Adaptive hydrostatic thrust bearing represents a mechatronic answer to the fast-growing industrial needs of high-performance rotary machineries. The aim of this research is to study the influencing factors of the temperature field characteristics of the adaptive hydrostatic thrust bearing, such as rotational speed, load, viscosity, and inlet flow rate. The temperature rise equation of the micro-gap oil film is derived, and a three-dimensional model of micro-gap oil film is established. Finite Volume Method and ANSYS FLUENT are used to explore the influence factors of the temperature rise of the micro-gap oil film based on the principle of Computational Fluid Dynamic. The results show that temperature rise on the downstream side of the oil cavity is higher than that on the countercurrent side, and the temperature rise on the edge of the outer oil sealing edge is higher than that on the inner oil sealing edge. The rotational speed has the greatest impact on the oil film temperature rise, followed by viscosity, inlet flow rate, and then load. The increment of oil film temperature rise with the load less than 16 t is higher than the increment of oil film temperature rise with the load greater than 16 t. When the rotational speed is lower than 80 rpm, the temperature rise of the oil film increases faster with the increase of the rotational speed than when the rotation speed is above 80 rpm. The inlet flow rate increases, the maximum temperature and average temperature rise of the oil film decreases, but there is little variation. The maximum temperature and average temperature rise increase with the increase of viscosity, and the greater the viscosity, the more obvious nonlinear.
{"title":"Research on influencing factors of oil film temperature field characteristics for adaptive hydrostatic thrust bearing","authors":"Xiaodong Yu, Fan Sun, Defan Zhou, Dianbin Huang, Shiwei Zhan, Fei Han, Jianhua Jiao, Hui Jiang","doi":"10.1177/09544054231213678","DOIUrl":"https://doi.org/10.1177/09544054231213678","url":null,"abstract":"Adaptive hydrostatic thrust bearing represents a mechatronic answer to the fast-growing industrial needs of high-performance rotary machineries. The aim of this research is to study the influencing factors of the temperature field characteristics of the adaptive hydrostatic thrust bearing, such as rotational speed, load, viscosity, and inlet flow rate. The temperature rise equation of the micro-gap oil film is derived, and a three-dimensional model of micro-gap oil film is established. Finite Volume Method and ANSYS FLUENT are used to explore the influence factors of the temperature rise of the micro-gap oil film based on the principle of Computational Fluid Dynamic. The results show that temperature rise on the downstream side of the oil cavity is higher than that on the countercurrent side, and the temperature rise on the edge of the outer oil sealing edge is higher than that on the inner oil sealing edge. The rotational speed has the greatest impact on the oil film temperature rise, followed by viscosity, inlet flow rate, and then load. The increment of oil film temperature rise with the load less than 16 t is higher than the increment of oil film temperature rise with the load greater than 16 t. When the rotational speed is lower than 80 rpm, the temperature rise of the oil film increases faster with the increase of the rotational speed than when the rotation speed is above 80 rpm. The inlet flow rate increases, the maximum temperature and average temperature rise of the oil film decreases, but there is little variation. The maximum temperature and average temperature rise increase with the increase of viscosity, and the greater the viscosity, the more obvious nonlinear.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"39 6","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138589037","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-12-08DOI: 10.1177/09544054231210916
H. M. Yehia, Omayma A Elkady, Abdel-Hady A El-Geassy, Tamer Abd-elmotaleb, Mohamed Bahlol, Abdullah Kamal
In this research, a new nano-open porous copper without using a pore-forming agent was innovated. Five copper samples which are pure copper, Cu/2.5%Al2O3, Cu/2.5(Al2O3-GNs)Ag, Cu/5(Al2O3-GNs)2.5Ag, and Cu/7.5(Al2O3-GNs)2.5Ag were prepared using the electroless coating process. The samples were characterized by studying their chemical composition, microstructure, total pore area, bulk density, apparent density, and porosity percent. Also, the hardness and corrosion rate were studied. The SEM emphasized the formation of open pores with homogeneous distribution. Agglomeration of the new hybrid (Al2O3/GNs) was observed at 7.5%. The porosity percent and total pore area were increased gradually by adding 2.5%Al2O3 and different ratios of the new hybrid. The 7.5% (Al2O3-GNs) sample recorded the highest porosity percentage 32.86%. The sample 7.5% (Al2O3-GNs) exhibits the highest incremental pore volume in the micro-pore regions. The 5% (Al2O3-GNs) sample recorded the highest cumulative pore volume in the nanopore diameter region. The hybrid reinforcement (Al2O3/GNs) achieved hardness better than the single reinforcement (Al2O3). The hardness decreased gradually due to increasing the porosity percent and forming some agglomerations of the (Al2O3/GNs)Ag at 7.5%. The Cu/2.5(Al2O3/GNs)Ag sample recorded the lowest corrosion rate of 3.31 mm/year.
