Development Trend of NC Machining Accuracy Control Technology for Aeronautical Structural Parts

High-performance five-axis computer numerical control machine tools are widely used in the processing of Aeronautical Structural parts. With the increase of service life, the precision of CNC machine tools equipped by aeronautical manufacturing enterprises is declining day by day, while the new generation of aircraft structural parts are developing towards integration, large-scale, complexity, thin-walled and lightweight. It is very easy to produce dimension overshoot and surface quality defects due to unstable processing technology. The machining accuracy of aircraft structural parts is also affected by complex factors such as cutting load, cutting stability, tool error, workpiece deformation, fixture deformation, etc. Because of the complexity of structure and characteristics of Aeronautical Structural parts, the consistency and stability of cutting process are poor. It is easy to cause machining accuracy problems due to tool wear, breakage and cutting chatter. Relevant scholars have carried out a lot of basic research on NC machining accuracy control and achieved fruitful results, but the research on NC machining accuracy control of Aeronautical structural parts is still less. This paper elaborates from three aspects: error modeling method of NC machine tools, error compensation method, prediction and control of machining accuracy, and combines the characteristics of Aeronautical Structural parts, the development trend and demand of NC machining accuracy control technology are put forward.

INFLUENCE OF WHEEL STRUCTURAL PARAMETERS ON MACHINING ACCURACY OF ULTRA-PRECISION PLANE HONING

A new idea for designing wheel patterns is presented so as to solve theproblems about machining accuracy of workpiece and wear of honing wheel in ultra-precision planehoning. The influence factors on motion principle and pattern structures are analyzed andoptimization machining parameters are obtained. By calculating effective cutting length on thesurface of workpiece cut by wheel's abrasive and the orbit of one point on the surface of workpiececontacting with wheel, the wear coefficient of different kinds of wheels and accuracy coefficient ofworkpiece machined by corresponding wheels are obtained. Furthermore, the simulation results showthat the optimal pattern structure of wheel turns out to have lower wheel wear and higher machiningaccuracy.

Modeling for Orientation Deviation of Workpiece and Analysis of Machining Accuracy

The machining accuracy of workpiece is influenced by its orientation deviation, which is caused by the fixture-workpiece error. Based on the spatial coordinate theory, the orientation deviation of workpiece is measured by using an on-machine verification system, which can take into account the errors resulting from fixture manufacturing, installation and adjustment, location and clamping of workpiece. According to the least square method, the model of orientation deviation is built to determine the relationship between the theoretical and actual coordinate systems. The influence of orientation deviation on machining accuracy is quantified, and it is shown that the orientation deviation only affects the dimensional precision and position precision, rather than shape precision. In the experiment, the compensation processing of realtime errors was conducted, and the perpendicularity and inclination errors of the tetragonal part were reduced by 38.46% and 47.06%, respectively.

IMPROVEMENT OF MACHINING ACCURACY OF CANTILEVER BORING BAR SYSTEM USING PIEZOELECTRIC ACTUATOR

This paper is concerned with the work involved in improving the machining accuracy of a cantilever boring bar by on line compensation with a piezoelectric actuator. A boring bar is made into lever structure, with strain gauges attached to the bar for measuring its force induced deflections. The piezoelectric actuator is employed to compensate the deflections of the boring bar for accuracy improvement. Due to the mechanical advantage of the structure, the boring bar can be made into smaller size. The diameter of the bar implemented is 10 mm and the ratio of length to diameter (L/D) is larger than 8. It is found that the machining accuracy is improved considerably by using the piezoelectric actuator compensation system.

EFFECT OF TOOL-PATH ON MILLING ACCURACY UNDER CLAMPING

To resolve the deformation problem for thin-walled aero-parts in the actual production, this paper simulates the effect of the tool-path on the machining accuracy of the thin-walled frame. The frame is shaped in the part milling under a given clamping condition by using the three-dimensional finite element method （FEM）. Result shows that the sidewall deformation has a big difference if only the tool-path changes. When the tool-path from the outside to the inside is used, the machining deformation is smaller than another three kinds of toolpaths. Simulation results are compared with experimental data, and the correctness of the simulation is verified.Reasonable processing paths can be found by FEM.

Effects of mask wall angle on matrix-hole shape changes during electrochemical machining by mask

The influences of the mask wall angle on the current density distribution,shape of the evolving cavity and machining accuracy were investigated in electrochemical machining(ECM) by mask.A mathematical model was developed to predict the shape evolution during the ECM by mask.The current density distribution is sensitive to mask wall angle.The evolution of cavity is determined by the current density distribution of evolving workpiece surface.The maximum depth is away from the center of holes machined,which leads to the island appearing at the center of cavity for mask wall angles greater than or equal to 90°(β≥90°).The experimental system was established and the simulation results were experimentally verified.The results indicate that the simulation results of cavity shape are consistent with the actual ones.The experiments also show that the repetition accuracy of matrix-hole for β≥90° is higher than that for β<90°.A hole taper is diminished,and the machining accuracy is improved with the mask wall angle increasing.

