Spindle dynamics identification using particle swarm optimization

Optimal parameters to eliminate machining chatter may be identified using analytical stability models which require the dynamics of the tool-holder-spindle-machine assembly. Receptance coupling substructure analysis (RCSA) provides a useful analytical tool to couple measured spindle-machine dynamics with tool-holder models to predict the tool point frequency response function for the assembly. Previous research has demonstrated a procedure to determine all required spindle receptances from a single measurement, where each mode within the measurement bandwidth was modeled as a fixed-free Euler–Bernoulli beam and fit using a manual, iterative procedure. Here, a particle swarm optimization technique is described for fitting the spindle-machine measurement using a fixed-free Euler–Bernoulli beam model for each mode. The performance of the optimization process and RCSA in predicting the tool tip frequency response is evaluated and the results are presented.     

Assessing the Performance of a Magnetostrictive-Actuated Tool Holder to Achieve Axial Modulations with Application to Dry Deep Hole Drilling

For machining operations such as drilling and tapping, the challenge of achieving dry machining is difficult due to the significant role that cutting fluid plays in lubrication and chip removal. A new approach for dry deep hole drilling of aluminum is presented. This new method utilizes a magnetostrictively actuated tool holder to modulate the axial position of a drill tip and thus vary the chip size. Under appropriate modulation conditions, small chips are produced that are relatively easy to evacuate through the drill flutes. The development of the magnetostrictive tool holder system is described and its performance is evaluated. The results of drilling tests performed with the magnetostrictive tool holder system are reported, and the new tool holder is demonstrated to offer promise as an alternative to drilling with a cutting fluid.     

Analysis of No. 50 Taper Joint Stiffness Under Axial and Radial Loading

This paper is concerned with the joint stiffness characteristics of the standard 7/24 taper interface. Experimental identification of joint stiffness parameters is performed on No. 50 tapers, using a special test setup, by implementing a frequency response function (FRF) based method for joint parameter identification, in conjunction with finite element modeling of the substructure. The effects of axial and radial loading as well as taper wear on the taper joint stiffness are examined. It is shown that taper joint stiffness nonuniformly increases with axial preloading and decreases with radial loading. Validation of the identified stiffness values is given by comparing the predicted natural frequencies of the taper assembly with experimentally measured values.     

An Approach to Theoretical Modeling and Simulation of Face Milling Forces

A new approach to theoretical modeling and simulation of face milling forces is presented. The present approach is based on a predictive machining theory in which machining characteristic factors in continuous cutting with a single-point cutting tool can be predicted from the workpiece material properties, tool geometry, and cutting conditions. The action of a milling cutter is considered as the simultaneous work of a number of single-point cutting tools, and the milling forces are predicted from input data of workpiece material properties, cutter parameters and tooth geometry, cutting condition, cutter and workpiece vibration structure parameters, and types of milling. A predictive force model for face milling is developed using this approach. In the model, the workpiece material properties are considered as functions of strain, strain rate, and temperature. The ratio of cutter tooth engagement over milling is taken into account for the determination of temperature in the cutting region. Cutter runout is included in the modeling for the chip load. The relative displacement between the cutter and workpiece due to the cutter and workpiece vibration is also included in the modeling to consider the effect on the undeformed chip thickness. A milling force simulation system has been developed using the model, and face milling experimental tests have been conducted to verify the simulation system. It is shown that the simulation results agree well with experimental results.     

A Postprocessor Based on the Kinematics Model for General Five-Axis Machine Tools

This paper presents a novel concept to describe the three types of five-axis machine tools by a generalized kinematic structure. A generic postprocessor capable of converting the cutter location (CL) data to machine control data was developed based on the generalized kinematics model of five-axis machine tools. The machine tool's form-shaping function matrix is derived according to the homogeneous coordinate transformation matrix and the kinematic parameters characterizing the configuration of general five-axis machine tools. The analytical equations for NC data are determined by equating the CL data matrix and the form-shaping function matrix. A trial-cut experiment on a typical five-axis machine tool and the verification on the coordinate measurement machine demonstrates the effectiveness of the proposed scheme. The algorithm proposed here can facilitate determination of the postprocessors for various five-axis machine tools more systematically.     

