Abstract: A reasonable finite element (FE) model of grinding temperature field has been developed
on the basis of analysis of the transient temperature field， and three kinds of boundary conditions
are loaded on the element of a moving heat source. The study, which is based on the finite element
principle, has been carried out using the numerical simulation software ANSYS. Many results have
been obtained including three dimensional temperature distribution map. The simulated results
under different conditions show good agreement with the experimental results. With the comparison
of the dry-grinding and wet-grinding, the result shows that the wet-grinding temperature with a
proper grinding fluid is rather lower than the dry-grinding temperature. Finally, the variable
coefficient of convective heat transfer and the different form heat source have been discussed in
Abstract: Based on the concept of the interaction between a magnetic and electric field, a magnetic
field was suppressed on the Electrochemical Machining (ECM) setup to improve the copying
accuracy of ECM. Mathematical modeling and finite element modeling of the magnetic field was
also developed using ANSYS to study the influence of permanent magnet design on the ECM
process. The results indicate that by introducing the magnetic field the threshold of electrochemical
reaction is decreased and the tracks of ions become complicated which makes the chemical reaction
more extensive and more uniform in the inter-electrode gap. The distribution of magnetic field in
the gap helps to improve the machining accuracy and the process efficiency, when the permanent
magnet is at the end of the electrodes. Experiments have been carried out to validate the results of
finite element analysis and the effect of a magnetic field on the ECM process is discussed.
Abstract: This paper proposes an optimal interpolation approach to generate cutter paths in the
form of polar coordinate for machining noncircular contours. The cutter path obtained with the
approach consists of a series of Archimedes’ spiral segments and the number of segments is the
fewest under the condition that the interpolation error completely satisfies the specified limit value.
It can be also evidenced that the profile error of the machined contour due to the cutter path is
perfectly controlled within the specified interpolation accuracy limit. The result of applying the
approach to the contour machining of a disc cam sufficiently illustrates the effectiveness of the
Abstract: The application of an ultrasonic vibration is one of promising means in machining
micro-holes. In this study, the differences of in the geometric machining mechanism between the
ultrasonic and the conventional drilling were investigated. Specifically, the uncut chip thickness
before machining and the tool trajectories of the cutting edges were formulated and compared with
machining results. Through the machining experiments, it was found that those these parameters
well matched with the appearance of both the disposed chips and the machined surface.
Furthermore, the results indicated that the change of uncut chip thickness resulted in decreased
machining resistance as well as improvement of the machined surface
Abstract: In this work, a coupled thermo-mechanical plane-strain large deformation FE cutting
model is developed to simulate diamond turning based on the updated Lagrangian formulation. As
expected, the effects of friction coefficient on cutting forces, chip deformation, cutting temperature,
flow stresses and shearing angle are investigated by FE simulations. The simulated results can be
adopted as a reference to select the reasonable friction coefficient in diamond turning process.
Abstract: The method of single point diamond turning is used to machine KDP crystal. A
regression analysis is adopted to construct a prediction model for surface roughness and cutting
force, which realizes the purposes of pre-machining design, prediction and control of surface
roughness and cutting force. The prediction model is utilized to analyze the influences of feed,
cutting speed and depth of cut on the surface roughness and cutting force. And the optimal cutting
parameters of KDP crystal on such condition are acquired by optimum design. The optimum
estimated values of surface roughness and cutting force are 7.369nm and 0.15N, respectively .Using
the optimal cutting parameters, the surface roughness Ra, 7.927nm, and cutting force, 0.19N, are
Abstract: The mechanism of brittle-ductile transition (BDT) in machined Si single crystal is
investigated by simulating dislocations emission from crack tip along (111) and (111) slip plane
under mixed-mode loading. One kind of compression-shear crack is taken into account and the law
of strain-energy-density-factor is applied as fracture criteria. The total number of the emitted
dislocations and the number of dislocations in each slip plane at the onset of cleavage are calculated.
It is found that the ratio of stress intensity factor kII to kI that the crack tip is subjected has
significant effect on the BDT in machined Si single crystal. Then the results are applied to study the
action of negative rake angle and edge radius of diamond tool in the ultra-precision turning.
Abstract: A grinding wheel spindle with squeeze film damper—SFD is designed based on squeeze
film damping theory and relevant grinding experiments have been performed. Experimental results
indicate that the rationality of design for SFD can make the vibration of the grinding wheel spindle is
reduced by 25%. The precision of hole machining is improved by 20%. At the same time, work
efficiency of the grinder can be raised about 15%. So it has very important research value and wide
application prospect in the field of machining.
Abstract: The HSK spindle/toolholder interface belongs to the complicated nonlinear contact
problem caused by taper interference fit. The experiment and the traditional Lame's equation are all
not suited for analyzing the contact stress distribution and deformation in the spindle/toolholder
interface. In this paper, the contact stress distribution and the deformation of the HSK-A63
spindle/toolholder interface caused by the taper interference fit were precisely simulated by means
of the finite element method. The simulated results showed that the toolholder shank was in partial
contact with the spindle bore, the interference specified by ISO was not enough for the high-speed
machining and larger interference should be introduced.
Abstract: In this paper, a coupled thermo-mechanical FE model is proposed to simulate the cutting
temperature’s distribution produced in diamond turning. Simulated results indicate that the heat
converting from plastic work has prominent effects on the distribution shape of cutting temperature
field, and with an increment in cutting velocity, the locating site of maximal cutting temperature
shifts from the contact area between tool tip and chip root to the contact area between rake face and
chip. Cutting edge radius has minute influence on the distribution shape of cutting temperature field,
but the bigger the cutting edge radius is, the higher the maximum cutting temperature in cutting
region. Rake angle also has slight effects on the maximal temperature when it is more than 10○.
While clearance angle reaches to 6○, the maximum cutting temperature approaches the smallest.