Fuzzy feed rate and cutting speed optimization in turning

There are several methods of monitoring metal cutting processes. In this study, the combination of various methods in order to define an overall “cutting state” of a turning process is discussed along with an application to use these methods for adaptive fuzzy feed rate and cutting speed optimising control. For this purpose, different methods of monitoring individual cutting phenomena such as chip length and vibration level are aggregated and the combination of this information is considered to be the cutting state of the process. Expert data has been collected from a series of experiments concerning the apparent state of these phenomena as well as required control action. An adaptive optimizing fuzzy controller has been designed based on the concept of the cutting state and collected expert rules. The automatically classified cutting state as well as the control action based on this state is compared to expert data. There are notable differences which are analysed and solutions and further research are suggested based on the points requiring further improvement.     

Investigation and optimization of lubrication parameters in high speed turning of superalloy Inconel 718

Dry machining is sometimes less effective when higher machining efficiency, better surface finish quality, and severe cutting conditions are required. For these situations, semi-dry operations utilizing very small amount of cutting fluids called minimum quantity lubrication is expected to become a powerful tool and played a significant role in a number of practical applications. It has been observed from the literature survey that a systematic research work has to be carried out to determine the optimum quantity of lubricant with appropriate cutting conditions for achieving better machinability characteristics of a material. Hence, an attempt has been made in this paper to enhance the machinability characteristics in high speed turning of superalloy Inconel 718 using quantity of lubricant, delivery pressure at the nozzle, frequency of pulses, direction of application of cutting fluid, cutting speed, and feed rate as the process parameters. Results indicated that the use of optimized minimum quantity lubrication parameters under pulsed jet mode leads to lower cutting force, cutting temperature, and flank wear.     

高速车削工件表面形貌及其粗糙度特征的试验研究

借助于扫描电镜照片、已加工样品表面形貌轮廓描绘和试验数据处理等手段,对高速车削工件已加工表面形貌与其表面粗糙度之间的关系以及它们的形成特征进行了分析研究.研究结果表明,切削速度和被切削材料的硬度是决定高速车削过程中被切削层材料变形和已加工表面形貌及其表面粗糙度形成的主要因素,随着被切削材料硬度和切削速度的提高,工件已加工表面质量在一定程度上得到了改善.在已加工表面上出现了犁垄和高速加工所特有的熔融金属涂抹现象,由此决定着已加工表面粗糙度值的变化.     

模糊免疫PID调速系统及其在缝纫机上的仿真

针对工业缝纫机采用传统PID调速方法无法满足其高动态性、高适应性的要求,借鉴生物免疫反馈机理,提出了模糊免疫PID控制方法,对永磁同步电动机(PMSM)进行了调速控制。通过研究遗传免疫算法和模糊控制算法,对传统的PID调速方法进行了改进,提出了模糊免疫PID调速控制模型,并且进行了仿真实验。仿真结果表明,与传统PID调速方法相比,该新型PID调速方法具有响应快速、超调量小、鲁棒性好、抗干扰能力强等优点。     

Study of surface quality in high speed turning of Inconel 718 with uncoated and coated CBN tools

Inconel 718 is known to be among the most difficult-to-machine materials due to its special properties which cause the short tool life and severe surface damages. The properties, which are responsible for poor machinability, include rapid work hardening during machining; tendency to weld with the tool material at high temperature generated during machining; the tendency to form a built-up edge during machining; and the presence of hard carbides, such as titanium carbide and niobium carbide, in their microstructure. Conventional method of machining Inconel 718 with cemented carbide tool restricts the cutting speed to a maximum 30?m/min due to the lower hot hardness of carbide tool, high temperature strength and low thermal conductivity of Inconel 718. The introduction of new coated carbide tools has increased cutting speed to 100?m/min; nevertheless, the time required to machine this alloy is still considerably high. High speed machining using advanced tool material, such as CBN, is one possible alternative for improving the productivity of this material due to its higher hot hardness in comparison with carbide tool. This paper specifically deals with surface quality generated under high speed finishing turning conditions on age-hardened Inconel 718 with focus on surface roughness, metallographic analysis of surface layer and surface damages produced by machining. Both coated and uncoated CBN tools were used in the tests, and a comparison between surfaces generated by both tools was also discussed.     