频域子结构方法在力学环境预示中的应用研究

目的利用频域子结构方法(FBSM,FRF Based Sub-structuring Method)对结构的力学环境进行准确高效地预示。方法分别对处理子结构间为刚性连接和弹性连接两种问题的FBSM进行理论推导。为了验证FBSM的正确性,设计连接为刚性连接和弹性连接两种算例结构,并将FBSM对算例结构频响函数的计算结果与有限元方法(FEM,Finite Element Method)的对应计算结果进行对比。其中,弹性连接利用空间梁单元进行等效,并将该等效方法与利用六自由度标量弹簧的等效方法进行对比。结果对于刚性连接和弹性连接两种情况,FBSM对频响函数的计算结果均与FEM的对应计算结果吻合程度良好。此外,空间梁单元的结点刚度矩阵为非对角阵,与六自由度标量弹簧相比,可更为准确地等效工程实际中的弹性连接。结论FBSM可对结构的力学环境进行准确高效的预示,且在处理具有弹性连接结构的力学环境预示问题时,可采用空间梁单元等效弹性连接。     

Identification and spatial patterns of coastal water pollution sources based on GIS and chemometric approach

Comprehensive and joint applications of GIS and chemometric approach were applied in identification and spatial patterns of coastal water pollution sources with a large data set （5 years （2000-2004）, 17 parameters） obtained through coastal water monitoring of Southern Water Control Zone in Hong Kong. According to cluster analysis the pollution degree was significantly different between September-next May （the 1st period） and June-August （the 2nd period）. Based on these results, four potential pollution sources, such as organic/eutrophication pollution, natural pollution, mineral/anthropic pollution and fecal pollution were identified by factor analysis/principal component analysis. Then the factor scores of each monitoring site were analyzed using inverse distance weighting method, and the results indicated degree of the influence by various potential pollution sources differed among the monitoring sites. This study indicated that hybrid approach was useful and effective for identification of coastal water pollution source and spatial patterns.     

High speed ball nose end milling of hardened AISI A2 tool steel with PCBN and coated carbide tools

High speed machining (HSM) of tool steels in their hardened state is emerging as an attractive approach for the mold and die industry due to its potential for significant cost savings and productivity improvement. An experimental study was conducted to investigate the tool wear mechanism and surface integrity in high speed ball nose end milling of hardened AISI A2 tool steel using coated tungsten carbide and polycrystalline cubic boron nitride (PCBN) tools. It is found that coated carbide tools can only be used at low speed (120 m/min) while high content PCBN tools are suitable for HSM range (470 m/min). PCBN tools produce a damage free workpiece with better surface finish and less work hardening. Despite the higher tool cost, HSM with PCBN tools lead to reduction in both total cost and production time per part.     

Analytical model of metalworking fluid penetration into the flank contact zone in orthogonal cutting

Metalworking fluids (MWFs) are used widely in machining process to dissipate heat, lubricate moving surfaces, and clear chips. They have also been linked to a number of environmental and worker health problems. To reduce these impacts, minimum quantity lubrication (MQL) sprays of MWF delivered in air or CO₂ have been proposed. MQL sprays can achieve performance comparable with conventional water-based or straight oil MWFs while only delivering a small fraction of the fluid. This performance advantage could be explained by the enhanced penetration into the cutting zone that results from delivering MWF in high pressure and precise sprays. To explore this hypothesis, an analytical model of MWF penetration into the flank face of the cutting zone is developed and validated using experimental data. The model is based on a derivation of the Navier–Stokes equation and the Reynolds equation for lubrication and applied to an orthogonal cutting geometry under steady-state conditions. A solution to the model is obtained using a numerical strategy of discretizing the analytical scheme with two-dimensional centered finite difference method. Penetration into the cutting zone is estimated for MQL sprays delivered in air, CO₂ and N₂ as well as two conventional MWFs, straight oil and semi-synthetic emulsion. The model suggests that conventional MWFs, do not penetrate the cutting zone fully and fail to provide direct cooling to the flank zone where wear is most likely to occur. MQL sprays do penetrate the cutting zone completely. Using convective heat transfer coefficients from a previous study, a finite element heat balance is carried out on the tool to understand how each fluid impacts temperature near the flank tip of the tool. The results of the modeling effort are consistent with experimental measurements of tool temperature during turning of titanium (6AL4V) using a K313 carbide tool. The prediction of temperature near the flank indicates that MQL sprays do suppress temperatures near the flank effectively. These results help explain the low levels of tool wear observed for some MQL sprays, particularly those based on high pressure CO₂. This modeling framework provides valuable insight into how lubricant delivery characteristics such as speed, viscosity, and cutting zone geometry can impact lubricant penetration.     

