Novel Batch Polishing Method of Ceramic Cutting Inserts for Reducing Tool Wear

Ceramic cutting inserts are a type of cutting tool commonly used in high-speed metal cutting applications.However,the wear of these inserts caused by friction between the workpiece and cutting inserts limits their overall effectiveness.In order to improve the tool life and reduce wear,this study introduces an emerging method called magnetic field-assisted batch polishing(MABP)for simultaneously polishing multiple ceramic cutting inserts.Several polishing experiments were conducted under different conditions,and the wear characteristics were clarified by cutting S136H steel.The results showed that after 15 min of polishing,the surface roughness at the flank face,edge,and nose of the inserts was reduced to below 2.5 nm,6.25 nm,and 45.8 nm,respectively.Furthermore,the nose radii of the inserts did not change significantly,and there were no significant changes in the weight percentage of elements before and after polishing.Additionally,the tool life of the batch polished inserts was found to be up to 1.75 times longer than that of unpolished inserts.These findings suggest that the MABP method is an effective way to mass polish ceramic cutting inserts,resulting in significantly reduced tool wear.Furthermore,this novel method offers new possibilities for polishing other tools.

Parameters Optimization of a Novel 5-DOF Gasbag Polishing Machine Tool

The research on the parameters optimization for gasbag polishing machine tools, mainly aims at a better kinematics performance and a design scheme. Serial structural arm is mostly employed in gasbag polishing machine tools at present, but it is disadvantaged by its complexity, big inertia, and so on. In the multi-objective parameters optimization, it is very difficult to select good parameters to achieve excellent performance of the mechanism. In this paper, a statistics parameters optimization method based on index atlases is presented for a novel 5-DOF gasbag polishing machine tool. In the position analyses, the structure and workspace for a novel 5-DOF gasbag polishing machine tool is developed, where the gasbag polishing machine tool is advantaged by its simple structure, lower inertia and bigger workspace. In the kinematics analyses, several kinematics performance evaluation indices of the machine tool are proposed and discussed, and the global kinematics performance evaluation atlases are given. In the parameters optimization process, considering the assembly technique, a design scheme of the 5-DOF gasbag polishing machine tool is given to own better kinematics performance based on the proposed statistics parameters optimization method, and the global linear isotropic performance index is 0.5, the global rotational isotropic performance index is 0.5, the global linear velocity transmission performance index is 1.012 3 m/s in the case of unit input matrix, the global rotational velocity transmission performance index is 0.102 7 rad/s in the case of unit input matrix, and the workspace volume is 1. The proposed research provides the basis for applications of the novel 5-DOF gasbag polishing machine tool, which can be applied to the modern industrial fields requiring machines with lower inertia, better kinematics transmission performance and better technological efficiency.

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.

Dynamic modeling of ultra-precision fly cutting machine tool and the effect of ambient vibration on its tool tip response

The dynamic performances of an ultra-precision fly cutting machine tool(UFCMT)has a dramatic impact on the quality of ultra-precision machining.In this study,the dynamic model of an UFCMT was established based on the transfer matrix method for multibody systems.In particular,the large-span scale flow field mesh model was created;and the variation in linear and angular stiffness of journal and thrust bearings with respect to film thickness was investigated by adopting the dynamic mesh technique.The dynamic model was proven to be valid by comparing the dynamic characteristics of the machine tool obtained by numerical simulation with the experimental results.In addition,the power spectrum density estimation method was adopted to simulate the statistical ambient vibration excitation by processing the ambient vibration signal measured over a long period of time.Applying it to the dynamic model,the dynamic response of the tool tip under ambient vibration was investigated.The results elucidated that the tool tip response was significantly affected by ambient vibration,and the isolation foundation had a good effect on vibration isolation.

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.

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.

Study of material removal behavior on R-plane of sapphire during ultra-precision machining based on modified slip-fracture model

In this paper, the modified slip/fracture activation model has been used in order to understand the mechanism of ductile-brittle transition on the R-plane of sapphire during ultra-precision machining by reflecting direction of resultant force. Anisotropic characteristics of crack morphology and ductility of machining depending on cutting direction were explained in detail with modified fracture cleavage and plastic deformation parameters. Through the analysis, it was concluded that crack morphologies were mainly determined by the interaction of multiple fracture systems activated while, critical depth of cut was determined by the dominant plastic deformation parameter. In addition to this, by using proportionality relationship between magnitude of resultant force and depth of cut in the ductile region, an empirical model for critical depth of cut was developed.

