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.

Systematic analysis of error sources during ultra-precision machining

During ultra-precision machining, machining accuracy is determined by many factors and interaction of these factors. Error sources are systematically analyzed for ultra-precision machine tools, and the influencing degree of each factor is presented to provide orientation for error reduction and error compensation.

Mesoplasticity Approach to Studies of the Cutting Mechanism in Ultra-precision Machining

There have been various theoretical attempts by researchers worldwide to link up different scales of plasticity studies from the nano-, micro- and macro-scale of observation, based on molecular dynamics, crystal plasticity and continuum mechanics. Very few attempts, however, have been reported in ultra-precision machining studies. A mesoplasticity approach advocated by Lee and Yang is adopted by the authors and is successfully applied to studies of the micro-cutting mechanisms in ultra-precision machining. Traditionally, the shear angle in metal cutting, as well as the cutting force variation, can only be determined from cutting tests. In the pioneering work of the authors, the use of mesoplasticity theory enables prediction of the fluctuation of the shear angle and micro-cutting force, shear band formation, chip morphology in diamond turning and size effect in nano-indentation. These findings are verified by experiments. The mesoplasticity formulation opens up a new direction of studies to enable how the plastic behaviour of materials and their constitutive representations in deformation processing, such as machining can be predicted, assessed and deduced from the basic properties of the materials measurable at the microscale.

Research of Digital Manufacturing Technology Application on Ultra-precision Optical Workpiece Machining

Digital manufacturing technology can be used in optical field to solve many problems caused by traditional machining. According to the characters of digital manufacturing and the practical applications of ultra-precision machining,the process of digital ultra-precision machining and its technical contents were presented in this paper. In the conclusions,it was stated that the digitalization of ultra-precision machining will be an economical and efficient way for the production of new sorts of optical workpieces.

345 GHz Band-Pass Filter Using Ultra-Precision Machining Technology

This paper presents a terahertz（THz）band-pass filter using ultra-precision machining technology based on Chebyshev filter prototype.This iris inductive window coupled waveguide filter was designed by using 8 resonant cavities with a center frequency of 345 GHz and a 7% bandwidth.The final design fulfills the desired specifications and presents the minimum insertion loss of 1.55 d B and the return loss of less than 15 d B at 345 GHz.The stop-band rejection is50 d B off the center frequency about 30 GHz,which means it has a good performance of high stop-band suppression.Compared with the recent development of THz filters,this filter possesses the characteristic of simple structure and is easy to machining.

Dynamic Accuracy Design Method of Ultra-precision Machine Tool

Ultra-precision machine tool is the most important physical tool to machining the workpiece with the frequency domain error requirement, in the design process of which the dynamic accuracy design(DAD) is indispensable and the related research is rarely available. In light of above reasons, a DAD method of ultra-precision machine tool is proposed in this paper, which is based on the frequency domain error allocation.The basic procedure and enabling knowledge of the DAD method is introduced. The application case of DAD method in the ultra-precision flycutting machine tool for KDP crystal machining is described to show the procedure detailedly. In this case, the KDP workpiece surface has the requirements in four different spatial frequency bands, and the emphasis for this study is put on the middle-frequency band with the PSD specifications. The results of the application case basically show the feasibility of the proposed DAD method. The DAD method of ultra-precision machine tool can effectively minimize the technical risk and improve the machining reliability of the designed machine tool. This paper will play an important role in the design and manufacture of new ultra-precision machine tool.

Active vibration control of spindle in ultra-precision turning machine

In order to minimize vibration and improve rotary precision of spindle, we apply active vibration control technique to ultra-precision turning machine based on the analysis of vibration characteristic of aerostatic bearing spindle. Using aerostatic bearing itself as actuator, the vibration of spindle is controlled by adjusting admission pressure respectively and by changing pressure distribution in the bearing. The experiments and simulations prove that this method can minimize the vibration of spindle effectively.

