An electromagnetic semi-active dynamic vibration absorber for thin-walled workpiece vibration suppression in mirror milling

As critical components of aircraft skins and rocket fuel storage tank shells,large thin-walled workpieces are susceptible to vibration and deformation during machining due to their weak local stiffness.To address these challenges,we propose a novel tunable electromagnetic semi-active dynamic vibration absorber(ESADVA),which integrates with a magnetic suction follower to form a followed ESADVA(follow-ESADVA)for mirror milling.This system combines a tunable magnet oscillator with a follower,enabling real-time vibration absorption and condition feedback throughout the milling process.Additionally,the device supports self-sensing and frequency adjustment by providing feedback to a linear actuator,which alters the distance between magnets.This resolves the traditional issue of being unable to directly monitor vibration at the machining point due to space constraints and tool interference.The frequency shift characteristics and vibration absorption performance are comprehensively investigated.Theoretical and experimental results demonstrate that the prototyped follow-ESADVA achieves frequency synchronization with the milling tool,resulting in a vibration suppression rate of approximately 47.57%.Moreover,the roughness of the machined surface decreases by18.95%,significantly enhancing the surface quality.The results of this work pave the way for higher-quality machined surfaces and a more stable mirror milling process.

Research on embedded locally resonant metamaterials used for vibration attenuation of thin-walled workpieces in mirror milling

The shell composed of large-scale parts is the essential component of mechanical structures in the aerospace,shipping,and railway industries.These workpieces are characterized by thin walls and weak rigidity,thus requiring an effective technology for high-performance machining.Accordingly,an embedded locally resonant metamaterial with double resonators is proposed and combined with the magnetic follow-up support technology to attenuate the vibration of thin-walled parts for the first time.The band structures and parametric adjustment laws are systematically investigated and validated by analytical calculation and finite element method,which proves the proposed model is broadband,lightweight,and flexible in low frequencies.Its characteristics,as well as the relatively simple structure,are unique advantages for thin-walled structure milling.Finally,mirror milling experiments have been performed to assess the slave module with the proposed substructure.From the results,the root mean square amplitude of the thin-walled workpiece with the combined device decreases by nearly 9%,which means that the performance has been improved by the combined device.Furthermore,this work provides an integrated and efficient solution for vibration suppression in thin-walled parts milling,which extends locally resonant metamaterials to practical engineering fields and helps to improve the status quo of mirror milling from the perspective of metamaterials.

Vibration suppression of thin-walled workpiece machining considering external damping properties based on magnetorheological fluids flexible fixture

Milling of the thin-walled workpiece in the aerospace industry is a critical process due to the high flexibility of the workpiece. In this paper, a flexible fixture based on the magnetorheological (MR) fluids is designed to investigate the regenerative chatter suppression during the machining. Based on the analysis of typical structural components in the aerospace industry, a general complex thin-walled workpiece with fixture and damping constraint can be equivalent as a rectangular cantilever beam. On the basis of the equivalent models, natural frequency and mode shape function of the thin-walled workpiece is obtained according to the Euler-Bernoulli beam assumptions. Then, the displacement response function of the bending vibration of the beam is represented by the product of all the mode shape function and the generalized coordinate. Furthermore, a dynamic equation of the workpiece-fixture system considering the external damping factor is proposed using the Lagrangian method in terms of all the mode shape function and the generalized coordinate, and the response of system under the dynamic cutting force is calculated to evaluate the stability of the milling process under damping control. Finally, the feasibility and effectiveness of the proposed approach are validated by the impact hammer experiments and several machining tests. (C) 2016 Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics.

Modeling and analysis for time-varying dynamics of thin-walled workpieces in mirror milling considering material removal

To reduce the vibration and deformation of large thin-walled workpieces during the milling process,mirror milling is widely used due to its point-to-point support and strong applicability.The influence of the support head on the workpiece’s dynamic characteristics is crucial in determining whether the mirror milling process is reliable and effective.Therefore,this study establishes a time-varying dynamic model for mirror milling of thin-walled workpieces with various boundary conditions to accurately analyze and predict the dynamic characteristics and response of the workpiece.First,a new analytical method for material removal with extensive applicability and high precision is proposed.In this method,the Ritz mode shape is used to approximate the workpiece’s mode shape as it changes during material removal.Next,the Hertz contact theory is adopted to establish a tool-workpiece-support head coupling model,which considers the jump-off phenomenon between them.Subsequently,the dynamic model is solved using the Newmark-β numerical integration method to obtain the workpiece’s time-domain acceleration and displacement responses under the forced vibration.Finally,the measured frequency response function(FRF)and vibration signals of workpieces verify the correctness of the proposed mirror milling model for thin-walled workpieces considering material removal.In addition,this paper analyzes the dynamic characteristics and forced vibration law of workpieces in mirror milling,which lays the foundation for high precision mirror milling.

