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 impo...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.展开更多
To solve the problem of difficulty in selecting NC cutting parameters by the redundancy technique, a method is put forward to optimize cutting parameters based on a revolutionary mathematical model and a revolutionary...To solve the problem of difficulty in selecting NC cutting parameters by the redundancy technique, a method is put forward to optimize cutting parameters based on a revolutionary mathematical model and a revolutionary cutting parameters database. By use of fuzzy inference rules, it can not only make the method itself evolved and updated, but also ensure data to be correct and feasible from the two optimization routes. Practical running and testing proved that this method can facilitate for the user to select parameters and greatly improve the processing efficiency.展开更多
Titanium alloys are widely used in the aviation and aerospace industries due to their unique mechanical and physical properties.Specifically,thin-walled titanium(Ti)cylinders have received increasing attention for the...Titanium alloys are widely used in the aviation and aerospace industries due to their unique mechanical and physical properties.Specifically,thin-walled titanium(Ti)cylinders have received increasing attention for their applications as rocket engine casings,aircraft landing gear,and aero-engine hollow shaft due to their observed improvement in the thrust-to-weight ratio.However,the conventional cutting(CC)process is not appropriate for thin-walled Ti cylinders due to its low thermal conductivity,high strength,and low stiffness.Instead,high-speed ultrasonic vibration cutting(HUVC)assisted processing has recently proved highly effective for Ti-alloy machining.In this study,HUVC technology is employed to perform external turning of a thinwalled Ti cylinder,which represents a new application of HUVC.First,the kinematics,tool path,and dynamic cutting thickness of HUVC are evaluated.Second,the phenomenon of mode-coupling chatter is analyzed to determine the effects and mechanism of HUVC by establishing a critical cutting thickness model.HUVC can increase the critical cutting thickness and effectively reduce the average cutting force,thus reducing the energy intake of the system.Finally,comparison experiments are conducted between HUVC and CC processes.The results indicate that the diameter error rate is 10%or less for HUVC and 51%for the CC method due to a 40%reduction in the cutting force.In addition,higher machining precision and better surface roughness are achieved during thin-walled Ti cylinder manufacturing using HUVC.展开更多
Cutting is an essential and complicated process in many fields.Efficient and low-consumption cutting operations are of great significance for environmental protection and energy conservation.The development of high pe...Cutting is an essential and complicated process in many fields.Efficient and low-consumption cutting operations are of great significance for environmental protection and energy conservation.The development of high performance cutting parts relies on a deep understanding of the cutting process and cutting mechanism.In this research,a new type of cutting test bench with high-speed photography was developed,and the cutting tests were conducted on the jute fiber bundle from quasi-static cutting at 10 mm/s to dynamic cutting in the speed range of 0.6-2.4 m/s.The cutting process was captured by a high-speed camera.Analysis shows that compression exists before quasi-static cutting,and the compression force curve with respect to the compression ratio follows an exponential function.The cutting speed has a significant effect on cutting energy.The cutting energy consumption is not a monotonous function of cutting speed owing to the combined effect of elastic deformation and friction of fibers.The cutting energy increases with increasing cutting speed in the range of 0.6-1.2 m/s due to the increase of the friction within fibers and the friction between the blade and fibers.The cutting energy decreases with increasing cutting speed in the range of 1.2-1.8 m/s,and tends to be a fixed value when the cutting speed exceeds 1.8 m/s due to the stabilized elastic deformation and friction coefficient.From the perspective of energy saving,it is meaningless to increase the blade speed excessively when cutting fiber bundles.展开更多
In this paper,we attempts to investigate cutting mechanisms in high-speed cutting of Al6061/Si C_(p)/15p composites using a semi-phenomenologically based damage model in the equivalent homogeneous material(EHM)framewo...In this paper,we attempts to investigate cutting mechanisms in high-speed cutting of Al6061/Si C_(p)/15p composites using a semi-phenomenologically based damage model in the equivalent homogeneous material(EHM)framework.By combining macroscale EHM modeling and underlying microscale physical mechanisms,a feasible semi-phenomenological plastic model is proposed for prediction of cutting forces and chip morphology during high-speed turning Al6061/Si C_(p)/15p composites.This model incorporates the modified Weibull weakest-link effect to represent the strain-based damage evolution in large deformations.This proposed semi-phenomenological constitutive model is implemented by compiling material subroutines into cutting finite element(FE)codes.The effects of the critical shear stresses on chip formation that depend on the toolchip frictional coefficient are accounted for in the cutting FE model.The chip formation mechanism affecting material removal behaviors during high-speed turning is further investigated.The capabilities of the proposed constitutive model are evaluated by comparing cutting forces and chip morphologies between experiments and simulations at different cutting speeds associated with strain rates.The EHM-based and microstructure-based models are further compared in both computational efficiency and accuracy.The simulation results show that the developed semiphenomenological constitutive formalism and cutting model are promising and efficient tools for further investigation of dynamic mechanical and cutting behaviors of particle-reinforced composites with different volume fraction and particle size.展开更多
