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| 1 | A review on machinability of carbon fiber reinforced polymer(CFRP)and glass fiber reinforced polymer(GFRP)composite materials显示文摘Fiber reinforced polymer(FRP) composite materials are heterogeneous and anisotropic materials that do not exhibit plastic deformation. They have been used in a wide range of contemporary applications particularly in space and aviation,automotive,maritime and manufacturing of sports equipment. Carbon fiber reinforced polymer(CFRP) and glass fiber reinforced polymer(GFRP) composite materials,among other fiber reinforced materials,have been increasingly replacing conventional materials with their excellent strength and low specific weight properties. Their manufacturability in varying combinations with customized strength properties,also their high fatigue,toughness and high temperature wear and oxidation resistance capabilities render these materials an excellent choice in engineering applications.In the present review study,a literature survey was conducted on the machinability properties and related approaches for CFRP and GFRP composite materials. As in the machining of all anisotropic and heterogeneous materials,failure mechanisms were also reported in the machining of CFRP and GFRP materials with both conventional and modern manufacturing methods and the results of these studies were obtained by use of variance analysis(ANOVA),artificial neural networks(ANN) model,fuzzy inference system(FIS),harmony search(HS) algorithm,genetic algorithm(GA),Taguchi's optimization technique,multi-criteria optimization,analytical modeling,stress analysis,finite elements method(FEM),data analysis,and linear regression technique. Failure mechanisms and surface quality is discussed with the help of optical and scanning electron microscopy,and profilometry. ANOVA,GA,FEM,etc. are used to analyze and generate predictive models. | Meltem Altin Karatas Hasan Gokkaya | 2018 | Defence Technology(防务技术)2018，14，4： | 31 |
| 2 | Analytical method for softness abrasive flow field based on discrete phase model显示文摘Aiming at the problem of difficult contact finishing for mini structural surface in course of mould manufacturing,a new no-tool precision machining method based on soft abrasive flow machining (SAFM) was proposed. It allocated restrained component near surface machined,constituted restrained abrasive flow passage,and made the surface become a segment of passage wall. It could control turbulence abrasive flow in restrained passage,realize micro cutting for passage wall,and utilize the irregular motion of abrasive flow to eliminate the mono-directional marks on machined surfaces,and the precision could reach the specular level. A two-phase dynamic model of abrasive flow oriented to SAFM combined with discrete phase model (DPM) was established,the law of two-phase flow motion and the related physical parameters was obtained by corresponding numerical simulation method,and the mechanism of precision machining in SAFM was discussed. Simulation results show that the abrasive flow machining process mainly appears as translation of ablating location with the influence by granular pressure,and as the variation of machining efficiency with the influence by near-wall particle velocity. Thus via control of the inlet velocity and its corresponding machining time,it is supposed to work out the machining process according to the machining requirements by using the Preston equation to seek the relationship among velocity,pressure and material removing rate. By tracking near-wall particles,it can be confirmed that the movement of near-wall abrasive particles is similar to stream-wise vortices. The cutting traces on workpiece surfaces assume disorderly arrangement,so the feasibility of the SAFM method can be reaffirmed. | JI ShiMing1,2, XIAO FengQing1,2 & TAN DaPeng1,2 1Key Laboratory of Special Purpose Equipment and Advanced Manufacturing Technology, (Zhejiang University of Technology), Ministry of Education, Hangzhou 310014, China 2Key Laboratory of Special Purpose Equipment and Advanced Manufacturing Technology of Zhejiang Province, Hangzhou 310014, China | 2010 | Science China(Technological Sciences)2010，53，10： | 28 |