{"title":"An innovative nano-porous copper composite without using a pore-forming agent","authors":"H. M. Yehia, Omayma A Elkady, Abdel-Hady A El-Geassy, Tamer Abd-elmotaleb, Mohamed Bahlol, Abdullah Kamal","doi":"10.1177/09544054231210916","DOIUrl":"https://doi.org/10.1177/09544054231210916","url":null,"abstract":"In this research, a new nano-open porous copper without using a pore-forming agent was innovated. Five copper samples which are pure copper, Cu/2.5%Al2O3, Cu/2.5(Al2O3-GNs)Ag, Cu/5(Al2O3-GNs)2.5Ag, and Cu/7.5(Al2O3-GNs)2.5Ag were prepared using the electroless coating process. The samples were characterized by studying their chemical composition, microstructure, total pore area, bulk density, apparent density, and porosity percent. Also, the hardness and corrosion rate were studied. The SEM emphasized the formation of open pores with homogeneous distribution. Agglomeration of the new hybrid (Al2O3/GNs) was observed at 7.5%. The porosity percent and total pore area were increased gradually by adding 2.5%Al2O3 and different ratios of the new hybrid. The 7.5% (Al2O3-GNs) sample recorded the highest porosity percentage 32.86%. The sample 7.5% (Al2O3-GNs) exhibits the highest incremental pore volume in the micro-pore regions. The 5% (Al2O3-GNs) sample recorded the highest cumulative pore volume in the nanopore diameter region. The hybrid reinforcement (Al2O3/GNs) achieved hardness better than the single reinforcement (Al2O3). The hardness decreased gradually due to increasing the porosity percent and forming some agglomerations of the (Al2O3/GNs)Ag at 7.5%. The Cu/2.5(Al2O3/GNs)Ag sample recorded the lowest corrosion rate of 3.31 mm/year.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"30 11","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138589157","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-12-08DOI: 10.1177/09544054231210023
Jianhui Zhu, Hang Gao, Yuchun Xu, Yanjun Zhao, Ningchang Wang, Chaoyu Shi
In the pursuit of achieving exceptional surface shape accuracy for MPCVD (Microwave Plasma Chemical Vapor Deposition) polycrystalline diamond wafers during the free abrasive lapping process, plane lapping based on rotary swing drive was employed in this study. The crux of this study lay in the development of a comprehensive kinematic model, scrutinizing the motion behavior of abrasive particles, and probing the influence of parameters on the uniformity of abrasive trajectories. The results show that the eccentricity, arc chord length and speed ratio affect the probability of track coincidence rate, and then affect the distribution uniformity. And then the verification experiments solidifying the reliability of our kinematic model and affirming the veracity of simulation results. The best surface shape accuracy ( PV) of the MPCVD polycrystalline diamond wafer was 2.3 μm under optimal parameters, representing a substantial advancement compared to the original lapping method, which only yielded a PV value of 8.4 μm. This study provides a promising method for high surface shape accuracy of MPCVD polycrystalline diamond wafers with large sizes.
