An experimental investigation for the stochastic modelling of the resultant force system in BTA deep hole machining

This paper presents the measurement and a statistical analysis of the resultant force system, consisting of an axial force and torque, in BTA deep hole machining. The measurements were performed using a specially designed two-component piezoelectric dynamometer and adopting the rotating cutting tool-stationary workpiece procedure. The dynamometer was calibrated for static and dynamic outputs and techniques were employed for increasing the measuring accuracy and reducing the cross-interference by obtaining the elements of the system transfer function. Experiments were carried out to measure the mean values and the dynamic fluctuations of the axial force and torque. The recorded data was processed and analysed to establish all major statistical properties of the axial force and torque. Results show that the dynamic fluctuations of the axial force and torque in BTA deep hole machining can be represented by a stationary wideband process with a gaussian density distribution function. Such a mathematical model is essential for evaluating the dynamic response of the machine-workpiece system as well as the true motion of the cutting tool tip, and to establish the reliability of the machining process.     

An analytical tim6 domain evaluation of the cutting forces in BTA deep hole machining using the thin shear plane model

This paper presents an analytical approach to describe the cutting forces in 1ST A deep hole machining processes in the time domain. The method takes into account the effect of different machining conditions. Since the cutting velocities employed in BTA deep hole machining process are relatively high, and since small chips are produced due to the presence of tool chip breakers, the analysis is developed on the basis of the thin shear plane model.

The cutting velocity is a linear function of radius and the rake angle. Cutting is different in the two regions of the cutting tool, so the total cutting force acting on the cutting tool is determined by integrating the force on a small incremental thickness of the cutting tool. This approach, to predict the value of the cutting forces without resorting to any empirical techniques, clearly illustrates the effect of various system parameters on the machining process.

The resultant force system on a new BTA cutting tool consists of an axial force and torque. But with the increase in the number of holes bored, not only does the cutting profile deteriorate, but the wear pads do too. The resultant force system will then consist of three force components and a torque, due to the fact that the forces are not balanced at the wear pads. Under such conditions, the cutting force equations derived in the latter half of the paper, coupled with the properties of the randomly varying component, can be used as the forcing function on the machine tool to evaluate not only the response but also the regions of stability and instability during the machining.     

基于多源融合理论的机床圆度误差测量不确定度评定

圆度误差是评价机床加工精度的重要指标.为实现机床圆度误差测量不确定度的评定,对基于球杆仪测量的机床圆度误差的贡献因素及不确定度评定方法进行研究.首先,采用最小二乘法(least sqaure method,LSM)对圆度误差进行评定.然后,基于黑箱理论提出了多源融合误差测量不确定度评定方法.接着,根据球杆仪测量机床圆度...     

基于单缝衍射原理的圆度误差测量方法

提出了一种全新的圆度误差光学自动测量方法.新方法基于单缝衍射原理,利用工件的圆度误差来改变衍射单缝的宽度,进而改变衍射条纹的间距.在测量单缝衍射中央明纹的宽度时,提出了用最小二乘法对测量到的衍射图像的光强分布进行二次曲线拟合,并由拟合得到的数学表达式,确定衍射暗条纹的精确位置.由导出的工件圆度误差与单缝衍射中央明纹宽度之间的关系,用最小二乘法对工件的圆度误差进行了评定.测量结果表明,新的圆度误差测量方法是可行的,圆度误差的相对不确定度小于1.4%,并且测量系统具有操作方便、精度高的优点,新方法也可应用于锥角、直线度误差等其它几何量的精密测量中.     

Cutter path preview for contour machining based on efficient identification of motion error sources

This paper presents an efficient approach to the identification of the motion error sources in CNC contour machining. The motion error sources include the mismatch of feed drives, the friction disturbances and the cutter path curvature. Their effects on the contour error in linear and circular motions are analyzed, respectively. On the basis of the analysis, the procedure for the identification of these error-source effects is developed. With the identification results, the cutter path trajectory can be previewed before the real run.     

An experimental investigation as to the effect of cutting parameters on roundness error and surface roughness in cylindrical grinding

This paper presents the results of an experimental investigation as to the effects of grinding parameters on roundness error and surface roughness in cylindrical grinding. Many variables including the wheel materials, wheel loading and dressing, workpiece metallurgy, work drive mechanisms, work holding methods, coolant types, feeds and speeds, machine stiffness and age, surface conditions, centre conditions, floor vibrations all influence the quality of ground parts. However, the composite sum of these grinding parameters creates static and dynamic forces. It is obvious that the roundness error and surface roughness are created by many parameters, but in this study, only the effects of the depth of cut, work speed and feed rate which create the grinding forces in cylindrical grinding are investigated. The grinding experiments were planned according to the principles of orthogonal arrays (OAs), developed by Taguchi, and were performed so as to understand the effects of these parameters on roundness error and surface roughness. The experimental data was analysed by using statistical tools: the percent contribution from an analysis of variance (ANOVA) and the correlation between machining parameters with roundness error (R) and also surface roughness (Ra). Roundness was found to be the most related with the cutting speed, grinding force and depth of cut, while surface roughness is related to feed rate and work speed.     

