Pub Date : 2024-10-01DOI: 10.1016/j.precisioneng.2024.09.022
Akshyn Biman-Telang , Philip Koshy , Daniel Schulze Brock , Ugur Küpper , Andreas Klink , Tim Herrig , Thomas Bergs
The widespread application of wire electrical discharge machining (WEDM) continues to be impeded by its low cutting rate, which in large part stems from constraints related to wire failure. This research therefore explored the implications of utilizing wires thicker than the industry-standard 0.25 mm diameter wire. Given that modern WEDM machines are limited to a maximum wire diameter of only 0.4 mm, a combination of numerical and experimental approaches was adopted to compute the optimal wire diameter in consideration of the competing influences of higher machining power and larger kerf width associated with thicker wires, and to project the corresponding cutting rates. The research offers new insights into phenomena underlying wire break, and underscores the significant prospects towards enhancing process performance by re-examining WEDM in terms of thick wires.
{"title":"Rethinking wire electrical discharge machining: A case for engineering thick wires to enhance performance","authors":"Akshyn Biman-Telang , Philip Koshy , Daniel Schulze Brock , Ugur Küpper , Andreas Klink , Tim Herrig , Thomas Bergs","doi":"10.1016/j.precisioneng.2024.09.022","DOIUrl":"10.1016/j.precisioneng.2024.09.022","url":null,"abstract":"<div><div>The widespread application of wire electrical discharge machining (WEDM) continues to be impeded by its low cutting rate, which in large part stems from constraints related to wire failure. This research therefore explored the implications of utilizing wires thicker than the industry-standard 0.25 mm diameter wire. Given that modern WEDM machines are limited to a maximum wire diameter of only 0.4 mm, a combination of numerical and experimental approaches was adopted to compute the optimal wire diameter in consideration of the competing influences of higher machining power and larger kerf width associated with thicker wires, and to project the corresponding cutting rates. The research offers new insights into phenomena underlying wire break, and underscores the significant prospects towards enhancing process performance by re-examining WEDM in terms of thick wires.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"91 ","pages":"Pages 383-389"},"PeriodicalIF":3.5,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417844","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Micro electrochemical machining (ECM) has the advantages of non-contact machining, no tool loss and no residual stress, and has great development potential in the field of microstructure manufacturing. However, the micron-scale machining gap is difficult to renew and discharge the electrolyte and electrolytic products in time. In this paper, a novel micro ECM with programmable dynamic eccentric rotating electrode (DER-ECM) is proposed, which can effectively improve the discharge of electrolytic products in the machining area. According to the process characteristics, a disc flexure hinge structure with one-stage amplification was designed, which was driven by a piezo-ceramic actuator, and the programmable eccentricity ranging from 0 to 20 μm. The multi-physics model of flow field and electric field of DER-ECM, micro ECM with eccentric rotating electrode (ER-ECM) and micro ECM with rotating electrode (R-ECM) were established. The theoretical simulation results showed that the flow rate generated by DER-ECM at the bottom of the electrode is 97 times that of ER-ECM. The current density generated by DER-ECM showed periodic pulsation, and the pulsation period was determined by the driving frequency of the piezo-ceramic actuator. The experimental results showed that DER-ECM could effectively eliminate the surface spike of the workpiece in the bottom machining area and effectively improve the machining accuracy. The micro-groove widths obtained under DER-ECM, ER-ECM and R-ECM were 418 μm, 446 μm and 468 μm, respectively. In addition, the influence of three types of dynamic eccentric rotation electrode trajectories on DER-ECM was studied. The experimental results showed that the sawtooth dynamic eccentric rotation electrode had better machining accuracy. Theoretical simulation and experimental results showed that DER-ECM could improve the flow field and achieve higher machining efficiency and machining localization.