Assessing environmental performance by combining life cycle assessment, multi-criteria analysis and environmental performance indicators

We present a new analytical tool, called COMPLIMENT, which can be used to provide detailed information on the overall environmental impact of a business. COMPLIMENT integrates parts of tools such as life cycle assessment, multi-criteria analysis and environmental performance indicators. It avoids disadvantages and combines complementary aspects of these three tools. The methodology is based on environmental performance indicators, expanding the scope of data collection towards a life cycle approach and including a weighting and aggregation step. A case study on the Thai pulp industry illustrates the usefulness of COMPLIMENT.     

筒形件无压边圈拉深工艺参数优化设计

通过对筒形件极限拉深系数的影响因素进行分析 ,确定合适的凸凹模圆角半径是提高拉深件质量的重要途径 ,将塑性理论和优化算法相结合 ,以筒形件达到最小的极限拉深系数为优化目标 ,对筒形件无压边圈拉深工艺参数优化设计进行了研究。并且通过具体算例证明了所采用的优化模型及算法是有效的     

含复杂管路的某机构模态参数识别研究

目的获取复杂结构产品的模态参数及动态性能。方法采用基于冲击激励的试件自由模态分析试验,综合分析频响函数曲线幅值,确定局部结构模态频率点,利用半功率带宽法和专用分析软件分别计算模态阻尼比和模态振型。结果识别出影响某机构动态性能关键部件的模态参数。结论发现机构外壳模态频率远离冷却装置频率点,冷却管一阶横向模态由自身结构特性产生,二阶及纵向模态由减压阀模态引起。气体导管的动态特性主要受冷却装置模态的影响。     

Modeling and validation of deformation process for incremental sheet forming

Incremental Sheet Forming (ISF) is an emerging sheet metal prototyping technology where a part is formed as one or more stylus tools are moving in a pre-determined path and deforming the sheet metal locally while the sheet blank is clamped along its periphery. A deformation analysis of incremental forming process is presented in this paper. The analysis includes the development of an analytical model for strain distributions based on part geometry and tool paths, numerical simulations of the forming process with LS-DYNA, and experimental validation of strain predictions using Digital Image Correlation (DIC) techniques. Three kinds of parts include hyperbolic cone, skew cone and elliptical cone are constructed and used as examples for the study. Analytical, numerical and experimental results are compared, and excellent correlations are found. It is demonstrated that the analytical model developed in this paper is reliable and efficient in the prediction of strain distributions for incremental forming process.     

Experimental analysis of friction stir forming for dissimilar material joining application

Mass reduction of automotive body structures is a critical part of achieving reduced CO₂ emissions in the automotive industry. There has been significant work on the application of ultra high strength steels and aluminum alloys. However, the next paradigm is the integrated use of both materials, which poses a challenge of how to join the dissimilar materials. Friction stir forming is a new manufacturing process for joining dissimilar materials. The concept of this process is stir heating one material and forming it into a mechanical interlocking joint with the second material. In this research the process was experimentally analyzed in a position controlled robotic friction stir welding machine between aluminum and steel workpieces. New tool geometries were evaluated toward the goal of optimizing joint strength. The significant process parameters were identified and their optimized settings for the current experimental conditions defined using a design of experiments methodology. A scanning electron microscope was used to characterize the bonding and joint structure for single and multi-pin configurations. Two failure modes, aluminum sheet peeling and bonding delamination, i.e. braze fracture, were identified. It was found that the presence of zinc coating on the steel and overall joint geometry greatly affected the joint strength. The aluminum–zinc braze joint appears to be the largest contributor to joint strength for the single-pin joint configuration. The multi-pin geometry enabled a distribution of load to the four pins following fracture of the braze for increased joint toughness and ductility. Thus, the FSF method has been shown to exhibit potential for joining of aluminum to steel.     

