Grinding temperature and energy ratio coefficient in MQL grinding of high-temperature nickel-base alloy by using different vegetable oils as base oil

This paper presents the precision enhancement of five-axis machine tools according to differential motion matrix, including geometric error modeling, identification and compensation. Differential motion matrix describes the relationship between transforming differential changes of coordinate frames. Firstly, differential motion matrix of each axis relative to tool is established based on homogenous transformation matrix of tool relative to each axis. Secondly, the influences of errors of each axis on accuracy of tool are calculated with error vector of each axis. The sum of these influences is integration of error components of machine tool in coordinate system of tool. It endows the error modeling clear physical meaning. Moreover, integrated error components are transformed to coordinate frame of working table for integrated error transformation matrix of machine tools. Thirdly, constructed Jacobian is established using differential motion matrix of each axis without extra calculation to compensate the integrated error components of tool. It makes compensation easy and convenient with reuse of intermediate. Fourthly, six-circle method of ballbar is developed based on differential motion matrix to identify all ten error components of each rotary axis. Finally, the experiments are carried out on SmartCNC500 five-axis machine tool to testify the effectiveness of proposed accuracy enhancement with differential motion matrix.

Accuracy enhancement of five-axis machine tool based on differential motion matrix: Geometric error modeling, identification and compensation

Specific grinding energy and surface roughness of nanoparticle jet minimum quantity lubrication in grinding

Recent developments in grinding machines

This paper proposes a product of exponential (POE) model to integrate the geometric errors of multi-axis machine tools. Firstly, three twists are established to represent the six basic error components of each axis in an original way according to the geometric definition of the errors and twists. The three twists represent the basic errors in x, y, and z directions, respectively. One error POE model is established to integrate the three twists. This error POE formula is homogeneous and can express the geometric meaning of the basic errors, which is precise enough to improve the accuracy of the geometric error model. Secondly, squareness errors are taken into account using POE method to make the POE model of geometric errors more systematic. Two methods are proposed to obtain the POE models of squareness errors according to their geometric properties: The first method bases on the geometric definition of errors to obtain the twists directly; the other method uses the adjoint matrix through coordinate system transformation. Moreover, the topological structure of the machine tools is introduced into the POE method to make the POE model more reasonable and accurate. It can organize the obtained 14 twists and eight POE models of the three-axis machine tools. According to the order of these POE models multiplications, the integrated POE model of geometric errors is established. Finally, the experiments have been conducted on an MV-5A three-axis vertical machining center to verify the model. The results show that the integrated POE model is effective and precise enough. The error field of machine tool is obtained according to the error model, which is significant for the error prediction and compensation.

Product of exponential model for geometric error integration of multi-axis machine tools

Systematic Geometric Error Modeling for Workspace Volumetric Calibration of a 5-axis Turbine Blade Grinding Machine

Dual Drive Curve Tool Path Planning Method for 5-axis NC Machining of Sculptured Surfaces

The current research of the 5-axis tool positioning algorithm mainly focuses on searching the local optimal tool position without gouging and interference at a cutter contact(CC) point, while not considering the smoothness and continuity of a whole tool path. When the surface curvature varies significantly, a local abrupt change of tool paths will happen. The abrupt change has a great influence on surface machining quality. In order to keep generated tool paths smooth and continuous, a five-axis tool positioning algorithm based on smooth tool paths is presented. Firstly, the inclination angle, the tilt angle and offset distance of the tool at a CC point are used as design variables, and the machining strip width is used as an objective function, an optimization model of a local tool positioning algorithm is thus established. Then, a vector equation of tool path is derived by using the above optimization model. By analyzing the equation, the main factors affecting the tool path quality are obtained. Finally, a new tool position optimization model is established, and the detailed process of tool position optimization is also given. An experiment is conducted to machine an aircraft turbine blade by using the proposed algorithm on a 5-axis blade grinding machine, and the machined blade surface is measured with a coordinate measuring machine(CMM). Experimental and measured results show that the proposed algorithm can ensure tool paths are smooth and continuous, improve the tool path quality, avoid the local abrupt change of tool paths, and enhance machining quality and machining efficiency of sculptured surfaces.

Tool Positioning Algorithm Based on Smooth Tool Paths for 5-axis Machining of Sculptured Surfaces

The design of small wing structures is mainly to determine the form, distribution and dimension of wing spars and ribs, so as to assure the structural strength and stiffness. By the reasonable distribution and combination of organism structures and materials, biological skeletons can meet the need of multifunction of the organisms, thus providing inexhaustible inspiration for the structural bionic design of aircrafts. The leaf vein is in the shape of hollow ellipse tubes, and its size gradually reduces along the vein axis. The main structural features are slant, stagger and bifurcation in order to adapt to the different characteristics of stress distribution in different parts. On the foundation of analyzing the characteristics of small wing structural design, by virtue of the structure characteristic of the vein and by using the similar theories, the bionic type wings are designed. The finite element analysis(FEA) results show that the bionic type wing has higher structure efficiency than the prototype wing. Static strength and rigidity experiments on the conventional and bionic samples fabricated with selective laser sintering(SLS) process, are carried out. Compared to the prototype wing, the bionic type wing has less weight, stress and deformation, which proves the effectiveness of structural bionics design and the reliability of FEA.

Structural Bionics Design and Experimental Analysis for Small Wing

The Composites are difficult machining materials which widely used in aerospace industry due to their excellent mechanical properties. Tool wear and delamination are considered the major concern in manufacture the parts and assembly. The thrust force and torque affect the tool life and delamination mostly. This paper investigated the drilling force and torque of carbon fibred composite with carbide drilling tools brazed diamond. The experiments were carried out under air cooling cutting conditions and the regulation of the drilling force influenced by the feed rate and cutting speed was obtained. The exponential formula of drilling force and torque were obtained through regression analysis method.)

Study of thrust force and torque in drilling carbon fibre reinforced plastics(CFRP) using twist drill brazed diamond

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