Multi-discharge EDM coring of single crystal SiC ingot by electrostatic induction feeding method

A new technique of EDM coring of single crystal silicon carbide (SiC) ingot was proposed in this paper. Currently single crystal SiC devices are still of high cost due to the high cost of bulk crystal SiC material and the difficulty in the fabrication process of SiC. In the manufacturing process of SiC ingot/wafer, localized cracks or defects occasionally occur due to thermal or mechanical causes resulted from fabrication processes which may waste the whole piece of material. To save the part of ingot without defects and maximize the material utilization, the authors proposed EDM coring method to cut out a no defect ingot from a larger diameter ingot which has localized defects. A special experimental setup was developed for EDM coring of SiC ingot in this study and its feasibility and machining performance were investigated. Meanwhile, in order to improve the machining rate, a novel multi-discharge EDM coring method by electrostatic induction feeding was established, which can realize multiple discharges in single pulse duration. Experimental results make it clear that EDM coring of SiC ingot can be carried out stably using the developed experimental setup. Taking advantage of the newly developed multi-discharge EDM method, both the machining speed and surface integrity can be improved.     

Local toolpath smoothing for five-axis machine tools

When five axis CNC machine tools follow series linear toolpath segments, the drives experience velocity, acceleration and jerk discontinuities at the block transition points. The discontinuities result in fluctuations on machine tool motions which lead to poor surface quality. This paper proposes to insert quintic and septic micro-splines for the tool tip and tool-orientation, respectively, at the adjacent linear toolpath segments. Optimal control points are calculated for position and orientation splines to achieve C³ continuity at the junctions while respecting user-defined tolerance limits. The geometrically smoothed corners are traveled at a smoothly varying feed with cubic acceleration trajectory profile. The proposed method is experimentally demonstrated to show improvements in motion smoothness and tracking accuracy in five-axis machining of free-form surfaces found in dies, molds and aerospace parts.     

菌型叶根动叶片叶根叶冠内径向的加工

菌型叶根动叶片是一种新型的动叶片,采用数控铣加工叶根内径向面时留0.1~0.2mm余量,然后在进行叶根内径向磨削,叶冠直接加工到位,没有后序磨削加工,由于叶根叶冠在加工过程中不是一次装夹完成的,根冠存在一定的落差,在后续的装配中容易产生配合间隙,无法达到要求。文中介绍了一种新的加工工艺,解决了这一问题。     

Abrasive waterjet micro-machining of channels in metals: Comparison between machining in air and submerged in water

Abrasive water jet technology can be used for micro-milling using recently developed miniaturized nozzles. Abrasive water jet (AWJ) machining is often used with both the nozzle tip and workpiece submerged in water to reduce noise and contain debris. This paper compares the performance of submerged and unsubmerged abrasive water jet micro-milling of channels in 316L stainless steel and 6061-T6 aluminum at various nozzle angles and standoff distances. The effect of submergence on the diameter and effective footprint of AWJ erosion footprints was measured and compared. It was found that the centerline erosion rate decreased with channel depth due to the spreading of the jet as the effective standoff distance increased, and because of the growing effect of stagnation as the channel became deeper. The erosive jet spread over a larger effective footprint in air than in water, since particles on the jet periphery were slowed much more quickly in water due to increased drag. As a result, the width of a channel machined in air was wider than that in water. Moreover, it was observed that the instantaneous erosion rate decreased with channel depth, and that this decrease was a function only of the channel cross-sectional geometry, being independent of the type of metal, the jet angle, the standoff distance, and regardless of whether the jet was submerged or in air, in either the forward or backward directions. It is shown that submerged AWJM results in narrower features than those produced while machining in air, without a decrease in centerline etch rate.     

Electromagnetism-like algorithms for optimized tool path planning in 5-axis flank machining

Optimization of tool path planning using metaheuristic algorithms such as ant colony systems (ACS) and particle swarm optimization (PSO) provides a feasible approach to reduce geometrical machining errors in 5-axis flank machining of ruled surfaces. The optimal solutions of these algorithms exhibit an unsatisfactory quality in a high-dimensional search space. In this study, various algorithms derived from the electromagnetism-like mechanism (EM) were applied. The test results of representative surfaces showed that all EM-based methods yield more effective optimal solutions than does PSO, despite a longer search time. A new EM-MSS (electromagnetism-like mechanism with move solution screening) algorithm produces the most favorable results by ensuring the continuous improvement of new searches. Incorporating an SPSA (simultaneous perturbation stochastic approximation) technique further improves the search results with effective initial solutions. This work enhances the practical values of tool path planning by providing a satisfactory machining quality.     