{"title":"Simulation and experimental research on the abrasive trajectories of plane lapping based on rotary swing drive","authors":"Jianhui Zhu, Hang Gao, Yuchun Xu, Yanjun Zhao, Ningchang Wang, Chaoyu Shi","doi":"10.1177/09544054231210023","DOIUrl":"https://doi.org/10.1177/09544054231210023","url":null,"abstract":"In the pursuit of achieving exceptional surface shape accuracy for MPCVD (Microwave Plasma Chemical Vapor Deposition) polycrystalline diamond wafers during the free abrasive lapping process, plane lapping based on rotary swing drive was employed in this study. The crux of this study lay in the development of a comprehensive kinematic model, scrutinizing the motion behavior of abrasive particles, and probing the influence of parameters on the uniformity of abrasive trajectories. The results show that the eccentricity, arc chord length and speed ratio affect the probability of track coincidence rate, and then affect the distribution uniformity. And then the verification experiments solidifying the reliability of our kinematic model and affirming the veracity of simulation results. The best surface shape accuracy ( PV) of the MPCVD polycrystalline diamond wafer was 2.3 μm under optimal parameters, representing a substantial advancement compared to the original lapping method, which only yielded a PV value of 8.4 μm. This study provides a promising method for high surface shape accuracy of MPCVD polycrystalline diamond wafers with large sizes.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"59 28","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138587915","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-25DOI: 10.1177/09544054231206589
Bo Qin, Yongqing Wang, Kuo Liu, Shi Qiao, Mengmeng Niu, Yeming Jiang
Advancements in artificial intelligence have significantly improved the monitoring of tool wear in machining processes, thereby enhancing the overall quality of machining. However, the scarcity of tool wear samples poses a challenge to the enhancement of model precision. This necessitates the exploration of monitoring techniques that are effective even with small sample sizes. A method involving a triplet long short-term memory (LSTM) neural network is introduced, which offers the potential for superior accuracy even with limited training data. During the machining process, spindle vibrations are captured using a triaxial accelerometer. The raw data is processed by a triplet network, which uses an LSTM as the base model, thereby facilitating the aggregation within classes and separation between classes. A soft-max classification layer is subsequently integrated into the model, which enables the precise determination of tool wear states. The base model is optimized using a Genetic Algorithm to ensure model efficiency and accuracy before it is expanded into a triplet network. Experimental results from a vertical machining center confirm that the triplet LSTM network offers superior accuracy compared to a standard LSTM network, even when the sample size is small.
{"title":"A tool wear monitoring approach based on triplet long short-term memory neural networks","authors":"Bo Qin, Yongqing Wang, Kuo Liu, Shi Qiao, Mengmeng Niu, Yeming Jiang","doi":"10.1177/09544054231206589","DOIUrl":"https://doi.org/10.1177/09544054231206589","url":null,"abstract":"Advancements in artificial intelligence have significantly improved the monitoring of tool wear in machining processes, thereby enhancing the overall quality of machining. However, the scarcity of tool wear samples poses a challenge to the enhancement of model precision. This necessitates the exploration of monitoring techniques that are effective even with small sample sizes. A method involving a triplet long short-term memory (LSTM) neural network is introduced, which offers the potential for superior accuracy even with limited training data. During the machining process, spindle vibrations are captured using a triaxial accelerometer. The raw data is processed by a triplet network, which uses an LSTM as the base model, thereby facilitating the aggregation within classes and separation between classes. A soft-max classification layer is subsequently integrated into the model, which enables the precise determination of tool wear states. The base model is optimized using a Genetic Algorithm to ensure model efficiency and accuracy before it is expanded into a triplet network. Experimental results from a vertical machining center confirm that the triplet LSTM network offers superior accuracy compared to a standard LSTM network, even when the sample size is small.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"120 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-11-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139236557","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-25DOI: 10.1177/09544054231210014
Che-Hua Yang, Van Nguyen Le, M. Saravana Kumar
Higher Order Mode Cluster (HOMC) guided waves (GW) have recently been proposed for ultrasonic testing of plates and pipes. The incident wave through the plastic wedge generates the HOMC-GW. A propagated distance, namely the HOMC formation field, is necessary to create the wave signal. Unfortunately, the HOMC wave is unstable in the formation region, which needs a longer distance for stability. This research examines the effect of sample thickness on the HOMC generation process. ABAQUS CAE simulated the HOMC generation in various samples with different thicknesses, such as 6, 7, 10, 15, and 20 mm. The results show that HOMC stability was achieved at a shorter distance in the smaller sample (6 mm) compared to the larger sample (20 mm). Moreover, the ABAQUS-Explicit 2D-FEA model was used for notch detection in a mild steel sample based on the HOMC status. The result shows that the transducer’s strength decreases along the formation regions, and the reflected amplitude becomes more robust when it reaches the stable region. When it travels further, the amplitude gets weaker due to the reduction in its energy. The experimental study was conducted similarly to the 2D-FEA model to compare the simulation and experimental results. The empirical findings show good agreement with the simulation results throughout notch detection. The precise distance required for the HOMC wave to become stable was determined via this work, optimizing the selection and employment of single modes.