Effect of Tool Edge Geometry on Workpiece Subsurface Deformation and Through-Thickness Residual Stresses for Hard Turning of AISI 52100 Steel

An experimental investigation was conducted to determine the effect of tool cutting edge geometry on workpiece subsurface deformation and through-thickness residual stresses for finish hard turning of through-hardened AISI 52100 steel. Polycrystalline cubic boron nitride (PCBN) inserts with “up-sharp” edges, edge hones, and chamfers were used as the cutting tools in this study. Examination of the workpiece microstructure reveals that large edge hone tools produce substantial subsurface plastic flow. Flow is not observed when turning with small edge hone tools or chamfered tools, and the workpiece microstructure appears random for these cases. Examination of through-thickness residual stresses shows that large edge hone tools produce deeper, more compressive residual stresses than are produced by small edge hone tools or chamfered tools. Explanations for these effects are offered based on assumed contact conditions between the tool and workpiece.     

火焰原子吸收分光光度法测定废水中总铬

研究环境样品中总铬用火焰原子吸收分光光度法测定。选择不同实验条件 ,确定了最佳的分析条件 ,并通过标准样品和实验样品的分析 ,验证了方法的准确度和精密度。实验证明 ,此方法快速方便、准确度高、精密度好。     

联合上限法和主应力法确定模具表面压力分布的研究(Ⅰ)

提出了一种联合上限法(Upper Bound Method)和主应力法(Slab Method)确定模具与金属接触表面压力分布的方法.这是一种基于利用上限法确定金属流动和变形区,然后根据主应力法原理计算接触面压力分布的方法,简称UBM/SM联合法.这种方法较其它方法简便,而且能给出计算压力分布的解析式.本文阐述该法的基本原理,并用它计算杯形件反挤时凸凹模表面的压力分布.     

Modelling the dry deposition velocity of aerosol particles to a spruce forest

A mathematical model is presented to calculate the size-specific deposition velocity of aerosol particles to coniferous forests, taking into account the plant morphology and micrometeorological parameters. In contrast to former studies on this topic the diffusion of the particles through laminar sublayers surrounding the plant surfaces was considered in detail. This necessitated the introduction of a formulation of the microscale roughness of the needle surfaces. Furthermore the ability of bursts in the sublayer to accelerate the particle transport was included.In order to calculate the overall deposition velocity the canopy was subdivided into a variable number of homogeneous height intervals. An analytical solution of the mass transfer equations containing the measured parameters was applied to each interval. The calculation scheme was then based on an initial value approach. The input parameters were the vertical profiles of wind speed and temperature and the height-specific vegetation density.The model was applied to a real spruce stand (Picea abies (L.) Karst.), and some typical results are presented. Finally, errors associated with inhomogeneities of the terrain are discussed.     

舵面结构热模态试验方法研究

目的 探究高温对舵面结构模态试验结果的影响.方法 以导弹舵面为研究对象,开展高温环境下结构模态试验方法研究.基于石英灯热辐射高温加热系统和模态测试系统搭建热模态试验测试平台,采用带水冷装置的耐高温加长激振杆实现激励的施加,设计耐高温陶瓷引伸杆进行振动信号的测试,通过有限元仿真分析与试验数据对比,验证所提热模态试验方案的可行性.结果 当激振杆的正弦扫频试验在20～1000 Hz范围内,其传递函数值接近于1,说明激振杆传递性能良好.陶瓷引伸杆对试验件前四阶模态频率及振型影响较小,验证了陶瓷引伸杆设计的有效性.试验数据表明,试验件材料的刚度随着环境温度的升高逐渐降低,导致各阶模态的频率呈逐渐降低的趋势.结论 高温会使舵面结构的模态参数降低,该研究为后续型号产品的热模态试验提供了的试验手段和技术支持.     

线性规划方法在环境容量资源分配中的应用

分析了最优化数学方法,尤其是线性规划方法在环境容量资源分配规划中的若干种应用类型,提出了相关的目标函数模型和约束条件模型以及建立模型的基本步骤.以大气环境容量资源分配为案例,建立了大气环境容量分配优化线性规划模型及其边界约束条件.计算表明,线性规划最优化方法是解决区域大气环境容量资源分配的科学可行的方法.