Digital twin-based analysis of volumetric error mapping procedures

The evaluation of the volumetric accuracy of a machine tool is an open challenge in the industry, and a wide variety of technical solutions are available in the market and at research level. All solutions have advantages and disadvantages concerning which errors can be measured, the achievable uncertainty, the ease of implementation, possibility of machine integration and automation, the equipment cost and the machine occupation time, and it is not always straightforward which option to choose for each application. The need to ensure accuracy during the whole lifetime of the machine and the availability of monitoring systems developed following the Industry 4.0 trend are pushing the development of measurement systems that can be integrated in the machine to perform semi-automatic verification procedures that can be performed frequently by the machine user to monitor the condition of the machine. Calibrated artefact based calibration and verification solutions have an advantage in this field over laser based solutions in terms of cost and feasibility of machine integration, but they need to be optimized for each machine and customer requirements to achieve the required calibration uncertainty and minimize machine occupation time.This paper introduces a digital twin-based methodology to simulate all relevant effects in an artefact-based machine tool calibration procedure, from the machine itself with its expected error ranges, to the artefact geometry and uncertainty, artefact positions in the workspace, probe uncertainty, compensation model, etc. By parameterizing all relevant variables in the design of the calibration procedure, this simulation methodology can be used to analyse the effect of each design variable on the error mapping uncertainty, which is of great help in adapting the procedure to each specific machine and user requirements. The simulation methodology and the analysis possibilities are illustrated by applying it on a 3-axis milling machine tool.     

Influence of temperature on acoustic emission source location accuracy in underground structure

An acoustic emission (AE) experiment was carried out to explore the AE location accuracy influenced by temperature. A hollow hemispherical specimen was used to simulate common underground structures. In the process of heating with the flame, the pulse signal of constant frequency was stimulated as an AE source. Then AE signals received by each sensor were collected and used for comparing localization accuracy at different temperatures. Results show that location errors of AE keep the same phenomenon in the early and middle heating stages. In the later stage of heating, location errors of AE increase sharply due to the appearance of cracks. This provides some beneficial suggestions on decreasing location errors of structural cracks caused by temperature and improves the ability of underground structure disaster prevention and control.     

中低温煤焦油基炭微球的制备

通过馏分切割、温和加氢相结合对中低温煤焦油进行精制处理，精制后的原料采用分级热聚制备中间相炭微球。考察了精制处理条件对原料性质、中间相炭微球宏观外貌及微晶结构的影响。采用FTIR、GC-MS、族组成、元素分析对原料进行表征，采用SEM、XRD对中间相炭微球进行表征。结果表明：中低温煤焦油中300～430℃馏分油是制备中间相炭微球的较佳馏分。300～430℃馏分油中正庚烷可溶物（HS）质量分数高达84.76%，吡啶不溶物（PI）质量分数低至0.23%，杂原子含量低，芳烃化合物的环数为2～4环。300～430℃馏分油在T_H=350℃、p=8MPa、t=1.5h、剂油比1∶40（质量比）的条件下温和加氢得到的精制原料，经420℃热聚6h得制备的中间相炭微球宏观外貌、微晶结构较好。中低温煤焦油基炭微球的粒径范围为5～15μm，小球表面光滑，微观结构为地球仪型，经1450℃高温煅烧后，石墨化度达到12.33%。     

Experimental investigation of different morphology textured ceramic tools by in-situ formed for the dry cutting

Surface texture is considered an important measure to improve the cutting performance of a tool. In this study, we have prepared three types of textured and conventional tools on the rake face by an in-situ formed method. During the experiment, the best parameters of three types of textured tools were selected for dry cutting AISI 1045 steel at different cutting speeds. Cutting forces, cutting temperatures, workpiece surface roughness, and tool wear were measured during the cutting process. The results showed that textured tools have significantly reduced cutting force, cutting temperature, and tool wear, and the roughness of the workpiece was improved compared with the conventional tool. The micro-pit texture tool has less stress contact region than the micro-groove width texture tool, but the micro-groove width texture tool exhibiting the best cutting performance. This investigation clearly showed that the textured tool prepared by the in-situ formed method has improved cutting performance.     

