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 th...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%.展开更多
This paper presents a new approach of designing the revolving cutter with constant pitch, and provides geometric models. The corresponding models in the non-numerically controlled manufacturing, such as designing the ...This paper presents a new approach of designing the revolving cutter with constant pitch, and provides geometric models. The corresponding models in the non-numerically controlled manufacturing, such as designing the helical groove, grinding wheel, relative feeding motion, and calculating the helical angle of the cutting edge, are introduced. The examples are given to testify that the design approach is simple and readily realized in machining the revolving cutter with constant pitch. The effective design and manufacture method provides general references for non-NC machining revolving cutter with constant pitch and reducing the equipments input.展开更多
A CO2 laser die-cutting system, which does not need die board any more, is a new technique for manufac-turing packing box. Two optical paths, the galvanometer scanning system and the flying optical system, are used to...A CO2 laser die-cutting system, which does not need die board any more, is a new technique for manufac-turing packing box. Two optical paths, the galvanometer scanning system and the flying optical system, are used to satisfy different processing needs. The scanning system is composed of galvanometer scanning mirrors and F-θ lens. And the flying optical system is driven by two servo motors. This paper presents the software and hardware design of the laser die-cutting system, the difference between the two optical paths, as well as the relationship among the cutting speed, thickness of wrapping paper and laser power. The cutting speed and thickness of wrapping paper are linearly increased by the incremental laser power, while the cutting speed is hyperbolically decreased by the incremental thickness of wrapping paper when the laser power is constant. The amount of incision is reduced by 20% and the processing time by 40% when tested by a low power RF CO2 laser die-cutting system using the optimized program. This tech- nique is also used for the reference of other rapid laser processing systems.展开更多
The thermal conditions like the temperature distribution and the heat fluxes during metal cutting have a major influence on the machinability, the tool lifetime, the metallurgical structure and thus the functionality ...The thermal conditions like the temperature distribution and the heat fluxes during metal cutting have a major influence on the machinability, the tool lifetime, the metallurgical structure and thus the functionality of the work piece. This in particular applies for manufacturing processes like milling, drilling and turning for high-value turbomachinery components like impellers, combustion engines and compressors of the aerospace and automotive industry as well as energy generation, which play a major role in modern societies. However, numerous analytical and experimental efforts have been conducted in order to understand the thermal conditions in metal cutting, yet many questions still prevail. Most models are based on a stationary point of view and do not include time dependent effects like in intensity and distribution varying heat sources, varying engagement conditions and progressive tool wear. In order to cover such transient physics an analytical approach based on Green＇s functions for the solution of the partial differential equations of unsteady heat conduction in solids is used to model entire transient temperature fields. The validation of the model is carried out in orthogonal cutting experiments not only punctually but also for entire temperature fields. For these experiments an integrated measurement of prevailing cutting force and temperature fields in the tool and the chip by means of high-speed thermography were applied. The thermal images were analyzed with regard to thermodynamic energy balancing in order to derive the heat partition between tool, chips and workpiece. The thus calculated heat flow into the tool was subsequently used in order to analytically model the transient volumetric temperature fields in the tool. The described methodology enables the modeling of the transient thermal state in the cutting zone and particular in the tool, which is directly linked to phenomena like tool wear and workpiece surface modifications.展开更多
The miniaturisation context leads to the rise of micro-machining processes. Micro-milling is one of the most flexible and fast of them. Although it is based on the same principles as macro-cutting, it is not a simple ...The miniaturisation context leads to the rise of micro-machining processes. Micro-milling is one of the most flexible and fast of them. Although it is based on the same principles as macro-cutting, it is not a simple scaling-down of it. This down-sizing involves new phenomena in the chip formation, such as the minimum chip thickness below which no chip is formed. This paper presents a review of the current state of the art in this field from an experimental and a numerical point of view. A 2D finite element model is then developed to study the influence of the depth of cut on the chip formation. After the model validation in macro-cutting, it highlights the phenomena reported in literature and allows to perform a minimum chip thickness estimation.展开更多
Three-dimensional molecular dynamics(MD)simulation was carried out to understand the mechanism of water lubrication in nanometric cutting.The water-lubricated cutting was compared with the dry cutting process in terms...Three-dimensional molecular dynamics(MD)simulation was carried out to understand the mechanism of water lubrication in nanometric cutting.The water-lubricated cutting was compared with the dry cutting process in terms of lattice deformation,cutting force,heat and pressure distribution,and machined surface integrity.It was found that water molecules effectively reduce the friction between the tool and workpiece,the heat in the cutting zone and the pressure being generated on the tool surface,thus leading to prolonged tool life.Water molecules also enlarged the pressure-affected area,which decreased the roughness of the machined surface.展开更多
基金Project(RTI04-01-03) supported by the Regional Technology Innovation Program of the Ministry of Knowledge Economy (MKE),Korea
文摘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%.
