摩托车曲柄锻模高速加工

介绍了锻模的高速加工，论述了实施高速加工的支撑技术。     

Finite element prediction of material removal rate due to electro-chemical spark machining

Electro-chemical spark machining (ECSM) is an innovative hybrid machining process, which combines the features of the electro-chemical machining (ECM) and electrodischarge machining (EDM). Unlike ECM and EDM, ECSM is capable of machining electrically non-conducting materials. This paper attempts to develop a thermal model for the calculation of material removal rate (MRR) during ECSM. First, temperature distribution within zone of influence of single spark is obtained with the application of finite element method (FEM). The nodal temperatures are further post processed for estimating MRR. The developed FEM based thermal model is found to be in the range of accuracy with the experimental results. Further the parametric studies are carried out for different parameters like electrolyte concentration, duty factor and energy partition. The increase in MRR is found to increase with increase in electrolyte concentration due to ECSM of soda lime glass workpiece material. Also, the change in the value of MRR for soda lime glass with concentration is found to be more than that of alumina. MRR is found to increase with increase in duty factor and energy partition for both soda lime glass and alumina workpiece material.     

Laser-assisted machining of compacted graphite iron

Compacted graphite iron (CGI) is a material currently under study for the new generation of engines, including blocks, cylinder liners, and cylinder heads. Its unique graphite structure yields desirable high strength, but makes it difficult to machine, thus resulting in a machining cost. Laser-assisted machining (LAM) is adopted to improve its machinability and hence machining economics. The machinability of CGI is studied by varying depth of cut, feed, and material removal temperature and then evaluating resultant cutting forces, specific cutting energy, surface roughness, and tool wear. At a material removal temperature of 400 °C and a feed of 0.150 mm/rev at a cutting speed of 1.7 m/s, it is shown that tool life is 60% greater than conventional conditions at a feed of 0.100 mm/rev. Surface roughness is improved 5% as compared to conventional machining at a feed of 0.150 mm/rev. CGI microstructure evaluated post machining by sectioning and polishing shows no change. An economic analysis shows that LAM can offer an approximately 20% cost savings for the machining of an engine cylinder liner.     

加工过程物理仿真技术研究

加工过程仿真是虚拟制造的底层关键技术，同时也是数字化制造系统的重要组成部分，而物理仿真是其中的研究重点和难点。建模难，通用性和实用性差是目前物理仿真中存在的主要问题。文章总结了物理仿真的研究内容和方法，分析了研究中存在的问题及加工过程建模的常用方法。     

Adaptive chatter mitigation control for machining processes with input saturations

Chatter is an unstable nonlinear dynamical phenomenon often encountered in machining operations because of the self‐excitation mechanism, which may lead to overcut or rapid tool wear, and hence, greatly influence the surface quality and productivity in milling operations. Recent years have witnessed an increasing industrial demand of high quality and high efficiency machining. This paper hereby develops a constrained active adaptive control method to mitigate the chatter dynamics with input saturations. To guarantee the feasibility of the proposed approach, moderate stable conditions of the closed‐loop system are afterwards derived by using the LaSalle–Yoshizawa theorem as well. Finally, numerical simulations are conducted to show the substantially enlarged stable region in the Lobe Diagram. Thus, the method can be expected to improve the efficiency of milling processes. Copyright © 2015 John Wiley & Sons, Ltd.     

弧齿锥齿轮数控加工和齿面接触点求解算法研究

在保证弧齿锥齿轮加工过程中刀盘相对于工件的运动关系不变的基础上,通过矩阵变换实现铣齿加工的数控展成.由于在数控加工每个插补周期中难以实现这种涉及大量运算的运动转换,因此将数控坐标轴的展成运动表示为以工件齿轮转角为参数的五次参数样条函数,保证了插补的实时性和精确性.文中将传统用于确定接触点位置时求解非线性方程组的问题,转化为带有3个设计变量的约束优化问题,简化了法线重合的条件,建立配对齿轮位置矢量相等的目标函数.最后给出实例对算法进行了说明和验证.     