| 3 | Third-order point contact approach for five-axis sculptured surface machining using non-ball-end tools (Ⅰ): Third-order approximation of tool envelope surface显示文摘In this paper, the geometric properties of a pair of line contact surfaces are investigated. Then, based on the observation that the cutter envelope surface contacts with the cutter surface and design surface along the characteristic curve and cutter contact (CC) path, respectively, a mathematical model describing the third-order approximation of the cutter envelope surface according to just one given cutter location (CL) is developed. It is shown that at the CC point both the normal curvature of the normal section of the cutter envelope surface and its derivative with respect to the arc length of the normal section can be determined by those of the cutter surface and design surface. This model characterizes the intrinsic relationship among the cutter surface, cutter envelope surface and design surface in the neighborhood of the CC point, and yields the mathematical foundation for optimally approximating the cutter envelope surface to the design surface by adjusting the cutter location. | ZHU LiMin1, DING Han2 & XIONG YouLun2 1 State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai 200240, China 2 State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China | 2010 | Science China(Technological Sciences)2010，53，7： | 25 |
| 4 | Machining of SiC ceramic matrix composites:A review显示文摘Continuous fiber reinforced SiC ceramic matrix composites(FRCMCs-SiC)are currently the preferred material for hot section components,safety–critical components and braking components(in the aerospace,energy,transportation)with high value,and have triggered the demand for machining.However,the high brittleness,anisotropy,and heterogeneity of materials bring great challenges to machining,due to high mechanical and thermal loads,severe tool wear,and poor machining quality.With the increasing demand of FRCMCs-SiC parts,high-quality and high-efficient machining has become a hot issue.This review paper provides a detailed literature survey on the machining of FRCMCs-SiC.The material removal mechanism,defect form,and interfacial mechanical properties of FRCMCs-SiC were summarized.The machining processes of FRCMCs-SiC were introduced,and their respective advantages and disadvantages were compared.Given the low machinability(high hardness,high brittleness,anisotropy,and heterogeneity)of FRCMCs-SiC,preliminary experiments have proved that ultrasonic-assisted machining and laser-assisted machining have shown unique advantages in reducing force and tool wear,improving machining quality and machining efficiency.The machined surface integrity was discussed,the influence of process parameters on the machined surface quality was analyzed,and the machining defects of FRCMCs-SiC were summarized.But for FRCMCs-SiC,the existing quantitative evaluation of the machined surface integrity was weak and unsystematic. | Qinglong AN Jie CHEN Weiwei MING Ming CHEN | 2021 | Chinese Journal of Aeronautics2021，34，4： | 21 |
| 5 | Mobile-robotic machining for large complex components:A review study显示文摘Even though the robotic machining has achieved great success in machining of small components, it lacks the competence to machine large complex components, such as wind turbine blade, train carriage, and aircraft wing. In order to cope with this issue,the mobile machining robot system, which consists of a robot arm integrated with a mobile platform, is proposed to achieve the large workspace and high dexterity, and thus has the potential to machine the large complex components. However, due to the limitation of motion accuracy and structural stiffness, the current mobile-robots are hard to satisfy the high precision requirement of machining tasks. In this paper, some historical mobile-robotic machining systems are reviewed firstly, followed by some key techniques related to structure optimization, dynamics of the machining process, localization, and control techniques, which are fundamental for the structural stiffness and motion accuracy of mobile-robots. Finally, the prospect of mobile-robotic machining and the open questions are addressed. | TAO Bo ZHAO XingWei DING Han | 2019 | Science China(Technological Sciences)2019，62，8： | 17 |
| 6 | Modification Design Method for an Enveloping Hourglass Worm Gear with Consideration of Machining and Misalignment Errors显示文摘The influences of machining and misalignment errors play a very critical role in the performance of the anti-backlash double-roller enveloping hourglass worm gear(ADEHWG).However,a corresponding efficient method for eliminating or reducing these errors on the tooth profile of the ADEHWG is seldom reported.The gear engagement equation and tooth profile equation for considering six different errors that could arise from the machining and gear misalignment are derived from the theories of differential geometry and gear meshing.Also,the tooth contact analysis(TCA) is used to systematically investigate the influence of the machining and misalignment errors on the contact curves and the tooth profile by means of numerical analysis and three-dimensional solid modeling.The research results show that vertical angular misalignment of the worm wheel(Δβ) has the strongest influences while the tooth angle error(Δα) has the weakest influences on the contact curves and the tooth profile.A novel efficient approach is proposed and used to minimize the effect of the errors in manufacturing by changing the radius of the grinding wheel and the approaching point of contact.The results from the TCA and the experiment demonstrate that this tooth profile design modification method can indeed reduce the machining and misalignment errors.This modification design method is helpful in understanding the manufacturing technology of the ADEHWG. | DENG Xingqiao WANG Jinge HORSTEMEYER Mark F | 2013 | Chinese Journal of Mechanical Engineering2013，26，5： | 16 |
