基于切削力实时测量的弱刚性件加工变形控制

针对整体多框弱刚性件切削易变形之问题,提出了基于切削力实时测量的进给速度实时调整方法。根据铣削变形仿真数据建立了加工过程中进给速度、切削力与工件最大变形之间的非线性数值模型,并通过非线性求根算法求解最大变形和切削力约束下的进给速度最优解,并在开放式数控系统中开发了相应的控制模块。利用所开发的无线轴式测力装置和控制模块开展了铝合金薄壁框切削变形控制实验,结果说明数值模型预测精度在90%以上,实施进给速度优化功能优化后,切削力和工件最大变形分别降低23%和12.3%左右。实验结果表明,经过切削力实时约束和弱刚性件加工进给速度自适应调整,可将薄壁框件侧壁变形控制在规定范围内。     

Optimal fixture design in peripheral milling of thin-walled workpiece

In order to optimize the positions of the locators in peripheral milling of a thin-walled workpiece, a finite element model along with an accurate cutting forces model is proposed in this paper. The finite element model takes into account the thickness variations of the workpiece in peripheral milling. The locators on the secondary locating surface directly influence the surface errors in peripheral milling of thin-walled workpiece, so this paper deals with the optimization of the positions of the locators on the secondary locating surface. A method including two steps is presented. In the first step, the initial positions of the locators are determined by adding the locators at the position with the maximum deformation. In the second step, a heuristic algorithm is proposed to optimize the positions of the locators. Finally, a simulation example is used to illustrate the method.     

复杂形状工件的端铣切削力模型

以传统的端铣切削力模型为基础，提出了一种新的端铣加工中静态切削力的预报模型。该模型考虑了复杂的工件形状和不同的铣刀进给轨迹。给出了一种新的工件和铣刀接触算法。     

一种新型管道微机器人驱动力的理论分析和实验研究

研究一种管道微机器人新型轮式驱动方法及结构,即由驱动轮表面与管道表面作用产生的牵引力和驱动轮表面结构的弹性变形力来驱动微机器人运动。分析了新型管道微机器人在运动时的受力情况,并推导得到驱动轮弹性变形驱动力和牵引力的计算公式。同时,笔者研制了一种微小力测试实验台,对驱动轮的弹性变形驱动力进行了测试。     

A real time machining error compensation method based on dynamic features for cutting force induced elastic deformation in flank milling

During the machining process, cutting forces cause deformation of thin-walled parts and cutting tools because of their low rigidity. Such deformation can lead to undercut and may result in defective parts. Since there are various unexpected factors that affect cutting forces during the machining process, the error compensation of cutting force induced deformation is deemed to be a very difficult issue. In order to address this challenge, this article proposes a novel real time deformation error compensation method based on dynamic features. A dynamic feature model is established for the evaluation of feature rigidity as well as the association between geometric information and real time cutting force information. Then the deformations are calculated based on the dynamic feature model. Eventually, the machining error compensation for elastic deformation is realized based on Function Blocks. A thin-walled feature is used as an example to validate the proposed approach. Machining experiment results show that the errors of calculated deformation with the monitored deformation is less than 10%, and the thickness errors were between ?0.05 mm and +0.06 mm, which can well satisfy the accuracy requirement of structural parts by NC (Numerical Control) machining.     

Optimization of the number and positions of fixture locators in the peripheral milling of a low-rigidity workpiece

In this paper, a method is proposed to optimize the fixture layout in the peripheral milling of a low-rigidity workpiece. Because the locators on the secondary locating surface directly influence the deformation of the workpiece in peripheral milling, this paper deals with the optimization of the number and positions of the locators on the secondary locating surface. The method proposed in this paper includes two stages. In the first stage, the initial number and positions of the locators are determined by adding the locators at the position with the maximum deformation. In the second stage, the number and positions of the locators are optimized. Using the method proposed in this paper, the number of locators is reduced, while the machining accuracy of the workpiece is retained.     