The ADC12 aluminum alloy is prone to severe tool wear and high cutting heat during high-speed milling because of its high hardness.This study analyzes the highspeed milling process from the perspective of different ch...The ADC12 aluminum alloy is prone to severe tool wear and high cutting heat during high-speed milling because of its high hardness.This study analyzes the highspeed milling process from the perspective of different chip morphologies.The influence of cutting temperature on chip morphology was expounded.A two-dimensional orthogonal cutting model was established for finite element analysis(FEA)of high-speed milling of ADC12 aluminum alloy.A theoretical analysis model of cutting force and cutting temperature was proposed based on metal cutting theory.The variations in chip shape,cutting force,and cutting temperature with cutting speed increasing were analyzed via FEA.The results show that,with the increase in cutting speed,the chip morphology changes from continuous to serrated,and then back to continuous.The serrated chip is weakened and the cutting temperature is lowered when the speed is lower than 600 m·min^(-1)or higher than 1800 m·min^(-1).This study provides a reference for reducing cutting temperature,controlling chip morphology and improving cutting tool life.展开更多
In this paper, the instantaneous undeformed chip thickness is modeled to include the dynamic modulation caused by the tool vibration while the dynamic regenerative effects are taken into account. The numerical method ...In this paper, the instantaneous undeformed chip thickness is modeled to include the dynamic modulation caused by the tool vibration while the dynamic regenerative effects are taken into account. The numerical method is used to solve the differential equations goveming the dynamics of the milling system. Several chatter detection criteria are applied synthetically to the simulated signals and the stability diagram is obtained in time-domain. The simulation results in time-domain show a good agreement with the analytical prediction, which is validated by the cutting experiments. By simulating the chatter stability lobes in the time-domain and analyzing the influences of different spindle speeds on the vibration amplitudes of the tool under a Fixed chip-load condition, conclusions could be drawn as follows： In rough milling, higher machining efficiency can be achieved by selecting a spindle speed corresponding to the axial depth of cut in accordance with the simulated chatter stability lobes, and in Fmish milling, lower surface roughness can be achieved by selecting a spindle speed well beyond the resonant frequency of machining system.展开更多
文摘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.
文摘To solve the problem of difficulty in selecting NC cutting parameters by the redundancy technique, a method is put forward to optimize cutting parameters based on a revolutionary mathematical model and a revolutionary cutting parameters database. By use of fuzzy inference rules, it can not only make the method itself evolved and updated, but also ensure data to be correct and feasible from the two optimization routes. Practical running and testing proved that this method can facilitate for the user to select parameters and greatly improve the processing efficiency.
基金supported by the Defense Industrial Technology Development Program of China(No.JCKY2018601C209)。
文摘Titanium alloys are widely used in the aviation and aerospace industries due to their unique mechanical and physical properties.Specifically,thin-walled titanium(Ti)cylinders have received increasing attention for their applications as rocket engine casings,aircraft landing gear,and aero-engine hollow shaft due to their observed improvement in the thrust-to-weight ratio.However,the conventional cutting(CC)process is not appropriate for thin-walled Ti cylinders due to its low thermal conductivity,high strength,and low stiffness.Instead,high-speed ultrasonic vibration cutting(HUVC)assisted processing has recently proved highly effective for Ti-alloy machining.In this study,HUVC technology is employed to perform external turning of a thinwalled Ti cylinder,which represents a new application of HUVC.First,the kinematics,tool path,and dynamic cutting thickness of HUVC are evaluated.Second,the phenomenon of mode-coupling chatter is analyzed to determine the effects and mechanism of HUVC by establishing a critical cutting thickness model.HUVC can increase the critical cutting thickness and effectively reduce the average cutting force,thus reducing the energy intake of the system.Finally,comparison experiments are conducted between HUVC and CC processes.The results indicate that the diameter error rate is 10%or less for HUVC and 51%for the CC method due to a 40%reduction in the cutting force.In addition,higher machining precision and better surface roughness are achieved during thin-walled Ti cylinder manufacturing using HUVC.
基金This work was financially supported by the National Key Research and Development Program of China(Grant No.2017YFD0700502)and the National Natural Science Foundation of China(Grant No.51705136 and 51375146).