{"title":"Determination of optimal sample thickness and positions of transducer for the effective Higher Order Mode Cluster-guided wave generation","authors":"Che-Hua Yang, Van Nguyen Le, M. Saravana Kumar","doi":"10.1177/09544054231210014","DOIUrl":"https://doi.org/10.1177/09544054231210014","url":null,"abstract":"Higher Order Mode Cluster (HOMC) guided waves (GW) have recently been proposed for ultrasonic testing of plates and pipes. The incident wave through the plastic wedge generates the HOMC-GW. A propagated distance, namely the HOMC formation field, is necessary to create the wave signal. Unfortunately, the HOMC wave is unstable in the formation region, which needs a longer distance for stability. This research examines the effect of sample thickness on the HOMC generation process. ABAQUS CAE simulated the HOMC generation in various samples with different thicknesses, such as 6, 7, 10, 15, and 20 mm. The results show that HOMC stability was achieved at a shorter distance in the smaller sample (6 mm) compared to the larger sample (20 mm). Moreover, the ABAQUS-Explicit 2D-FEA model was used for notch detection in a mild steel sample based on the HOMC status. The result shows that the transducer’s strength decreases along the formation regions, and the reflected amplitude becomes more robust when it reaches the stable region. When it travels further, the amplitude gets weaker due to the reduction in its energy. The experimental study was conducted similarly to the 2D-FEA model to compare the simulation and experimental results. The empirical findings show good agreement with the simulation results throughout notch detection. The precise distance required for the HOMC wave to become stable was determined via this work, optimizing the selection and employment of single modes.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"95 31","pages":""},"PeriodicalIF":2.6,"publicationDate":"2023-11-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139238197","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-14DOI: 10.1177/09544054231209791
Yu Du, Tao Yang, Chang Liu, Sinan Liu
Thermoplastic carbon fiber reinforced polyetheretherkrtone (CF/PEEK) and thermoset carbon fiber reinforced epoxy (CF/epoxy) composites are being widely applied in aviation and aerospace fields for their excellent performance. To compare the drilling characteristics of two typical carbon fiber reinforced composites under varying feed speeds, drilling experiments were carried out using three different special drills involving twist, brad, and dagger drills. The drilling performance of CF/epoxy and CF/PEEK composites was analyzed in terms of chip morphology, drilling temperature, thrust force, delamination damage, and surface morphology. The results show that CF/PEEK composites produced continuous chips, so that CF/PEEK composites generated higher drilling temperature and thrust force than that of CF/epoxy composites. CF/epoxy composites showed larger delamination damage and poorer machined surface than CF/PEEK composite due to its poor interlaminar toughness. Burrs produced agglomeration and crimping at the hole edges of the CF/PEEK composites due to PEEK resin is softened by heat, matrix plastic deformation. Brad drill revealed fewer burrs and merely a tearing damage at the exit. Dagger drill showed more burrs. The hole wall damage is minimal for brad drill. The results provide guidance for drilling of high quality thermoset and thermoplastic composites.
{"title":"Toward understanding the drilling performance of thermoplastic CF/PEEK and thermoset CF/epoxy composites using special drills","authors":"Yu Du, Tao Yang, Chang Liu, Sinan Liu","doi":"10.1177/09544054231209791","DOIUrl":"https://doi.org/10.1177/09544054231209791","url":null,"abstract":"Thermoplastic carbon fiber reinforced polyetheretherkrtone (CF/PEEK) and thermoset carbon fiber reinforced epoxy (CF/epoxy) composites are being widely applied in aviation and aerospace fields for their excellent performance. To compare the drilling characteristics of two typical carbon fiber reinforced composites under varying feed speeds, drilling experiments were carried out using three different special drills involving twist, brad, and dagger drills. The drilling performance of CF/epoxy and CF/PEEK composites was analyzed in terms of chip morphology, drilling temperature, thrust force, delamination damage, and surface morphology. The results show that CF/PEEK composites produced continuous chips, so that CF/PEEK composites generated higher drilling temperature and thrust force than that of CF/epoxy composites. CF/epoxy composites showed larger delamination damage and poorer machined surface than CF/PEEK composite due to its poor interlaminar toughness. Burrs produced agglomeration and crimping at the hole edges of the CF/PEEK composites due to PEEK resin is softened by heat, matrix plastic deformation. Brad drill revealed fewer burrs and merely a tearing damage at the exit. Dagger drill showed more burrs. The hole wall damage is minimal for brad drill. The results provide guidance for drilling of high quality thermoset and thermoplastic composites.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"21 6","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134954053","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Glass-ceramic is difficult to be ultra precision machined due to its high hardness and brittleness. Laser-assisted fast tool servo machining (LAFTSM) of glass-ceramic optical free-form surface was carried out with tool wear as the characteristic value to study the machining quality of glass-ceramic. Orthogonal experiments on LAFTSM were conducted using the Taguchi method (TM). The range of tool wear reduction obtained by comparing laser-assisted machining (LAM) with fast tool servo (FTS) machining is 48.83%–64.12%. The order of contribution of each machining parameter obtained through variance analysis to the reduction of tool wear is: spindle speed > laser power > feed rate > piezoelectric frequency. The optimal combination of machining parameters that can minimize tool wear obtained through signal-to-noise ratio (S/N) analysis is: spindle speed 55 rpm, feed rate 0.01 mm/rev, piezoelectric frequency 8 Hz, laser power 75 W. Artificial neural network (ANN) and genetic algorithm (GA) were used to fit and optimize the machining parameters and experimental results in TM orthogonal experiments. The fitting values of ANN are highly consistent with the orthogonal experimental results. The optimal combination of machining parameters obtained after GA optimization analysis is: spindle speed 50 rpm, feed rate 0.015 mm/rev, piezoelectric frequency 4 Hz, laser power 75 W. Experiments were conducted using the optimal combination of machining parameters of TM and ANN, the results showed that ANN performs better than TM in predicting minimum tool wear and optimizing machining parameters. This study provides a reference for LAFTSM and the research methods of tool wear.