A feature-based approach for optimal workpiece localization and determination of feasible clamping regions

In this paper, we present an approach for optimally selecting the locating positions of workpieces and identifying feasible clamping regions that meet the requirements of the form-closure principle for fixture layout. This approach firstly finds an optimal configuration of locating points on a set of faces of the workpiece which minimizes the error transfer from locating points to machining features. In the formulation of the optimization, the error transfer is modeled using an error transfer matrix. The eigenvalues of the matrix are used as objective functions of the optimization. Secondly, this approach computes the clamping wrench cone and its member wrench can form a form-closure fixture layout, together with the formerly selected locating points. Finally, it generates the feasible clamping regions by projecting the clamping wrench cone onto faces of the clamping feature faces. An example is included to illustrate the effectiveness of the proposed approach. Compared with traditional methods in which only error transfer from the locating points to the workpiece’s mass-center is considered, the error transfer control in this approach is more effective and of greater efficiency. In addition, the clamping wrench cone projection method for the generation of feasible clamping regions is more suitable for handling cases with concave clamping faces than traditional convex-combination-based methods.     

刚性质量对自由梁的弹粘塑性次撞击

采用过应力模型,考虑局部撞击接触变形和自由梁动力响应中的材料应变率效应,提出能够考虑多次撞击接触行为的单轴压缩弹粘塑性局部接触变形模型,并结合有限差分方法和撞击与分离条件,研究刚性质量水平撞击弹粘塑性自由梁的全过程。研究发现,该水平撞击过程实际上是一个复杂的弹粘塑性次撞击过程,梁材料的应变率效应在局部接触变形行为和自由梁的动力响应行为中有着显著的作用,导致撞击力幅值、弹性变形和塑性变形等发生明显的变化。通过与三维动力有限元法的计算结果的比较表明,所提方法是合理的。     

The prediction of cutting force in milling Inconel-718

Due to the enormous engineering advancement in modern industries, the competition in manufacturing technologies has been increasingly intense, as can be seen in automobile and aerospace industries. Nickel-based superalloys are widely in the manufacture of components for aircraft turbine engines for cryogenic tankage, in liquid rockets, reciprocating engines, space vehicles, heat-treating equipment, chemical and petrochemical industries, because of their ability to retain high-strength at elevated temperatures. But, because of its characteristics of high-strength, poor thermal diffusion and work hardening, the cutting of nickel-based superalloys results in decreased tool life and poor efficiency of works. This is much more prominent than in other materials. AISI4340 are widely used in the manufacture of component parts for gear, pistons, and automobiles.     

Analysis on nonlinear dynamics of a thin-plate workpiece in milling process with cutting force nonlinearities

This paper aims to investigate the nonlinear dynamics of a thin-plate workpiece during milling process with cutting force nonlinearities. By modeling the thin-plate workpiece as a cantilevered thin plate and applying the Hamilton’s principle, the equations of motion of the thin-plate workpiece are derived based on the Kirchhoff-plate theory and the von Karman strain-displacement relations. Using the Galerkin’s approach, the equations of motion are reduced to a two-degree-freedom nonlinear system. The method of Asymptotic Perturbation is utilized to obtain the averaged equations in the case of 1:1 internal resonance and foundational resonance. Numerical methods are used to find the periodic and chaotic oscillations of the cantilevered thin-plate workpiece. The results show that the cantilevered thin-plate workpiece demonstrate complex dynamic behaviors under time-delay effects, the external and parametric excitations.     

基于CATIA平台的夹具快速设计与制造系统的构建

重点研究CATIA在专用夹具设计及制造过程中的应用问题。夹具设计涉及到数值计算 ,图形绘制等一些算法问题。CATIA在解决这类问题时显示出其优越性。关键是研究如何在CATIA环境下建立专用夹具设计、制造快速响应系统的总体结构 ,特别是在如何建立专用夹具元件库及夹具可行性分析等方面作了一些研究。对有关夹具相似性比较的推理方法也作了一些探讨。     