| 7 | Laser machining of transparent brittle materials: from machining strategies to applications显示文摘Transparent brittle materials such as glass and sapphire are widely concerned and applied in consumer electronics, optoelectronic devices, etc. due to their excellent physical and chemical stability and good transparency. Growing research attention has been paid to developing novel methods for high-precision and high-quality machining of transparent brittle materials in the past few decades. Among the various techniques, laser machining has been proved to be an effective and flexible way to process all kinds of transparent brittle materials. In this review, a series of laser machining methods, e.g. laser full cutting, laser scribing, laser stealth dicing, laser filament, laser induced backside dry etching (LIBDE), and laser induced backside wet etching (LIBWE) are summarized. Additionally, applications of these techniques in micromachining, drilling and cutting, and patterning are introduced in detail. Current challenges and future prospects in this field are also discussed. | Xiaozhu Xie Caixia Zhou Xin Wei Wei Hu Qinglei Ren | 2019 | Opto-Electronic Advances2019，2，1： | 13 |
| 8 | Wholly smoothing cutter orientations for five-axis NC machining based on cutter contact point mesh显示文摘Cutting forces with respect to different cutter orientations are analyzed for five-axis NC machining of a ball-end cutter.A measure is then defined to quantify the effects of cutter orientation variation.According to the measure,a novel model and algorithm are proposed to wholly optimize cutter orientations based on a cutter contact(CC) point mesh.The method has two advantages.One is that the cutter orientation smoothnesses along the feed direction and pick-feed direction are both wholly optimized.The other is that only the accessibility cones of mesh points are required to compute and the computation efficiency is improved.These advantages are shown by simulating the machining efficiency,the stability of feed velocities and the smoothness of cutting force.A computational example and a cutting experiment are finally given to illustrate the validity of the proposed method. | BI QingZhen,WANG YuHan,ZHU LiMin & DING Han State Key Laboratory of Mechanical System and Vibration,School of Mechanical Engineering,Shanghai Jiaotong University,Shanghai 200240,China | 2010 | Science China(Technological Sciences)2010，53，5： | 12 |
| 9 | Magnetization of microorganism cells by sol-gel method显示文摘Microorganism cells could be used as templates during fabrication of magnetic or conductive microstructures in different standard shapes. In this paper, feasibility of magnetizing microorganism cells by sol-gel method, which is to coat cells of Spirulina (a type of natural micro-helical microorganism) with the ferrite (a kind of magnetic material), was discussed and investigated. Then the cell form, components and the phase structure were observed and analyzed using various tools including optical microscopy, scanning electron microscopy (SEM), energy dispersive X-ray detector (EDX), transmission electron microscopy (TEM), and X-ray diffraction analysis (XRD). Results showed that spirulina cells could be coated with ferrite after the sol-gel process, with the shape of natural helixes well kept, that the components of different sampling points on the surface layer were consistent and the thickness of layer was uniform, and that the type of the surface ferrite layer formed was cubic Fe3O4. It was also observed that there were nano-particles yielded in the cells and certain deposit on the walls between cells. The kinetics of the cell magnetization technology by sol-gel was also discussed. | CHEN Bo ZHAN TianZhuo LIAN ZhiYang ZHANG DeYuan | 2008 | Science China(Technological Sciences)2008，51，5： | 11 |
