For settling the question of feeding speed in applying the cored-wire method to spheroidize ductile iron melt, ANSYS software was applied to simulate the heat transfer and mass transfer, and the melt time of the steel...For settling the question of feeding speed in applying the cored-wire method to spheroidize ductile iron melt, ANSYS software was applied to simulate the heat transfer and mass transfer, and the melt time of the steel strip in the iron melt was determined by linking the heat transfer and mass transfer, and then the feeding speed was calcufated. Conclusions have been drawn that the iron layer was formed on the surface of the cored-wire during the wire-feeding process. The thickness is 0.073 mm when the temperature of the iron melt is 1500℃, the time from formation to remelting of the iron layer is 0.063 s. When the temperature of the iron melt is below 1500℃, the time taken for the steel strip to melt is rapidly shortened. When the temperature of the iron melt is above 1500℃, the variation amplitude of the steel strip melt change with time is gradually diminished. The melt time of the steel strip is rapidly increased with the increase of the steel strip thickness. When the temperature of the iron melt is 1500℃ and the carbon content is 4%, the melt time of a steel strip, which has a thickness of 0.5 mm, is thrice that of a steel strip whose thickness is 0.3 mm. The calculation results of the feeding speed are basically in agreement with the applied feeding speed in the factory.展开更多
A numerical control (NC) tool path of digital CAD model is widely generated as a set of short line segments in machining. However, there are three shortcomings in the linear tool path, such as discontinuities of tange...A numerical control (NC) tool path of digital CAD model is widely generated as a set of short line segments in machining. However, there are three shortcomings in the linear tool path, such as discontinuities of tangency and curvature, huge number of line segments, and short lengths of line segments. These disadvantages hinder the development of high speed machining. To smooth the linear tool path and improve machining efficiency of short line segments, this paper presents an optimal feed interpolator based on G^2 continuous Bézier curves for the linear tool path. First, the areas suitable for fitting are screened out based on the geometric characteristics of continuous short segments (CSSs). CSSs in every area are compressed and fitted into a G^2 Continuous Bézier curve by using the least square method. Then a series of cubic Bézier curves are generated. However, the junction between adjacent Bézier curves is only G^0 continuous. By adjusting the control points and inserting Bézier transition curves between adjacent Bézier curves, the G^2 continuous tool path is constructed. The fitting error is estimated by the second-order Taylor formula. Without iteration, the fitting algorithm can be implemented in real-time environment. Second, the optimal feed interpolator considering the comprehensive constraints (such as the chord error constraint, the maximum normal acceleration, servo capacity of each axis, etc.) is proposed. Simulation and experiment are conducted. The results shows that the proposed method can generate smooth path, decrease the amount of segments and reduce machining time for machining of linear tool path. The proposed research provides an effective method for high-speed machining of complex 2-D/3-D profiles described by short line segments.展开更多
Parts with varied curvature features play increasingly critical roles in engineering, and are often machined under high-speed continuous-path running mode to ensure the machining efficiency. However, the continuous-pa...Parts with varied curvature features play increasingly critical roles in engineering, and are often machined under high-speed continuous-path running mode to ensure the machining efficiency. However, the continuous-path running trajectory error is significant during high-feed-speed machining, which seriously restricts the machining precision for such parts with varied curvature features. In order to reduce the continuous-path running trajectory error without sacrificing the machining efficiency, a pre-compensation method for the trajectory error is proposed. Based on the formation mechanism of the continuous-path running trajectory error analyzed, this error is estimated in advance by approximating the desired toolpath with spline curves. Then, an iterative error pre-compensation method is presented. By machining with the regenerated toolpath after pre-compensation instead of the uncompensated toolpath, the continuous-path running trajectory error can be effectively decreased without the reduction of the feed speed. To demonstrate the feasibility of the proposed pre-compensation method, a heart curve toolpath that possesses varied curvature features is employed. Experimental results indicate that compared with the uncompensated processing trajectory, the maximum and average machining errors for the pre-compensated processing trajectory are reduced by 67.19% and 82.30%, respectively. An easy to implement solution for high efficiency and high precision machining of the parts with varied curvature features is provided.展开更多
In order to realize high speed machining, the special requirements for feed transmission system of the CNC machine tool have to be satisfied. A high velocity feed unit driven by a induction linear motor is developed. ...In order to realize high speed machining, the special requirements for feed transmission system of the CNC machine tool have to be satisfied. A high velocity feed unit driven by a induction linear motor is developed. The compositions of the high velocity CNC feed unit and main problems in the unit design are discussed.展开更多