{"title":"Study on micro electrochemical milling with programmable dynamic eccentric rotating electrode","authors":"Zhichao Li, Weiyu Zhou, Guixian Liu, Hongping Luo, Yongjun Zhang","doi":"10.1016/j.precisioneng.2024.09.024","DOIUrl":"10.1016/j.precisioneng.2024.09.024","url":null,"abstract":"<div><div>Micro electrochemical machining (ECM) has the advantages of non-contact machining, no tool loss and no residual stress, and has great development potential in the field of microstructure manufacturing. However, the micron-scale machining gap is difficult to renew and discharge the electrolyte and electrolytic products in time. In this paper, a novel micro ECM with programmable dynamic eccentric rotating electrode (DER-ECM) is proposed, which can effectively improve the discharge of electrolytic products in the machining area. According to the process characteristics, a disc flexure hinge structure with one-stage amplification was designed, which was driven by a piezo-ceramic actuator, and the programmable eccentricity ranging from 0 to 20 μm. The multi-physics model of flow field and electric field of DER-ECM, micro ECM with eccentric rotating electrode (ER-ECM) and micro ECM with rotating electrode (R-ECM) were established. The theoretical simulation results showed that the flow rate generated by DER-ECM at the bottom of the electrode is 97 times that of ER-ECM. The current density generated by DER-ECM showed periodic pulsation, and the pulsation period was determined by the driving frequency of the piezo-ceramic actuator. The experimental results showed that DER-ECM could effectively eliminate the surface spike of the workpiece in the bottom machining area and effectively improve the machining accuracy. The micro-groove widths obtained under DER-ECM, ER-ECM and R-ECM were 418 μm, 446 μm and 468 μm, respectively. In addition, the influence of three types of dynamic eccentric rotation electrode trajectories on DER-ECM was studied. The experimental results showed that the sawtooth dynamic eccentric rotation electrode had better machining accuracy. Theoretical simulation and experimental results showed that DER-ECM could improve the flow field and achieve higher machining efficiency and machining localization.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"91 ","pages":"Pages 300-320"},"PeriodicalIF":3.5,"publicationDate":"2024-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417838","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"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 : 2024-09-29DOI: 10.1016/j.precisioneng.2024.09.023
J.B. Li , J.Y. Tian , H.P. Su , C.X. Bian , Y.F. Xia , T.Y. Liu , X.J. Chen , P. Wang , D.Z. Li
The stiffness and contact stress of the bearing spindle system are the key factors affecting its machining accuracy and service life under the condition of high-speed service, which will be affected by different structural parameters and service conditions. It is essential to establish an efficient and accurate computational simulation model to understand the influence of complex factors on the nonlinear dynamic characteristics of the bearing spindle system. Firstly, in the paper, a 2D axisymmetric finite element model of the bearing, aims at the relationship between stiffness and contact stress of the bearing under high-speed service, has been built based on a classical dynamic analysis model and the reversed method of material parameters of equivalent rolling balls. Additionally, for the BT30 spindle, the 2D axisymmetric finite element model of the bearing spindle system also has been built and applied in mechanical analysis of spindle under different conditions of assembly and service, based on the bearing model. The results show that the axial force of bearings decreases as the rotational speed increases, and an augmentation in speed will result in a reduction in the axial stiffness of the BT30 spindle. In addition, the maximum contact stress exhibits a slight decline as the rotational speed increases. Furthermore, with an escalating preload, the stiffness and contact stress of the spindle undergo substantial increments, however, these parameters will cease to alter once a certain threshold is reached.
