Micro fabrication of freeform surface parts made of hard and brittle materials is always a tough job in micro machining field. This paper tries to fabricate freeform surface feature by using smooth surface of tool ele...Micro fabrication of freeform surface parts made of hard and brittle materials is always a tough job in micro machining field. This paper tries to fabricate freeform surface feature by using smooth surface of tool electrode after tool wear in micro EDM. According to the skin effect theory, the tool end shape in the stage of uniform wear can be changed by adjusting the frequency of discharge pulse. The electrical energy distributing rule of tool electrode section in RC circuit has been investigated under the influence of skin effect, and the law of spark location change has been summarized. The experimental studies demonstrate that different shapes of tool ends can be achieved by varying the pulse frequencies of discharge power supply. Additionally, a micro part of freeform surface feature with high precision and good surface quality has been successfully obtained by micro EDM through adopting the smooth surface after tool wear.展开更多
The methodology of 5-axis cutter selection to avert collision for free-form surface machining by flat-end cutters is presented. The combination of different cutters is adopt aiming at short machining time and high pre...The methodology of 5-axis cutter selection to avert collision for free-form surface machining by flat-end cutters is presented. The combination of different cutters is adopt aiming at short machining time and high precision. The optimal small cutter is determined based on the geometric information of the points where a cutter most probably collide with the machined surface. Several larger cutters are selected to machine the surface in order to find the interference-free area. The difference of machining time for this area between the optimal small cutter and the large cutters is calculated. The functional relationship between the machining time and the radius of a cutter is established, by which the optimal number of cutters is obtained. The combination of cutters, which possesses the minimum overall machining time, is selected as the optimal cutter sizes. A case study has demonstrated the validity of the proposed methodology and algorithms.展开更多
Electrostatic delivery of charged uniform metal droplets is a novel method to deposit metal parts with short process period and low cost. But the delivery process is unstable and delivery accuracy of charged droplets ...Electrostatic delivery of charged uniform metal droplets is a novel method to deposit metal parts with short process period and low cost. But the delivery process is unstable and delivery accuracy of charged droplets deteriorates because of actions of mutual interactions of closely charged droplets. A droplet generator with droplet charging and deflecting system has been established to find out the way for stably and accurately deflecting droplets. The parameters for generating uniform droplets were first studied. Then the droplet deflections and metal parts depositions with different charge methods were discussed. The results show that the unbalanced electrostatic repelling forces are the main factor to cause the unstable deflection of droplets. The droplets deflection distance can be predicted and controlled by balancing the repelling forces of charged droplets. The metal parts are stably deposited after combining the board charged pulse and substrate motion, indicating that the work can provide useful theoretical and experimental guide for droplet-based freeform fabrication.展开更多
基金Supported by the National Natural Science Foundation of China （50635040） and the National Science Foundation of USA（CMMI-0728294 and CMMI- 0928873）
文摘Micro fabrication of freeform surface parts made of hard and brittle materials is always a tough job in micro machining field. This paper tries to fabricate freeform surface feature by using smooth surface of tool electrode after tool wear in micro EDM. According to the skin effect theory, the tool end shape in the stage of uniform wear can be changed by adjusting the frequency of discharge pulse. The electrical energy distributing rule of tool electrode section in RC circuit has been investigated under the influence of skin effect, and the law of spark location change has been summarized. The experimental studies demonstrate that different shapes of tool ends can be achieved by varying the pulse frequencies of discharge power supply. Additionally, a micro part of freeform surface feature with high precision and good surface quality has been successfully obtained by micro EDM through adopting the smooth surface after tool wear.
基金Funded by the Doctorate Degree Program Foundation of the Ministry of Education (No. 2000061120)
文摘The methodology of 5-axis cutter selection to avert collision for free-form surface machining by flat-end cutters is presented. The combination of different cutters is adopt aiming at short machining time and high precision. The optimal small cutter is determined based on the geometric information of the points where a cutter most probably collide with the machined surface. Several larger cutters are selected to machine the surface in order to find the interference-free area. The difference of machining time for this area between the optimal small cutter and the large cutters is calculated. The functional relationship between the machining time and the radius of a cutter is established, by which the optimal number of cutters is obtained. The combination of cutters, which possesses the minimum overall machining time, is selected as the optimal cutter sizes. A case study has demonstrated the validity of the proposed methodology and algorithms.
基金supported by the National High Technology Research and Development Program of China ("863"Program) (Grant No. 2008AA03A238)the National Natural Science Foundation of China (Grant No. 51005186)Foundation for the Author of National Excellent Doctoral Dissertation of China (Grant No. 2007B3)
文摘Electrostatic delivery of charged uniform metal droplets is a novel method to deposit metal parts with short process period and low cost. But the delivery process is unstable and delivery accuracy of charged droplets deteriorates because of actions of mutual interactions of closely charged droplets. A droplet generator with droplet charging and deflecting system has been established to find out the way for stably and accurately deflecting droplets. The parameters for generating uniform droplets were first studied. Then the droplet deflections and metal parts depositions with different charge methods were discussed. The results show that the unbalanced electrostatic repelling forces are the main factor to cause the unstable deflection of droplets. The droplets deflection distance can be predicted and controlled by balancing the repelling forces of charged droplets. The metal parts are stably deposited after combining the board charged pulse and substrate motion, indicating that the work can provide useful theoretical and experimental guide for droplet-based freeform fabrication.