| 10 | Four-axis trochoidal toolpath planning for rough milling of aero-engine blisks显示文摘The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutter in the rough machining of a blisk channel, the trochoidal milling is a promising strategy since it can keep a small immersion angle in the rough milling process while maintaining the high machining efficiency. However, while toolpaths are being planned for the trochoidal milling process, the conventional methods are mainly for the planar machining area with fixed tool orientations, which cannot be used for complex channels where the multi-axis machining should be employed. To this end, this paper presents a four-axis trochoidal toolpath planning method with a ball-end cutter, and thus the blisk channel can be machined efficiently.For this to happen, the trochoidal paths are planned in the parametric domain and then mapped into the physical domain, with tool orientations controlled by the quaternion interpolation method to have smooth tool movement along the toolpaths. Both geometric simulation and physical milling experiments of the proposed method have convincingly demonstrated the validation of the proposed method. | Ming LUO Ce HAH Hafiz M.HAFEEZ | 2019 | Chinese Journal of Aeronautics2019，32，8： | 9 |
| 11 | Broaching Performance of Superalloy GH4169 Based on FEM显示文摘The nickel-based superalloy GH4169 is an important material for high temperature applications in the aerospace industry. However, due to its poor machinability, GH4169 is hard to be cut and generates saw-tooth chips during high speed machining, which could significantly affect the dynamic cutting force, cutting temperature fluctuation, tool life, and the surface integrity of the parts. In this paper, the saw-tooth chip formation mechanism of superalloy GH4169 was investigated by the elasto-viscoplastic finite element method (FEM). Using the finite element software of ABAQUS/Explicit, the deformation of the part during high speed machining was simulated. The effective plastic strain, the temperature field, the stress distribution, and the cutting force were analyzed to determine the influence of the cutting parameters on the saw-tooth chip formation. The study on broaching performance has great effect on selecting suitable machining parameters and improving tool life. | Xiangwei Kong Bin Li Zhibo Jin Wenran Geng. | 2011 | Journal of Materials Science & Technology2011，27，12： | 9 |
| 12 | Vibration suppression of thin-walled workpiece machining considering external damping properties based on magnetorheological fluids flexible fixture显示文摘Milling of the thin-walled workpiece in the aerospace industry is a critical process due to the high flexibility of the workpiece. In this paper, a flexible fixture based on the magnetorheological(MR) fluids is designed to investigate the regenerative chatter suppression during the machining.Based on the analysis of typical structural components in the aerospace industry, a general complex thin-walled workpiece with fixture and damping constraint can be equivalent as a rectangular cantilever beam. On the basis of the equivalent models, natural frequency and mode shape function of the thin-walled workpiece is obtained according to the Euler–Bernoulli beam assumptions. Then,the displacement response function of the bending vibration of the beam is represented by the product of all the mode shape function and the generalized coordinate. Furthermore, a dynamic equation of the workpiece-fixture system considering the external damping factor is proposed using the Lagrangian method in terms of all the mode shape function and the generalized coordinate, and the response of system under the dynamic cutting force is calculated to evaluate the stability of the milling process under damping control. Finally, the feasibility and effectiveness of the proposed approach are validated by the impact hammer experiments and several machining tests. | Ma Junjin Zhang Dinghua Wu Baohai Luo Ming Chen Bing | 2016 | Chinese Journal of Aeronautics2016，29，4： | 8 |
| 13 | Jerk-limited feedrate scheduling and optimization for five-axis machining using new piecewise linear programming approach显示文摘In this paper, a new computation method and an optimization algorithm are presented for feedrate scheduling of five-axis machining in compliance with both machine drive limits and process limits. Five-axis machine tool with its ability of controlling tool orientation to follow the sculptured surface contour has been widely used in modern manufacturing industry. Feedrate scheduling serving as a kernel of CNC control system plays a critical role to ensure the required machining accuracy and reliability for five-axis machining. Due to the nonlinear coupling effects of all involved drive axes and the saturation limit of servo motors, the feedrate scheduling for multi-axis machining has long been recognized and remains as a critical challenge for achieving five-axis machine tools’ full capacity and advantage. To solve the nonlinearity nature of the five-axis feedrate scheduling problems, a relaxation mathematical process is presented for relaxing both the drive motors’ physical limitations and the kinematic constraints of five-axis tool motions. Based on the primary optimization variable of feedrate, the presented method analytically linearizes the machining-related constraints, in