Prediction Model for BTA Deep-Hole Machining using Fuzzy Clustering Approach: Experimental Study

In this article, a subtractive clustering-based fuzzy identification method and a Sugeno-type fuzzy inference system are used for modeling in metal cutting. This approach is considered with its application on the experimental study of Boring and Trepanning Association (BTA) deep-hole drilling. The model for the surface roughness is identified by using the cutting speed and feed as input data and roughness as the output data. Using subtractive clustering in both input and output spaces performs the model-building process. Minimum error model is obtained through enumerative search of clustering parameters. The fuzzy model obtained is capable of predicting the surface roughness for a given set of inputs (speed and feed). Therefore, the operator can predict the quality of the surface for a given set of working parameters and will then be able to set the machining parameters to achieve a certain surface quality. The fuzzy model is verified experimentally by further experimentation using different sets of inputs. The tool life is also investigated using the same approach. The fuzzy inference system obtained is capable of predicting the tool life for a given set of cutting parameters. Therefore, the operator will be able to predict how many minutes the cutting tool is going to last and will set the time for the next tool change.     

自由曲面五坐标数控加工干涉检查

提出了一种新方法，用于环刀五坐标数控加工的干涉检查。该方法将干涉检查分为刀轴及侧刃干涉检查和端面干涉检查。首先将加工曲面分片，选取合适的初始点。然后利用自由曲面的微分特性，确定跟踪方向和步长，迅速计算出工件和刀具的最短距离，从而判断是否发生干涉。实验仿真表明，达到同样精度时，该算法计算效率远高于常规的三角面片法。     

Investigation into polishing process of CVD diamond films

A new technique used for polishing chemical vapor deposition (CVD) diamond films has been investigated, by which rough polishing of the CVD diamond films can be achieved efficiently. A CVD diamond film is coated with a thin layer of electrically conductive material in advance, and then electro-discharge machining (EDM) is used to machine the coated surface. As a result, peaks on the surface of the diamond film are removed rapidly. During machining, graphitization of diamond enables the EDM process to continue. The single pulse discharge shows that the material of the coated layer evidently affects removal behavior of the CVD diamond films. Compared with the machining of ordinary metal materials, the process of EDM CVD diamond films possesses a quite different characteristic. The removal mechanism of the CVD diamond films is discussed.     

COLLISION DETECTION AMONG MOVING OBJECTSIN MACHINING PROCESS SIMULATION

ＣＯＬＬＩＳＩＯＮＤＥＴＥＣＴＩＯＮＡＭＯＮＧＭＯＶＩＮＧＯＢＪＥＣＴＳＩＮＭＡＣＨＩＮＩＮＧＰＲＯＣＥＳＳＳＩＭＵＬＡＴＩＯＮＹａｎｇＨｅｍｉｎｇ；ＬｕＡｎｓｈｅｎｇ；ＺｈｏｕＪｉＣＯＬＬＩＳＩＯＮＤＥＴＥＣＴＩＯＮＡＭＯＮＧＭＯＶＩＮＧＯＢＪＥＣ...     

A Linear Cross-Coupled Control System for High-Speed Machining

We present a linear cross-coupled controller to improve highspeed contouring accuracy independently of tracking accuracy in a biaxial machine tool feed drive servomechanism. Unlike conventional cross-coupled controllers, the cross-coupled controller presented here is a linear system, so it is very easy to perform the stability and steady-state error analysis, and to optimise the controller parameters. The proposed controller is evaluated experimentally on a CNC LOM machine and compared to an uncoupled controller and a conventional cross-coupled controller. Controller performance is evaluated for a circular contour at a feedrate of 30 m min _1 . The experimental results show that the proposed controller can greatly reduce the contour error at large feedrates. The linear cross-coupled controller is simple to implement and is practical.