Papers by Author: De Jin Hu

Abstract: A novel truing and dressing method, namely dry electrical discharge (dry-ECD) assisted truing and dressing, is proposed to overcome the shortcomings associated with conventional mechanical dressing methods, ELID and ECD methods. The macro/micro complex feed mechanism in dry –ECD assisted truing and dressing equipment is designed to maintain continuous discharge between the tool electrode and diamond wheel in dry-ECD automatically. A series of basic performance experiments of the micro feed mechanism show that the position accuracy of the micro-feed mechanism is below 0.35μm using the micro-positioning control system. Whereas，the position accuracy of the mobile negative electrode is 1μm without macro/micro complex feed mechanism.

Abstract: Image analysis was used to evaluate the curve grinding process. The measurement system organization and its principle of operation were introduced. Some key technologies that influence the system precision were also studied in details. Real-time image of work piece and wheel grinding can be gathered while using CCD camera. For image de-noising, a kind of wavelet threshold function was presented to calculate the new wavelet coefficients. Local threshold algorithm was used to compute different scale threshold, another threshold is suggested when MSE is minimum. Image signals are reconstructed through invert discrete wavelet transformation with the new wavelet coefficients. For the purpose of increasing the measurement precision, a closed mathematical model of sub-pixel edge detection operator was founded according to the gray moment operator’s invariant characteristics and Tabatabai’s first three sample gray moments. An application of system validity and the comparison results of work piece were also given. From experiments it can be said that the proposed method in this paper is effective, and its detection precision and results are reasonable.

Abstract: This research is to investigate the dynamic characteristics of the grinding process. A kind of robust grinding wheel reciprocating arrangement is schemed out, which realizes the precise point-grinding machining. The grinding wheel reciprocating movement is driven by a linear motor to replace the traditional crank or hydraulic pressure drive device. Based on the time series method, the modal experimental analysis technique has been adopted in this paper. By acquiring acceleration signals of multiple positions of the grinding wheel slide, the dynamic characteristics are analyzed and the modal parameters of the structure are identified by virtual analysis program. The boundary condition of the finite element model is adjusted for optimizing its dynamic characteristic. The equivalent substructure is created and modified in order to improve the surface grinding quality. This study has got satisfying results. The grinding wheel movement realizes the self-regulation control and reduces the surface waviness and roughness during high speed point-grinding operation.

Abstract: In traditional NC curve grinding, the grinding wheel’s rotary surface is generally not on the grinding point’s normal direction, which will bring the distortion of grinding wheel and decrease the machining precision. This paper presents a new technology, which is called the non-interference normal tracking for NC curve grinding process. By controlling the worktable to rotate in the x-y plane, the superposition between the rotary surface of the grinding wheel and the normal vector of the workpiece’s contour is realized, and the interference between the wheel’s body and the workpiece could be avoided at the same time. A mathematic model is established and an algorithm to calculate the worktable’s rotary angle is proposed. Finally, the algorithm is applied in a new-type digital curve grinder successfully. The results show that the method is reliable and effective.

Abstract: Present modeling algorithm for large-sized revolving parts’ camber can not ensure the smoothness, so a new modeling algorithm based on NURBS Curve was proposed in this study. In detail, the new modeling algorithm is as following: Firstly transfer these discrete points, which are measured along the part’s axial lead by equal distant, into a weighting unity sequence. Secondly filter this sequence by wavelet de-noising algorithm. Thirdly replace the discrete points’ amplitudes by the corresponding weights of filtered sequence, thus yield a group of new discrete points. Lastly calculate the control vertexes and weighting factors by local rational interpolation algorithm, and construct a spatial NURBS Curve through the new discrete points to obtain the model of large-sized revolving parts’ camber. It was experimentally confirmed that this model can represent drilling stem’s camber smoothly and improve its pressure straightening precision.

Abstract: The experimental results for silicon carbide (SiC) wheel with fine grit size grinding of silicon carbide (Si3N4) revealed that the grinding parameters affect not only the ground silicon nitride surface roughness, but also the degree of surface damage. There exists complex non-linear relationship between the grinding parameters and surface quality. Better surface roughness doesn’t surely mean less surface damage. A method of prediction of grinding quality based on support vector regression is then presented according to the condition of small samples. The result shows the prediction accuracy based on this method is obviously higher than neural network, which provides an effective way for optimizing the grinding parameters to ensure the grinding quality as well as grinding efficiency while grinding of silicon carbide using conventional abrasive.

Abstract: Ceramic coating materials own some advantages, for example high-rigidity, good abradability and good performance under high temperature. At the same time, ceramic coating materials are also difficult-to-machine materials. High machining precision and efficiency can be obtained in grinding WC-Co coating by cup wheel. The affection of grinding temperature is very important for grinding processing. But there is no research on grinding temperature of WC-Co coating by cup wheel. So in this paper, grinding temperature by cup wheel is researched on theory, the new concept, which is effectiveness width of arc moving heat source, is presented, and theoretical formula of grinding temperature is also built. Then experimental research on grinding temperature of WC-Co coating by cup wheel is done by use of thermocouple temperature measurement technology. The experimental results show the validity and effectivity of the theoretical formula. The affection of grinding parameters to grinding temperature is researched also.

Abstract: This paper deals with an application for achieving precision curve grinding by automatic dressing and compensation of diamond wheel wear through non-contact measuring method. A realtime vision measurement combined with vibration analysis method for the wear of a grinding wheel is presented. The wear condition is evaluated by analyzing the topography changes of the wheel surface and the vibration signals in the grinding process. A kind of PC-based integrated control system with dynamic monitoring and automatic dressing function is investigated, and the control algorithm is also proposed. The benefits of the proposed methods are confirmed by the grinding experiments. Dynamic monitoring of the wheel facilitates determining the optimum dressing amount and interval. A much higher abrasive machining precision and efficiency are attained by the real-time error measurement and compensation arrangement.

Abstract: Both diamond wheel and CBN wheel belong to super-abrasive wheels. Diamond wheels have superior grinding performance. The metal-bonded diamond wheel can grind hard brittle material component with a complicated shape precisely and efficiently. Because dielectric liquid is forbidden on numerical control optical profile grinder, the information on profile truing and dressing diamond wheel mounted on numerical control optical profile grinder is not readily available. In this paper, a novel truing and dressing method, namely dry electrical discharge (dry-ECD) assisted truing and dressing, is proposed. The experiments of dry-ECD assisted profile truing and dressing of diamond wheel are done by the authors. The experimental results show that both geometrical accuracy and surface topography of diamond wheel have attained technical requirement under appropriate truing and dressing conditions. There is not much difference in grinding abilities of new diamond wheel and dry-ECD assisted truing and dressing diamond wheel.

Abstract: Experimental study on the laser direct fabrication (LDF) of stainless steel powder is carried out. Microstructure and properties of the deposited components are analyzed and tested with optical microscopy (OM), scanning electron microscopy (SEM) and electron probe microanalysis (EPMA) etc. Cracking generation mechanisms of this material are investigated, corresponding cracking control strategies have been proposed. Finally, fully dense stainless steel components free of defects and with perfect comprehensive mechanical properties have been produced.