Thermo-mechanical properties of bowl-shaped grinding wheel and machining error compensation for grinding indexable inserts

In order to meet the technical requirements of grinding the circumferential cutting edge of indexable inserts, thermo-mechanical properties of bowl-shaped grinding wheel in high speed grinding process and the influence of dimension variations of the grinding wheel on machining accuracy were investigated. Firstly, the variation trends of the dimension due to centrifugal force generated in different wheel speeds were studied and the effect of stress stiffening and spin softening was presented. Triangular heat flux distribution model was adopted to determine temperature distribution in grinding process. Temperature field cloud pictures were obtained by the finite element software. Then, dimension variation trends of wheel structure were acquired by considering the thermo-mechanical characteristic under combined action of centrifugal force and grinding heat at different speeds. A method of online dynamic monitoring and automatic compensation for dimension error of indexable insert was proposed. By experimental verification, the precision of the inserts satisfies the requirement of processing.

Modeling and Compensation Technology for the Comprehensive Errors of Fixture System

Error modelling and compensating technology is an effective method to improve the processing precision.The position and orientation deviation of workpiece is caused by the fixing and manufacturing errors of the fixture.How to reduce the position and orientation deviation of workpiece has become a technical problem of improving the processing quality of workpiece.In order to increase machining accuracy,an implementation scheme of fixture system comprehensive errors（FSCE） compensation is proposed.A FSCE parameter model is established by analyzing the influence of contact points on the position and orientation of workpiece.Meanwhile,a parameter identification method for FSCE parameter model is presented by using the 3-2-1 deterministic positioning fixture,which determines the model parameters.Moreover,a FSCE compensation model is formulated to study the compensation value of the cutting position.By using RenishawOMP60 Probe and combining vertical machining centre（SKVH850） equipment with SKY2001 Open CNC System,on-machine verification system（OMVS） is built to measure FSCE successfully.The processing error can be reduced by analyzing the cutting position of the tool with the homogeneous transformation of space coordinate system.Finally,the compensation experiment of real time errors is conducted,and the cylindricality and perpendicularity errors of hole surface are reduced by 30.77% and 28.57%,respectively.This paper provides a new way of realizing the compensation of FCSE,which can improve the machining accuracy of workpiece largely.

Development of analysis model for geometric error in turning processes

A finite element model was established for analyzing the geometric errors in turning operations and a two-step analyzing process was proposed. In the first analyzing step, the cutting force and the cutting heat for the cutting conditions were obtained using the AdvantEdge. Also, the deformation of a workpiece was estimated in the second step using the ANSYS. The deformation was analyzed for a 150 mm-long workpiece at three different measuring points, such as 10, 70 and 130 mm from a reference point, and the amounts of the deformation were compared through experiments. /n the results of the comparison and analysis, the values obtained from these comparison and analysis represent similar tendencies. Also, it is verified that their geometric errors increase with the increase in temperature. In addition, regarding the factors that affect the deformation of a workpiecc, it can be seen that the geometric error in the lathe is about 15%, the error caused by the cutting force is about 10%, and the deformation caused by the heat is about 75%.

Optimization of Honing Wheel Structure Parameters in Ultra-precision Plane Honing

Free abrasive particle machining in simple machine such as: honing, polishing can get higher surface finish mirror, but surface error, and working procedure is hard to control. Therefore, the vertical disposed ultra-precision plane honing method by ultra-particle diamond honing wheel is put forward to. The results of experiments indicate: plane-honing wheel has higher machining accuracy and machining efficiency. But at the same time the structure parameters of honing wheel effects on machining accuracy. By analyzing the relation of honing wheel structure parameters and workpiece machining accuracy, the relation of honing wheel and wear coefficient, then this paper gets honing wheel structure parameters in the condition of best accuracy coefficient and wear coefficient, and resolve the problem of choosing honing wheel structure parameters in ultra-precision plane honing at last. This paper analyses the relation of honing wheel structure parameters and workpiece machining accuracy coefficient and wear coefficient, by building relative movement math model of honing wheel and workpiece in plane honing. Through theory calculating, the result indicate: about honing machine tools for large volume manufacture, honing wheel wear is main effect factor, so honing wheel should adopt obverse triangle radial structure. About honing machining for high accuracy and low-batch quantities, machining accuracy coefficient is main factors; so honing wheel should adopt reverse triangle radial structure. Neglected the manufacturing factors of honing wheel, then we can design honing wheel with high power curve structure to meet the need of machining accuracy coefficient and honing wheel wear coefficient in higher accuracy honing.

Research on new software compensation method of static and quasi-static errors for precision motion controller

To reduce mechanical vibrations induced by big errors compensation, a new software compensation method based on an improved digital differential analyzer (DDA) interpolator for static and quasi-static errors of machine tools is proposed. Based on principle of traditional DDA interpolator, a DDA interpolator is divided into command generator and command analyzer. There are three types of errors, considering the difference of positions between compensation points and interpolation segments. According to the classification, errors are distributed evenly in data processing and compensated to certain interpolation segments in machining. On-line implementation results show that the proposed approach greatly improves positioning accuracy of computer numerical control (CNC) machine tools.