The Nickel base Superalloys are the most famous complicated and useable of Superalloys to make hot zone components of the gas turbines. The complicated dimensional tolerances, specially at the root of the blade show i...The Nickel base Superalloys are the most famous complicated and useable of Superalloys to make hot zone components of the gas turbines. The complicated dimensional tolerances, specially at the root of the blade show importance of grinding processes at the production of blades root. The prediction of the effect of machining parameters on the soundness of component surface strengthening for reaching to a suitable surface finishing and avoiding from crack formation at the work part during machining operation often is not easy and feasible so needs to more industrial investigation. This research is about frame 5 blade designed by GE and made from Superalloy IN738LC has been investigated. The formation of a plastically deformed and heat affected zone during grinding of Superalloy IN738LC with a high depth of cut but slow work speed (creep feed grinding) was investigated. Parameters such as work speed, depth of cut and radial dressing speed have been considered as variables and their effects have been studied. During experimental performed, the voltage and current of motor measured and power and special energy calculated. Some samples heat-treated (of the 1176°C for 1 hr under neutral argon gas and cooling rate of 15°C /min up to 537°C and then air cooling) to study grains recrystallization. Other samples have been created from the roots of blades and then coated by Nickel to measure boundary layer micro-hardness. The results show that increasing work speed leads to increasing the use power. Increasing the depth of cut, by increasing material removal rate, and the radial dressing speed, by decreasing power, lead to decreasing special energy. The temperature created by grinding lead to decreasing plastic deformation and boundary layer formation. When the radial dressing speed changes from 1 to 0.6 u,m/rev and other parameters are kept unchanged the roughness of surface increases and the special energy decreases. Sufficient dressing is very essential in limiting the width of the molten zone to few micrometers. As a result, it was found that local melting at contact spots to be a rather common mechanism during grinding of superalloys, lead to so-called white layers which can easily be observed on metallographic cross sections.展开更多
The article consists of studying the influence of the speed of the saw cylinder on the quality of the fiber and the productivity of the machine, as well as on the change in the density and composition of the seed roll.
文摘For settling the question of feeding speed in applying the cored-wire method to spheroidize ductile iron melt, ANSYS software was applied to simulate the heat transfer and mass transfer, and the melt time of the steel strip in the iron melt was determined by linking the heat transfer and mass transfer, and then the feeding speed was calcufated. Conclusions have been drawn that the iron layer was formed on the surface of the cored-wire during the wire-feeding process. The thickness is 0.073 mm when the temperature of the iron melt is 1500℃, the time from formation to remelting of the iron layer is 0.063 s. When the temperature of the iron melt is below 1500℃, the time taken for the steel strip to melt is rapidly shortened. When the temperature of the iron melt is above 1500℃, the variation amplitude of the steel strip melt change with time is gradually diminished. The melt time of the steel strip is rapidly increased with the increase of the steel strip thickness. When the temperature of the iron melt is 1500℃ and the carbon content is 4%, the melt time of a steel strip, which has a thickness of 0.5 mm, is thrice that of a steel strip whose thickness is 0.3 mm. The calculation results of the feeding speed are basically in agreement with the applied feeding speed in the factory.
基金Supported by National Natural Science Foundation of China(Grant No.50875171)National Hi-tech Research and Development Program of China(863 Program,Grant No.2009AA04Z150)
文摘A numerical control (NC) tool path of digital CAD model is widely generated as a set of short line segments in machining. However, there are three shortcomings in the linear tool path, such as discontinuities of tangency and curvature, huge number of line segments, and short lengths of line segments. These disadvantages hinder the development of high speed machining. To smooth the linear tool path and improve machining efficiency of short line segments, this paper presents an optimal feed interpolator based on G^2 continuous Bézier curves for the linear tool path. First, the areas suitable for fitting are screened out based on the geometric characteristics of continuous short segments (CSSs). CSSs in every area are compressed and fitted into a G^2 Continuous Bézier curve by using the least square method. Then a series of cubic Bézier curves are generated. However, the junction between adjacent Bézier curves is only G^0 continuous. By adjusting the control points and inserting Bézier transition curves between adjacent Bézier curves, the G^2 continuous tool path is constructed. The fitting error is estimated by the second-order Taylor formula. Without iteration, the fitting algorithm can be implemented in real-time environment. Second, the optimal feed interpolator considering the comprehensive constraints (such as the chord error constraint, the maximum normal acceleration, servo capacity of each axis, etc.) is proposed. Simulation and experiment are conducted. The results shows that the proposed method can generate smooth path, decrease the amount of segments and reduce machining time for machining of linear tool path. The proposed research provides an effective method for high-speed machining of complex 2-D/3-D profiles described by short line segments.
