Lightweight Design and Verification of Gantry Machining Center Crossbeam Based on Structural Bionics

The lightweight and high efficiency of natural structures are the inexhaustible sources for engineering improvements. The goal of the study is to find innovative solutions for mechanical lightweight design through the application of structural bionic approaches. Giant waterlily leaf ribs and cactus stem are investigated for their optimal framework and superior performance. Their structural characteristics are extracted and used in the bio-inspired design of Lin MC6000 gantry machining center crossbeam. By mimicking analogous network structure, the bionic model is established, which has better load-carrying capacity than conventional distribution. Finite Element Method （FEM） is used for numerical simulation. Results show better specific stiffness of the bionic model, which is increased by 17.36%. Finally the scaled models are fabricated by precision casting for static and dynamic tests. The physical experiments are compared to numerical simulation. The results show that the maximum static deformation of the bionic model is reduced by about 16.22%, with 3.31% weight reduction. In addition, the first four natural frequencies are improved obviously. The structural bionic design is a valuable reference for updating conventional mechanical structures with better performance and less material consumption.

Modified Layer-Removal Method for Measurement of Residual Stress in Pre-stretched Aluminium Alloy Plate

Residual stress is one of the factors affecting the machining deformation of monolithic structure parts in the aviation industry. Thus, the studies on machining deformation rules induced by residual stresses largely depend on correctly and efficiently measuring the residual stresses of workpieccs. A modified layer-removal method is proposed to measure residual stress by analysing the characteristics of a traditional, layer-removal method. The coefficients of strain release are then deduced according to the simulation results using the finite element method （FEM）. Moreover, the residual stress in a 7075T651 aluminium alloy plate is measured using the proposed method, and the results are then analyzed and compared with the data obtained by the traditional methods. The analysis indicates that the modified layer-removal method is effective and practical for measuring the residual stress distribution in pre-stretched aluminium alloy plates.

Turning Affected Layers of GH4169 with Worn Tools

To solve problems of surface integrity of GH4169 caused by tool wear during machining,residual stresses layers(RSL),deformation layers(DL),and surface roughness of machined surface were studied in this work.Jobs were done at the turning parameters of v_(c)=15 m/min and f_(z)=0.05 mm/r and ap=1 mm with6 different worn tools.Firstly,tool nose wear closes to minor flank face and how it influenced machined surface were discussed.Details were given by image processing and it concluded to 5 tool w ear states according to cutting time.Secondly,relationships between tool wear states and tensile residual stresses(RS)were built so the RS range is manageable by placing a cutting time limit.Thirdly,affected layers’depths were associated w ith tool wear and the consistency betw een RSL and DL was presented.At last,roughness values variation with cutting time were discussed.Results show that RS in peripheral direction is far larger than that in axial direction.The total cutting time of a tool should be controlled within 37 min and a time period 30-37 min before severely worn owns excellent cutting effects.Tensile RS of 400 M Pa can be set as a reference value for evaluating tool quality from angle of workpiece.

Analysis on the Wear Performances of Cemented Carbide Tools Containing Ti in the Coatings When Machining Ti⁃6Al⁃4V Alloys

Because of the high affinity of the same element Ti,cemented carbide tools containing Ti seem to be non⁃optimal in machining titanium alloys.However,in practice,cemented carbide tools containing Ti are still widely used in machining titanium alloys.Cutting experiments were conducted in order to systematically explain the contradictions between the practice and theory.The diffusion process between titanium alloys and the cemented carbide tools was analyzed by auger electron spectroscopy detecting the cutting regions.It was also analyzed by Ti/Co diffusion behavior simulated by molecular thermodynamics.The experimental results and the simulation results showed that the mutual diffusion of Ti/Co atoms was the major reason for the diffusion wear.The dissolution⁃diffusion wear was one of the main wear mechanisms for the cemented carbide tools containing Ti in the coatings.Moreover,four types of cemented carbide tools and two other types of cermet tools were used to machine the Ti⁃6Al⁃4V alloys at different cutting speeds to further verify the high affinity of cutting tools containing Ti in the substrate/coating.The verification experiments results showed that the cemented carbide tools containing Ti generally cannot be used for machining titanium alloys,but could show less affinity in the cutting regions with reasonable cutting conditions.

Tool wear mechanisms in the machining of Nickel based super-alloys： A review

Nickel based super-alloys are widely employed in aircraft engines and gas turbines due to their high temperature strength, corrosion resistance and, excellent thermal fatigue properties. Conversely, these alloys are very difficult to machine and cause rapid wear of the cutting tool, frequent tool changes are thus required resulting in low economy of the machining process. This study provides a detailed review of the t0ol wear mechanism in the machining of nickel based super-alloys. Typical tool wear mechanisms found by different researchers are analyzed in order to find out the most prevalent wear mechanism affecting the tool life. The review of existing works has revealed interesting findings about the tool wear mechanisms in the machining of these alloys. Adhesion wear is found to be the main phenomenon leading to the cutting tool wear in this study.

Positioning error compensation for parallel mechanism with two kinematic calibration methods

Compared with serial mechanisms, the parallel mechanism(PM) theoretically exhibited higher positioning accuracy, dynamic performance, strength-to-weight ratio, and lower manufacturing cost, but they had not been widely used in the practical application. One key issue, positioning accuracy, which directly affected their performance and was greatly influenced by the errors of kinematic structure parameters was analyzed. To effectively enhance the positioning precision of PMs, a novel modeless kinematic calibration method, namely the split calibration, was presented and its compensation effect of the positioning error was comprehensively compared with that of an integrated method on two different types of PMs. A strange phenomenon-correct and incorrect identified results were derived from two different PMs by the same integrated method, respectivelywhich had not been reported yet was discovered, and the origin of it was revealed utilizing numerical simulations. Finally, respective merits and drawbacks of these two methods obtained in this paper provided underlying insights to guide the practical application of the kinematic calibration for PMs.