用于工业实时测控的智能仪器的抗干扰技术

本介绍了用于工业现场恶劣环境下的时测控系统的抗干扰原理，电路和措施。     

The analysis of tool life and wear mechanisms in spindle speed variation machining

Regenerative chatter vibrations generally limit the achievable material removal rate in machining. The diffusion of spindle speed variation (SSV) as a chatter suppression strategy is mainly restricted to academy and research centers. A lack of knowledge concerning the effects of non-stationary machining is still limiting its use in real shop floors. This research is focused on the effects of spindle speed variation technique on tool duration and on wear mechanisms. No previous researches have been performed on this specific topic. Tool wear tests in turning were carried out following a factorial design: cutting speed and cutting speed modulation were the investigated factors. The carbide life was the observed process response. A statistical approach was used to analyze the effects of the factors on the tool life. Moreover, the analysis was extended to the wear mechanisms involved during both constant speed machining and SSV. The worn-out carbide surfaces were examined under a scanning electron microscope equipped with an energy dispersive X-ray spectrometer. Significant differences were appreciated. It was observed that SSV tends to detach the coatings of the inserts, entailing a mechanism that is quite unusual in wet steel turning and thus fostering the wear of the tool. The performed analysis allowed to deduce that the intensified tool wear (in SSV cutting) is mainly due to thermo-mechanical fatigue.     

Modeling and analysis of boring bar vibration response in internal turning due to variation of the amount of DVA rubber in finish boring cut

Journal of Mechanical Science and Technology - In boring processes, excessive vibration often occur due to low tool stiffness. To solve this problem, a mechanical vibration suppression called...     

AlTiN涂层刀具精铣TC4钛合金工艺参数的影响与优化

采用AlTiN涂层4刃φ10 mm硬质合金立铣刀,在VMC850立式加工中心上对TC4钛合金进行铣削精加工试验.利用高精密数字化检测设备,对加工成形的TC4钛合金试件表面粗糙度、平面度、平行度、表面形貌、残余应力及显微硬度测量.分析AlTiN涂层刀具在设定不同工艺参数条件下TC4钛合金的整体加工质量和表面形貌变化规律....     

Methodological approach to planning and justifying technological innovation in manufacturing

The outline of a preliminary but general model of an innovation process, satisfying a number of previously defined specifications, is the aim of this paper. A model of the innovation process is first formulated, and the paper goes on to formulate the innovation design problem based on this model. Next, the main concepts for approaching the task of designing interventions for plant modification are outlined, and finally the problem of conditioning demands from customers is examined.     

高速车削钛合金时硬质合金刀具和涂层刀具的寿命分析

采用硬质合金刀具和硬质合金TiMN涂层刀具对Ti-6Al-4V钛合金进行高速干车削正交试验,并通过多元线性回归分析得出硬质合金刀具和涂层刀具的寿命经验公式.分析表明:随着所选用的切削参数值的升高,刀具的使用寿命急剧减少,其中速度v对刀具使用寿命的影响最大.涂层刀具在低速切削加工钛合金时其寿命优于未涂层刀具,随着速度的提高,涂层刀具的优势迅速减小.当切削速度低于85 m/min,刀具寿命经验公式可以作为数控机床自动换刀的刀具寿命标准.     

Overview from oil seeds to industrial products: Present and future oleochemistry

In this paper the available technologies for the preparation of oils, fats and their derivatives using oil seeds as a starting material are discussed. Currently, 15 million tonnes per year of fatty products are used for industrial purposes, and their applications are discussed with particular reference to biodiesel, biolubricants, biosolvents, and printing inks. For each product, the discussion concerns the state of the art as well as the prospects for the future, and existing barriers to development. Also, the problem of glycerol production in terms of both economic significance and new outlets for surplus production is discussed. The paper ends with a brief overview of recent trends in research in the field of chemical and technical utilisation of vegetable oils.     

Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel

In this study, the effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and resultant forces in the finish hard turning of AISI H13 steel were experimentally investigated. Cubic boron nitrite inserts with two distinct edge preparations and through-hardened AISI H13 steel bars were used. Four-factor (hardness, edge geometry, feed rate and cutting speed) two-level fractional experiments were conducted and statistical analysis of variance was performed. During hard turning experiments, three components of tool forces and roughness of the machined surface were measured. This study shows that the effects of workpiece hardness, cutting edge geometry, feed rate and cutting speed on surface roughness are statistically significant. The effects of two-factor interactions of the edge geometry and the workpiece hardness, the edge geometry and the feed rate, and the cutting speed and feed rate also appeared to be important. Especially honed edge geometry and lower workpiece surface hardness resulted in better surface roughness. Cutting-edge geometry, workpiece hardness and cutting speed are found to be affecting force components. The lower workpiece surface hardness and honed edge geometry resulted in lower tangential and radial forces.     