{"title":"Study on the 2D equivalent nonlinear dynamics simulation model related to high speed precision bearing and spindle","authors":"J.B. Li , J.Y. Tian , H.P. Su , C.X. Bian , Y.F. Xia , T.Y. Liu , X.J. Chen , P. Wang , D.Z. Li","doi":"10.1016/j.precisioneng.2024.09.023","DOIUrl":"10.1016/j.precisioneng.2024.09.023","url":null,"abstract":"<div><div>The stiffness and contact stress of the bearing spindle system are the key factors affecting its machining accuracy and service life under the condition of high-speed service, which will be affected by different structural parameters and service conditions. It is essential to establish an efficient and accurate computational simulation model to understand the influence of complex factors on the nonlinear dynamic characteristics of the bearing spindle system. Firstly, in the paper, a 2D axisymmetric finite element model of the bearing, aims at the relationship between stiffness and contact stress of the bearing under high-speed service, has been built based on a classical dynamic analysis model and the reversed method of material parameters of equivalent rolling balls. Additionally, for the BT30 spindle, the 2D axisymmetric finite element model of the bearing spindle system also has been built and applied in mechanical analysis of spindle under different conditions of assembly and service, based on the bearing model. The results show that the axial force of bearings decreases as the rotational speed increases, and an augmentation in speed will result in a reduction in the axial stiffness of the BT30 spindle. In addition, the maximum contact stress exhibits a slight decline as the rotational speed increases. Furthermore, with an escalating preload, the stiffness and contact stress of the spindle undergo substantial increments, however, these parameters will cease to alter once a certain threshold is reached.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"91 ","pages":"Pages 358-371"},"PeriodicalIF":3.5,"publicationDate":"2024-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417842","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"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 : 2024-09-26DOI: 10.1016/j.precisioneng.2024.09.021
Yanjun Lu , Mingrong Guo , Yongqi Dai , Qiang Wang , Hu Luo , Yongbo Wu
Quartz glass is extensively utilized in the aviation and biomedical fields. However, achieving high-quality ultrafine micro-holes on quartz glass is difficult because edge chipping and internal surface defects are prone to occur during processing. Therefore, the ultrasonic vibration-assisted grinding (UVAG) was proposed to realize efficient and low-damage precision machining of quartz glass micro-holes. First, the brittle-to-plastic transition depth and theoretical motion trajectory of a single grit of quartz glass in UVAG were analyzed. Subsequently, comparative experiments were conducted between UVAG and conventional grinding (CG) to machine quartz glass micro-holes. Finally, the influences of different parameters on grinding force, edge chipping, entrance and exit diameters, and internal surface quality were investigated. The experiments demonstrated that the grinding force, edge chipping at the entrance and exit, and internal surface roughness can be effectively reduced by UVAG compared to CG. After UVAG, the axial grinding force, size of the edge chips at the entrance and exit, and internal surface roughness decreased by 40.97 %, 36.28 %, 42.09 %, and 12.59 %, respectively. After optimizing the process parameters of UVAG, the size of edge chipping at the entrance and exit were 6.5 μm and 7 μm, respectively, and the internal surface roughness reached 0.146 μm. In this case, the diameter of the micro-hole was 112 μm, and had a depth-to-diameter ratio greater than 10.
{"title":"Ultrasonic vibration-assisted grinding of quartz glass micro-hole","authors":"Yanjun Lu , Mingrong Guo , Yongqi Dai , Qiang Wang , Hu Luo , Yongbo Wu","doi":"10.1016/j.precisioneng.2024.09.021","DOIUrl":"10.1016/j.precisioneng.2024.09.021","url":null,"abstract":"<div><div>Quartz glass is extensively utilized in the aviation and biomedical fields. However, achieving high-quality ultrafine micro-holes on quartz glass is difficult because edge chipping and internal surface defects are prone to occur during processing. Therefore, the ultrasonic vibration-assisted grinding (UVAG) was proposed to realize efficient and low-damage precision machining of quartz glass micro-holes. First, the brittle-to-plastic transition depth and theoretical motion trajectory of a single grit of quartz glass in UVAG were analyzed. Subsequently, comparative experiments were conducted between UVAG and conventional grinding (CG) to machine quartz glass micro-holes. Finally, the influences of different parameters on grinding force, edge chipping, entrance and exit diameters, and internal surface quality were investigated. The experiments demonstrated that the grinding force, edge chipping at the entrance and exit, and internal surface roughness can be effectively reduced by UVAG compared to CG. After UVAG, the axial grinding force, size of the edge chips at the entrance and exit, and internal surface roughness decreased by 40.97 %, 36.28 %, 42.09 %, and 12.59 %, respectively. After optimizing the process parameters of UVAG, the size of edge chipping at the entrance and exit were 6.5 μm and 7 μm, respectively, and the internal surface roughness reached 0.146 μm. In this case, the diameter of the micro-hole was 112 μm, and had a depth-to-diameter ratio greater than 10.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"91 ","pages":"Pages 321-335"},"PeriodicalIF":3.5,"publicationDate":"2024-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417839","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"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 : 2024-09-26DOI: 10.1016/j.precisioneng.2024.09.020