大断面切眼支护技术研究与实践

针对古城煤矿S1303综采工作面切眼的地质构造与施工条件,提出了大断面切眼采用“锚网索+π型梁棚+预注浆”联合支护方案,有效地控制了大断面切眼留顶煤施工期间的支护难题,保障了S1303综采面切眼能够满足设计要求和如期完成施工,为同类条件下的切眼施工提供了一定参考。     

Experimental study of crystal anisotropy based on ultra-precision cylindrical turning of single-crystal calcium fluoride

To realize ultimately efficient signal processing, it is necessary to replace electrical signal processing circuits with optical ones. The optical micro-resonator, which localizes light at a certain spot, is an essential component in optical signal processing. Single-crystal calcium fluoride (CaF₂) is the most suitable material for a highly efficient optical micro-resonator. The CaF₂ resonator can only be manufactured by ultra-precision machining processes, because its crystal anisotropy does not allow the application of chemical etching. However, the optical micro-resonator's performance depends definitely on the surface integrity.This study investigated the relationship between surface quality after ultra-precision machining and crystal anisotropy. Firstly, crack initiation was investigated on the (1 0 0), (1 1 0), and (1 1 1) planes using the micro-Vickers hardness test. Secondly, brittle-ductile transition was investigated by orthogonal cutting tests. Finally, cutting performance of cylindrical turning was evaluated, which could be a suitable method for manufacturing the CaF₂ resonator. The most difficult point in cylindrical turning of CaF₂ is that the crystalline plane and cutting direction vary continuously. In order to manufacture the CaF₂ optical micro-resonator more efficiently, analysis was conducted on crack initiation and surface quality of all crystallographic orientations from the perspective of slip system and cleavage.     

Study on the non-uniform contact during ELID groove grinding

This paper introduces the potential feasibility that ELID (electrolytic in-process dressing) grinding replaces superfinishing in bearing manufacturing, but ELID grinding will bring new challenges. Different regions present distinguish surface profile due to the non-uniform contact in ELID groove grinding. However, few reports explaining the non-uniform contact are available. This article explores the mechanisms of the non-uniform contact during ELID groove grinding. Experiments on the non-uniform contact between bearing raceway and grinding wheel have been carried out under different conditions. The results show that non-uniform contact exists in ELID groove grinding process and it exerts influence on the profile of the raceway surface. Non-uniform contact influences the Rsk and Rku value all the time, but it influences the Ra value occasionally. Improvement strategies of eliminating the non-uniform contact are also discussed based on the experimental study.     

冷轧平整机机前甩尾轧制工艺的开发与应用

本文介绍了柳钢冷轧板带厂1550 mm单机架平整机机前甩尾轧制的工艺。改进前轧制每卷钢卷生产效率低,钢卷成材率低,改进后生产效率、成材率明显提高,部分规格的钢卷能实现带尾剪切长度为零。     

Influences of chip serration on micro-topography of machined surface in high-speed cutting

Saw-tooth chip changes from macroscopically continuous ribbon to separated segments with the increase of cutting speed. The aim of this study is to find the correlations between chip morphology and machined surface micro-topography at different chip serration stages encountered in high speed cutting. High strength alloy steel AerMet100 was employed in orthogonal cutting experiments to obtain chips at different serration stages and corresponding machined surfaces. The chips and machined surfaces obtained were then examined with optical microscope (OM), scanning electron microscope (SEM), and white light interferometer (WLI). The result shows that chip serration causes micro-waves on machined surface, which increases machined surface roughness. However, wave amplitudes (surface roughness) at different serration stages are different. The principal factor influencing wave amplitude is the thickness of the sawed segment (tooth) of saw-tooth chip. With cutting parameters in this study, surface roughness contributed by chip serration ranges from 0.39 μm to 1.85 μm. This may bring on serious problems in the case of trying to replace grinding with high-speed cutting in rough machining. Some suggestions have been proposed to control the chip serration-caused surface roughness in high-speed cutting based on the results of the current study.     

面向流屑角突变建模的切削状态参数经验公式的获得及应用

从提高流屑角突变模型的预测精度出发,建立了切削状态参数与3个切削控制参数之间关系的新经验公式。提出了一种通过迭代法准确设定有限元仿真软件刀-屑摩擦因数的方法,并通过直角切削Al6061-T6工件的有限元仿真试验,获得了一组不同切削控制参数组合条件下的切削状态参数数据。根据该数据拟合出剪切角φ、刀-屑摩擦角β、剪切应力τs关于刀具前角γ0、进给量f和切削速度v的经验公式,并通过一组直角切削试验,验证了所得经验公式的有效性。将新建经验公式应用于流屑角突变建模过程后,所得模型关于突变临界切削宽度的平均预测误差减小了27.2%。