Five-axis tool path generation for a flat-end tool based on iso-conic partitioning

Traditionally, for the flat-end tool, due to the intertwined dependence relationship between its axis and reference point, most 5-axis tool-path generation algorithms take a decoupled two-stage strategy: first, the so-called cutter contact (CC) curves are placed on the part surface; then, for each CC curve, tool orientations are decided that will accommodate local and/or global constraints such as minimum local gouging and global collision avoidance. For the former stage, usually simplistic “offset” methods are adopted to determine the cutter contact curves, such as the iso-parametric or iso-plane method; whereas for the latter, a common practice is to assign fixed tilt and yaw angle to the tool axis regardless the local curvature information and, in the case of considering global interference, the tool orientation is decided solely based on avoiding global collision but ignoring important local machining efficiency issues. This independence between the placement of CC curves and the determination of tool orientations, as well as the rigid way in which the tilt and yaw angle get assigned, incurs many undesired problems, such as the abrupt change of tool orientations, the reduced efficiency in machining, the reduced finishing surface quality, the unnecessary dynamic loading on the machine, etc. In this paper, we present a 5-axis tool-path generation algorithm that aims at alleviating these problems and thus improving the machining efficiency and accuracy. In our algorithm, the CC curves are contour lines on the part surface that satisfy the iso-conic property — the surface normal vectors on each CC curve fall on a right small circle on the Gaussian sphere, and the tool orientations associated to a CC curve are determined by the principle of minimum tilt (also sometimes called lead) angle that seeks fastest cutting rate without local gouging. Together with an elaborate scheme for determining the step-over distance between adjacent CC curves that seeks maximum material removal, the presented algorithm offers some plausible advantages over most existing 5-axis tool-path generation algorithms, particularly in terms of reducing the angular velocity and acceleration of the rotary axes of the machine. The simulation experiments of the proposed algorithm and their comparison with a leading commercial CAM software toolbox are also provided that demonstrate the claimed advantages.     

虚拟加工中工件毛坯模型的建立

为解决虚拟加工中工件毛坯模型的识别问题,提出对规则形状工件毛坯采用OpenGL建模、对复杂形状工件毛坯采用美国初始图形交换规范（Initial Graphics Exchange Specification,IGES）文件进行模型数据转换的方法.该方法利用CAD软件为工件毛坯进行三维造型,生成IGES文件,然后在虚拟加工环境下读取IGES文件并生成工件毛坯模型,从而实现工件毛坯模型在新环境中的建立.经过建立具体的工件毛坯模型,验证相关理论的正确性,为在虚拟加工环境下工件毛坯模型的建立提供可行的依据.     

基于Z-map模型的加工区域边界抽取算法研究

为了快速精确地进行加工区域边界抽取,给出了一种Z-map加工模型的加工区域边界抽取算法,该算法首先把Z-map模型下规则网格点阵转化为二元图进行边界抽取;然后以基于段长的方式,逐行扫描步长段,并利用上下行段之间的关系确定段左右节点的连接,以形成有向环,从而确定边界为外轮廓或为内轮廓,该算法时间复杂度为O(n),n为步长段的数量;接着通过对环中段间的连接关系分析,恢复了加工区域完整的边界信息;最后给出了该算法时间与段、行、列数之间的关系,同时与以前的算法进行了比较。结果表明,该算在效率和实施难度上都较以前算法有了一定的提高。     

Investigation of machining characteristics in rotary ultrasonic machining of alumina ceramic

Alumina ceramic is well documented as a much-demanded advanced ceramic in the present competitive structure of manufacturing and industrial applications owing to its excellent and superior properties. The current article aimed to experimentally investigate the influence of several process variables, namely: spindle speed, feed rate, coolant pressure, and ultrasonic power, on considered machining characteristics of interest, i.e., chipping size and material removal rate in the rotary ultrasonic machining of alumina ceramic. Response surface methodology has been employed in the form of a central composite rotatable design to design the experiments. Variance analysis testing has also been performed with a view to observing the consequence of the considered parameters. The microstructure of machined rod samples was evaluated and analyzed using a scanning electron microscope. This analysis has revealed and confirmed the presence of plastic deformation that caused removal of material along with brittle fractures in rotary ultrasonic machining of alumina ceramic. The validity and competence of the developed mathematical model have been verified with test results. The multi-response optimization of machining responses (material removal rate and chipping size) has also been attempted by employing a desirability approach, and at an optimized parametric setting the obtained experimental values for material removal rate and chipping size were 0.4166?mm³/s and 0.5134?mm, respectively, with a combined desirability index value of 0.849.