Tool deflection compensation in peripheral milling of curved geometries

This paper presents compensation of surface error due to cutting force-induced tool deflections in a peripheral milling process. Previous research attempts on this topic deal with error compensation in machining of straight geometries only. This paper is concerned with peripheral milling of variable curvature geometries where the workpiece curvature changes continuously along the path of cut. In the case of curved geometries, both process geometry and the cutting forces have shown to have strong dependence on workpiece curvature and hence variation of surface error along the path of cut. This calls for a different error compensation strategy than the one which is normally used for machining straight geometries. The present work is an attempt to improve accuracy in machining of curved geometries by use of CNC tool path compensation. Mechanistic model for cutting force estimation and cantilever beam model for cutter deflection estimation are used. The results based on machining experiments performed on a variety of geometries show that the dimensional accuracy can be improved significantly in peripheral milling of curved geometries.     

奥氏体不锈钢车削时刀具磨损对切削因素和表面质量的影响研究

研究了奥氏体不锈钢车削加工过程中刀具后刀面磨损对切削力、切削温度、粗糙度及残余应力影响规律。试验结果表明:当刀具后刀面磨损在一定范围内,F_x与F_z随磨损量的增加而显著增大,而F_y基本保持不变;温度随刀具后刀面磨损量增加而显著增大;工件的表面粗糙度随刀具后刀面磨损量增大而增大;当车刀后刀面磨损为0.167 mm时,工件加工表面的残余应力最大。     

Virtual machining considering dimensional,geometrical and tool deflection errors in three-axis CNC milling machines

Virtual manufacturing systems can provide useful means for products to be manufactured without the need of physical testing on the shop floor. As a result, the time and cost of part production can be decreased. There are different error sources in machine tools such as tool deflection, geometrical deviations of moving axis and thermal distortions of machine tool structures. Some of these errors can be decreased by controlling the machining process and environmental parameters. However other errors like tool deflection and geometrical errors which have a big portion of the total error, need more attention. This paper presents a virtual machining system in order to enforce dimensional, geometrical and tool deflection errors in three-axis milling operations. The system receives 21 dimensional and geometrical errors of a machine tool and machining codes of a specific part as input. The output of the system is the modified codes which will produce actual machined part in the virtual environment.     

Tool path generation framework for accurate manufacture of complex 3D sheet metal parts using single point incremental forming

The prototyping of complex sheet metal parts using single point incremental forming (SPIF) requires the generation of optimal tool paths and/or tool path sequences that ensure that the formed part is within geometric design specifications. The presence of a multitude of features on complex parts leads to multiple inaccuracy inducing phenomena occurring simultaneously due to interactions between the features. This paper proposes a network analysis methodology using topological conceptual graphs to capture the effects of different phenomena on the final accuracy of a sheet metal part manufactured by SPIF. Using this framework optimized tool paths can be generated that compensate for the inaccuracy inducing behavior. Tool path generation algorithms to create partial tool paths that account for the accuracy of specific features in the part based on the proposed framework are also presented. Finally, the creation of integrated tool paths maintaining complementarity between tool paths and desired continuity behavior using non-uniform cubic B-splines is illustrated. A number of case studies demonstrating the applicability of the integrated framework are discussed, where the maximum deviations in the part are significantly reduced and the average absolute deviations for the complete part are brought down to less than 0.5 mm.     

Avoiding,finding and fixing spreadsheet errors – A survey of automated approaches for spreadsheet QA

Spreadsheet programs can be found everywhere in organizations and they are used for a variety of purposes, including financial calculations, planning, data aggregation and decision making tasks. A number of research surveys have however shown that such programs are particularly prone to errors. Some reasons for the error-proneness of spreadsheets are that spreadsheets are developed by end users and that standard software quality assurance processes are mostly not applied. Correspondingly, during the last two decades, researchers have proposed a number of techniques and automated tools aimed at supporting the end user in the development of error-free spreadsheets. In this paper, we provide a review of the research literature and develop a classification of automated spreadsheet quality assurance (QA) approaches, which range from spreadsheet visualization, static analysis and quality reports, over testing and support to model-based spreadsheet development. Based on this review, we outline possible opportunities for future work in the area of automated spreadsheet QA.     

A comprehensive approach to evaluating watershed models for predicting river flow regimes critical to downstream ecosystem services

Selection of strategies that help reduce riverine inputs requires numerical models that accurately quantify hydrologic processes. While numerous models exist, information on how to evaluate and select the most robust models is limited. Toward this end, we developed a comprehensive approach that helps evaluate watershed models in their ability to simulate flow regimes critical to downstream ecosystem services. We demonstrated the method using the Soil and Water Assessment Tool (SWAT), the Hydrological Simulation Program–FORTRAN (HSPF) model, and Distributed Large Basin Runoff Model (DLBRM) applied to the Maumee River Basin (USA). The approach helped in identifying that each model simulated flows within acceptable ranges. However, each was limited in its ability to simulate flows triggered by extreme weather events, owing to algorithms not being optimized for such events and mismatched physiographic watershed conditions. Ultimately, we found HSPF to best predict river flow, whereas SWAT offered the most flexibility for evaluating agricultural management practices.     

全启发式教学法在“金属切削机床与刀具”课程中的应用

针对当代大学生的特点,阐述了来自于建构主义的全启发式教学方法的理论,对“金属切削机床与刀具”课程内容进行问题分解,采用以启发诱导、共同协作为核心的全启发式教学方法,对该课程的教学环节进行了合理的设计。     

环形刀高度变化刀路轨迹规划方法

为提高汽车覆盖件模具加工效率,将环形刀应用于汽车模具小曲率面的半精及精加工过程.通过对三坐标铣削小曲率面的刀具切触几何分析,确定环形刀最佳进给方向应沿工件高度变化方向,此时可使有效切削带宽达到最大.基于此结论,分别对两类特殊型面进行了刀路轨迹规划.对于单一方向曲率变化面采用垂直截面法,截面方向沿最大主曲率方向,实验表明:垂直截面法与等高线法相比可提高加工效率25%,并且有较好的表面质量;对于圆鼓面采用放射精加工方法,仿真结果表明:此方法与三维偏置方法相比可提高加工效率22.64%,并且避免了周边欠切.     

并联机床的历史、现状及展望

本文介绍了并联机床的基本概念、分类方法及其基本特性，详细地阐述了并联机床在国内外的发展历史、研究状况以及关键基础零部件的发展状况，在此基础上，分析了并联机床结构上的优缺点，表明了并联机床走向实用化所面临的一些问题，本文的最后对并联机床的发展趋势作了展望。     

An experimental study of tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts

Inconel 718 is a difficult-to-cut nickel-based superalloy commonly used in aerospace industry. This paper presents an experimental study of the tool wear propagation and cutting force variations in the end milling of Inconel 718 with coated carbide inserts. The experimental results showed that significant flank wear was the predominant failure mode affecting the tool life. The tool flank wear propagation in the up milling operations was more rapid than that in the down milling operations. The cutting force variation along with the tool wear propagation was also analysed. While the thermal effects could be a significant cause for the peak force variation within a single cutting pass, the tool wear propagation was believed to be responsible for the gradual increase of the mean peak force in successive cutting passes.