Position-varying surface roughness prediction method considering compensated acceleration in milling of thin-walled workpiece

Machined surface roughness will affect parts?service performance.Thus,predicting it in the machining is important to avoid rejects.Surface roughness will be affected by system position dependent vibration even under constant parameter with certain toolpath processing in the finishing.Aiming at surface roughness prediction in the machining process,this paper proposes a position-varying surface roughness prediction method based on compensated acceleration by using regression analysis.To reduce the stochastic error of measuring the machined surface profile height,the surface area is repeatedly measured three times,and Pauta criterion is adopted to eliminate abnormal points.The actual vibration state at any processing position is obtained through the single-point monitoring acceleration compensation model.Seven acceleration features are extracted,and valley,which has the highest/^-square proving the effectiveness of the filtering features,is selected as the input of the prediction model by mutual information coefficients.Finally,by comparing the measured and predicted surface roughness curves,they have the same trends,with the average error of 16.28%and the minimum error of 0.16%.Moreover,the prediction curve matches and agrees well with the actual surface state,which verifies the accuracy and reliability of the model.

Variation characteristic of drilling force and influence of cutting parameter of SiCp/Al composite thin-walled workpiece

In this paper,the variation characteristic of the drilling force,and the influences of cutting speed,feed rate,and workpiece thickness on the drilling force,were eval・uated when drilling a silicon carbide particle reinforced aluminum matrix(SiCp/Al)composite thin-walled workpiece with a high volume fraction.Under the condition that the workpiece thickness was less than the drill tip height,three characteristic stages of drilling force variation were proposed.The results indicate that there is a sign币cant difference between the variations in the drilling force when drilling a thin-walled workpiece compared to thick-walled workpiece.When the chisel edge drills out the lower surface of the workpiece,there is an abrupt decrease in the thrust forces of the thin-walled and thick-walled workpieces.In addition,there is an abrupt decrease in the torque of the thick-walled workpiece,whereas that of the thinwalled workpiece increases.According to the thickness of the thin-walled workpiece,the instant of the abrupt decrease in the thrust force may lead or lag behind the theoretical instant at which the chisel edge reaches the lower surface of the workpiece without deformation.When drilling a thin-walled hole,the cutting speed has a slight influence on the thrust force,and there is a slight increase in the torque in accordance with an increase in the cutting speed.The thrust force and torque increase in accordance with an increase in the feed rate.When drilling a thinwalled workpiece with a thickness of 1 mm,the critical thickness of workpiece cracking decreases in accordance with an increase in the cutting speed,and increases in accordance with an increase in the feed rate.When drilling a thin-walled workpiece with a thickness of 0.5 mm,the concave deformation of the workpiece and the critical thickness of the workpiece cracking increase in accordance with an increase in the feed rate.However,the increment in the critical thickness of the workpiece cracking is less than that in the concave deformation of the workpiece.

Experimental Study on Entropy Features in Machining Vibrations of A Thin-Walled Tubular Workpiece

In machining processes,chatter vibrations are always regarded as one of the major limitations for production quality and efficiency.Accurate and timely monitoring of chatter is helpful to maintain stable machining operations.At present,most chatter monitoring methods are based on the energy level at specified chatter frequencies or frequency bands.However,the spectral features of chatter could change during machining operations due to complexity and time-varying dynamics of the physical machining process.The purpose of this paper is to investigate the time-varying chatter features in turning of thin-walled tubular workpieces from the perspective of entropy.The airborne acoustics was selected as the source of information for machining condition monitoring.First,corresponding to the distinguishing surface topographies relevant to machining conditions,the features of the sound signal emitted during turning of the thin-walled cylindrical workpieces were extracted using the spectral analysis and wavelet packet transform,respectively.It was shown that the dominant vibration frequency as well as the energy distribution could shift with the transition of the machining status.After that,two relative entropy indicators based on the spectrum and the wavelet packet energy were constructed to identify chattering events in turning of the thin-walled tubes.The experimental results demonstrate that the proposed indicators could accurately reflect the transition of machining conditions with high sensitivity and robustness in comparison with the traditional FFT-based methods.The achievement of this study lays the foundations of the online chatter monitoring and control technique for turning of the thin-walled tubular workpieces.