terms of the machines’ axis velocities, axis accelerations and axis jerks. The nonlinear multi-constrained feedrate scheduling problem is transformed into a manageable linear programming problem. An optimization algorithm is presented to find the optimal feedrate scheduling solution for the five-axis machining problems. Both computer implementation and laboratorial experiment testing by actual machine cutting were conducted and presented in this paper. The experiment results demonstrate that the proposed method can effectively generate efficient feedrate scheduling for five-axis machining with constraints of the machine tool physical constraints and limits. Compared with other existing numerical methods, the proposed method is able to find an accurate analytical solution for the nonlinear constrained five-axis feedrate scheduling problems without compromising the efficiency of the machining processes. | SUN YuWen CHEN ManSen JIA JinJie LEE Yuan-Shin GUO DongMing | 2019 | Science China(Technological Sciences)2019，62，7： | 7 |
| 14 | Nanometer lapping technology at high speed显示文摘In floating lapping with solid abrasives, the workpiece is taken as an isolated body. The forces that act on it are analyzed. A differential equation about the forces that act on it is set up, so the forces that act on it and its motion rule are received. Combining it with known lapping tool motion, the relative motion rule between the lapping tool and workpiece is determined too. According to the relative motion, the distribution of abrasives density is designed reasonably, which makes the lapping tool wear uniformly, which, in turn, avoids redressing the lapping tool, saves abra-sives, and increases machining accuracy. Combining it with advantages in high speed lapping with solid abrasives, the low cost, high efficiency nanometer lapping at high speed is realized. | YANG JianDong TIAN ChunLin WANG ChangXing | 2007 | Science China(Technological Sciences)2007，50，1： | 6 |
| 15 | An Optimal Feed Interpolator Based on G^2 Continuous Bézier Curves for High-Speed Machining of Linear Tool Path显示文摘A numerical control (NC) tool path of digital CAD model is widely generated as a set of short line segments in machining. However, there are three shortcomings in the linear tool path, such as discontinuities of tangency and curvature, huge number of line segments, and short lengths of line segments. These disadvantages hinder the development of high speed machining. To smooth the linear tool path and improve machining efficiency of short line segments, this paper presents an optimal feed interpolator based on G^2 continuous Bézier curves for the linear tool path. First, the areas suitable for fitting are screened out based on the geometric characteristics of continuous short segments (CSSs). CSSs in every area are compressed and fitted into a G^2 Continuous Bézier curve by using the least square method. Then a series of cubic Bézier curves are generated. However, the junction between adjacent Bézier curves is only G^0 continuous. By adjusting the control points and inserting Bézier transition curves between adjacent Bézier curves, the G^2 continuous tool path is constructed. The fitting error is estimated by the second-order Taylor formula. Without iteration, the fitting algorithm can be implemented in real-time environment. Second, the optimal feed interpolator considering the comprehensive constraints (such as the chord error constraint, the maximum normal acceleration, servo capacity of each axis, etc.) is proposed. Simulation and experiment are conducted. The results shows that the proposed method can generate smooth path, decrease the amount of segments and reduce machining time for machining of linear tool path. The proposed research provides an effective method for high-speed machining of complex 2-D/3-D profiles described by short line segments. | Yongqiao Jin Sheng Zhao Yuhan Wang | 2019 | Chinese Journal of Mechanical Engineering2019，32，3： | 6 |
| 16 | Prediction of cutting forces in flank milling of parts with non-developable ruled surfaces显示文摘Predicting the cutting forces required for five-axis flank milling is a challenging task due to the difficulties involved in determining the Undeformed Chip Thickness(UCT) and CutterWorkpiece Engagement(CWE). To solve these problems, this paper presents a new mechanistic cutting force model based on the geometrical analysis of a flank milling process. In the model,the part feature and corresponding cutting location data are taken as input information. The UCT considering cutter runout is calculated according to the instantaneous feed rate of the element cutting edges. A solid-discrete-based method is used to precisely and efficiently identify the CWE between the end mill and the surface being machined. Then, after calibrating the specific force coef-ficients, the mechanistic milling force can be obtained. During the validation process, two practical operations, three-axis flank milling of a vertical surface and five-axis flank milling of a nondevelopable ruled surface, are conducted. Comparisons between predicted and measured cutting forces demonstrate the reliability of the proposed cutting force model. | Liping WANG Hao SI Liheng GU | 2019 | Chinese Journal of Aeronautics2019，32，7： | 6 |