Case study: A comparison of error sources in high-speed milling

This paper describes a case study devised to quantify the relative contributions of geometric, thermal, contouring, and cutting force errors to machined part dimensional errors. Measurements were performed to independently evaluate the: (1) quasi-static geometric errors using the laser ball bar; (2) variations in geometric errors due to thermal effects; (3) spindle thermal growth errors using a capacitance gage nest; (4) two-dimensional contouring errors using a grid plate encoder; and (5) surface location error due to (stable) forced vibrations during cutting. The effects of the first three error components were related to part dimensions using a homogeneous transformation matrix approach integrated into a Monte Carlo simulation. A comparison of the individual influences of these error sources showed that the cutting force error was dominant for the high-speed machining center/tool-holder combination selected for this study.     

Angle error compensation in wheel force transducer

Wheel force transducers (WFTs) have performance characteristics that make them attractive for applications in endurance evaluation of road vehicles, ride and handling optimization, tire development and vehicle dynamics. Since the WFT is mounted on the wheel and rotates with it, the rotational angle of the wheel is indispensable to calculate the real wheel forces. Unfortunately, an angle error caused by the steering of the vehicle will be incorporated into the measurement of the rotational angle, resulting in great error in the wheel force calculation. A new compensation algorithm is proposed in this paper to eliminate this angle error. In this algorithm, the GPS speed has been introduced to modify the measurement of the rotational angle in real time. Simulations with designed vehicle movement are carried out to demonstrate the effectiveness of the compensation algorithm. Furthermore, the results of real vehicle test show that this algorithm can be successfully used in practice to get more reasonable wheel loads.     

Analysis of cutting force coefficients in high-speed ball end milling at varying rotational speeds

In high-speed ball end milling, cutting forces influence machinability, dimensional accuracy, tool failure, tool deflection, machine tool chatter, vibration, etc. Thus, an accurate prediction of cutting forces before actual machining is essential for a good insight into the process to produce good quality machined parts. In this article, an attempt has been made to determine specific cutting force coefficients in ball end milling based on a linear mechanistic model at a higher range of rotational speeds. The force coefficients have been determined based on average cutting force. Cutting force in one revolution of the cutter was recorded to avoid the cutter run-out condition (radial). Milling experiments have been conducted on aluminum alloy of grade Al2014-T6 at different spindle speeds and feeds. Thus, the dependence of specific cutting force coefficients on cutting speeds has been studied and analyzed. It is found that specific cutting force coefficients change with change in rotational speed while keeping other cutting parameters unchanged. Hence, simulated cutting forces at higher range of rotational speed might have considerable errors if specific cutting force coefficients evaluated at lower rotational speed are used. The specific cutting force coefficients obtained analytically have been validated through experiments.     

In-process estimation of radial immersion ratio in face milling using cutting force

In order to prevent tool breakage in milling, maximum total cutting force is regulated at a specific constant level, or threshold, through feed rate control. Since the threshold is a function of the immersion ratio, an estimation of the immersion ratio is necessary to flexibly determine the threshold. In this paper, a method of in-process estimation of the radial immersion ratio in face milling is presented. When an insert finishes sweeping, a sudden drop in cutting forces occurs. These force drops are equal to the cutting forces that act upon a single insert at the swept cutting angle and they can be acquired from cutting force signals in the feed and cross-feed directions. Average cutting forces per tooth period can also be calculated from the cutting force signals in two directions. The ratio of cutting forces acting upon a single insert at the swept angle of cut and the ratio of average cutting forces per tooth period are functions of the swept angle of cut and the ratio of radial to tangential cutting force. Using these parameters, the radial immersion ratio is estimated. Various experiments are performed to verify the proposed method. The results show that the radial immersion ratio can be estimated by this method regardless of other cutting conditions.Nomenclature F_T, F_R tangential and radial forces - F_X, F_Y cutting forces in feed direction and cross feed direction - dF_X, dF_Y cutting force differences before and after the immersion angle in X and Y direction - K_s specific cutting pressure - a depth of cut - r ratio between tangential force and radial force - s_t feed per tooth - instantaneous angle of cut - _s swept angle of cut - _T tooth spacing angle - w radial width of cut - R cutter radius - z number of inserts     

