An Optimal Feed Interpolator Based on G^2 Continuous Bézier Curves for High-Speed Machining of Linear Tool Path

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.

Pre-Compensation for Continuous-Path Running Trajectory Error in High-Speed Machining of Parts with Varied Curvature Features

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.

Development of High-speed Machining Database with Case-based Reasoning

Applying high-speed machining technology in shop floor has many benefits, such as manufacturing more accurate parts with better surface finishes. The selection of the appropriate machining parameters plays a very important role in the implementation of high-speed machining technology. The case-based reasoning is used in the developing of high-speed machining database to overcome the shortage of available high-speed cutting parameters in machining data handbooks and shop floors. The high-speed machining database developed in this paper includes two main components: the machining database and the case-base. The machining database stores the cutting parameters, cutting tool data, work pieces and their materials data, and other relative data, while the case-base stores mainly the successfully solved cases that are problems of work pieces and their machining. The case description and case retrieval methods are described to establish the case-based reasoning high-speed machining database. With the case retrieval method, some succeeded cases similar to the new machining problem can be retrieved from the case-base. The solution of the most matched case is evaluated and modified, and then it is regarded as the proposed solution to the new machining problem. After verification, the problem and its solution are packed up into a new case, and are stored in the case-base for future applications.

PRECISION OF HSK TOOLING SYSTEM IN HIGH SPEED MACHINING

Based on the theory of elastic mechanics and material mechanics, the orientation precision of the hohl schaft kegel（HSK） tooling system in static and dynamic states is theoretically and experimentally studied. The relation between the clamping force and the shank taper is obtained. And a proper clamping force is found to be essential to assure the axial and radial orientation precisions of the HSK tooling system in high speed machining （HSM）. Analytical results show that the reason why the HSK tooling system can keep high precision at the high rotational speed is that the actual axial clamping force keeps the two surfaces of the shank and the spindle in contact all the time.

Research on cubic polynomial acceleration and deceleration control model for high speed NC machining

To satisfy the need of high speed NC (numerical control) machining, an acceleration and deceleration (acc/dec) control model is proposed, and the speed curve is also constructed by the cubic polynomial. The proposed control model provides continuity of acceleration, which avoids the intense vibration in high speed NC machining. Based on the discrete characteristic of the data sampling interpolation, the acc/dec control discrete mathematical model is also set up and the discrete expression of the theoretical deceleration length is obtained furthermore. Aiming at the question of hardly predetermining the deceleration point in acc/dec control before interpolation, the adaptive acc/dec control algorithm is deduced from the expressions of the theoretical deceleration length. The experimental result proves that the acc/dec control model has the characteristic of easy implementation, stable movement and low impact. The model has been applied in multi-axes high speed micro fabrication machining successfully.

Short-term wind speed forecasting bias correction in the Hangzhou area of China based on a machine learning model

准确的风速预报具有重要的社会意义.在本研究中,使用名为WSFBC-XGB的XGBoost机器学习模型对中国浙江省杭州市自动气象站的短期风速预报误差进行校正.WSFBC-XGB使用本地数值天气预报系统的产品作为输入.将WSFBC-XGB校正的结果与传统MOS(模型输出统计)方法校正的结果进行了比较.结果表明:WSFBC-XGB预报风速的均方根误差(RMSE)/准确率(ACC)分别比NWP和MOS降低/提高了26.1%和7.64%/35.6%和7.02%;对于90%的站点WSFBC-XGB的RMSE/ACC均小于/高于MOS.此外,采用平均杂质减少法对WSFBC-XGB的可解释性进行分析,以帮助用户增加对模型的信任.结果表明:10米风速(47.35%),10米风的经向分量(12.73%),日循环(9.97%)和1000百帕风的经向分量(7.45%)是前4个最重要的特征.WSFBC-XGB模型将有助于提高短期风速预报的准确性,为大型户外活动提供支持.

MOTION VELOCITY SMOOTH LINK IN HIGH SPEED MACHINING

To deal with over-shooting and gouging in high speed machining, a novel approach for velocity smooth link is proposed. Considering discrete tool path, cubic spline curve fitting is used to find dangerous points, and according to spatial geometric properties of tool path and the kinematics theory, maximum optimal velocities at dangerous points are obtained. Based on method of velocity control characteristics stored in control system, a fast algorithm for velocity smooth link is analyzed and formulated. On-line implementation results show that the proposed approach makes velocity changing more smoothly compared with traditional velocity control methods and improves productivity greatly.

