this method is verified using active damping device actuator(ADD) in the milling of steel.
文摘Microstructured roll workpieces have been widely used as functional components in the precision industries. Current researches on quality control have focused on surface profile measurement of microstructured roll workpieces, and types of measurement systems and measurement methods have been developed. However, low measurement efficiency and low measurement accuracy caused by setting errors are the common disadvantages for surface profile measurement of microstructured roll workpieces. In order to shorten the measurement time and enhance the measurement accuracy, a method for self-calibration and compensation of setting errors is proposed for surface profile measurement of microstructured roll workpieces. A measurement system is constructed for the measurement, in which a precision spindle is employed to rotate the roll workpiece and an air-bearing displacement sensor with a micro-stylus probe is employed to scan the microstructured surface of the roll workpiece. The resolution of the displacement sensor is 0.14 nm and that of the rotary encoder of the spindle was 0.15r~. Geometrical and mathematical models are established for analyzing the influences of the setting errors of the roll workpiece and the displacement sensor with respect to the axis of the spindle, including the eccentric error of the roll workpiece, the offset error of the sensor axis and the zero point error of the sensor output. Measurement experiments are carded out on a roll workpiece on which periodic microstructures are a period of 133 i^m along the circumferential direction. Experimental results demonstrate the feasibility of the self-compensation method. The proposed method can be used to detect and compensate the setting errors without using any additional accurate artifact.
基金This project is supported by National Natural Science Foundation of China(No.50275104)
文摘In order to achieve active grinding control, a novel numerical controlmicropositioning workpiece table with a resolution of 6 nm has been developed. The table is drivenby three piezoelectric actuators mounted on the base. An elastic structure with three half-notchflexure hinges is designed to apply preload to the piezoelectric actuators. The position of flexurebinges is also elaborately designed with consideration to reduce the bending deformation of themoving part. Three capacitive sensors are used to form close loop control system. Considering thetable as a damped 3-DOF mass-spring system, the models of static and dynamic stiffness and errorowing to the action of external forces have been established. In order to make the table have highresolution and positioning accuracy, an error compensation algorithm is implemented by using theestablished models. The experimental testing has been carried out to verify the performance of theworkpiece table and the established models of the micropositioning workpiece table.