Milling Parameters Optimization of Al-Li Alloy Thin-Wall Workpieces Using Response Surface Methodology and Particle Swarm Optimization

To improve the milling surface quality of the Al-Li alloy thin-wall workpieces and reduce the cutting energy consumption.Experimental research on the milling processing of AA2195 Al-Li alloy thin-wall workpieces based on Response Surface Methodology was carried out.The single factor and interaction of milling parameters on surface roughness and specific cutting energy were analyzed,and the multi-objective optimization model was constructed.The Multiobjective Particle Swarm Optimization algorithm introducing the Chaos Local Search algorithm and the adaptive inertial weight was applied to determine the optimal combination of milling parameters.It was observed that surface roughness was mainly influenced by feed per tooth,and specific cutting energy was negatively correlated with feed per tooth,radial cutting depth and axial cutting depth,while cutting speed has a non-significant influence on specific cutting energy.The optimal combination of milling parameters with different priorities was obtained.The experimental results showed that the maximum relative error of measured and predicted values was 8.05%,and the model had high reliability,which ensured the low surface roughness and cutting energy consumption.It was of great guiding significance for the success of Al-Li alloy thin-wall milling with a high precision and energy efficiency.

Optimization of Fixture Number in Large Thin-Walled Parts Assembly Based on IPSO

There are lots of researches on fixture layout optimization for large thin-walled parts.Current researches focus on the positioning problem,i.e.,optimizing the positions of a constant number of fixtures.However,how to determine the number of fixtures is ignored.In most cases,the number of fixtures located on large thin-walled parts is determined based on engineering experience,which leads to huge fixture number and extra waste.Therefore,this paper constructs an optimization model to minimize the number of fixtures.The constraints are set in the optimization model to ensure that the part deformation is within the surface profile tolerance.In addition,the assembly gap between two parts is also controlled.To conduct the optimization,this paper develops an improved particle swarm optimization(IPSO)algorithm by integrating the shrinkage factor and adaptive inertia weight.In the algorithm,particles are encoded according to the fixture position.Each dimension of the particle is assigned to a sub-region by constraining the optional position range of each fixture to improve the optimization efficiency.Finally,a case study on ship curved panel assembly is provided to prove that our method can optimize the number of fixtures while meeting the assembly quality requirements.This research proposes a method to optimize the number of fixtures,which can reduce the number of fixtures and achieve deformation control at the same time.

Development of Fixture Layout Optimization for Thin-Walled Parts:A Review

An increasing number of researchers have researched fixture layout optimization for thin-walled part assembly during the past decades.However,few papers systematically review these researches.By analyzing existing literature,this paper summarizes the process of fixture layout optimization and the methods applied.The process of optimization is made up of optimization objective setting,assembly variation/deformation modeling,and fixture layout optimization.This paper makes a review of the fixture layout for thin-walled parts according to these three steps.First,two different kinds of optimization objectives are introduced.Researchers usually consider in-plane variations or out-of-plane deformations when designing objectives.Then,modeling methods for assembly variation and deformation are divided into two categories:Mechanism-based and data-based methods.Several common methods are discussed respectively.After that,optimization algorithms are reviewed systematically.There are two kinds of optimization algorithms:Traditional nonlinear programming and heuristic algorithms.Finally,discussions on the current situation are provided.The research direction of fixture layout optimization in the future is discussed from three aspects:Objective setting,improving modeling accuracy and optimization algorithms.Also,a new research point for fixture layout optimization is discussed.This paper systematically reviews the research on fixture layout optimization for thin-walled parts,and provides a reference for future research in this field.