Effects of honing treatment on AIP-TiN and TiAlN coated end-mill for high speed machining

The objective of this work is to compare the tool performance of TiN and TiA1N coated carbides end-mills deposited by an arc ion plating （ALP） method, using honing treatment to polish the cutting edge surface sleekly. The curve of surface roughness versus honing time showed a rapid improvement initially and thereafter became steady, manifesting a saturation effect. The optimal honing time related to surface roughness was determined to be approximately 20 s. As the surface roughness increased, the critical loads reduced. At an average surface roughness （Ra） of 0.028 p.m, the highest critical loads of TiN and TiAlN coating layers were 98 and 114 N, respectively. Tool performances of uncoated and coated tools were conducted under high speed machining （HSM） of AISI D2 cold-worked die steel （62 HRC）. Consequently, the TiAlN coated end-mill using honing treatment showed excellent tool life under HSM conditions.

Assessment of Deformation of Shear Localized Chip in High Speed Machining

As the cutting speed goes higher, the mechanism of chip deformation will be changed significantly, i.e., continuous chip in low cutting speed will shift to serrated chip with shear localization. For the shear localized chip, the parameters used to assess the chip deformation for continuous chip, such as shorten coefficient ξ, shear angle φ and shear strain ε, can not describe the chip deformation correctly or comprehensively. This paper deals with the assessment of chip deformation of shear localization. There are two deformation regions in shear localized chip, one is the chip segment body with relative smaller plastic deformation, another one is the boundary between segments with shear localization, so called shear band. Considering the two distinct deformation regions, two parameters are used to define their deformation respectively. According to the analysis of chip formation process, the equations have been deduced to calculate the shear strains of shear band ε, shear strain of chip segment ε 1 and shear rate so that the shear localized chip deformation can be assessed correctly and comprehensively. By use of this assessment, the chip deformation in machining selenium treated stainless steel (STSS) and common stainless steel at various cutting conditions is investigated. The experiment results obtained by the machining of stainless steel prove that: (1) the shear strain and strain rate increase with the increasing of cutting speed; (2) the shear strain in shear band can be over 10 when cutting speed exceeding 200 m/min for both types of stainless steel, and it is much higher than the strain of chip segment. The difference will be enlarged as the cutting speed increasing; (3) As the comparison, the shear strain for the STSS is a little lower than that for JIS304; (4) The stain rate is extremely high (= 2.5×10 5 1/s ). In range of cutting speed less than 180 m/min, the strain rate for STSS is lower than that for JIS304. However, when the cutting speed is higher than 180 m/min, the strain rate for STSS is higher than that for JIS304.

Characterization and Analysis of Inconel 718 Alloy Ground at Different Speeds

Inconel 718(IN718)alloy is widely applied to fabricate high temperature resistant or corrosion resistant parts due to its excellent mechanical performance.However,the machining of IN718 alloy is difficult as it may cause serious tool wear and poor surface quality(SQ)of the workpiece.In this work,grinding experiments on IN718 alloy at different speeds were conducted by using a CBN grinding wheel.The relationship between grinding speed,SQ and subsurface damage(SSD)was well studied.With increasing grinding speed,surface roughness decreased,and SQ was greatly improved.Meanwhile,the microhardness of the grinding surface declined as the grinding speed increased.The SSD depth was almost unchanged when the grinding speed was lower than 15 m/s,then it decreased with higher grinding speeds.It was attributed to the mechanical-thermal synergistic effect in the grinding process.The results indicated that increasing grinding speed can effectively improve the SQ and reduce the SSD of IN718 alloy.The conclusion in the work may also provide insight into processing other hard-to-machining materials.