{"title":"Study on tool wear and optimization of machining parameters in laser-assisted fast tool servo machining of glass-ceramic","authors":"Mingxu Fan, Xiaoqin Zhou, Jinzhou Song, Shan Jiang, Ke Gao, Shunfa Chen","doi":"10.1177/09544054231209798","DOIUrl":"https://doi.org/10.1177/09544054231209798","url":null,"abstract":"Glass-ceramic is difficult to be ultra precision machined due to its high hardness and brittleness. Laser-assisted fast tool servo machining (LAFTSM) of glass-ceramic optical free-form surface was carried out with tool wear as the characteristic value to study the machining quality of glass-ceramic. Orthogonal experiments on LAFTSM were conducted using the Taguchi method (TM). The range of tool wear reduction obtained by comparing laser-assisted machining (LAM) with fast tool servo (FTS) machining is 48.83%–64.12%. The order of contribution of each machining parameter obtained through variance analysis to the reduction of tool wear is: spindle speed > laser power > feed rate > piezoelectric frequency. The optimal combination of machining parameters that can minimize tool wear obtained through signal-to-noise ratio (S/N) analysis is: spindle speed 55 rpm, feed rate 0.01 mm/rev, piezoelectric frequency 8 Hz, laser power 75 W. Artificial neural network (ANN) and genetic algorithm (GA) were used to fit and optimize the machining parameters and experimental results in TM orthogonal experiments. The fitting values of ANN are highly consistent with the orthogonal experimental results. The optimal combination of machining parameters obtained after GA optimization analysis is: spindle speed 50 rpm, feed rate 0.015 mm/rev, piezoelectric frequency 4 Hz, laser power 75 W. Experiments were conducted using the optimal combination of machining parameters of TM and ANN, the results showed that ANN performs better than TM in predicting minimum tool wear and optimizing machining parameters. This study provides a reference for LAFTSM and the research methods of tool wear.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"40 14","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134954250","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-14DOI: 10.1177/09544054231209786
Yang Li, Yinming Bai, Jingyao Tian, Huijie Zhang, Wanhua Zhao
As the core component of precision CNC machine tools, a lot of heat is generated from the internal heat source of electric spindles during operation, resulting in thermal deformation and thermal errors that affect machining accuracy. Thermal error compensation is an economical method for reducing thermal errors, through which the impact of thermal errors on machining accuracy can effectively decrease. Taking a high-speed electric spindle as the research object, the temperature measurement points are selected as its front and rear bearing seat, as well as some positions far from the heat source. The temperature changes at the front and rear bearing as well as in the environment are monitored, then the thermal errors are measured using a Lion spindle rotation accuracy instrument. The optimal training parameters of the gated recurrent unit (GRU) network are optimized utilizing the global optimization ability of a Harris Hawks optimizer (HHO). Finally, the thermal error prediction model of the GRU electric spindle optimized using the Harris Hawks optimizer (HHO-GRU) is established, based on which axial thermal error compensation experiments are conducted. The results show that using the HHO-GRU prediction model for compensation, the axial thermal errors of the electric spindle can be reduced by more than 80%, which can be controlled within 5 μm.
