Prediction of cutting forces in flank milling of parts with non-developable ruled surfaces

Predicting the cutting forces required for five-axis flank milling is a challenging task due to the difficulties involved in determining the Undeformed Chip Thickness(UCT) and CutterWorkpiece Engagement(CWE). To solve these problems, this paper presents a new mechanistic cutting force model based on the geometrical analysis of a flank milling process. In the model,the part feature and corresponding cutting location data are taken as input information. The UCT considering cutter runout is calculated according to the instantaneous feed rate of the element cutting edges. A solid-discrete-based method is used to precisely and efficiently identify the CWE between the end mill and the surface being machined. Then, after calibrating the specific force coef-ficients, the mechanistic milling force can be obtained. During the validation process, two practical operations, three-axis flank milling of a vertical surface and five-axis flank milling of a nondevelopable ruled surface, are conducted. Comparisons between predicted and measured cutting forces demonstrate the reliability of the proposed cutting force model.

Cutting Path Planning for Ruled Surface Impellers

At present, most commercial computer-aided manufacturing （CAM） systems are deficient in efficiency and performances on generating tool path during machining impellers. To solve the problem, this article develops a special software to plan cutting path for ruled surface impellers. An approximation algorithm to generate cutting path for machining integral ruled surface impellers is proposed. By fitting sampling data points of an impeller blade into a curve, a model of ruled surface blade of an impeller is built up. Furthermore, by calculating the points where the cutter axis vector intersects the free-form hub surface of an impeller, problems about, for instance, the ambiguity in calculation and machining the wide blade surface with a short flute cutter are solved. Finally, an integral impeller cutting path is planned by way of an integrated cutter location control algorithm. Simulation and machining tests with an impeller are performed on a 5-axis computer numerically controlled （CNC） mill machine, which shows the feasibility of the proposed algorithm.

On the Ruled surfaces in Minkowski 3-space R1^3

Izumiya and Takeuchi （2003） obtained some characterizations for Ruled surfaces. Turgut and Haclsalihoglu （1998） defined timelike Ruled surfaces and obtained some characterizations in timelike Ruled surfaces. Choi （1995） and Jung and Pak （1996） studied Ruled surfaces. This study uses the method in （lzumiya and Takeuchi, 2003） to investigate cylindrical helices and Bertrand curves as curves on timelike Ruled surfaces in Minkowski 3-space R1^3. We have studied singularities of the rectifying developable （surface） of a timelike curve. We observed that the rectifying developable along a timelike curve a is non-singular if and only if a is a cylindrical helice. In this case the rectifying developable is a cylindrical surface.

Evolutions of the Ruled Surfaces via the Evolution of Their Directrix Using Quasi Frame along a Space Curve

In this paper, evolutions of ruled surfaces generated by the quasi normal and quasi binormal vector fields of space curve are presented. These evolutions of the ruled surfaces depend on the evolutions of their directrix using quasi frame along a space curve.

RULED SURFACE MACHINING BY 4-AXES SIMULTANEOUS CONTROL WIRE-EDM

On the tasis of study in the mathematical model of 3-dimensional ruled surface (RS),this paper introduces a new concept of distance paramcter (DP) and also puts forward that themethod of modeling a RS depends on not only two boundary curves but also DP. According toabove theory, the formulas to calculate corresponding point coordinates to any kind of top and bot-tom profile of a workpiece and formulas to calcuate the maximum inclination angle of ruling linehave been obtained. Then a different top and bottom RS mathining method including profile withline-are combination as well as parametric curves has been achieved by 4-axes simultancous con-trol programming proposed.

CAD/CAM ALGORITHM OF RULED SURFACE BASED ON LINE GEOMETRY

A new concept of design and manufacturing of ruled surface based on line geometry is proposed. Some practical algorithm for CAD system is derived. Some problems in design and manufacturing of ruled surface can be solved by using the algorithm.

Surface borehole synthesis tension deformation fracture time-space rule

In order to release the tension and shear effect of the superjacent rock strata movement during excavation in coal mine,protect the surface borehole case from fracturing fast and make a good use of the surface borehole during goaf methane drawing,a common synthesis tension deformation fracture model was set up based on the synthesis tension effect of the rock strata,and the deformation rule of the surface borehole case with time and space was researched.The results suggest that,to reduce the deformation the surface borehole should be built between the boundary of the stope and the knee of subsidence curve.At the same time,a 3DEC simulation model and an engineering example were carried out to examine the rules of theoretical model.The result suggests that the model and the rules accord to the test and have good building and protection engineering application values to the surface borehole.

γ-p-S_a-S_m-N SURFACE THEORY AND TWO-DIMENSIONAL RELIABILITY MINER RULE FOR FATIGUE RELIABILITY-BASED DESIGN

First of all, the concept of γ_p_S a_S m_N (confidence level_reliability_stress amplitude_stress mean_fatigue life) surface is presented. Then the formulas of p_S a_S m_N surface and γ_p_S a_S m_N surface are derived. In addition, fatigue strength distribution function and two_dimensional reliability Miner rule are obtained. At last, an example is given.