文摘This paper presents a new approach of designing the revolving cutter with constant pitch, and provides geometric models. The corresponding models in the non-numerically controlled manufacturing, such as designing the helical groove, grinding wheel, relative feeding motion, and calculating the helical angle of the cutting edge, are introduced. The examples are given to testify that the design approach is simple and readily realized in machining the revolving cutter with constant pitch. The effective design and manufacture method provides general references for non-NC machining revolving cutter with constant pitch and reducing the equipments input.
基金Supported by by Major State Basic Research Development Program of China ("973" Program, No. 2010CB327800)
文摘A CO2 laser die-cutting system, which does not need die board any more, is a new technique for manufac-turing packing box. Two optical paths, the galvanometer scanning system and the flying optical system, are used to satisfy different processing needs. The scanning system is composed of galvanometer scanning mirrors and F-θ lens. And the flying optical system is driven by two servo motors. This paper presents the software and hardware design of the laser die-cutting system, the difference between the two optical paths, as well as the relationship among the cutting speed, thickness of wrapping paper and laser power. The cutting speed and thickness of wrapping paper are linearly increased by the incremental laser power, while the cutting speed is hyperbolically decreased by the incremental thickness of wrapping paper when the laser power is constant. The amount of incision is reduced by 20% and the processing time by 40% when tested by a low power RF CO2 laser die-cutting system using the optimized program. This tech- nique is also used for the reference of other rapid laser processing systems.
文摘The thermal conditions like the temperature distribution and the heat fluxes during metal cutting have a major influence on the machinability, the tool lifetime, the metallurgical structure and thus the functionality of the work piece. This in particular applies for manufacturing processes like milling, drilling and turning for high-value turbomachinery components like impellers, combustion engines and compressors of the aerospace and automotive industry as well as energy generation, which play a major role in modern societies. However, numerous analytical and experimental efforts have been conducted in order to understand the thermal conditions in metal cutting, yet many questions still prevail. Most models are based on a stationary point of view and do not include time dependent effects like in intensity and distribution varying heat sources, varying engagement conditions and progressive tool wear. In order to cover such transient physics an analytical approach based on Green＇s functions for the solution of the partial differential equations of unsteady heat conduction in solids is used to model entire transient temperature fields. The validation of the model is carried out in orthogonal cutting experiments not only punctually but also for entire temperature fields. For these experiments an integrated measurement of prevailing cutting force and temperature fields in the tool and the chip by means of high-speed thermography were applied. The thermal images were analyzed with regard to thermodynamic energy balancing in order to derive the heat partition between tool, chips and workpiece. The thus calculated heat flow into the tool was subsequently used in order to analytically model the transient volumetric temperature fields in the tool. The described methodology enables the modeling of the transient thermal state in the cutting zone and particular in the tool, which is directly linked to phenomena like tool wear and workpiece surface modifications.
文摘The miniaturisation context leads to the rise of micro-machining processes. Micro-milling is one of the most flexible and fast of them. Although it is based on the same principles as macro-cutting, it is not a simple scaling-down of it. This down-sizing involves new phenomena in the chip formation, such as the minimum chip thickness below which no chip is formed. This paper presents a review of the current state of the art in this field from an experimental and a numerical point of view. A 2D finite element model is then developed to study the influence of the depth of cut on the chip formation. After the model validation in macro-cutting, it highlights the phenomena reported in literature and allows to perform a minimum chip thickness estimation.
基金supported by the National Natural Science Foundation of China (Grant No. 90923038)the National Basic Research Program of China ("973" Project) (Grant No. 2011CB706703)the "111" project by the State Administration of Foreign Experts Affairs and the Ministry of Education of China (Grant No. B07014)
文摘Three-dimensional molecular dynamics(MD)simulation was carried out to understand the mechanism of water lubrication in nanometric cutting.The water-lubricated cutting was compared with the dry cutting process in terms of lattice deformation,cutting force,heat and pressure distribution,and machined surface integrity.It was found that water molecules effectively reduce the friction between the tool and workpiece,the heat in the cutting zone and the pressure being generated on the tool surface,thus leading to prolonged tool life.Water molecules also enlarged the pressure-affected area,which decreased the roughness of the machined surface.