Multi-model ensemble forecasting of 10-m wind speed over eastern China based on machine learning optimization

风对人类活动和电力运行有重大影响,准确预报短期风速具有深远的社会和经济意义.基于中国东部100个站点,本研究首先评估了5个业务模式对10米风速的预报能力,日本气象厅JMA模式在减少预报误差方面表现最好.进一步,利用5种数值模式和多种机器学习方法,将动力和统计相结合,对每个站点分别进行了特征工程和机器学习算法优选,建立了10米风速多模式集成预报模型。针对24至96小时预报时长,将该方法的预报性能与基于岭回归的多模式集成和JMA单模式进行比较.结果表明,基于机器学习优选的多模型集成方法可以将JMA模式的预报误差降低39%以上,预报效果的提升在11月最明显.此外,该方法优于基于岭回归的多模式集成方法.

Thermodynamics Analysis of Oxidation Wear Behavior of Cemented Carbide Tools in High Speed Machining

The essence of oxidation wear machanism of cenmented carbide tool was studied based on thermodynamics. Standard Gibbs free energy of possible reactions in cutting process at different temperature was calculated using substance Gibbs free energy function methods, and the sequence of reaction possibility order was researched as well as characteristics of every reaction. Theoretical calculation shows that WO3, Co3O4, TiO2 and CoWO4 are the main resultants, which are proved with the experiment results.

The Impact of High Speed Machining on Computing and Automation

Machine tool technologies, especially Computer Numerical Control （CNC） High Speed Machining （HSM） have emerged as effective mechanisms for Rapid Tooling and Manufacturing applications. These new technologies are attractive for competitive manufacturing because of their technical advantages, i.e. a significant reduction in lead-time, high product accuracy, and good surface finish. However, HSM not only stimulates advancements in cutting tools and materials, it also demands increasingly sophisticated CAD^CAM software, and powerful CNC controllers that require more support technologies. This paper explores the computational requirement and impact of HSM on CNC controller, wear detection, look ahead programming, simulation, and tool management.

Research on fault time prediction method for high speed rail BTM unit based on multi method interactive validation

The Balise Transmission Module(BTM)unit of the on-board train control system is a crucial component.Due to its unique installation position and complex environment,this unit has a higher fault rate within the on-board train control system.To conduct fault prediction for the BTM unit based on actual fault data,this study proposes a prediction method combining reliability statistics and machine learning,and achieves the fusion of prediction results from different dimensions through multi-method interactive validation.Firstly,a method for predicting equipment fault time targeting batch equipment is introduced.This method utilizes reliability statistics to construct a model of the remaining faultless operating time distribution considering uncertainty,thereby predicting the remaining faultless operating probability of the BTM unit.Secondly,considering the complexity of the BTM unit’s fault mechanism,the small sample size of fault cases,and the potential presence of multiple fault features in fault text records,an individual-oriented fault prediction method based on Bayesian-optimized Gradient Boosting Regression Tree(Bayes-GBRT)is proposed.This method achieves better prediction results compared to linear regression algorithms and random forest regression algorithms,with an average absolute error of only 0.224 years for predicting the fault time of this type of equipment.Finally,a multi-method interactive validation approach is proposed,enabling the fusion and validation of multi-dimensional results.The results indicate that the predicted fault time and the actual fault time conform to a log-normal distribution,and the parameter estimation results are basically consistent,verifying the accuracy and effectiveness of the prediction results.The above research findings can provide technical support for the maintenance and modification of BTM units,effectively reducing maintenance costs and ensuring the safe operation of high-speed railway,thus having practical engineering value for preventive maintenance.

A Novel Half-Bridge Power Supply for High Speed Drilling Electrical Discharge Machining

High Speed Drilling Electrical Discharge Machining (HSDEDM) uses controlled electric sparks to erode the metal in a work-piece. Through the years, HSDEDM process has widely been used in high speed drilling and in manufacturing large aspect ratio holes for hard-to-machine material. The power supplies of HSDEDM providing high power applica-tions can have different topologies. In this paper, a novel Pulsed-Width-Modulated (PWM) half-bridge HSDEDM power supply that achieves Zero-Voltage-Switching (ZVS) for switches and Zero-Current-Switching (ZCS) for the dis-charge gap has been developed. This power supply has excellent features that include minimal component count and inherent protection under short circuit conditions. This topology has an energy conservation feature and removes the need for output bulk capacitors and resistances. Energy used in the erosion process will be controlled by the switched IGBTs in the half-bridge network and be transferred to the gap between the tool and work-piece. The relative tool wear and machining speed of our proposed topology have been compared with that of a normal power supply with current limiting resistances.