Shiyun Wu , Jianjun Du , Jianguo Lei , Jiang Ma , Likuan Zhu
This paper presents a new type of flexure hinge and its fabrication method based on micro-ultrasonic powder molding (micro-UPM). A right-circular notch-type flexure hinge (RFR-RC hinge) comprising an aluminum alloy 7075 (Al 7075) rigid structure and a polypropylene (PP) flexible structure was designed and fabricated. This composite RFR-RC hinge was experimentally studied, and the results helped confirm that the hinge could be considered a complete single structure; the flexible structure had a good forming quality, and the interlocking performance met normal use requirements. The RFR-RC hinge was evaluated in terms of its motion range, stiffness, and stiffness ratio through finite element analysis (FEA) and then compared with a single-material right-circular flexure hinge (RC hinge). The RFR-RC hinge provided a significantly wider operation range with a lower actuation force than the Al 7075-RC hinge and a higher motion pureness and accuracy than the PP-RC hinge. The motion stiffness obtained from the FEA was in agreement with the bending test results, thus validating the FEA results to some extent. From the bending tests, the elastic and total motion ranges of the RFR-RC hinge were found to be 0.068 rad and 0.202 rad, respectively. Finally, the fabrication of a 3-RRR compliant parallel mechanism and four typical applications were taken as examples to demonstrate that the RFR-RC hinge and its fabrication method have a wide range of applications.
{"title":"Design and performance analysis of a composite flexure hinge based on micro-ultrasonic powder molding","authors":"Shiyun Wu , Jianjun Du , Jianguo Lei , Jiang Ma , Likuan Zhu","doi":"10.1016/j.precisioneng.2024.09.020","DOIUrl":"10.1016/j.precisioneng.2024.09.020","url":null,"abstract":"<div><div>This paper presents a new type of flexure hinge and its fabrication method based on micro-ultrasonic powder molding (micro-UPM). A right-circular notch-type flexure hinge (RFR-RC hinge) comprising an aluminum alloy 7075 (Al 7075) rigid structure and a polypropylene (PP) flexible structure was designed and fabricated. This composite RFR-RC hinge was experimentally studied, and the results helped confirm that the hinge could be considered a complete single structure; the flexible structure had a good forming quality, and the interlocking performance met normal use requirements. The RFR-RC hinge was evaluated in terms of its motion range, stiffness, and stiffness ratio through finite element analysis (FEA) and then compared with a single-material right-circular flexure hinge (RC hinge). The RFR-RC hinge provided a significantly wider operation range with a lower actuation force than the Al 7075-RC hinge and a higher motion pureness and accuracy than the PP-RC hinge. The motion stiffness obtained from the FEA was in agreement with the bending test results, thus validating the FEA results to some extent. From the bending tests, the elastic and total motion ranges of the RFR-RC hinge were found to be 0.068 rad and 0.202 rad, respectively. Finally, the fabrication of a 3-RRR compliant parallel mechanism and four typical applications were taken as examples to demonstrate that the RFR-RC hinge and its fabrication method have a wide range of applications.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"91 ","pages":"Pages 372-382"},"PeriodicalIF":3.5,"publicationDate":"2024-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417843","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"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 : 2024-09-25DOI: 10.1016/j.precisioneng.2024.09.019
Masatoshi Tsuchida, Takeshi Morita
The mechanical quality factor (Q-factor), which is the reciprocal of the vibration loss constant, is one of the most important parameters in vibration engineering; however, there are no methods for its precise measurement. Q-factor databases are thus commonly used. This study proposes a completely non-contact measurement system for the Q-factor that combines non-contact excitation (achieved using an electromagnetic acoustic transducer) with non-contact support (achieved using near-field ultrasonic levitation based on two Langevin transducers). The proposed method was used to measure the Q-factor for a stainless steel (SUS304) sample (thin cylindrical rod with a diameter of 1.5 mm and a length of 80 mm)and a duralumin (A2017). The 5 times average Q-factor was 2010 with standard deviation of 50 for stainless steel (SUS304), and 49,000 with standard deviation of 3900 for duralumin (A2017). The proposed method also allowed for the measurement of Young’s modulus, resulting in 217.17 ± 0.34 GPa for stainless steel (SUS304), and 71.39 ± 0.20 GPa for duralumin (A2017).