Fully Integrated Machine Control for Ultra Precision Machining

To meet the demands for highly advanced components with ultra precise contour accuracy and optical surface quality arising in the fields of photonics and optics, automotive, medical applications and biotechnology, consumer electronics and renewable energy, more advanced production machines and processes have to be developed. As the complexity of machine tools rises steadily, the automation of manufacture increases rapidly, processes become more integrated and cycle times have to be reduced significantly, challenges of engineering efficient machine tools with respect to these demands expand every day. Especially the manufacture of freeform geometries with non-continuous and asymmetric surfaces requires advanced diamond machining strategies involving highly dynamic axes movements with a high bandwidth and position accuracy. Ultra precision lathes additionally equipped with Slow Tool and Fast Tool systems can be regarded as state-of-the-art machines achieving the objectives of high quality optical components. The mechanical design of such ultra precision machine tools as well as the mechanical integration of additional highly dynamic axes are very well understood today. In contrast to that, neither advanced control strategies for ultra precision machining nor the control integration of additional Fast Tool systems have been sufficiently developed yet. Considering a complex machine setup as a mechatronic system, it becomes obvious that enhancements to further increase the achievable form accuracy and surface quality and at the same time decrease cycle times and error sensitivity can only be accomplished by innovative, integrated control systems. At the Fraunhofer Institute for Production Technology IPT a novel, fully integrated control approach has been developed to overcome the drawbacks of state-of-the-art machine controls for ultra precision processes. Current control systems are often realized as decentralized solutions consisting of various computational hardware components for setpoint generation, machine control, HMI （human machine interface）, Slow Tool control and Fast Tool control. While implementing such a distributed control strategy, many disadvantages arise in terms of complex communication interfaces, discontinuous safety structures, synchronization of cycle times and the machining accuracy as a whole. The novel control approach has been developed as a fully integrated machine control including standard CNC （computer numerical control） and PLC （programmable logic controller） functionality, advanced setpoint generation methods, an extended HMI as well as an FPGA （field programmable gate array）-based controller for a voice coil driven Slow Tool and a piezo driven Fast Tool axis. As the new control system has been implemented as a fully integrated platform using digital communication via EtherCAT, a continuous safety strategy could be realized, the error sensitivity and EMC susceptibility could be significantly decreased and the overall process accuracy from setpoint generation over path interpolation to axes movements could be enhanced. The novel control at the same time offers additional possibilities of automation, process integration, online data acquisition and evaluation as well as error compensation methods.

Tool path generation of ultra-precision diamond turning: A state-of-the-art review

With the increasing market demand for optical complex surface parts,the application of multi-axis ultraprecision single-point diamond turning is increasing.A tool path generation method is very important to decrease manufacturing time,enhance surface quality,and reduce cost.Compared with the tool path generation of the traditional multi-axis milling,that of the ultra-precision single-point diamond turning requires higher calculation accuracy and efficiency.This paper reviews the tool path generation of ultra-precision diamond turning,considering several key issues:cutter location(CL)points calculation,the topological form of tool path,interpolation mode,and G code optimization.

RESEARCH ON TECHNOLOGY AND SYSTEM FOR ON－LINE MEASUREMENT OF SURFACE ROUGHNESS IN ULTRA＝PRECISION MACHINING

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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.

Active Vibration Isolation System for Sub microultra precision Turning Machine

Now vibration isolation of ultra precision machine tool is usually achieved through air springs systems. As far as HCM I sub micro turning machine developed by HIT, an active vibration isolation system that consists of air springs and electro magnetic actuators was presented. The primary function of air springs is to support the turning machine and to isolate the high frequency vibration. The electro magnetic actuators controlled by fuzzy neural networks isolate the low frequency vibration. The experiment indicates that active vibration isolation system isolates base vibration effectively in all the frequency range. So the vibration of the machine bed is controlled under 10 -6 g and the surface roughness is improved.

Advances in molecular dynamics simulation of ultra-precision machining of hard and brittle materials

Hard and brittle materials, such as silicon, SiC, and optical glasses, are widely used in aerospace, military, integrated circuit, and other fields because of their excellent physical and chemical properties. However, these materials display poor machinability because of their hard and brittle properties. Damages such as surface micro-crack and subsurface damage often occur during machining of hard and brittle materials. Ultra-precision machining is widely used in processing hard and brittle materials to obtain nanoscale machining quality. However, the theoretical mechanism underlying this method remains unclear. This paper provides a review of present research on the molecular dynamics simulation of ultra-precision machining of hard and brittle materials. The future trends in this field are also discussed.

Dynamic analysis of double racks gear 3D roll forming machine

3 D roll-forming for high strength steel sheets is a new technology at present.Double racks gear 3D roll forming machine developed by our research group can be used to perform variable cross section roll forming for high strength steel.In the paper,a dynamic model of 8-DOF double rack gear 3D roll-forming machine is established by the method of Lagrange equation.The expression of the angle acceleration of the system response is obtained by solving the dynamic equations.Through an actual engineering example,the dynamical characters of the 3D roll forming machine are revealed.The results can support the design of 3D roll forming machine.Meanwhile,the research will play an active role in the development of control system.