Experimental and computational analysis of the coolant distribution considering the viscosity of the cutting fluid during machining with helical deep hole drills

An experimental analysis regarding the distribution of the cutting fluid is very difficult due to the inaccessibility of the contact zone within the bore hole. Therefore, suitable simulation models are necessary to evaluate new tool designs and optimize drilling processes. In this paper the coolant distribution during helical deep hole drilling is analyzed with high-speed microscopy. Micro particles are added to the cutting fluid circuit by a developed high-pressure mixing vessel. After the evaluation of suitable particle size, particle concentration and coolant pressure, a computational fluid dynamics (CFD) simulation is validated with the experimental results. The comparison shows a very good model quality with a marginal difference for the flow velocity of 1.57% between simulation and experiment. The simulation considers the kinematic viscosity of the fluid. The results show that the fluid velocity in the chip flutes is low compared to the fluid velocity at the exit of the coolant channels of the tool and drops even further between the guide chamfers. The flow velocity and the flow pressure directly at the cutting edge decrease to such an extent that the fluid cannot generate a sufficient cooling or lubrication. With the CFD simulation a deeper understanding of the behavior and interactions of the cutting fluid is achieved. Based on these results further research activities to improve the coolant supply can be carried out with great potential to evaluate new tool geometries and optimize the machining process.The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-021-00383-w     

Development of residual cutting tool life prediction algorithm by processing on CNC machine tool

The paper is dedicated to the decision of a problem of cutting tool diagnostics and working out of a remaining cutting tool life prediction algorithm. The example for practical realization of such algorithm on the CNC machine tool by machining under specified conditions is given. The question of working error compensation by means of corrective adjustment is considered.     

On effect of tool rotation on performance of rotary tool micro-ultrasonic machining

The present research paper is based on a comparative study of stationary tool micro-ultrasonic machining (STMUSM) and rotary tool micro-ultrasonic machining (RTMUSM). Microchannels were developed on glass work material by using both processes. The effect of tool rotation on the performance of micro-USM was investigated. The performance of both processes was compared on the basis of material removal rate (MRR) and depth of channel (DOC) as response characteristics. The power rating, work feed rate, concentration of abrasive slurry, and abrasive mesh size were chosen as variable input process parameters in this investigation. The form accuracy of the fabricated microchannels was analyzed with the help of imaging technique. Also, a qualitative analysis of tool wear was carried out with the help of microscopic images. The experimental results revealed that the tool rotation significantly improved the performance of micro-USM. The RTMUSM resulted in 155% and 147% higher MRR and DOC as compared to STMUSM. The tool wear was also found to be lesser in RTMUSM as compared to STMUSM and as a result of that form accuracy of machined microchannels improved.     

Identification of machining features based on available resources of cutting tools

In research on machining feature recognition, the problems of interacting features and availability of cutting tools are considered two major obstacles for developing industrial applications. In this research, a new machining feature recognition approach is developed to address these problems. In this work, a new concept called cutting mode is introduced to associate generic machining surfaces and cutting motions. In the feature recognition process, the machining surfaces of a part are first mapped to cutting modes, and these cutting modes are further mapped to available cutting tools. Among all the created candidate machining processes, heuristic rules are employed to identify the optimal solution that requires the minimum number of setups. When a number of machining surfaces are associated with a cutting tool in the same setup, these surfaces are grouped as a machining feature. Therefore the interacting features are recognised by the different cutting tools to produce these features. A database of available cutting tools is used to avoid the identification of features which cannot be machined in a machine shop. Three mechanical parts with interacting features are selected in the case studies to demonstrate the effectiveness of the developed approach.     

Plasma-applied machining of a narrow and deep hole in a metal using a dielectric-encased wire electrode

Electro discharge machining (EDM) utilizing transferred arc plasma is widely accepted for the drilling or the molding of metals. In the present study, a new type of EDM system employing a composite electrode fabricated a narrow and deep hole (diameter: 0.70 mm, depth: 150 mm) in a steel block. The composite electrode consisted of a metal rod encased in a dielectric pipe jacket. The dielectric jacket prevents secondary discharges occurring between the sidewalls of the rod electrode and the fabricated hole, enabling fabrication of a deep and narrow hole. The system design and set-up, operation, and machining performance of the new system are described here.     

基于预测的多描述图像编码冗余插入的研究

为了研究图像、视频在不可靠网络上传输的鲁棒性问题,系统采用多描述编码方法,该方法通过去除冗余信息以达到数据的压缩,同时保留一部分冗余信息使得编码后的数据流在网络上传输具有一定的鲁棒性.本文针对采用多相下抽样实现的多描述编码,提出了一种新的基于预测的预处理和后处理方案,该方案能对多描述编码产生的数据流中冗余信息进行灵活插入,以达到多描述编码中的中央解码器与边沿解码器的效率进行拆衷控制.仿真实验结果表明该方法计算复杂度降低,冗余控制的灵活性大,编码后的数据流更能适应各种网络传输状况.     