Constant angle surfaces constructed on curves

The Frenet-Serret formula is used to characterize the constant angle ruled surfaces in R3. When the surfaces are the tangent developmental and normal surfaces, that is, r（s, v） = tr（s） ＋v（cosα（s） . t（s） ＋sina（s） . n（s））, it is shown that each of these surfaces is locally isometric to a piece of a plane or a certain special surface. When the surfaces are normal and binormal surfaces, that is, r （ s, v ） = σ （ s ） ＋ v （ cosa （ s ） . n（s） ＋ since（s） . b（s））, it is shown that each of these surfaces is locally isometric to a piece of a plane or a cylindrical surface.

Surface coal mine permit application for successful reclamation, semi-arid shortgrass prairie （Wyoming, USA）

Approximately 40% of USA coal originates in an ecologically sensitive area of semi-arid shortgrass prairie in Wyoming. Before a surface coal mine can begin operation in the USA, it must secure a mining permit and comply with regulations and performance standards under the USA Surface Mining Control and Reclamation Act （SMCRA）, other federal environmental acts, and state programs. The Wyoming Department of Environmental Quality （WDEQ）/Land Quality Division （LQD） administers Wyoming＇s coal regulatory program. The permit application and bonding process for the largest surface coal mine permit in the USA, North Antelope Rochelle Mine （NARM） located in short grassland prairie in the northeast Wyoming, is discussed. The permit application process begins with the collection of baseline environ- mental data that characterizes premining conditions of the permit area. The permit application includes adjudication information, baseline information, mine and operation plans, and reclamation plans. Fulfillment of permit commitments and requirements of rules and regulations are inspected monthly by the LQD＇ s representative in the field. Before a mine permit is issued, the mine operator must submit a reclamation bond to secure the performance of reclamation obligations that is later revised annually. In Wyoming, four reclamation bond release phases indicate the completion of various stages of the reclamatikon process. NARM＇s specific bond release verification cirteria, performance standards, and field verificatoins of bond release phases are discussed. The Bond Release Geodatabase （a GIS/GPS approach） was developed for this mine to monitor progress in meeting criteria and performance standards for incremental bond release. The Bond Release Geodatabase significantly reduces the time needed to track bond release progress, reach agreement between operator and regulator, and improve the state inspector＇s ability to assess reclamation adequacy and progress.

Tool path generation for 5-axis flank milling of ruled surfaces with optimal cutter locations considering multiple geometric constraints

Ruled surfaces found in engineering parts are often blended with a constraint surface,like the blade surface and hub surface of a centrifugal impeller.It is significant to accurately machine these ruled surfaces in flank milling with interference-free and fairing tool path,while current models in fulfilling these goals are complex and rare.In this paper,a tool path planning method with optimal cutter locations(CLs)is proposed for 5-axis flank milling of ruled surfaces under multiple geometric constraints.To be specific,a concise three-point contact tool positioning model is firstly developed for a cylindrical cutter.Different tool orientations arise when varying the three contact positions and a tool orientation pool with acceptable cutter-surface deviation is constructed using a meta-heuristic algorithm.Fairing angular curves are derived from candidates in this pool,and then curve registration for cutter tip point on each determined tool axis is performed in respect of interference avoidance and geometric smoothness.On this basis,an adaptive interval determination model is developed for deviation control of interpolated cutter locations.This model is designed to be independent of the CL optimization process so that multiple CLs can be planned simultaneously with parallel computing technique.Finally,tests are performed on representative surfaces and the results show the method has advantages over previous meta-heuristic tool path planning approaches in both machining accuracy and computation time,and receives the best comprehensive performance compared to other multi-constrained methods when machining an impeller.

Existence Criteria of Blending Surfaces of Three Quadric Surfaces——Wu Wen-tsun's Formulae

Smoothly blending several implicit quadric surfaces with surfaces of the lowest degree is very useful in engineering technology.

直纹面面齿轮共轭小齿轮的滚齿加工研究

针对直纹面面齿轮与圆柱齿轮不满足共轭关系而限制其在小传动比应用场合的情况,提出与直纹面面齿轮共轭的小齿轮及其滚齿加工方法。首先建立了直纹面面齿轮及其共轭小齿轮的齿面方程,获得共轭小齿轮相比圆柱齿轮的齿面偏差形貌;随后推导了阿基米德齿轮滚刀的齿面方程,并根据滚齿加工运动坐标系和啮合原理建立了圆柱齿轮的数学模型;在滚齿加工圆柱齿轮的运动基础上,通过增加滚刀的径向移动和工件的附加转动使滚刀切削刃逼近共轭齿面,附加运动由泰勒多项式表示,通过建立敏感矩阵方程并采用奇异值分解法迭代求解方程获得附加数控运动多项式系数,最后获得数控加工齿面;为评价直纹面面齿轮副的传动性能,进行了齿面承载接触分析,并与传统面齿轮-圆柱齿轮副进行了对比。研究结果表明:相同参数下,直纹面面齿轮副与传统面齿轮副的承载性能基本相同,完全能够代替传统面齿轮副传动;数值算例和仿真加工对该方法的验证表明,其数值算例误差不超过1μm,仿真结果误差不超过6μm,证明了该方法的可行性和准确性。

