Papers by Author: Dong Hui Wen

Abstract: The milling vibration affects machined surface quality and the size of the error, and has an important impact on the machining accuracy. This paper studies the different cutting parameters on cutting conditions on milling vibration during ball end milling Cr12MoV hardened steel assembled with different hardness steels, and use LMS. Test. Lab software to analyze the vibration signal on the condition of different spindle speed milling direction, axial depth of cut, and the vibration signal of transitional zone and the non-transitional zone are compared, providing the basis for a reasonable choice of milling parameters.

Abstract: A new tool path generation method based on Z-buffer method is proposed for free-form surface machining by using ball-end cutters. Firstly, to avoid ball-end mill cutting the workpiece, we make the cutter shaft which is perpendicular to machining surface tilt angle θ, then determine the examining area and then judge there is or not a interference occurring between ball-end mill and examining area, if there is, then make a adjustment for cutter shaft. The discretized points within the examining area are efficiently read in and stored directly by the computer hardware; no extra searching and iterative methods are needed. Simulation results show that, comparing with the traditional algorithm, the tool-position calculation time is shorter, and the phenomenon of workpiece squeezed and scratched is less in this algorithm. It meets the basic needs of five axis machining accuracy. Finally we make a practical machining experiment for cutter location generated.

Abstract: A half of covering angle processing method is proposed for optimizing process efficiency and quality with ball-end tool axis tilt. Firstly, according to the features of ball-end tool structural, this paper introduced traditional no-tilt processing problems, such as tool fast wear and poor processing quality, and then verified the effect of tool tilt processing by analyzing and comparing cutting quality with the differences of the no-tilt processing and tilt processing. Finally, it introduced two optimization methods about tool tilt processing, and also made a comparison with its feature. The results show that traditional processing brings about more extrusion and scratches, while little and high efficiency with method of tool tilt processing. Conclusion: it not only brings higher processing quality and efficiency, but also can make the ball-end cutter be longevity of service.

Abstract: Vibrations in polishing machinery may affect the manual or automatic controls and reduce the efficiency of the operations to be carried out. In this article, an experimental and numerical analysis on the dynamic characteristic of a gearbox casing in polishing machinery have been carried out. The numerical investigation was achieved with NASTRAN based on a 3D FEM model and the experimental modal analysis for the determination of the natural frequencies and the associated eigenmodes of the gearbox casing with LMS structural vibration test system was performed. The fundamental modal parameters including the first 10-order natural frequencies, damping ratios and mode shapes were estimated and identified. Analytical and experimental results have been compared and discussed. Agreement between measurements and calculations is satisfactory and the results can be used as reliable reference for improving the dynamic behavior of the gearbox casing.

Abstract: To obtain high surface quality and high finishing efficiency in machining SUS440 stainless steel, a novel machining technology employing a semi-fixed abrasive plate (SFAP) is adopted. The SFAP is developed for preventing lapped surface from damage caused by larger particles (from grain size dispersion or from outside of processing area, larger particles could bring uneven load distribution on processing region). The effects of different parameters on the surface quality and the material removal rate (MRR) of SUS440 stainless steel which is lapped by SFAP are investigated in this paper. The control parameters of the lapping process include the lapping time, the load, the rotating speed of the lapping plate, and etc. SFAP of 800# SiC abrasive used, Experimental results indicate that SFAP can avoid the large scratch effectively and the surface roughness (Ra) of the workpiece could be improved from 250 nm to 50 nm in 12 Min. A nearly mirror-like surface can be obtained.

Abstract: The most typical example of hard and brittle material is advanced ceramics, for its ultra-precision machining difficulty and wide applications, now it becomes a focus of attention. Semi-fixed abrasive plate (SFAP) is newly developed tool for machining advanced ceramics; As a result of SFAP abrasion, a gradual change takes place in the SFAP topography to influence on machining results and productivity. The paper shows experiment procedures to evaluate SFAP abrasion rate and workpiece material removal. The results of experiments are discussed and analyzed, it indicates that wet status of SFAP have great influences on the removal rate and SFAP abrasion. Compared with dry status of SFAP, wet status of SFAP can achieve higher processing efficiency.