基于主成份回归的铣削力系数辨识及仿真

基于平均力法建立了铣削力模型,采用二次回归方程,构造了对铣削过程适应性强的铣削力系数模型。通过运用主成分法对系数模型进行分析,发现此模型具有严重的多重共线性,因此不能应用普通的回归估计方法得到精确的系数估计值,在此情况下本文提出了快速有效的主成分回归估计法,并利用同位级正交设计方法,结合具体切削条件,设计了铣削力系数识别试验及验证仿真试验。试验结果表明,采用主成分预测精度要高于普通最小二乘法,而且试验次数少,计算量小,模型简单,参数具有明显的物理意义。     

轨道式球阀启闭力的设计计算

论述了新型硬密封轨道式球阀的工作原理，分析研究了由阀杆头部作用于球体的最大启闭力及其特性，总结了结构设计和验算用的启闭力的计算公式，提出的设计计算方法已用于轨道式球阀系列产品设计中。     

Prediction of dynamic cutting force and regenerative chatter stability in inserted cutters milling

Currently, the modeling of cutting process mainly focuses on two aspects: one is the setup of the universal cutting force model that can be adapted to a broader cutting condition; the other is the setup of the exact cutting force model that can accurately reflect a true cutting process. However, there is little research on the prediction of chatter stablity in milling. Based on the generalized mathematical model of inserted cutters introduced by ENGIN, an improved geometrical, mechanical and dynamic model for the vast variety of inserted cutters widely used in engineering applications is presented, in which the average directional cutting force coefficients are obtained by means of a numerical approach, thus leading to an analytical determination of stability lobes diagram (SLD) on the axial depth of cut. A new kind of SLD on the radial depth of cut is also created to satisfy the special requirement of inserted cutter milling. The corresponding algorithms used for predicting cutting forces, vibrations, dimensional surface finish and stability lobes in inserted cutter milling under different cutting conditions are put forward. Thereafter, a dynamic simulation module of inserted cutter milling is implemented by using hybrid program of Matlab with Visual Basic. Verification tests are conducted on a vertical machine center for Aluminum alloy LC4 by using two different types of inserted cutters, and the effectiveness of the model and the algorithm is verified by the good agreement of simulation result with that of cutting tests under different cutting conditions. The proposed model can predict the cutting process accurately under a variety of cutting conditions, and a high efficient and chatter-free milling operation can be achieved by a cutting condition optimization in industry applications.     

惯性力静力等效法计算误差的模拟研究

在计算柴油机曲柄连杆机构运动过程中的惯性力时,由于理论计算公式过于复杂,通常将曲柄连杆机构中的连杆和曲柄按静力等效的原则进行简化。这里用多体系统MBS（Muhi—Bodv System）动力学模拟方法,以S195柴油机为例研究了静力等效法计算曲柄连杆机构惯性力的误差。以期为单缸柴油机曲轴平衡块和辅助动平衡机构的设计提供依据。     

叠加式力标准装置系统误差修正研究

超大力值叠加式力标准装置是力值计量领域研究的前沿和热点,消除系统误差对提高叠加式力标准装置的准确度水平具有重要意义。提出一种叠加式力标准装置系统误差修正的方法与流程,并对本方法中系统误差的外推提出了4种不同的外推方法。通过对3台不同结构的300 k N和一台20 MN叠加式力标准装置的实验对比研究,确定最优误差外推方法,并利用该方法对一台60 MN叠加式力标准装置进行力值修正,该装置修正后与英国国家物理实验室30 MN叠加式力标准机的力值比对相对偏差不超过±0.06%,E_n值小于1。研究结果表明:在叠加式力标准装置修正前示值误差方程的外推中,宜采用1次或2次多项式方程进行外推,避免因方程次数较高,导致外推结果发散;在叠加式力标准装置结构设计时,应尽量优化其线性度,减小外推误差,提高示值误差外推的准确性;本方法能有效减小叠加式力标准装置的系统误差,提高装置的力值准确度。