Meter-Scale Thin-Walled Structure with Lattice Infill for Fuel Tank Supporting Component of Satellite:Multiscale Design and Experimental Verification

Lightweight thin-walled structures with lattice infill are widely desired in satellite for their high stiffness-to-weight ratio and superior buckling strength resulting fromthe sandwich effect.Such structures can be fabricated bymetallic additive manufacturing technique,such as selective laser melting(SLM).However,the maximum dimensions of actual structures are usually in a sub-meter scale,which results in restrictions on their appliance in aerospace and other fields.In this work,a meter-scale thin-walled structure with lattice infill is designed for the fuel tank supporting component of the satellite by integrating a self-supporting lattice into the thickness optimization of the thin-wall.The designed structure is fabricated by SLM of AlSi10Mg and cold metal transfer welding technique.Quasi-static mechanical tests and vibration tests are both conducted to verify the mechanical strength of the designed large-scale lattice thin-walled structure.The experimental results indicate that themeter-scale thin-walled structure with lattice infill could meet the dimension and lightweight requirements of most spacecrafts.

Numerical Analysis of Cold-Formed Thin-Walled Steel Short Columns with Pitting Corrosion during Bridge Construction

Pitting corrosion is harmful during bridge construction,which will lead to uneven roughness of steel surfaces and reduce the thickness of steel.Hence,the effect of pitting corrosion on the mechanical properties of cold-formed thin-walled steel stub columns is studied,and the empirical formulas are established through regression fitting to predict the ultimate load of web and flange under pitting corrosion.In detail,the failure modes and load-displacement curves of specimens with different locations,area ratios,and depths are obtained through a large number of non-linear finite element analysis.As for the specimens with pitting corrosion on the web,all the specimens are subject to local buckling failure,and the failure mode will not change with pitting corrosion,but the failure location will change with pitting corrosion location;the size,location,and area ratio of pitting corrosion have little influence on the ultimate load of cold-formed thin-walled steel short columns,but the loss rate of pitting corrosion section area has a greater impact on the ultimate bearing capacity.As for the specimen with flange pitting corrosion,the location and area ratio of pitting corrosion have less influence on the ultimate load of cold-formed thin-walled steel short columns,and the section area loss rate has greater influence on the ultimate bearing capacity;the impact of web pitting corrosion on the ultimate load is greater than that of flange pitting corrosion under the same condition of pitting corrosion section area.The prediction formulas of limit load which are suitable for pitting corrosion of web and flange are established,which can provide a reference for performance evaluation of corroded cold-formed thin-walled steel.

Measurement Uncertainty Analysis of the Rotary-scan Method for the Measurable Dimension of Cylindrical Workpieces

The measurement uncertainty analysis is carried out to investigate the measurable dimensions of cylindrical workpieces by the rotary-scan method in this paper.Due to the difficult alignment of the workpiece with a diameter of less than 3 mm by the rotary scan method,the measurement uncertainty of the cylindrical workpiece with a diameter of 3 mm and length of 50 mm which is measured by a roundness measuring machine,is evaluated according to GUM(Guide to the Expression of Uncertainty in Measurement)as an example.Since the uncertainty caused by the eccentricity of the measured workpiece is different with the dimension changing,the measurement uncertainty of cylindrical workpieces with other dimensions can be evaluated the same as the diameter of 3 mm but with different eccentricity.Measurement uncertainty caused by different eccentricities concerning the dimension of the measured cylindrical workpiece is set to simulate the evaluations.Compared to the target value of the measurement uncertainty of 0.1μm,the measurable dimensions of the cylindrical workpiece can be obtained.Experiments and analysis are presented to quantitatively evaluate the reliability of the rotary-scan method for the roundness measurement of cylindrical workpieces.

FEM analysis of workpiece curvature influence on groove deformation during plough process

To investigate the workpiece curvature influence on groove deformation,numerical studies with curvature varying from negative to positive were conducted on copper material.Groove deformations were analyzed,including groove geometry,effective stress distribution and plough force.The curled groove shape whose workpiece curvature was 0.133 mm-1 was validated by experiments.Moreover,a series of geometry models with various curvatures were introduced to analyze the change of groove deformation.The results show that positive curvatures influence groove deformation more intensively than negative or zero curvature.It is mainly due to the action of the tool forming face during plough process.

Sensitivity of springback and section deformation to process parameters in rotary draw bending of thin-walled rectangular H96 brass tube

In order to study the effects of the process parameters on springback and section deformation, a sensitivity analysis model was established based on the combination use of the multi-parameter sensitivity analysis method and the springback/section deformation prediction finite element model, and by using this model the sensitivities of the springback and the section deformation to process parameters were analyzed and compared. The results show that the most sensitive process conditions for springback angle are the boost speed and the pressure of pressure die, and the most sensitive process condition for section deformation is the number of cores. When the clamp force, the boost speed and the pressure of pressure die are utilized to control section deformation, the effect of these process parameters on springback should be considered. When the process parameters are mainly used to control springback, the effect of these process parameters on the section deformation should be always considered.

