e-Engineering & Digital Enterprise Technology

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Authors: Ying Guang Li, T.L. Fang, S.J. Cheng, W.H. Liao
Abstract: Feature-based programming is one of tendency of NC programming technology, and it is also an important portion for CAD/CAPP/CAM integration in the manufacturing enterprises. Because of selecting geometry repeatedly, random programming and bad integration during programming for the aircraft NC parts, the technology of rapid programming based on features is put forward in this paper. On the basis of features, the technology of feature recognition for aircraft NC parts and the algorithm of tool path generation based on features are integrated by taking XML as data transfer standard. With this method, the programming for aircraft NC parts can be realized quickly in the condition of CAD/CAPP/CAM integration. The system developed has been well applied to the programming for aircraft NC parts in an aircraft corporation.
Authors: Zhong Qiu Wang, J. Sun, Jian Feng Li, I. Al-Zkeri
Abstract: Residual stress on the machined surface and the subsurface is one of the most important factors that can influence the service quality of a component, such as fatigue life, tribological properties, and distortion. In this work, a 2D FEM model of AISI 52100 hard turning processes is setup. The material properties are widely selected to describe the material property more precisely. By using user subroutine named Konti-Cut, the steady state of cutting process is simulated and the cutting forces and residual stresses in this time are investigated. By comparing the cutting forces, the FEM model can gives quite good appliance with experimental data. And the basic relations between residual stresses and cutting parameter, tool geometry are drawn.
Authors: Yue Qing Sun, Jian Zhong Zhou, Yi Bin Chen, Shu Huang
Abstract: Using Taguchi method to optimize the critical parameters of laser peening (LP) is presented firstly. The objective of the study is to assess the impact of laser parameters on the laser peen strengthening for the 6061-T6 aluminum alloy and optimize the process parameters to achieve higher surface residual compressive stress. In order to reduce the process cost and time, the finite element method was applied to simulate the LP process. The Taguchi method is used to formulate the experimental layout and establish the order of predominance among the identified critical parameters, and predict the optimal setting for each process parameter. The results show that three parameters related to the magnitude of compressive residual stress imply different effects. Laser shot diameter ranks first, followed by pulse width and laser power in terms of their effects on the magnitude of compressive residual stress. The best combination of levels is given by the levels (3, 3, 2). The optimal result was confirmed with a superior ultimate surface residual compressive stress of 125MP.
Authors: Hong Bo Lan, Yu Cheng Ding, Jun Hong, B.H. Lu
Abstract: This paper proposes a novel integrated modeling method based on cross-sectional imaging system which can implement the rapid and low-cost development for various engine cylinder bodies. The integrated modeling method which involves four steps: object pre-processing, cross-sectional image acquisition, CAD model reconstruction and redesign, is presented. Furthermore, an engine cylinder body was used to demonstrate the application of the integrated modeling method. The integrated modeling method proposed is characterized by simple process, short design cycle, and low-cost. It is particularly suitable for the 3D CAD modeling of an object with complex external and internal features. As a result, the method offers a good solution to implement the CAD modeling for a variety of complex objects with undercuts, hidden and internal features.
Authors: Sheng Wen Zhang, Chan Yuan Gong, Xi Feng Fang, Gui Cheng Wang
Abstract: The effect of cutting tool geometry on cutting process is very prominent and cannot be ignored, especially the interactions between tool geometries. In this study, the effects of the rake angle, the clearance angle, the cutting edge radius and the interaction between rake angle and clearance angle on cutting force and cutting temperature are numerically investigated using finite element method. Four-factor three-lever orthogonal experimental design is adopted in the finite element simulation of orthogonal cutting process. An analysis of range is performed to identify significant trends in the cutting force and cutting temperature and the optimal level values of each factor. The result shows that the effect of the rake angle on cutting force is significant. The effect of interaction between rake angle and clearance angle on cutting temperature also appeared to be important. Finally, the optimal parameter combinations of tool geometries for cutting force and cutting temperature are obtained, respectively.
Authors: N. Fan, Pei Quan Guo, Xian Chi, Z.H. Gao
Abstract: Cutting tool wear has relation with the cutting forces. By way of signal processing, the power spectrums of cutting forces in different tool wear stages are analyzed in the present paper. It is proved that several characteristic frequencies exist within a wide frequency range during the cutting process as long as cutting process parameters keep constant. The power value of the characteristic frequency increase with the increase of tool wear. Thus, the tool wear could be predicted by the changes of characteristic frequencies and their power values.
Authors: Yue Dong Lang, Ying Xue Yao, Ping Jun Xia
Abstract: Due to the worldwide competition of manufacturing industry and the development of virtual reality (VR) technology, virtual assembly (VA) has attracted many researchers to reduce development cost and improve product quality. As a typical application of VR in engineering, VA has become increasingly important for modern industry. In this paper, a survey of research progress about VA is analyzed. The conception and architecture of VA are introduced at first, the classification is also presented, then the main research contents and key techniques are discussed, finally the limitations and future works are pointed out.
Authors: Ri Liang Liu, Cheng Rui Zhang, Xian Zhi Zhang
Abstract: The emerging standard ISO 14649, informally known as STEP-NC, presents an opportunity to revolutionize computer numerical control (CNC) machine tools, which plays an ever-increasingly important role in modern manufacturing. This paper proposes a framework for the future CNC systems aimed to fit in a STEP-compliant manufacturing scenario. The proposed system (ST-CNC), which consists of five functional modules namely interpretation, micro-process planning, simulation, control and supervision, and in-process inspection modules, is designed as an intelligent system capable of both decision-making and machine control to support intelligent manufacturing and streamline the information flow in the process chain. Major technological issues such as part program interpretation, micro-process planning and toolpath calculation at the machine are also addressed, and a number of functional modules have been implemented along with the prototype development based on an open CNC kernel.
Authors: Li Zhang, Shi Ming Ji, Yi Xie, Qiao Ling Yuan, Yin Dong Zhang, Z.N. Yao
Abstract: The image of cutting tools provides reliable information regarding the extent of tool wear. In this paper, we propose the theory of image processing based on rough sets and mathematical morphology to analyzing the flank faces which are chosen as our monitoring object. First, through plotting the appropriate subset, the rough sets filter is used to enhancement the image of tool wear. Then, the mathematical morphology theory is applied to process the translated binary image. Finally, tool condition monitoring is realized by measuring the area of tool wear. This paper gives the corresponding monitoring principal and proposes a new algorithm to process the cutting tool image. The algorithm is also flexible and fast enough to be implemented in real time for online tool wear or tool condition monitoring.
Authors: Z.C. Du, P. Zhang, Jian Guo Yang, M.S. Hong
Abstract: The accuracy of spindle rotation is one of the most important precision indexes of CNC machine tools. And the spindle rotation induced error is one of the main influence factors of cutting accuracy. It will greatly affect the shape precision and surface roughness of workpiece. A new measurement method of the spindle radial rotation induced error is proposed using the cross grid encoder. The Spindle rotation induced error of machining center is analyzed in frequency domain and time-frequency domain separately to comparably study the measurement results by KGM 182 grid encoder and Double ball bar. The results indicate that the performance of the cross grid encoder test for measuring the CNC machine tool motion error is better than that of the Double ball bar, especially in the details of motion errors because of its unique characteristics. A wavelet packet algorithm is developed to analyze the singularity of signal. On machine measuring experiment has been carried out on a new Cincinnati 750 Arrow II vertical machining center. The measuring experiment result shows that the spindle radial rotation induced error of the machining center is about 0.6 μm and the cycle time is every rotation time.

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