基金Supported by National Natural Science Foundation of China(Grant Nos.51575087,51205041)Science Fund for Creative Research Groups(Grant No.51321004)+1 种基金Basic Research Foundation of Key Laboratory of Liaoning Educational Committee,China(Grant No.LZ2014003)Research Project of Ministry of Education of China(Grant No.113018A)
文摘Parts with varied curvature features play increasingly critical roles in engineering, and are often machined under high-speed continuous-path running mode to ensure the machining efficiency. However, the continuous-path running trajectory error is significant during high-feed-speed machining, which seriously restricts the machining precision for such parts with varied curvature features. In order to reduce the continuous-path running trajectory error without sacrificing the machining efficiency, a pre-compensation method for the trajectory error is proposed. Based on the formation mechanism of the continuous-path running trajectory error analyzed, this error is estimated in advance by approximating the desired toolpath with spline curves. Then, an iterative error pre-compensation method is presented. By machining with the regenerated toolpath after pre-compensation instead of the uncompensated toolpath, the continuous-path running trajectory error can be effectively decreased without the reduction of the feed speed. To demonstrate the feasibility of the proposed pre-compensation method, a heart curve toolpath that possesses varied curvature features is employed. Experimental results indicate that compared with the uncompensated processing trajectory, the maximum and average machining errors for the pre-compensated processing trajectory are reduced by 67.19% and 82.30%, respectively. An easy to implement solution for high efficiency and high precision machining of the parts with varied curvature features is provided.
基金This project is supported by National Natural Science Foundation of China !(59575063) Provincial Natural Science Foundation
文摘In order to realize high speed machining, the special requirements for feed transmission system of the CNC machine tool have to be satisfied. A high velocity feed unit driven by a induction linear motor is developed. The compositions of the high velocity CNC feed unit and main problems in the unit design are discussed.
文摘The Nickel base Superalloys are the most famous complicated and useable of Superalloys to make hot zone components of the gas turbines. The complicated dimensional tolerances, specially at the root of the blade show importance of grinding processes at the production of blades root. The prediction of the effect of machining parameters on the soundness of component surface strengthening for reaching to a suitable surface finishing and avoiding from crack formation at the work part during machining operation often is not easy and feasible so needs to more industrial investigation. This research is about frame 5 blade designed by GE and made from Superalloy IN738LC has been investigated. The formation of a plastically deformed and heat affected zone during grinding of Superalloy IN738LC with a high depth of cut but slow work speed (creep feed grinding) was investigated. Parameters such as work speed, depth of cut and radial dressing speed have been considered as variables and their effects have been studied. During experimental performed, the voltage and current of motor measured and power and special energy calculated. Some samples heat-treated (of the 1176°C for 1 hr under neutral argon gas and cooling rate of 15°C /min up to 537°C and then air cooling) to study grains recrystallization. Other samples have been created from the roots of blades and then coated by Nickel to measure boundary layer micro-hardness. The results show that increasing work speed leads to increasing the use power. Increasing the depth of cut, by increasing material removal rate, and the radial dressing speed, by decreasing power, lead to decreasing special energy. The temperature created by grinding lead to decreasing plastic deformation and boundary layer formation. When the radial dressing speed changes from 1 to 0.6 u,m/rev and other parameters are kept unchanged the roughness of surface increases and the special energy decreases. Sufficient dressing is very essential in limiting the width of the molten zone to few micrometers. As a result, it was found that local melting at contact spots to be a rather common mechanism during grinding of superalloys, lead to so-called white layers which can easily be observed on metallographic cross sections.
文摘The article consists of studying the influence of the speed of the saw cylinder on the quality of the fiber and the productivity of the machine, as well as on the change in the density and composition of the seed roll.