Investigation on surface structuring generated by electrochemical micromachining

Surface geometrical features and their function- ality depend on the manufacturing process which is employed for fabrication of surface structures. Maskless electrochemical micromachining （EMM） is used to generate various surface structures for diminishing and controlling friction and wear to increase the lifetime, reliability, and efficiency of mechanical systems. This paper presents a method for the generation of structured surfaces on stainless steel （SS-304） surfaces by using maskless EMM. The micropatterned tool is composed of 800 μm diameter circular holes in a 5 × 5 matrix form. The indigenously developed EMM set up consists of an EMM cell, electrical power supply system, and a controlled vertical cross-flow electrolyte circulation arrangement to control the influence of process parameters during the generation of the micro features of structured surfaces. The single structured cathode tool is used for the mass production of structured surfaces with a short fabrication time in the industrial context by avoiding the use of an individual masking process for each workpiece. The process has been characterized in terms of the effects of predominant process parameters such as machining voltage, electrolyte concentration, duty ratio, pulsed frequency, and machining time on the machined surface characteristics such as current efficiency, machining accuracy, and depth of the circular pattern on the stainless steel surfaces. A mathematical model is also developed to determine the theoretical depth of the dimple pattern and correlate the theoretical depths with actual depths as obtained by experimentation. Moreover, an effort has been made to study the structuringcharacteristics on the basis of micrographs obtained duringthe EMM.

Coupling evaluation for material removal and thermal control on precision milling machine tools

Machine tools are one of the most representative machining systems in manufacturing.The energy consumption of machine tools has been a research hotspot and frontier for green low-carbon manufacturing.However,previous research merely regarded the material removal(MR)energy as useful energy consumption and ignored the useful energy consumed by thermal control(TC)for maintaining internal thermal stability and machining accuracy.In pursuit of energy-efficient,high-precision machining,more attention should be paid to the energy consumption of TC and the coupling relationship between MR and TC.Hence,the cutting energy efficiency model considering the coupling relationship is established based on the law of conservation of energy.An index of energy consumption ratio of TC is proposed to characterize its effect on total energy usage.Furthermore,the heat characteristics are analyzed,which can be adopted to represent machining accuracy.Experimental study indicates that TC is the main energy-consuming process of the precision milling machine tool,which overwhelms the energy consumption of MR.The forced cooling mode of TC results in a 7%reduction in cutting energy efficiency.Regression analysis shows that heat dissipation positively contributes 54.1%to machining accuracy,whereas heat generation negatively contributes 45.9%.This paper reveals the coupling effect of MR and TC on energy efficiency and machining accuracy.It can provide a foundation for energyefficient,high-precision machining of machine tools.

Ion beam figuring of continuous phase plates based on the frequency filtering process

Ion beam figuring （IBF） technology is an effective technique for fabricating continuous phase plates （CPPs） with small feature structures. This study proposes a multi-pass IBF approach with different beam diameters based on the frequency filtering method to improve the machining accuracy and efficiency of CPPs during IBF. We present the selection principle of the frequency filtering method, which incorporates different removal functions that maximize material removal over the topographical frequencies being imprinted. Large removal functions are used early in the fabrication to figure the surface profile with low frequency. Small removal functions are used to perform final topographical correction with higher fre- quency and larger surface gradient. A high-precision surface can be obtained as long as the filtering frequency is suitably selected. This method maximizes the high removal efficiency of the large removal function and the high corrective capability of the small removal function. Consequently, the fast convergence of the machining accuracy and efficiency can be achieved.

Prediction of effluent concentration in a wastewater treatment plant using machine learning models

Of growing amount of food waste, the integrated food waste and waste water treatment was regarded as one of the efficient modeling method. However, the load of food waste to the conventional waste treatment process might lead to the high concentration of total nitrogen（T-N） impact on the effluent water quality. The objective of this study is to establish two machine learning models-artificial neural networks（ANNs） and support vector machines（SVMs）, in order to predict 1-day interval T-N concentration of effluent from a wastewater treatment plant in Ulsan, Korea. Daily water quality data and meteorological data were used and the performance of both models was evaluated in terms of the coefficient of determination（R^2）, Nash-Sutcliff efficiency（NSE）, relative efficiency criteria（d rel）. Additionally, Latin-Hypercube one-factor-at-a-time（LH-OAT） and a pattern search algorithm were applied to sensitivity analysis and model parameter optimization, respectively. Results showed that both models could be effectively applied to the 1-day interval prediction of T-N concentration of effluent. SVM model showed a higher prediction accuracy in the training stage and similar result in the validation stage.However, the sensitivity analysis demonstrated that the ANN model was a superior model for 1-day interval T-N concentration prediction in terms of the cause-and-effect relationship between T-N concentration and modeling input values to integrated food waste and waste water treatment. This study suggested the efficient and robust nonlinear time-series modeling method for an early prediction of the water quality of integrated food waste and waste water treatment process.