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.

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.

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.

大型绿色智能型纯电动地坪磨抛车传动系统设计与分析

基于地坪工程装备正向纯电动、绿色化产业升级的时代背景,设计了一种基于面齿轮传动的高效、磨抛面广的新型纯电动地坪磨抛车传动系统。解决传统地坪磨抛机磨抛面积小、工作效率低、能耗高的问题。通过有限元软件仿真模拟验证传动系统设计的可靠性,为后续开展地坪磨抛车电控系统、循环除尘系统及样机制作提供了理论依据。

机器人曲面零件抛光粗糙度预测模型研究

为提高抛光后曲面零件的表面质量,应建立粗糙度模型选取合理工艺参数,因此本文提出一种基于支持向量机(SVM)的建模方法。通过对机器人抛光过程及抛光工艺参数的研究,将刀具转速、抛光力、行间距、机器人进给速度等作为输入量,粗糙度作为输出量。结合粒子群算法(PSO)与SVM建立曲面零件抛光粗糙度预测模型,并与回归分析方法作对比。试验结果表明:回归分析方法的预测误差较大,而基于SVM建立的曲面零件抛光粗糙度预测模型与试验结果高度吻合,试验测量值与预测值间的平均相对误差为2.84%。最后,通过全局寻优获得最佳工艺参数组合,该模型为合理选择抛光工艺参数提供了依据。

离子束抛光对单晶硅表面质量影响的分子动力学模拟研究

离子束抛光作为一种超精密加工技术,被应用于材料表面抛光的精抛阶段,而其原子量级的去除效果使得它的加工过程与加工效果难以直接观察,因此为了能够从微观尺度研究离子束抛光的加工效果以及加工参数对材料表面粗糙度与表面损伤的影响,提出使用分子动力学模拟的方法研究离子束抛光过程,通过对氩离子轰击单晶硅的仿真模拟,分析加工参数对单晶硅表面粗糙度与晶格损伤的影响规律,指导实际的加工工艺设计.研究发现,在不同加工角度下,离子剂量对于表面粗糙度的影响规律不同,低角度(0°~40°)低剂量以及高角度(>50°)高剂量的加工有助于达到较低的表面粗糙度;随着加工角度的增加,离子束对晶体表面造成的损伤逐渐减少,当加工角度大于40°时能够大幅度减少晶格损伤.模拟结果显示在实际的离子束抛光过程中,为了得到高质量的表面,应该采取高角度高剂量的加工方式以达到既降低材料表面粗糙度又减小对材料表面晶格产生损伤的目的.

基于MCD的龙门机械臂抛光机的运动仿真

龙门机械臂结构具有运动灵活性高,有效工作范围广和加工零件适应性强等优点,将此结构用于抛光工艺可以提高加工效率并提升加工质量。利用NX软件中机电概念设计模块(MCD)可以快速有效地进行龙门机械臂抛光机数字样机设计。通过规划抛光头中心点的运动轨迹,软件可以自动计算出龙门导轨与机械臂各个关节轴的实时位移量。龙门机械臂抛光机的数字模型和运动仿真数据为实体样机的生产和运动控制提供了关键的参考数据。

Research status and challenges in the manufacturing of IR conformal optics

The infrared conformal window is one of the most critical components in aircraft.Conformal windows with high performance bring low aberrations,high aerodynamic performance,reliability in extreme working environments,and added value for aircraft.Through the past decades,remarkable advances have been achieved in manufacturing technologies for conformal windows,where the machining accuracy approaches the nanometer level,and the surface form becomes more complex.These advances are critical to aircraft development,and these manufacturing technologies also have significant reference values for other directions of the ultra-precision machining field.In this review,the infrared materials suitable for manufacturing conformal windows are introduced and compared with insights into their performances.The remarkable advances and concrete work accomplished by researchers are reviewed.The challenges in manufacturing conformal windows that should be faced in the future are discussed.