航空发动机主轴轴承数据统计处理及寿命评估

航空发动机主轴轴承台架试验费用昂贵且多为小子样无失效 ,在此情况下讨论其分布函数实为困难。因此 ,由现场收集大量的使用数据 ,以初步探讨其寿命分布规律及其可靠性水平 ,为航空发动机轴承可靠性研究打下了基础。附表 5个     

MRT letter: high speed scanning has the potential to increase fluorescence yield and to reduce photobleaching

True confocal microscopy requires point-shaped illumination and detection. To generate an image, a diffraction limited spot is moved over the sample. Single spot scanning has suffered in the past from low image rates; a solution is the employment of very fast scanning devices (resonant scanners) for x-movement. In the process of introducing resonant scanning devices, it was found that both signal yield is improved and bleaching is decreased-in contrary to the assumed performance. This article will show by a simple and well understood model a straightforward explanation for the potential increase of signal yield and decrease in photobleaching. The time that is ruling the dose-rate effects is the effective time; a fluorochrome is illuminated. This time depends on the diameter of the spot that is moved over the sample and the speed at which the spot moves. In essence, the scan process causes a pulsed illumination of the fluorochromes. Various schemes of pulsed illumination are simulated with a fluorescence model. The model includes a dark state, where fluorochromes will exit the fluorescence process and slowly decay back into the ground state. Upon splitting a single dose into two pulses separated by a dark time-reflecting an increased scan speed-the amount of fluorescence emission is increased and bleaching is reduced. These results show a potential increase of fluorescence and a lower photobleaching upon higher scan speed. As illumination during the bleach-phase in a FRAP-experiment is similar to a light pulse, the findings also suggest to critically consider the very beginning of fluorescence recovery in terms of triplet relaxation process that potentially could falsify the measurements.     

Detecting transition to chatter mode in peakless tool turning by monitoring vibration and acoustic emission signals

Stability of a peakless tool turning on slender shafts was studied under conditions of low- and high-magnitude vibrations by registering and short-time Fourier transformation (STFT) processing of acoustic emission (AE) and vibration acceleration (VA) signals. Both VA and AE signals have been registered in three positions of the cutting tool on the workpiece and for different shaft diameters. Both amplitude- and frequency-dependent AE and VA characteristics were obtained and analyzed for overall process signal length as well as for single frames. It was shown that power spectrum characteristic could be used for monitoring the fast-occurring changes in the cutting process stability. A criterion of the cutting process stability based on the power spectrum has been offered.     

A predictive hybrid force modeling in turning: application to stainless steel dry machining with a coated groove tool

The International Journal of Advanced Manufacturing Technology - This paper presents an hybrid numerical/analytical modeling for estimation of cutting forces in machining process. The approach...     

Effect of wedge angle on surface roughness in finish turning: analytical and experimental study

Most of the theoretical models for surface roughness in finish turning assume that the work piece surface profile is formed by the rounded tip of the tool nose. The effect of the straight flank section in the tool nose region on the surface roughness is usually neglected. In this work, the straight flank section is taken into account in order to predict the arithmetic average roughness R _a and root-mean-square roughness R _q more accurately. The analytical models for R _a and R _q are developed as a function of three parameters, namely feed rate, nose radius, and wedge angle. These models were verified using digital simulation method. The surface roughness determined using the new three-parameter models were compared with the existing two-parameter models that consider only the feed rate and nose radius. Decreasing wedge angle was found to lower the surface roughness significantly. An experiment was conducted to test the validity of the three-parameter model at different feed rates in real machining operation. The experimental results agreed more closely with the proposed three-parameter models compared to the two-parameter models.     

Sheet metal plate design: a structured approach to product optimization in the presence of technological constraints

Geometrical optimization of structural components is a topic of high interest for engineers involved with design activities mainly related to mass reduction. The study described in these pages focuses on the optimization of plates subjected to bending for which stiffness is obtained by a pattern of ribs. Although stiffening by means of ribs is a well-known and old technique, the design of ribs for maximum stiffness is often based on practice and experience. Classical optimization methods such as topological, topographical and parametric optimization fail to give an efficient design with a reasonable programming effort, especially when dealing with many and complex constraints. These constraints are both technical and technological. A most promising technique to obtain optimal rib patterns was to define a set of feasible rib trajectories and then to select the subset with the most efficient combinations. The result is not unique and a method to select the optimal patterns is required. In fact, the stiffening effect increases with increasing rib length, but at a greater cost. A trade-off must be found between structural performance and cost: The tools to guide this selection process is the main objective of the paper, with particular attention in evaluating the stiffening due to the presence of beads on the plate with a close link with the production system and possible technological constraints which can occur during manufacturing processes, such as minimum rib distance or the presence of discontinuities or the presence of holes or other elements on the plate. A special tool with enforced rib cross section is considered, and optimal rib deployment has to be found. Numerical examples attached show the methodology and obtainable results.