{"title":"Non-contact mechanical Q-factor measurement system based on electromagnetic acoustic transducer","authors":"Masatoshi Tsuchida, Takeshi Morita","doi":"10.1016/j.precisioneng.2024.09.019","DOIUrl":"10.1016/j.precisioneng.2024.09.019","url":null,"abstract":"<div><div>The mechanical quality factor (Q-factor), which is the reciprocal of the vibration loss constant, is one of the most important parameters in vibration engineering; however, there are no methods for its precise measurement. Q-factor databases are thus commonly used. This study proposes a completely non-contact measurement system for the Q-factor that combines non-contact excitation (achieved using an electromagnetic acoustic transducer) with non-contact support (achieved using near-field ultrasonic levitation based on two Langevin transducers). The proposed method was used to measure the Q-factor for a stainless steel (SUS304) sample (thin cylindrical rod with a diameter of 1.5 mm and a length of 80 mm)and a duralumin (A2017). The 5 times average Q-factor was 2010 with standard deviation of 50 for stainless steel (SUS304), and 49,000 with standard deviation of 3900 for duralumin (A2017). The proposed method also allowed for the measurement of Young’s modulus, resulting in 217.17 ± 0.34 GPa for stainless steel (SUS304), and 71.39 ± 0.20 GPa for duralumin (A2017).</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"91 ","pages":"Pages 390-395"},"PeriodicalIF":3.5,"publicationDate":"2024-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417845","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-09-23DOI: 10.1016/j.precisioneng.2024.09.018
Alexander Pechhacker, Ernst Csencsics, Georg Schitter
This paper presents an air gap design approach to improve the linearity of rotational Hybrid Reluctance Actuators (HRAs) used in fast steering mirrors. The approach involves modeling a one-degree-of-freedom HRA with a magnetic equivalent circuit to identify and analyze sources of non-linearities. On the basis of the verified model, solutions for an improved linear system behavior are analytically searched. Two linearized HRA designs are proposed, one with linear cross-section dependency and the other with hyperbolic air gap length dependency. Finite element method simulations are employed to evaluate the performance with respect to the linearity and the motor constant of these designs, showing factor 50 improved system linearity.
本文介绍了一种气隙设计方法，用于提高快速转向镜中使用的旋转混合磁阻致动器（HRA）的线性度。该方法包括用磁性等效电路对单自由度 HRA 进行建模，以识别和分析非线性的来源。在验证模型的基础上，通过分析寻找改进线性系统行为的解决方案。提出了两种线性化 HRA 设计，一种与横截面线性相关，另一种与双曲气隙长度相关。采用有限元法模拟评估了这些设计在线性度和电机常数方面的性能，结果显示系统线性度提高了 50 倍。
{"title":"Decreasing the non-linearity of hybrid reluctance actuators by air gap design","authors":"Alexander Pechhacker, Ernst Csencsics, Georg Schitter","doi":"10.1016/j.precisioneng.2024.09.018","DOIUrl":"10.1016/j.precisioneng.2024.09.018","url":null,"abstract":"<div><div>This paper presents an air gap design approach to improve the linearity of rotational Hybrid Reluctance Actuators (HRAs) used in fast steering mirrors. The approach involves modeling a one-degree-of-freedom HRA with a magnetic equivalent circuit to identify and analyze sources of non-linearities. On the basis of the verified model, solutions for an improved linear system behavior are analytically searched. Two linearized HRA designs are proposed, one with linear cross-section dependency and the other with hyperbolic air gap length dependency. Finite element method simulations are employed to evaluate the performance with respect to the linearity and the motor constant of these designs, showing factor 50 improved system linearity.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"91 ","pages":"Pages 255-262"},"PeriodicalIF":3.5,"publicationDate":"2024-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142322544","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-09-20DOI: 10.1016/j.precisioneng.2024.09.015
Yijie Tao , Guolong Li , Yu Wang
The objective of this paper is to present a numerical approach to investigate the formation mechanism of tooth surface waviness in CGG of electric vehicle gears while independently analyzing each influencing factor and ignoring the mutual influences between them. A tooth surface waviness simulation model is proposed considering the system vibration and tool wear. According to the characterization of grinding worm wear and the main shaft vibration in CGG, the grinding worm wheel and the grinding trajectories are modeled. Based on the analysis of the geometric contact characterizations through the whole grinding process, tooth surface topography is modeled, and tooth surface waviness is extracted. By comparing the tooth surface waviness in the frequency domain, the influence of grinding worm local wear, global wear, and the main shaft vibrations on tooth surface waviness is studied. Local wear and global wear affect tooth surface waviness differently by changing the amplitude and the distribution pattern of the frequencies. The main shaft vibrations have limited direct impacts on the amplitude in profile and flank spectrums, among which the vibration Z plays a leading role.
