Papers by Author: Zi Yang Cao

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Authors: Zi Yang Cao, Ning He, Liang Li
Abstract: In order to investigate the effects of cutting edge radius on micro/meso-scale cutting process, the current paper is concerned with a fundamental investigation of the contribution of cutting edge radius to cutting temperature, stress field and size effect by means of two-dimensional finite-element simulation for orthogonal cutting process. The results indicated that cutting edge radius has remarkable effects on cutting temperature and stress field, and the existence of cutting edge radius is one of the main reasons generating size effect. The cutting edge radius affects the micro/meso scale cutting process at smaller uncut chip thickness by altering the effective rake angle and enhancing the plowing effect, affecting the material deformation process, expanding and widening the plastic deformation zone, and causing higher energy dissipation due to increased tool-chip contact length.
631
Authors: Zi Yang Cao, Hua Li
Abstract: To create miniaturized components, a 3-axis micro-milling machine tool composed of linear motor stages, high-speed air-bearing spindle and motion control card DMC-1842 is developed in this paper. The CNC system of the parallel double CPU based on industrial control computer and Windows operating system is constructed. The application software of CNC system is exploited by modularized mind in C# programming language, reasonable human-computer interface is designed. Finally, in order to validate the performance of the micro-milling machine, the miniaturized parts are machined o by developed CNC system. Through these tests analysis, the hardware and software architecture of the CNC system is verified to meet the requirements of the micro-milling machine tool. Micro-milling process with developed micro-milling machine tool is proved to be feasible and applicable, and can fully satisfy the producing requires of miniaturized components.
1068
Authors: Zi Yang Cao, Hua Li
Abstract: Miniaturized components are increasingly in demand for various industries. Micro milling operations can fabricate miniaturized components with high relative accuracy. In micro milling process, the analysis of cutting force plays an important role in characterizing the machining process, as the tool wear and surface texture depending on the cutting force. In this paper, the orthogonal experiments under slot-milling and side-milling with typical micro three dimensional parts are done by the developed three-axis micro milling machine tool, and the micro milling force is measured and analyzed. In order to improve the processing efficiency and processing accuracy of micro milling process, the impact law of the spindle speed, axial cutting depth, feed per tooth and other parameters on cutting force is deeply studied, and the machining parameters is also optimized.
1074
Authors: Ou Xie, Yi Sheng Liu, Zi Yang Cao
Abstract: According to the design requirements of open CNC system,an open soft-CNC system design was proposed in this paper. The embedded microprocessor ARM and embedded operating systemμc/os-ii was used as the system development latform, introducing of hardware and software design ideas to complete the soft-CNC design and the software was packaged into components, simplified the system hardware architecture, improved the reliability, openness, and real-time of the system.
1172
Authors: Zi Yang Cao, Hua Li
Abstract: The milling characteristics experiments with typical micro three dimensional parts are done by the developed 3-axis micro-milling machine tool, and the micro burr formed in micro-milling process is observed and analyzed. Burr formation and its influence factors in micro-milling process are studied and general influencing rule of each factor to burr formation is summarized. Based on the results, the purpose to reduce the burr is achieved through choosing proper machining parameters and tool material.
612
Authors: Zi Yang Cao, Hua Li
Abstract: To improve the dynamic performance of developed micro-milling system, the servo parameters were adjusted and the PID values were optimized respectively by considering the different characteristics of the servo driver under the position, velocity and torque control modes. Then, the different effects of three control modes on the micro-milling system were comparatively analyzed by means of orthogonal test. A control mode with better dynamic performance was chosen properly for the micro-milling system. Given the acceleration of 30m/s2 and feed speed of 200mm/s, the positioning error of micro-milling system was less than 1μm.
23
Authors: Zhen Yin, Hua Li, Zi Yang Cao, Ou Xie, Yan Li
Abstract: A new ultrasonic elliptic vibrator design method was proposed, the ultrasonic elliptic vibration was achieved by the structural curve of the longitudinal and torsional vibrations. The model, harmonic and transient analyses of the new longitudinal-torsional composite ultrasonic elliptical vibrator were performed by using the software ANSYS, the prototype of the new vibrator was tested by using impedance analyzer and PSV-400 laser Doppler vibrometer, the correctness of the finite element simulation results and the feasibility of the new longitudinal-torsional composite ultrasonic elliptical vibrator design methods were verified.
79
Authors: Zhen Yin, Hua Li, Zi Yang Cao, Yu Can Fu
Abstract: Aiming at the deficiency of existing focused ultrasonic technology, a new high-power Spherical Shell Focused Ultrasonic Transducer (SSFUT) was designed. The SSFUT is composed of a sandwich piezoelectric ultrasonic transducer and a bending vibration spherical shell. Simulation on acoustic field of SSFUT was carried out. the acoustic field pressure distribution nephogram and the axial acoustic pressure curve of the SSFUT were obtained. The consistency of finite element simulation results and experimental results was verified by testing. The research provides a theoretical basis for implementation and application of the new focused ultrasonic technology.
281
Authors: Zi Yang Cao, Hua Li
Abstract: A coupled thermo-mechanical model is used to simulate two-dimensional orthogonal cutting process based on simulation model of micro-cutting. The temperature effect in micro-cutting process is studied deeply through FEM combined with micro-cutting experiments. The results indicate that cutting temperature decreases at the tool-chip interface with reduction in uncut chip thickness at high cutting speed and large uncut chip thickness. The temperature drop tends to have a hardening effect on the material strength, which in turn causes an increase in the specific cutting energy.
2077
Authors: Hua Li, Zi Yang Cao
Abstract: In this paper,the mechanical properties of the elliptic ultrasonic vibratioon cutting were proposed systemiticaly through thoretical analysis,the model of the average cutting force in the elliptic ultrasonic vibration cutting process was established. The performance of the the properties to the machining acurracy and the surface roughness was studied through experiment.
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