Papers by Keyword: Spherical Surface

Abstract: In view of the fact that the endo-prosthesis heads of human hip-joint are operated in extreme conditions, in respect of load, the selection of corresponding material and also increase of precision and quality of machining of spherical surfaces is rather topical task.In the submitted work are reviewed the problems connected with definition of the influence degree of orientation of the sapphire crystal on its workability during diamond grinding with a butt of the ring and elaboration of the perspective, original scheme of formation of the incomplete spherical surface, particularly, of the sapphire head of endo-prosthesis of the human hip-joint.

Abstract: In this paper, cutting mechanism and cutting performance of ball end mill for spherical surface with contour path method is investigated. Ball end mills are used to produce molds, dies and so on. However, the edge shape is complex, so cutting process is not clear. Then, it is not clear effectively using method of the tool based on good cutting performance. Therefore, in this study, the purpose is proposal of high efficient and high accurate cutting method is using 5-axis control machine tool. At first, cutting model assembled by a ball end mill (R8 mm) and a workpiece with convex or concave spherical surface (Workpiece radius 20 mm) is carried out using 3D-CAD (SolidWorks). The pick feed direction which is from bottom to top is defined “Stepped up”, the one which is inverse direction is defined “Stepped down”. In addition, both cutting methods include up milling and down milling, then there are four cutting modes. The radius of tool path for contour path are varied from 14.0 mm to 19.4 mm for convex spherical surface, from 6.5 to 9.2 mm for concave spherical surface. The lead angle of the tool is defined the plus sign when the tool is inclined to the tool feed direction and varied from-45° to 45°. Secondly, the cutting cross-sectional area is calculated by the interference of a rake surface of the tool and an uncut chip volume which can be removed by one cutting operation. Thirdly, cutting experiments are done in order to measure cutting force. Finally, analytical and experimental results are discussed, and then the cutting conditions which are expected good cutting performance are considered.

Abstract: Oil pocket has been reported that it may improve tribology characteristic and thus prolong the lifespan of the joint. In order to implement it on spherical surface, appropriate positioning system is required. This paper reports the investigation of three axes workpiece positioning system in order to machine oil pocket (micro-pits) on hip implant. A conventional linear x-y-z axes configuration (Cartesian coordinate) and two configuration of spherical coordinate (swing-swing and swing-rotate configuration) are applied in simulation. All machined workpiece are investigated in pits distribution, shape, and machined angle. The inspection concludes that spherical method with swing-rotate configuration is the most suitable method for machining oil pocket on spherical surface.

Abstract: The scale of influence of the single crystal sapphire crystallographic plane orientation and grinding conditions on the material removal rate, surface finish and the state of sub-surface layer have been studied under Low-Temperature Precision Grinding (LPG). The schemes of forming partial spherical heads for human hip joints endoprostheses are considered and elaborated. The possible versions of forming the spherical heads of endoprosthesis based on the novelties in kinematics and the mode of material removal are discussed.

Abstract: Through establishing the mathematical models of velocity and grinding force to optimize the installation angle with inclined axis grinding technology, the spherical surface of the ultra-hard alloy material was ground by formed electroplated diamond wheel. After analyzing the abrasion of grinding wheel, the results show that the inclined axis grinding technology of the formed grinding wheel can avoid the rotation dead spots of grinding wheel, and can make the grinding wheel surface contacted with work-piece fully which could make the worn more evenly. Finally, it obtains a surface in a high quality with the surface roughness of Ra is 12.88nm, and the form accuracy of PV is 124nm.

Abstract: As the consumer market in the optics, electronics and aerospace industries grows, the profile accuracy demand for ultra-precision flat, spherical and aspheric optical surface micro-lens increases. Previous studies have found that machine system accuracy, tool alignment error and tool radius measurement error impact greatly on the profile accuracy of the machined surface. In this paper, we developed a grinding system based on the ultra-precision diamond lathe, presented a unified mathematical model of effects of all the geometric errors to the shape error by using the multi-body system theory. Aiming at the main source of profile error, the practical mathematical model is derived, and their propagation coefficients to profile error are calculated. By means of simulation analysis and grinding experiments of spherical part of tugnsten carbide, we conclude that the radial tool alignment error is the main influencing factor for the profile error of spherical surface; while tool radius measurement error influence the radius of sphere only.

Abstract: This paper is a comprehensive analysis about circular saws exerted the inertia stresses, thermal stresses and residual stresses inducted roll and hammer tensioning in working procedures. And analyze the weaknesses and the advantages of two methods of roll tensioning and hammer tensioning. In order to take advantages to compensate the weaknesses to bring forward a new tensioning method compressed many areas i.e. the tensioning spots compressed by using the roll-head whose surface is spherical, cylindrical or cone. The X-ray stress-checking instrument is used to test the residual stresses in the tensioned circular sawblades compressed on many spots. The result explains the stress distribution curve is very ideal and the residual stresses by tensioning almost offset the total inertia and thermal stresses inducted in the work. This explains it is a new circular tensioning method with developing value by compressing many spots. It exists in certain residual stresses on the rim of the sawblade’s central bore, outside and the areas near the slot bore because of the influence of the machine processes.

Abstract: This paper establishes an analytical solution for describing the trajectories of abrasives in polishing spherical surfaces when the motions of the tool and workpiece involve three independent angular velocities. As an example of its applications, the solution is used to show the effect of angular velocities on the trajectory coverage uniformity on a spherical surface – a key aspect for the control of a uniform material removal in a polishing operation. This solution provides a theoretical tool for the parameter selection of such machining processes.

Abstract: This paper presents the results of a series of experiments performed to examine the validity of a theoretical analysis for evaluation of machining error in ball end milling of spherical surface. In the analysis, the trochoidal paths of cutting edges are considered in the evaluation of chip geometry. The cutting forces are evaluated based on the theory of oblique cutting. The machining errors resulting from cutting force induced tool deflections are calculated at various parts of the machined surface. The experiments are carried out at various cutting conditions for convex spherical surface, and the influences of cutting mode and milling position angle on machining error are examined.