Papers by Author: De Jin Hu

Abstract: The feed drive system model of NC precision sphere grinding machine (MD6040) is constructed. Although a large number of researchers pay more attention on advanced controllers, most high performance machine tools still adopt PID (Proportion Integration Differentiation) controller today. In this paper, PDF (Pseudo-Derivative Feedback) controller and PDFF (Pseudo-Derivative Control with feedforward Gain) controller which evolved from PID controller are studied. The performance of PID controller, PDF controller and PDFF controller is investigated by simulation and experiment. Both simulation results and experiment results showed that PID controller has severe overshoot and less rise time, PDF controller has strong robustness and long rise time and PDFF controller possesses the advantages of the other two controllers. PDFF controller is more suitable for NC precision sphere grinding machine feed drive system.

Abstract: Laser rapid forming is a kind of new developed technology combining laser surface modification and rapid prototyping technology. It provides a powerful tool for the manufacturing and repairing of metal components. Laser rapid forming repairing experiments of 45 and 2Cr12 steel have been carried out with 316L stainless steel powder. Microstructure and properties of the repaired components are analyzed and tested with optical microscopy (OM), scanning electron microscopy (SEM) and electronic tensile experimental machine etc. Repaired components of different materials have been metallurgically bonded with the deposited layers, with fine microstructure, better mechanical properties and free of defects.

Abstract: This paper presented a new technique, which was the online wear evaluation of wheel in grinding WC-Co coating by using wavelet packet decomposition. Based on the measurement method, theory of online wear evaluation of wheel was introduced. The selection principle of characteristic signals was brought up, and the grinding acceleration signal was the best choice among many characteristic signals. The time domain signal analysis method of wavelet packet decomposition was analyzed. Lastly, experiments on the wear of wheel were performed, and experimental results showed the validity of the method.

Abstract: To investigate the effect of micro-topography on the wear properties of the cold roller, rough surface was characterized with fractal geometry, and the profile of laser-textured surface was measured based on the analysis of surface profile self-similarity, feasibility of fractal characterization of the surface was studied with power law method. Results show that Isotropic surfaces tend to be fractal and surfaces processed under definite technological conditions can be characterized with fractal geometry. On this basis, effects of surface fractal parameters on the wear rate of the roller were analyzed with fractal geometry model for wear prediction. Condition of achieving optimal fractal dimension was presented and the expression of the optimal fractal dimension was derived for the minimum normalized wear rate. It shows that normalized wear rate is mainly determined by fractal dimension besides the material properties and an optimal fractal dimension existed for the engineering surface is affected by the plastic index, normalized true contact area and scale coefficient. The results will provide bases for the studies of friction and lubrication of the textured steel sheet and guidance for the actual processing.

Abstract: The surface texture of sheet steel plays an important role for automotive applications. To achieve appropriate surface topographies and press-forming behaviour, a new laser coating texturing (LCT) technique aimed at texturing steel work-rolls was proposed. The laser texturing process was realized by applying laser pulses at very high repetition rates to produce innumerable micro-craters with the required shape profile on the surface of the rolls. Moreover, the surface alloying of the dimples was carried out on the substrates of bearing steel GCr15. The submicron WC-Co alloy metal powder was melted into the micro-craters by high laser energy. The effects of processing parameters on the properties of the laser textured samples were investigated. The dimpled surfaces were examined by a 3-dimensional surface profilometer. Microstructures of the coating layers were assessed by optical and scanning electron microscopy. The experimental investigations show that the laser-dimpled hard-coated surfaces exhibit compatible metallurgical interfaces with the substrates. The laser coating textured roll is demonstrated to have excellent abrasion resistance and a much longer service life. The abrasive wear resistance was 5 times higher than that of the substrates. The average surface microhardness values were as high as 700HV.

Abstract: The processing parameters of laser texturing are linked with the wear property of roller surface based on the relationship between the fractal parameters and surface roughness. The influence of laser power density, scanning speed and pulse width on the roughness is analyzed though experiments. The effect of fractal parameters on the wear rate of the roller is analyzed with fractal geometry model for wear prediction. Condition of achieving engineering surface with optimal fractal dimension is presented and the expression of the optimal fractal dimension is derived. It shows that the roughness of laser textured surface and normalized wear rate are mainly determined by laser power density and fractal dimension, respectively. Moreover, to get the textured surface with smallest nominal wear rate, processing parameters of laser texturing, especially the laser power density, should be controlled properly besides the material properties of the roller. The result will provide guidance for the processing.

Abstract: This paper deals with an on-line mismachining error measurement for curve grinding based on digital image processing. Using CCD camera, the contour of the workpiece’s finished surface is captured and the image is preprocessed for denoising and edge detecting. The worktable is guided by the image of the finished workpiece to follow the path of the finished contour and then the real curve of the finished workpiece is measured by fitting a curve according to the moving path of the worktable. Finally, the machining error is obtained by comparing the measured curve with the theoretical curve of the workpiece. This method is applied to a CNC curve grinding machine MD9040. A measurement experiment is given. The experiment results show that the measurement method offers high detection precision and can be used in wide fields, especially for measuring the parts with complex curve.

Abstract: This paper deals with an application to automatic compensation of grinding wheel wear by an image processing based real-time measurement method in dry curve grinding. An online image measurement system was schemed out and its principle was introduced in detail. Real time image of workpiece and grinding wheel is grabbed by CCD camera during grinding process. For the purpose of increasing the measurement precision, a new sub-pixel level accuracy edge detection approach combining Zernike moments operator with Sobel operator is proposed for locating the edge of the machined workpiece, which has advantages of fast processing speed and high edge locating accuracy. The wear amount of the grinding wheel is calculated by the image processing software, and is compensated automatically by NC controller. Finally, this method is applied to a new type CNC curve grinding machine MD9040. The experimental results show that the measurement and compensation method proposed in this paper is effective, and the contour error of the workpiece with real-time compensation is less than the feeding resolution for a compensation of 2μm.

Abstract: Spindle thermal deformation is the main error source of many precision profile grinders. In this paper, the relationship between spindle temperature and either radial or axial thermal deformation is studied based on experiments. The placement and amount of temperature sensors are optimized. Then a kind of thermal error modeling method based on support vector machine is presented and applied in the modeling of thermal error of profile grinding. The result shows the model is robust and the on-line accurate prediction of grinding thermal error is realized based on monitoring of temperature rise of spindle. Finally, the error compensation strategy is discussed for further application of thermal error modeling.

Abstract: This paper presented a new technology, which was the online wheel wear evaluation in grinding WC-Co ceramic coating by using wavelet packet decomposition. On the basis of the measurement methods, theory of online wear evaluation of wheel was introduced. And the selection principle of characteristic signals was brought forward, the grinding acceleration signal was the best choice among many characteristic signals. The time domain signal analysis method of wavelet packet decomposition was analyzed. Lastly, experiments on the wear of wheel were performed, and the experimental results showed the validity of the method.