基于事故树的深孔爆破边坡稳定性分析

为了能够对爆破后形成的露天边坡稳定性进行合理的分析评价,结合大小鱼山岛露天爆破边坡失稳的情况,采用事故树分析方法,建立了工程爆破现场露天边坡失稳事故树模型。计算出事故树的最小割集96个,最小径集3个以及基本事件的结构重要度系数,并得到基本事件结构重要度排序,找出了导致边坡失稳的主要原因是边坡监测和边坡支护。然后根据基本事件结构重要度的排序,制定合理有序的预防措施。事故树分析方法可以全面阐述露天矿边坡失稳的各种因素和逻辑关系,并通过对结构重要性分析,提出合理预防措施,为爆破露天边坡的安全管理提供参考依据。     

基于事故树的深孔爆破边坡稳定性分析

为了能够对爆破后形成的露天边坡稳定性进行合理的分析评价,结合大小鱼山岛露天爆破边坡失稳的情况,采用事故树分析方法,建立了工程爆破现场露天边坡失稳事故树模型。计算出事故树的最小割集96个,最小径集3个以及基本事件的结构重要度系数,并得到基本事件结构重要度排序,找出了导致边坡失稳的主要原因是边坡监测和边坡支护。然后根据基本事件结构重要度的排序,制定合理有序的预防措施。事故树分析方法可以全面阐述露天矿边坡失稳的各种因素和逻辑关系,并通过对结构重要性分析,提出合理预防措施,为爆破露天边坡的安全管理提供参考依据。     

Online estimate and compensation of the gear machining error based on electronic gearbox cross-coupling controller

Forschung im Ingenieurwesen - A novel method for online estimate and compensation of the gear machining error based on the flexible electronic gearbox (EGB) is introduced. EGB is...     

Comparative study of the effect of surface texturing on cutting tool in dry cutting

Recent researches in the field of dry machining have indicated that surface texture has the potential to influence tribological conditions. Researchers have studied the application of controlled surface microtextures on cutting tool surfaces to improve machining performance by changing the tribological conditions at the interfaces of tool–chip and tool–work piece. An experiment to study the performance of the microtextured high-speed steel cutting implement within the machining of steel and aluminum samples was performed. Surface textures were introduced using Rockwell hardness tester, Vickers hardness tester, and by scratching with diamond dresser on the face of single point cutting tool. Machining in dry conditions was applied on mild steel (EN3B) and aluminum (AA 6351) samples using lathe machine with microtextured and traditional cutting tool for the constant range of feed, depth of cut, and for varying range of cutting speeds. Measurement of cutting force, cutting temperature, and surface roughness of the work surfaces after machining were made. The results showed reduction in cutting forces and cutting temperature with textured tools in comparison with those of the untextured tool. Chips collected from different samples were studied under a microscope and the results showed that textures created on the tool surface by various methods exhibited variations in chip formation. Cutting tools without texture and with texture were comparatively studied and the outcomes of the experimental study are presented in this paper.     

切削液扰动对BTA深孔加工系统横向振动频率的影响

为探究切削液扰动下BTA深孔镗削系统横向振动频率的影响,通过建立BTA深孔镗杆系统计及内、外切削液流固耦合及其自由液面效应的横向振动模型,解析系统不同情况下的横向振动的一、二阶频率表达式,并以不同情况下,深孔镗杆内、外切削液的横截面面积及其对深孔镗杆的附加质量来表征对应的自由液面变化,通过计算,明确了BTA深孔镗杆的横向振动频率对切削液流速、轴向力的敏感性及其运动转换趋势。BTA深孔镗杆横向振动频率对轴向力的敏感性规律为:在共振脊区域,在内、外切削液都无自由液面时最大;内、外切削液都有自由液面时最小;在共振翅区域,只内切削液有自由液面时最大,内、外切削液都无自由液面时最小。BTA深孔镗杆横向振动频率对切削液流速的敏感性规律为:在共振脊区域,只内切削液有自由液面时最大,内、外切削液都无自由液面时最小;在共振翅区域,内、外切削液都无自由液面时最大,只内切削液有自由液面时最小。系统在切削液流速、轴向力达到临界等效值时,发生弯曲或屈曲;在静力失稳后,系统将会在更高的切削液流速值以混阶模态形式发生耦合颤振等复杂运动。该研究结果可为BTA深孔镗削加工的生产实践提供一定理论指导。     

基于受损区域运动特征的时域错误隐藏算法

为解决视频压缩数据在网络传输中的误码或丢包问题,提出了一种适用于数字视频编码标准H.264的时域错误隐藏算法。该算法结合H.264中多尺寸编码块模式的特点,通过对受损块邻域块的模式分析来判定受损块模式,并针对各子块的运动类型分别建立相应的运动矢量候选集,从而选择最优运动矢量重建受损块。实验结果表明,该算法有效增强了对复杂运动区域重建的适应性,在不同的网络丢包率环境下均可实现较好的主观和客观重建图像质量。