Calculation of torque and speed of induction machines under rotor winding faults

Based on the multi-loop method, the rotating torque and speed of theinduction machine are analyzed. The fluctuating components of the torque and speed caused by rotorwinding faults are studied. The models for calculating the fluctuating components are put forward.Simulation and computation results show that the rotor winding faults will cause electromagnetictorque and rotating speed to fluctuate; and fluctuating frequencies are the same and their magnitudewill increase with the rise of the severity of the faults. The load inertia affects the torque andspeed fluctuation, with the increase of inertia, the fluctuation of the torque will rise, while thecorresponding speed fluctuation will obviously decline.

Optimum cutting speed of block-cutting machines in natural stones for energy saving

Energy consumption of block-cutting machines represents a major cost item in the processing of travertines and other natural stones. Therefore, determining the optimum sawing conditions for a particular stone is of major importance in the natural stone-processing industry. An experimental study was carried out utilizing a fully instrumented block-cutter to investigate the sawing performances of five different types of travertine blocks during cutting with a circular diamond saw. The sawing tests were performed in the down-cutting mode. Performance measurements were determined by measuring the cutting speed and energy consumption. Then, specific energy was determined. The one main cutting parameter, cutting speed, was varied in the investigation of optimum cutting performance. Furthermore, some physico-mechanical properties of file travertine blocks were determined in the laboratory. As a result, it is found that the energy consumption （specific energy） of block cutting machines is highly affected by cutting speed. It is determined that specific energy value usually decreases when cutting speed increases. When the cutting speed is higher than the determined value, the diamond saw can become stuck in the travertine block; this situation can be a problem for the block-cutting machine. As a result, the optimum cutting speed obtained for the travertine mines examined is approximately 1.5-2.0 m/min.

CUTTING REGULARITY AND DISCHARGE CHARACTERISTICS BY USING COMPOSITE COOLING LIQUID IN WIRE CUT ELECTRICAL DISCHARGE MACHINE WITH HIGH WIRE TRAVELING SPEED

The analysis of cutting regularity is provided through using and comparing two typical cooling liquids. It is proved that cutting regularity is greatly affected by cooling liquid＇s washing ability. Discharge characteristics and theoretic analysis between two electrodes are also discussed based on discharge waveform. By using composite cooling liquid which has strong washing ability, the efficiency in the first stable cutting phase has reached more than 200 mm^2/min, and the roughness of the surface has reached Ra〈0.8 μm after the fourth cutting with more than 50 mm^2/min average cutting efficiency. It is pointed out that cutting situation of the wire cut electrical discharge machine with high wire traveling speed （HSWEDM） is better than the wire cut electrical discharge machine with low wire traveling speed （LSWEDM） in the condition of improving the cooling liquid washing ability. The machining indices of HSWEDM will be increased remarkably by using the composite cooling liquid.

ZERO TRANSMISSION AND ITS APPLICATION IN HIGH SPEED CNC MACHINE TOOLS

In order to realize high speed machining,the special requirements for the transmission and sturctrue of CNC machine tool have to be satisfied.A high speed spindle unit driven by a built-in motor is developed.An oil-water heat exchange system is used for cooling the spindle motor.The spindle is supported by Si_4N_3 ceramic ball angular contact bearings. An oil-air lubricator is used to lubricate and cool the spindle bearings.Some special structures are taken for balancing the spindle.

Development of CAD/CAM system and profile measuring device for CNC grinding machine to obtain an optimal grinding speed

Cam mechanics is one of the most popular devices for generating irregular motions and is widely used in automatic equipment,such as textile machines,internal combustion engines,and other automatic devices.In order to obtain a positive motion from the follower using a rotating cam,its shape should be correctly designed and manufactured.The development of an adequate CAD/CAM system for a cam profile CNC grinding machine is necessary to manufacture high-precision cams.The purpose of this study is the development of a CAD/CAM system and profile measuring device for a CNC grinding machine to obtain an optimal grinding speed with a constant surface roughness.Three types of disk cams were manufactured using the proposed algorithm and procedures to verify effectiveness of the developed CAD/CAM system.