Experimental investigation,prediction and optimization of cylindricity and perpendicularity during drilling of WCB material using grey relational analysis

Manufacturing is always the heart of majority of industries. Drilling is an extremely important and an essential machining process which requires a lot of attention as in most of the cases it is required for assembly purposes. Majority of the holes produced during drilling are made with the help of Vertical Machining Centre (VMC) meant for pin- hole assembly. Though the tolerance is within limit, assembly problems arise due to the improper geometry of these holes. Various geometrical tolerances like cylindricity, circularity, perpendicularity and position errors are responsible for such assembly problems. This investigation is focussed on cylindricity and perpendicularity in the drilling of Wrought Cast Steel Grade B (WCB) material using SOMX 050204 DT insert. In this work, effect of machining variables like cutting speed, feed rate and depth of cut (canned cycle) are investigated and optimized using grey relational analysis (GRA). Reliable experiments are conducted based on a 3³ full factorial, replicated twice. Second order regression models are developed for predicting cylindricity and perpendicularity. The models’ adequacy has been checked by calculating correlation coefficient. It shows that the developed models are well fitted for the prediction of responses within the specific range of input variables.     

Use of cryogenic machining to improve the adhesion of sphene bioceramic coatings on titanium substrates for dental and orthopaedic applications

Rods of commercially pure titanium were machined using standard oil-based emulsion and cryogenic cooling, and were then coated with sphene (CaTiSiO₅) bioceramic by spray coating using an automatic airbrush. The sphene bioceramic was synthesized in-situ starting from a suspension of polysiloxane that used as SiO₂ precursor, CaCO₃ and TiO₂ nanoparticles. The suspension was deposited on the machined substrates, which were heat treated up to 950?°C in order to promote the formation of sphene ceramic. The produced coated prototypes were characterized to evaluate the effect of the machining conditions on surface roughness and microstructure of the substrate, and thereby their effect on coating adhesion. Nanoindentation tests were employed to determine the hardness and elastic modulus of the coating through its thickness. Results showed that the reduced amount of defects on the surface of the cryo-machined substrates, contributed to increase the hardness, elastic modulus and adhesion strength of the coating-substrate interfaces compared to standard machined samples, therefore improving adhesion of the coating to the underlying substrate.     

高频主轴驱动器RS51在磨床上的应用

随着高速切削、精密加工、快速制造等先进制造技术的发展,高频电主轴及其驱动装置成了制造业实现数字化的关键,是决定高速、高精、多轴联动的高档数控机床性能、可靠性、成本价格的关键因素     

A mechanism informed neural network for predicting machining deformation of annular parts

Controlling machining deformation of annular parts is crucial for ensuring the performance of high value products and equipment. For example, during manufacturing of critical parts in aircrafts and spacecrafts, accurate prediction of machining deformation is the basis for guiding the formulation of deformation control strategies. However, due to the complexity of the machining deformation of annular parts, existing methods still have limitations in accurate prediction. To this end, this paper proposes a mechanism informed neural network (MINN) to predict machining deformation of annular parts. MINN is realized by establishing the dual sub-networks structure and using enhanced loss functions with the consideration of the deformation mechanism model characteristics of annular parts. The deformation was decomposed into the axisymmetric portion and the non-axisymmetric portion according to the deformation superposition principle, and modeled separately based on the thin-shell theory and Fourier series. Experiment results showed that the proposed method could predict the machining deformation of annular parts more accurately and stably with a small amount of training data, compared with previous methods.     

高速纺纱锭子弹性管减振机制与振动特性

为探究锭子弹性管的减振机制,将其开螺旋槽部分作为矩形弹簧模型处理,建立了减振弹性管的抗弯刚度及底部振幅的理论数学模型,并利用MatLab仿真分析了减振弹性管关键结构参教与其抗弯刚度和底部振动特性的耦合关系,同时结合有限元仿真及模态测试得到弹性管各阶固有频率。研究结果表明:随着槽宽和圈数的增大,刚度降低,底部振幅增加;随着壁厚、螺距、螺旋升角、弹性模量的增大,刚度增加,底部振幅降低;弹性管固有频率和锭子系统共振频率区间一致,且工作频率有效避开了共振频率。     

Developments in the non-traditional machining of particle reinforced metal matrix composites

The non-traditional machining of particulate reinforced metal matrix composites is relatively new. However, researchers seem to pay more attention in this field recently as the traditional machining of particulate reinforced metal matrix composites is very complex. This research investigates different non-traditional machining, such as electro-discharge, laser beam, abrasive water jet, electro-chemical and electro-chemical discharge machining of this composite materials. The machining mechanism, material removal rate/machining speed and surface finish have been analysed for every machining process. This analysis clearly shows that vaporisation, melting, chemical dissolution and mechanical erosion are the main material removal mechanisms during non-traditional machining. The thermal degradation and the presence of reinforcement particles mainly damage the machined surface. The understanding of electro-discharge, laser beam and abrasive water jet machining is more developed than that of electro-chemical and electro-chemical discharge machining for particulate reinforced MMC.     

基于SolidWorks的CA6140主轴箱三维建模

基于三维设计软件SolidWorks创建了主轴箱零件实体,实现了各零部件的虚拟装配以及主传动链的传动运动,在虚拟装配时,齿轮配合、凸轮配合等不同于标准配合,除了添加必要的配合关系外还要添加辅助草图.     

基于ANSYS的某型载重子午胎成型机主轴箱的改进设计

针对一次法载重子午胎成型机主轴箱在轮胎生产厂家所出现的主轴轴承磨损严重问题进行改进,主轴支撑由单轴承改进为双轴承支撑.从生产中遇到的问题入手,分析了问题产生的原因,提出了改进方案,通过理论计算和有限元分析为改进的设计方案奠定了理论基础,同时也是对改进设计的有效验证.     

Monitoring and processing signal applied in machining processes – A review

In machining processes several phenomena occur during material cutting. These phenomena can affect the production through the reduction of quality or accuracy, or by increasing costs (tools, materials, time). Thus, an understanding of machining phenomena is needed not only to define the cutting parameters for maximizing production, but also to ensure worker safety. An easy way to identify these phenomena is by monitoring machining processes, such as the measurement of cutting force, temperature and vibration. The acquired signal can have information about tool life, quality of cutting and defects in the workpiece. This review paper discusses the first steps involved in choosing and defining various techniques that may be used to monitor machining processes. Furthermore, this paper also outlines the techniques to acquire and process the signals of the monitoring processes. Hence, the objective of this paper is to help the reader understand the procedures for monitoring machining processes, and define methods, parameters, targets and other factors involved in doing so.     

CBN高效深磨砂轮主轴的建模分析与实验研究

基于对CBN端面砂轮的研究,提出一种高效率深度端面磨削的砂轮主轴系统.主轴单元的静态特征和影响因素分析了理论计算和建模仿真分析,并验证主轴结构和参数的合理性.基于模态分析理论,砂轮主轴系统的模态测试是由锤击方法,并得到了前6阶模态参数和分析结果.结果表明:该磨削主轴系统满足了高效深磨技术要求.最后,研磨应用开发测试平台应用了磨削主轴单元和一些实验来完成高效深磨的研究.对Cr12Mo1V1工件在砂轮转速为80 ～ 100 m/s时进行了端面磨削实验,其结果为:切削深度0.175～0.5 mm,表面粗糙度0.8～3.2 μm以及圆柱度5-10 μm.