文摘Cutting is an essential and complicated process in many fields.Efficient and low-consumption cutting operations are of great significance for environmental protection and energy conservation.The development of high performance cutting parts relies on a deep understanding of the cutting process and cutting mechanism.In this research,a new type of cutting test bench with high-speed photography was developed,and the cutting tests were conducted on the jute fiber bundle from quasi-static cutting at 10 mm/s to dynamic cutting in the speed range of 0.6-2.4 m/s.The cutting process was captured by a high-speed camera.Analysis shows that compression exists before quasi-static cutting,and the compression force curve with respect to the compression ratio follows an exponential function.The cutting speed has a significant effect on cutting energy.The cutting energy consumption is not a monotonous function of cutting speed owing to the combined effect of elastic deformation and friction of fibers.The cutting energy increases with increasing cutting speed in the range of 0.6-1.2 m/s due to the increase of the friction within fibers and the friction between the blade and fibers.The cutting energy decreases with increasing cutting speed in the range of 1.2-1.8 m/s,and tends to be a fixed value when the cutting speed exceeds 1.8 m/s due to the stabilized elastic deformation and friction coefficient.From the perspective of energy saving,it is meaningless to increase the blade speed excessively when cutting fiber bundles.
基金co-supported by the National Natural Science Foundation of China(No.51575051)Fundamental Research Funds for the Central Universities(No.G2020KY0501)。
文摘In this paper,we attempts to investigate cutting mechanisms in high-speed cutting of Al6061/Si C_(p)/15p composites using a semi-phenomenologically based damage model in the equivalent homogeneous material(EHM)framework.By combining macroscale EHM modeling and underlying microscale physical mechanisms,a feasible semi-phenomenological plastic model is proposed for prediction of cutting forces and chip morphology during high-speed turning Al6061/Si C_(p)/15p composites.This model incorporates the modified Weibull weakest-link effect to represent the strain-based damage evolution in large deformations.This proposed semi-phenomenological constitutive model is implemented by compiling material subroutines into cutting finite element(FE)codes.The effects of the critical shear stresses on chip formation that depend on the toolchip frictional coefficient are accounted for in the cutting FE model.The chip formation mechanism affecting material removal behaviors during high-speed turning is further investigated.The capabilities of the proposed constitutive model are evaluated by comparing cutting forces and chip morphologies between experiments and simulations at different cutting speeds associated with strain rates.The EHM-based and microstructure-based models are further compared in both computational efficiency and accuracy.The simulation results show that the developed semiphenomenological constitutive formalism and cutting model are promising and efficient tools for further investigation of dynamic mechanical and cutting behaviors of particle-reinforced composites with different volume fraction and particle size.
基金the National Natural Science Foundation of China(No.51975123)Fuzhou Science and Technology Plan Project(No.2019G42)。
文摘The ADC12 aluminum alloy is prone to severe tool wear and high cutting heat during high-speed milling because of its high hardness.This study analyzes the highspeed milling process from the perspective of different chip morphologies.The influence of cutting temperature on chip morphology was expounded.A two-dimensional orthogonal cutting model was established for finite element analysis(FEA)of high-speed milling of ADC12 aluminum alloy.A theoretical analysis model of cutting force and cutting temperature was proposed based on metal cutting theory.The variations in chip shape,cutting force,and cutting temperature with cutting speed increasing were analyzed via FEA.The results show that,with the increase in cutting speed,the chip morphology changes from continuous to serrated,and then back to continuous.The serrated chip is weakened and the cutting temperature is lowered when the speed is lower than 600 m·min^(-1)or higher than 1800 m·min^(-1).This study provides a reference for reducing cutting temperature,controlling chip morphology and improving cutting tool life.
基金National Key Technologies R&D Program (2006BA103A16)Fundamental Research Project of COSTIND (K1203020507, B2120061326)
文摘In this paper, the instantaneous undeformed chip thickness is modeled to include the dynamic modulation caused by the tool vibration while the dynamic regenerative effects are taken into account. The numerical method is used to solve the differential equations goveming the dynamics of the milling system. Several chatter detection criteria are applied synthetically to the simulated signals and the stability diagram is obtained in time-domain. The simulation results in time-domain show a good agreement with the analytical prediction, which is validated by the cutting experiments. By simulating the chatter stability lobes in the time-domain and analyzing the influences of different spindle speeds on the vibration amplitudes of the tool under a Fixed chip-load condition, conclusions could be drawn as follows： In rough milling, higher machining efficiency can be achieved by selecting a spindle speed corresponding to the axial depth of cut in accordance with the simulated chatter stability lobes, and in Fmish milling, lower surface roughness can be achieved by selecting a spindle speed well beyond the resonant frequency of machining system.