Integrated Passive and Active Vibration Control of Ultra precision Lathe

In ultra precision cutting process, vibration is one of the key factors affecting the machining quality. In this paper, the damping methods of HCM I Ultra precision Lathe are discussed in both complete machine and slide. It is pointed out that integrated passive and active vibration control (IPAVC) by combining passive vibration control (PVC) and active vibration control (AVC) can not only eliminate high frequency vibration but also improve the damping effect to low frequency vibration. Experiment results show the effectiveness of the integrated passive and active vibration control.

A Collaborative Machine Learning Scheme for Traffic Allocation and Load Balancing for URLLC Service in 5G and Beyond

Key challenges for 5G and Beyond networks relate with the requirements for exceptionally low latency, high reliability, and extremely high data rates. The Ultra-Reliable Low Latency Communication (URLLC) use case is the trickiest to support and current research is focused on physical or MAC layer solutions, while proposals focused on the network layer using Machine Learning (ML) and Artificial Intelligence (AI) algorithms running on base stations and User Equipment (UE) or Internet of Things (IoT) devices are in early stages. In this paper, we describe the operation rationale of the most recent relevant ML algorithms and techniques, and we propose and validate ML algorithms running on both cells (base stations/gNBs) and UEs or IoT devices to handle URLLC service control. One ML algorithm runs on base stations to evaluate latency demands and offload traffic in case of need, while another lightweight algorithm runs on UEs and IoT devices to rank cells with the best URLLC service in real-time to indicate the best one cell for a UE or IoT device to camp. We show that the interplay of these algorithms leads to good service control and eventually optimal load allocation, under slow load mobility. .

URLLC场景下信道可靠连通度预测

第五代移动通信技术(5th generation,5G)中高可靠低时延通信(ultra reliability and low latency communication,URLLC)应用场景,十分契合航空5G机场场面宽带移动通信系统建设要求。以丢包率为定义的可靠性指标没有反应时变无线信道的时间依赖性和不同URLLC服务所需的持续时间。针对以上存在的问题,运用生存分析的方法,将URLLC关键技术与可靠性理论中失效率相结合,提出了可靠连通度指标,基于接收端信号强度,建立理论分布模型和数据驱动模型,对时变信道在未来1子帧内可靠连通度进行预测,并建立城市宏单元非视距簇时延线信道模型算例对模型进行对比分析,并在不同雨衰条件下,分析信道系统的可靠连通度。结果表明,数据驱动模型可靠性预测的均方误差(mean square error,MSE)可达0.1%,优于理论分布模型,且在恶劣天气情况下,多输入多输出信道可靠性相比于多输入单输出信道具有更高的抗衰落能力。

基于接收信号强度预测的自适应垂直切换算法

城市部署的超密集异构无线网络中车辆终端的运动状态和业务类型差异巨大,针对不同运动状态和业务类型的终端并发接入导致的频繁切换和拥塞问题,提出一种基于接收信号强度预测的自适应垂直切换算法。在切换触发阶段使用长短时记忆神经网络预测接收信号强度,在信道链路质量恶化之前提前触发切换,在网络选择阶段综合考虑网络参数以及终端在不同运动状态和业务类型下的接入偏好,并选出综合效益值最高的网络作为切换目标网络。仿真结果表明,该算法能更好地适应终端运动状态和业务类型的变化,能降低不必要的切换次数和网络拥塞度。

基于不同加工工艺的微孔节流空气静压轴承的特性研究

随着超精密加工技术和地面微低重力仿真的发展,相关产业对空气静压轴承的性能要求越来越高。由于传统的孔式节流器其结构特点不能完全满足实际使用的需要,节流孔直径与气膜间隙同一数量级的微孔节流空气静压轴承因其良好的刚度和承载特性,越来越受到关注。但在微孔节流器的发展过程中,微孔的加工工艺却限制了其推广应用。针对目前常用的三类微孔加工工艺,进行了理论仿真研究,通过建立不同加工工艺轴承仿真模型,运用双向流固耦合仿真方法,对比分析了基于不同加工工艺的微孔节流空气静压轴承的动静态特性。研究结果表明:锥孔类轴承承载性能优于其他两类,但耗气量大且在小间隙时刚度较差;薄壁直孔类轴承承载性能稍逊,但在大间隙下轴承刚度较佳;嵌套类轴承承载性能较差,但在小间隙下轴承刚度较大且耗气量较低。