3D printing for ultra-precision machining:current status,opportunities,and future perspectives

Additive manufacturing,particularly 3D printing,has revolutionized the manufacturing industry by allowing the production of complex and intricate parts at a lower cost and with greater efficiency.However,3D-printed parts frequently require post-processing or integration with other machining technologies to achieve the desired surface finish,accuracy,and mechanical properties.Ultra-precision machining(UPM)is a potential machining technology that addresses these challenges by enabling high surface quality,accuracy,and repeatability in 3D-printed components.This study provides an overview of the current state of UPM for 3D printing,including the current UPM and 3D printing stages,and the application of UPM to 3D printing.Following the presentation of current stage perspectives,this study presents a detailed discussion of the benefits of combining UPM with 3D printing and the opportunities for leveraging UPM on 3D printing or supporting each other.In particular,future opportunities focus on cutting tools manufactured via 3D printing for UPM,UPM of 3D-printed components for real-world applications,and post-machining of 3D-printed components.Finally,future prospects for integrating the two advanced manufacturing technologies into potential industries are discussed.This study concludes that UPM is a promising technology for 3D-printed components,exhibiting the potential to improve the functionality and performance of 3D-printed products in various applications.It also discusses how UPM and 3D printing can complement each other.

Magnetic field-assisted batch polishing method for the mass production of precision optical glass components

The demand for optical glass has been rapidly increasing in various industries,where an ultra-smooth surface and form accuracy are critical for the functional elements of the applications.To meet the high surface-quality requirements,a polishing process is usually adopted to finish the optical glass surface to ensure an ultra-smooth surface and eliminate sub-surface damage.However,current ultra-precision polishing processes normally polish workpieces individually,leading to a low production efficiency and high polishing costs.Current mass-finishing methods cannot be used for optical glasses.Therefore,magnetic-field-assisted batch polishing(MABP)was proposed in this study to overcome this research gap and provide an efficient and cost-effective method for industrial use.A series of polishing experiments were conducted on typical optical components under different polishing parameters to evaluate the polishing performance of MABP on optical glasses.The results demonstrated that MABP is an efficient method to simultaneously polish multiple lenses while achieving a surface roughness,indicated by the arithmetic mean height(Sa),of 0.7 nm and maintained a sub-micrometer surface form for all the workpieces.In addition,no apparent sub-surface damage was observed,indicating the significant potential for the high-quality rapid polishing of optical glasses.The proposed method is highly competitive compared to the current optical polishing methods,which has the potential to revolutionize the polishing process for small optics.

基于粒子图像测速法的大米抛光机内米粒运动规律分析

[目的]通过研究抛光机运行参数、米粒运动规律、产生碎米率之间的关系,寻求抛光机的较优参数调控依据。[方法]通过分析抛光室内米粒的运动过程、开展全因素试验以及应用粒子图像测速法(PIV)对米粒运动轨迹进行分析,明确米粒的运动状态、碎米率与抛光机转速及压力门开度之间的关系。[结果]当压力门开度20 mm时,在试验转速范围内均不能形成有规律的米粒运动形态,此时不能达到米粒抛光要求。当压力门开度4 mm、转速为600~1400 r/min时,米粒呈现出螺旋升角较小且高低速区域交替出现的运动形态。当压力门开度8 mm、转速1400 r/min时,米粒呈现出高低速(速度差>3 m/s)区域交替出现的运动形态。上述两种工况下,米粒因过度揉搓或压力过大导致碎米率较高(>4%)。在试验范围内的其余工况下,米粒均呈现出螺旋角大小适中的高低速(速度差为2~3 m/s)区域交替出现的运动形态,此时碎米率为2%~4%,能够达到较好的抛光效果。[结论]不同工况下米粒形成的运动形态与产生的碎米率不同,在合适的压力门开度和转速下,米粒呈现出适当的运动形态,能达到较好的抛光效果。

基于机器视觉的人防门智能打磨系统

针对人工识别易出错、清理效率低、打磨环境恶劣等难题,基于机器视觉原理结合双机械臂研制一种人防门智能打磨系统,其中视觉系统主要由1台视觉控制器VC3300和2台500万像素相机构成。通过视觉系统识别工件的顶点坐标,建立待打磨坐标系与顶点坐标系的映射关系,解决塞焊孔位置及埋弧焊位置难以有效识别、数据难以高效协同、高精度打磨难以实现的难题。实验结果表明:此视觉系统能够有效保证较高的定位准确率和精度,整体工序相较于人工提速33.3%,打磨后焊点的平均高度0.115 mm,满足实际工业生产需求,具有较好的实用价值。