{"title":"Modeling and compensation of the axial thermal error of electric spindles based on HHO-GRU method","authors":"Yang Li, Yinming Bai, Jingyao Tian, Huijie Zhang, Wanhua Zhao","doi":"10.1177/09544054231209786","DOIUrl":"https://doi.org/10.1177/09544054231209786","url":null,"abstract":"As the core component of precision CNC machine tools, a lot of heat is generated from the internal heat source of electric spindles during operation, resulting in thermal deformation and thermal errors that affect machining accuracy. Thermal error compensation is an economical method for reducing thermal errors, through which the impact of thermal errors on machining accuracy can effectively decrease. Taking a high-speed electric spindle as the research object, the temperature measurement points are selected as its front and rear bearing seat, as well as some positions far from the heat source. The temperature changes at the front and rear bearing as well as in the environment are monitored, then the thermal errors are measured using a Lion spindle rotation accuracy instrument. The optimal training parameters of the gated recurrent unit (GRU) network are optimized utilizing the global optimization ability of a Harris Hawks optimizer (HHO). Finally, the thermal error prediction model of the GRU electric spindle optimized using the Harris Hawks optimizer (HHO-GRU) is established, based on which axial thermal error compensation experiments are conducted. The results show that using the HHO-GRU prediction model for compensation, the axial thermal errors of the electric spindle can be reduced by more than 80%, which can be controlled within 5 μm.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"28 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134954370","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-14DOI: 10.1177/09544054231210024
Ali Asgari, Mohammad Sedighi, Hassan Delavar
Machining of metal matrix composites (MMC) is a challenging process as they are difficult to cut and cutting tools get worn out in a short time. In this paper, the performance of two industrial carbide grades and a cubic boron nitride (CBN) tool are assessed when machining of AZ91/SiC composites. Mg-based composites with different volume fractions and particle sizes are machined at various cutting conditions to evaluate the tools wear resistance and finished surface. The surface of the worn-out tools and machined samples are analyzed by scanning electron microscope (SEM), energy-dispersive X-ray spectroscopy (EDS), and roughness tester. Results revealed that the tool wear increased for composites reinforced by smaller particles regardless of the tool type. Additionally, tool grade TH1000 resulted in longer tool life when machining of Mg-based composites compared to the CP500 grade so that at a cutting speed of 70 m/min and feed rate of 0.1 mm/rev, tool life improved nearly 250%. CBN tools showed the best performance when machining of Mg-based composites as tools became worn out after 255 s which is considerable compared to carbide tools. Also, the finished surface caused by cemented carbide CP500 indicated the worst quality.
{"title":"A comparative study on the machinability of Mg-based composites: Cemented carbide and cubic boron nitride tools performance","authors":"Ali Asgari, Mohammad Sedighi, Hassan Delavar","doi":"10.1177/09544054231210024","DOIUrl":"https://doi.org/10.1177/09544054231210024","url":null,"abstract":"Machining of metal matrix composites (MMC) is a challenging process as they are difficult to cut and cutting tools get worn out in a short time. In this paper, the performance of two industrial carbide grades and a cubic boron nitride (CBN) tool are assessed when machining of AZ91/SiC composites. Mg-based composites with different volume fractions and particle sizes are machined at various cutting conditions to evaluate the tools wear resistance and finished surface. The surface of the worn-out tools and machined samples are analyzed by scanning electron microscope (SEM), energy-dispersive X-ray spectroscopy (EDS), and roughness tester. Results revealed that the tool wear increased for composites reinforced by smaller particles regardless of the tool type. Additionally, tool grade TH1000 resulted in longer tool life when machining of Mg-based composites compared to the CP500 grade so that at a cutting speed of 70 m/min and feed rate of 0.1 mm/rev, tool life improved nearly 250%. CBN tools showed the best performance when machining of Mg-based composites as tools became worn out after 255 s which is considerable compared to carbide tools. Also, the finished surface caused by cemented carbide CP500 indicated the worst quality.","PeriodicalId":20663,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture","volume":"35 5","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134953792","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-13DOI: 10.1177/09544054231210018
Abhinav Arun Munghate, Shivraman Thapliyal
The bead profile in the activated tungsten inert gas welding process depends on process parameters and flux composition. Using a conventional statistical-based model, the correlation of these input parameters with the bead shape geometry is complex. Therefore, machine learning-based techniques were implemented to predict the bead shape geometry, that is, penetration (D), width (w), and D/w ratio in the A-TIG welding process of austenitic stainless steel. Random forest regression and classification models were implemented to predict bead shape geometry in the A-TIG welding process. Based on the results, classification-based modeling was appropriate for predicting the bead profile. In addition, the correlation of the process parameters and flux composition with the bead profile was established.
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