| 17 | The principle of second generation wavelet for milling cutter breakage detection显示文摘Performance degradation or failure of manufacturing equipment will badly influence machining quality.Because of discontinuousness of the milling process,dynamic signals produced in the milling process become non-stationary.This paper indicates that the essence of SGW(second generation wavelet) transform in non-stationary signal processing is the mathematics principle of inner product transform of a dynamic signal with basis functions.Namely,by means of the inner product operation of a signal with basis functions containing scale function and wavelet function,signal decomposition and reconstruction are obtained.Acoustic emission signals generated in the milling processes of a CNC machine were analyzed by using the basis functions of SGW which are oscillation,decay and compact support.The features of end milling cutter breakage have been extracted,and the influences on machining surface quality have been identified effectively,which provide scientific bases for fault diagnosis,error tracing and quality control. | HE ZhengJia CAO HongRui LI Zhen ZI YanYang CHEN XueFeng | 2009 | Science China(Technological Sciences)2009，52，5： | 5 |
| 18 | 变截面异型螺旋型腔电解加工流场分析显示文摘针对闭式整体构件电解加工间隙流场分布不均匀的,基于电解加工间隙流场,设计了阴极过水孔工作端面,比较了不同背压条件下电解加工间隙流场,分析了间隙流场空穴、涡流现象.研究结果表明,通过改变过水孔分的疏密,孔径的大小和形状,增加背压,消除了间隙流场中低流速区域,电解液较低流速区域的速度由0.239 7m/s提升至0.508 5m/s,减少了空穴和涡流现象的发生,优化了阴极结构. | 范植坚 穆倩 李清良 范庆明 | 2014 | 西安工业大学学报2014，34，2： | 5 |
| 19 | Cathode design investigation based on iterative correction of predicted profile errors in electrochemical machining of compressor blades显示文摘Electrochemical machining(ECM) is an effective and economical manufacturing method for machining hard-to-cut metal materials that are often used in the aerospace field. Cathode design is very complicated in ECM and is a core problem influencing machining accuracy, especially for complex profiles such as compressor blades in aero engines. A new cathode design method based on iterative correction of predicted profile errors in blade ECM is proposed in this paper. A mathematical model is first built according to the ECM shaping law, and a simulation is then carried out using ANSYS software. A dynamic forming process is obtained and machining gap distributions at different stages are analyzed. Additionally, the simulation deviation between the prediction profile and model is improved by the new method through correcting the initial cathode profile. Furthermore, validation experiments are conducted using cathodes designed before and after the simulation correction. Machining accuracy for the optimal cathode is improved markedly compared with that for the initial cathode. The experimental results illustrate the suitability of the new method and that it can also be applied to other complex engine components such as diffusers. | Zhu Dong Liu Cheng Xu Zhengyang Liu Jia | 2016 | Chinese Journal of Aeronautics2016，29，4： | 5 |
| 20 | Data-Driven Anomaly Diagnosis for Machining Processes显示文摘To achieve zero-defect production during computer numerical control(CNC)machining processes,it is imperative to develop effective diagnosis systems to detect anomalies efficiently.However,due to the dynamic conditions of the machine and tooling during machining processes,the relevant diagnosis systems currently adopted in industries are incompetent.To address this issue,this paper presents a novel data-driven diagnosis system for anomalies.In this system,power data for condition monitoring are continuously collected during dynamic machining processes to support online diagnosis analysis.To facilitate the analysis,preprocessing mechanisms have been designed to de-noise,normalize,and align the monitored data.Important features are extracted from the monitored data and thresholds are defined to identify anomalies.Considering the dynamic conditions of the machine and tooling during machining processes,the thresholds used to identify anomalies can vary.Based on historical data,the values of thresholds are optimized using a fruit fly optimization(FFO)algorithm to achieve more accurate detection.Practical case studies were used to validate the system,thereby demonstrating the potential and effectiveness of the system for industrial applications. | Y.C.Liang S.Wang W.D.Li X.Lu | 2019 | Engineering2019，5，4： | 5 |
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