(3-RPS)+(2-RCR)混联机构末端约束分析

为探索“并+并”型少自由度混联机构末端约束的特点,以(3-RPS)+(2-RCR)机构为研究对象,提出了求解其末端约束的螺旋系求交法。阐述了(3-RPS)+(2-RCR)机构末端约束/自由度组成原理,给出了末端约束/自由度计算公式;结合线几何分析了机构在不同几何位形下的末端自由度数目;应用解析几何理论和螺旋理论建立子约束螺旋系对应的直纹面和母线方程,得到了螺旋三系和四系的交集解析模型,确定了机构末端约束螺旋;讨论了不同几何位形下的末端约束/自由度性质,给出机构在3种不同位形下末端约束求解的数值算例。研究表明,在一般位形下,该机构末端约束并非约束力/力偶,而是一般形式的力螺旋。提出的螺旋系交集求解方法为此类混联机构末端约束问题研究提供了有效的解决方案。

基于双NURBS曲线的叶轮叶片工业机器人GMAW增材制造

以双NURBS曲线获得的直纹面广泛存在于各行业复杂零件中,如何实现复杂直纹面的增材制造一直是增材制造领域中极为关心的问题。以双NURBS曲线描述叶片模型,进一步获得直纹面,采用优化工艺参数,以GMAW方法实现了叶轮叶片的增材制造,增材获得的叶片完整,成形良好,表明以GMAW工艺实现双NURBS曲线叶片增材制造是可行的。为叶片模型构建、复杂形状叶片的电弧增材制造提供了新方法,对复杂形状零件增材制造过程控制具有借鉴意义。

大连梭鱼湾专业足球场外幕墙结构设计

大连梭鱼湾专业足球场外幕墙结构采用钢桁架+交叉索网支承单层乙烯⁃四氟乙烯共聚物(ETFE)膜体系,连接于主体结构的56榀径向钢桁架、环向框架坡道及环向水平支撑共同构成外幕墙结构抗侧力体系,环形框架坡道之间设置平行交叉索网,支承单层ETFE膜形成足球场外立面幕墙。依据风洞试验和场地自然条件,对外幕墙结构进行抗风荷载、抗温度作用、抗震等计算分析。结构动力特性分析、结构变形及应力分析、索结构初始态找形分析结果均满足结构设计控制目标要求。外幕墙结构优化分析结果表明,在框架柱等距设置悬挑桁架,增加水平支撑并设置钢立杆,减小索长并降低预拉力,可以减小预拉力对悬挑桁架的作用力。外墙膜作为次结构外挂在双向斜交索网上,结构受力合理,契合建筑直纹曲面设计理念,结构与建筑协调统一。

基于螺旋接触线的五轴侧铣刀具定位方法

针对五轴侧铣加工非可展直纹面时刀具与设计曲面相互干涉的问题,提出了一种基于螺旋接触线的刀具定位方法。首先,基于Z-buffer法建立单个刀位下的误差解析模型,以评估刀具定位方法的优劣。其次,根据非可展直纹面的扭转特性,构造刀轴矢量的数学模型,同时分析刀具-工件接触线的性质及参数表达式。再次,考虑实际加工中的非线性加工误差,通过运动学变换对全局刀位进行路径插补优化。最后,基于改进两点偏置法、最小二乘法及所提出的方法进行仿真分析并对比3种方法所产生的误差,同时基于后2种方法进行实验验证。仿真和实验结果表明,所提出的方法能够有效减小侧铣加工中的原理误差,可为非可展直纹面的五轴侧铣加工提供一定的参考依据。

基于生物启发神经网络的无人水面艇实时避障路径规划

针对无人水面艇(unmanned surface vehicle,USV)自主航行过程中的避障与遵守海事交通规则之间潜在的冲突问题,设计基于生物启发神经网络并且遵守《1972年国际海上避碰规则》(Convention on the International Regulations for Preventing Collisions At Sea,1972,COLREGs)的实时避障路径规划方法。运用STM32嵌入式平台搭建包括超声波、红外激光、陀螺仪和GPS传感器的小型USV水面环境感知硬件架构,将多传感器输出的动态环境信息通过栅格地图映射到二维神经网络中。USV根据神经网络活性势图自动规划通向目标点的无碰撞路径。通过多种船舶航行交汇局面的实验,证明该方法既安全又符合COLREGs的要求。

地下管线在基坑开挖过程中变形规律的分析及关键影响因素研究

对地下管线在基坑开挖中的变形规律进行分析,采用地基模型改进、管线模型简化和边界条件设置等技术手段进行方法优化。研究结果表明,在地表超载条件下,管线的竖向位移和水平位移都显著增加,分别约为原来的2.6倍和4.4倍,最大竖向位移约为3.1 mm,最大水平位移约为-4.2 mm。同时,竖向和水平弯矩增幅达21.2%和37.8%,表明地表超载对管线的位移和弯矩产生显著影响,尤其是对水平位移和水平弯矩的影响更为明显。