VIBRATION IN HIGH-SPEED MILLING OF THIN-WALLED COMPONENTS

To investigate the vibration principle in machining thin-walled components, a dynamic model for end milling of flexible structures is built based on considering the variations in the dynamic chip thickness and the differences between up-milling and down-milling. Two milling experiments verify the model. Experimental results show that the model can predict the milling force and displacements simultaneously in the dynamic milling process.

WORKPIECE LOCATING AND POST PROCESSING SYSTEMS ON 6-DOF CNC MILLING MACHINE

A conventional non-computerized numerical control （CNC） machine is updated by mounting a six degree-of-free （DOF） parallel mechanism on it, thus obtaining a new CNC one. The structure of this CNC milling machine is introduced, and the workpiece locating system and the post processing system of the cutter location （CL） data file are analyzed. The new machine has advantages of low costs, simple structure, good rigidity, and high precision. It is easy to be transformed and used to process the workpiece with a complex surface.

Warm bending mechanism of extrados and intrados of large diameter thin-walled CP-Ti tubes

In order to develop the warming bending technology of the large diameter thin-walled（LDTW） commercial pure titanium alloy CP-Ti tubes, the warm bending mechanism of the extrados and intrados of LDTW CP-Ti tubes was researched. By EBSD analysis and Vickers hardness test, the changes of microstructure and strength of the tubes at different bending temperatures of 293, 423 and 573 K, were analyzed. The results show： 1） The extrados of the bent tube deforms mainly by slip, along with few twinning, and the preferred orientation is similar to that of the initial tube; the intrados of the bent tube experiences compression deformation mainly by {1 012} tensile twinning, and the twinning makes the preferred orientation of wall materials change sharply. 2） The Vickers hardness values of both the extrados and intrados of the samples after bending increase greatly; the Vickers hardness values of the intrados are much higher than those of the extrados, and Vickers hardness values of the RD-TD planes are always higher than those of the RD-LD planes, which are related to the different deformation mechanisms.

Automatic Method for Synchronizing Workpiece Frames in Twin-robot Nondestructive Testing System

The workpiece frames relative to each robot base frame should be known in advance for the proper operation of twin-robot nondestructive testing system. However, when two robots are separated from the workpieces, the twin robots cannot reach the same point to complete the process of workpiece frame positioning. Thus, a new method is proposed to solve the problem of coincidence between workpiece frames. Transformation between two robot base frames is initiated by measuring the coordinate values of three non-collinear calibration points. The relationship between the workpiece frame and that of the slave robot base frame is then determined according to the known transformation of two robot base frames, as well as the relationship between the workpiece frame and that of the master robot base frame. Only one robot is required to actually measure the coordinate values of the calibration points on the workpiece. This requirement is beneficial when one of the robots cannot reach and measure the calibration points. The coordinate values of the calibration points are derived by driving the robot hand to the points and recording the values of top center point（TCP） coordinates. The translation and rotation matrices relate either the two robot base frames or the workpiece and master robot. The coordinated are solved using the measured values of the calibration points according to the Cartesian transformation principle. An optimal method is developed based on exponential mapping of Lie algebra to ensure that the rotation matrix is orthogonal. Experimental results show that this method involves fewer steps, offers significant advantages in terms of operation and time-saving. A method used to synchronize workpiece frames in twin-robot system automatically is presented.

DEVELOPMENT OF A 3-DOF MICRO-POSITIONING WORKPIECE TABLE

In order to achieve active grinding control, a novel numerical controlmicropositioning workpiece table with a resolution of 6 nm has been developed. The table is drivenby three piezoelectric actuators mounted on the base. An elastic structure with three half-notchflexure hinges is designed to apply preload to the piezoelectric actuators. The position of flexurebinges is also elaborately designed with consideration to reduce the bending deformation of themoving part. Three capacitive sensors are used to form close loop control system. Considering thetable as a damped 3-DOF mass-spring system, the models of static and dynamic stiffness and errorowing to the action of external forces have been established. In order to make the table have highresolution and positioning accuracy, an error compensation algorithm is implemented by using theestablished models. The experimental testing has been carried out to verify the performance of theworkpiece table and the established models of the micropositioning workpiece table.