Electrical arc contour cutting(EACC)is a novel high-efficiency material cutting process that applies arc plasma to perform efficient and economical contour cutting of difficult-to-cut materials.Compared to conventiona...Electrical arc contour cutting(EACC)is a novel high-efficiency material cutting process that applies arc plasma to perform efficient and economical contour cutting of difficult-to-cut materials.Compared to conventional electrical arc machining(EAM),this process can remove the allowance of open structures and plates in bulk mode,rather than entirely in the form of debris.Compared with existing contour cutting methods,EACC possesses the advantages of high cutting efficiency and a deep cutting depth.Particularly,a compound arc breaking mechanism(CABM),which integrates hydrodynamic force and mechanical motion,has been applied to control the discharge arc column in EACC,while also strengthening the debris expelling effect in the narrow discharge gap.The CABM implementation conditions were studied,based on arc column distortion images captured by a high-speed camera and simulation results of the flow field and debris distribution.A set of machining experiments was designed and conducted to optimize the performance of the proposed process.Finally,a SiC_(p)/Al metal matrix composite(MMC)space station workpiece was machined to verify the feasibility and efficiency of this process.展开更多
The welding deviation detection is the basis of robotic tracking welding, but the on-line real-time measurement of welding deviation is still not well solved by the existing methods. There is plenty of information in ...The welding deviation detection is the basis of robotic tracking welding, but the on-line real-time measurement of welding deviation is still not well solved by the existing methods. There is plenty of information in the gas metal arc welding（GMAW） molten pool images that is very important for the control of welding seam tracking. The physical meaning for the curvature extremum of molten pool contour is revealed by researching the molten pool images, that is, the deviation information points of welding wire center and the molten tip center are the maxima and the local maxima of the contour curvature, and the horizontal welding deviation is the position difference of these two extremum points. A new method of weld deviation detection is presented, including the process of preprocessing molten pool images, extracting and segmenting the contours, obtaining the contour extremum points, and calculating the welding deviation, etc. Extracting the contours is the premise, segmenting the contour lines is the foundation, and obtaining the contour extremum points is the key. The contour images can be extracted with the method of discrete dyadic wavelet transform, which is divided into two sub contours including welding wire and molten tip separately. The curvature value of each point of the two sub contour lines is calculated based on the approximate curvature formula of multi-points for plane curve, and the two points of the curvature extremum are the characteristics needed for the welding deviation calculation. The results of the tests and analyses show that the maximum error of the obtained on-line welding deviation is 2 pixels（0.16 ram）, and the algorithm is stable enough to meet the requirements of the pipeline in real-time control at a speed of less than 500 mm/min. The method can be applied to the on-line automatic welding deviation detection.展开更多
基金The authors acknowledge the National Science Foundation of China(Grants Nos.51235007 and 51575351)the State Key Laboratory of Mechanical System and Vibration of China(Grant No.MSV201305)for their financial support of this research.
文摘Electrical arc contour cutting(EACC)is a novel high-efficiency material cutting process that applies arc plasma to perform efficient and economical contour cutting of difficult-to-cut materials.Compared to conventional electrical arc machining(EAM),this process can remove the allowance of open structures and plates in bulk mode,rather than entirely in the form of debris.Compared with existing contour cutting methods,EACC possesses the advantages of high cutting efficiency and a deep cutting depth.Particularly,a compound arc breaking mechanism(CABM),which integrates hydrodynamic force and mechanical motion,has been applied to control the discharge arc column in EACC,while also strengthening the debris expelling effect in the narrow discharge gap.The CABM implementation conditions were studied,based on arc column distortion images captured by a high-speed camera and simulation results of the flow field and debris distribution.A set of machining experiments was designed and conducted to optimize the performance of the proposed process.Finally,a SiC_(p)/Al metal matrix composite(MMC)space station workpiece was machined to verify the feasibility and efficiency of this process.
基金Supported by National Natural Science Foundation of China(Grant Nos.51275051,51505035)National Hi-tech Research and Development Program of China(863 Program,Grant No.2009AA04Z208)Beijing Education Commission Innovation Ability Upgrade Program of China(Grant No.TJSHG201510017023)
文摘The welding deviation detection is the basis of robotic tracking welding, but the on-line real-time measurement of welding deviation is still not well solved by the existing methods. There is plenty of information in the gas metal arc welding（GMAW） molten pool images that is very important for the control of welding seam tracking. The physical meaning for the curvature extremum of molten pool contour is revealed by researching the molten pool images, that is, the deviation information points of welding wire center and the molten tip center are the maxima and the local maxima of the contour curvature, and the horizontal welding deviation is the position difference of these two extremum points. A new method of weld deviation detection is presented, including the process of preprocessing molten pool images, extracting and segmenting the contours, obtaining the contour extremum points, and calculating the welding deviation, etc. Extracting the contours is the premise, segmenting the contour lines is the foundation, and obtaining the contour extremum points is the key. The contour images can be extracted with the method of discrete dyadic wavelet transform, which is divided into two sub contours including welding wire and molten tip separately. The curvature value of each point of the two sub contour lines is calculated based on the approximate curvature formula of multi-points for plane curve, and the two points of the curvature extremum are the characteristics needed for the welding deviation calculation. The results of the tests and analyses show that the maximum error of the obtained on-line welding deviation is 2 pixels（0.16 ram）, and the algorithm is stable enough to meet the requirements of the pipeline in real-time control at a speed of less than 500 mm/min. The method can be applied to the on-line automatic welding deviation detection.
