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.     

Monitoring of tool wear using measured machining forces and neuro-fuzzy modelling approaches during machining of GFRP composites

The challenges of machining, particularly milling, glass fibre-reinforced polymer (GFRP) composites are their abrasiveness (which lead to excessive tool wear) and susceptible to workpiece damage when improper machining parameters are used. It is imperative that the condition of cutting tool being monitored during the machining process of GFRP composites so as to re-compensating the effect of tool wear on the machined components. Until recently, empirical data on tool wear monitoring of this material during end milling process is still limited in existing literature. Thus, this paper presents the development and evaluation of tool condition monitoring technique using measured machining force data and Adaptive Network-Based Fuzzy Inference Systems during end milling of the GFRP composites. The proposed modelling approaches employ two different data partitioning techniques in improving the predictability of machinability response. Results show that superior predictability of tool wear was observed when using feed force data for both data partitioning techniques. In particular, the ANFIS models were able to match the nonlinear relationship of tool wear and feed force highly effective compared to that of the simple power law of regression trend. This was confirmed through two statistical indices, namely r² and root mean square error (RMSE), performed on training as well as checking datasets.     

不同载荷工况下机床主轴预紧力选取的数值分析方法

为研究预紧力对机床主轴的影响,提出在不同载荷工况下机床主轴预紧力选取的数值分析方法.计算得到预紧力与轴承刚度的关系,在轴系结构有限元模型中设置不同预紧力下的轴承刚度值,通过静力学分析求解轴系变形和刚度;计算得到预紧力与轴承发热量的关系,在轴系热分析有限元模型中设置轴承热源,通过传热分析求解主轴温升.计算结果表明,该方法...     

Direct 5-axis tool-path generation from point cloud input using 3D biarc fitting

In reverse engineering, geometrical information of a product is obtained directly from a physical shape by a digitizing device. To fabricate the product, manufacturing information (usually tool-path) must be generated from a CAD model. The data digitized must be processed and in most cases, a surface model is constructed from them using some of the surface fitting technologies. However, these technologies are usually complicated and the process for constructing a surface patch from a massive digitizing data is time-consuming. To simplify the process for getting tool-path information, a simple algorithm is proposed in this paper. The algorithm is used to generate a 5-axis machining tool-path. Instead of implementing any complicated surface fitting techniques, a direct method is proposed for constructing three-dimensional (3D) triangular mesh from the digitizing data with the mesh points considered as the tool contact locations. Depending on the locations of the points digitized, a decimation procedure is applied such that some of the digitizing data will be filtered out. Then, the tool axis orientations which must be determined in 5-axis tool-path are calculated and the tool center locations are determined accordingly. A 3D biarc fitting technique is applied for all the tool center locations so that a complete 5-axis tool-path is obtained.     

Application of artificial neural network for determination of standard time in machining

The purpose of this article is to present the application of neural network for time per unit determination in small lot production in machining. A set of features considered as input vector and time consumption in manufacturing process was presented and treated as output of the neural net. A neural network was used as a machining model. Sensitivity analysis was made and proper topology of neural network was determined.     

电主轴冷却系统设计与仿真优化

为解决电主轴因内部温度场复杂而造成冷却效果差的问题,设计了一种用于电主轴冷却的水冷机系统。根据电主轴热特性分析结果,提出了水冷机冷却方案,计算了相关的传热参数,并建立了电主轴温度-流速控制模型。然后,利用ANSYS Fluent软件对电主轴进行了流体冷却有限元仿真,并通过电主轴冷却实验对仿真结果进行了验证。通过对比仿真结果和实验结果可知,冷却后电主轴电机定子最高温度约下降了60%,转轴的形变量约降低了70%。结果表明：利用水冷机系统对电主轴进行冷却具有良好的冷却效果,这可为高精密机床主动热控制技术的研究提供一定的借鉴和参考。     

一种新型加工中心加工球面的研究

介绍一种采用 STEWART机构的新型加工中心 .对这种加工中心加工球面时各“腿”长度变化的规律进行了分析 .结果表明 :各“腿”长度呈正 (余 )弦规律变化 ,且其变化周期与幅度均相同 ;它们的变化曲线依次相差 1 2 0°到达峰顶 ,其顺序与加工球面上截面圆各点的逆时针顺序相互对应 .导出的各“腿”长度变化的公式可用于指导数控编程     

A knowledge base model for complex forging die machining

Recent evolutions on forging process induce more complex shape on forging die. These evolutions, combined with High Speed Machining (HSM) process of forging die lead to important increase in time for machining preparation. In this context, an original approach for generating machining process based on machining knowledge is proposed in this paper. The core of this approach is to decompose a CAD model of complex forging die in geometrical features. Technological data and topological relations are aggregated to a geometrical feature in order to create machining features. Technological data, such as material, surface roughness and form tolerance are defined during forging process and dies design. These data are used to choose cutting tools and machining strategies. Topological relations define relative positions between the surfaces of the die CAD model. After machining features identification cutting tools and machining strategies currently used in HSM of forging die, are associated to them in order to generate machining sequences. A machining process model is proposed to formalize the links between information imbedded in the machining features and the parameters of cutting tools and machining strategies. At last machining sequences are grouped and ordered to generate the complete die machining process. In this paper the identification of geometrical features is detailed. Geometrical features identification is based on machining knowledge formalization which is translated in the generation of maps from STL models. A map based on the contact area between cutting tools and die shape gives basic geometrical features which are connected or not according to the continuity maps. The proposed approach is illustrated by an application on an industrial study case which was accomplished as part of collaboration.     

A genetic algorithm-based artificial neural network model for the optimization of machining processes

Artificial intelligent tools like genetic algorithm, artificial neural network (ANN) and fuzzy logic are found to be extremely useful in modeling reliable processes in the field of computer integrated manufacturing (for example, selecting optimal parameters during process planning, design and implementing the adaptive control systems). When knowledge about the relationship among the various parameters of manufacturing are found to be lacking, ANNs are used as process models, because they can handle strong nonlinearities, a large number of parameters and missing information. When the dependencies between parameters become noninvertible, the input and output configurations used in ANN strongly influence the accuracy. However, running of a neural network is found to be time consuming. If genetic algorithm-based ANNs are used to construct models, it can provide more accurate results in less time. This article proposes a genetic algorithm-based ANN model for the turning process in manufacturing Industry. This model is found to be a time-saving model that satisfies all the accuracy requirements.     

普通车床数控改造方案

利用普通车床,加装部分数控装置,使其达到数控车床的功能.在此基础上,完善现有机械设备的技术改造.