本文旨在提出一种数值方法来研究电动汽车齿轮 CGG 中齿面波纹的形成机理，同时独立分析各个影响因素，忽略它们之间的相互影响。考虑到系统振动和刀具磨损，提出了齿面波纹模拟模型。根据 CGG 中磨削蜗杆磨损和主轴振动的特征，对磨削蜗轮和磨削轨迹进行建模。根据对整个磨削过程中几何接触特征的分析，建立了齿面形貌模型，并提取了齿面波形。通过比较频域中的齿面波形，研究了磨削蜗杆局部磨损、整体磨损和主轴振动对齿面波形的影响。局部磨损和整体磨损通过改变频率的振幅和分布模式对齿面波纹度产生不同的影响。主轴振动对轮廓和齿面频谱振幅的直接影响有限，其中振动 Z 起主导作用。
{"title":"Numerical investigation on tooth surface waviness in continuous generating grinding of electric vehicle gears considering the main shaft vibration and grinding worm wear","authors":"Yijie Tao , Guolong Li , Yu Wang","doi":"10.1016/j.precisioneng.2024.09.015","DOIUrl":"10.1016/j.precisioneng.2024.09.015","url":null,"abstract":"<div><div>The objective of this paper is to present a numerical approach to investigate the formation mechanism of tooth surface waviness in CGG of electric vehicle gears while independently analyzing each influencing factor and ignoring the mutual influences between them. A tooth surface waviness simulation model is proposed considering the system vibration and tool wear. According to the characterization of grinding worm wear and the main shaft vibration in CGG, the grinding worm wheel and the grinding trajectories are modeled. Based on the analysis of the geometric contact characterizations through the whole grinding process, tooth surface topography is modeled, and tooth surface waviness is extracted. By comparing the tooth surface waviness in the frequency domain, the influence of grinding worm local wear, global wear, and the main shaft vibrations on tooth surface waviness is studied. Local wear and global wear affect tooth surface waviness differently by changing the amplitude and the distribution pattern of the frequencies. The main shaft vibrations have limited direct impacts on the amplitude in profile and flank spectrums, among which the vibration Z plays a leading role.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"91 ","pages":"Pages 242-254"},"PeriodicalIF":3.5,"publicationDate":"2024-09-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142313010","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"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 : 2024-09-19DOI: 10.1016/j.precisioneng.2024.09.017
Zhipeng Cheng , Xuanping Wang , Hang Gao , Dongming Guo
During the water dissolution polishing process of soft brittle materials, the pad's groove geometry plays a significant role in determining the performance. This not only affects the flow of the slurry but also directly impacts the overall distribution of the water core on the pad surface, thereby influencing the polishing effect. A trajectory model of the water core on the workpiece surface was established through kinematic analysis and the characteristics and effects of the pad's groove geometry in circular, radial, composite, and grid were studied combined with the trajectory analysis. The coefficient of variation and power spectral density were established to evaluate the trajectory uniformity. The trajectory density distribution was quantitatively analyzed to obtain a better understanding of the material removal uniformity. The simulation and experiment results indicated that the existence of groove geometry will greatly affect the flow of slurry and the surface quality. The grid groove had a better distribution of water core, which means better material removal. There exists a tradeoff between the number of grooves and their spacing. These insights offer a fresh perspective and serve as a valuable reference for further research and analysis into the groove characteristics of pads.
{"title":"Study on the groove geometry of pad in water dissolution polishing of soft brittle materials based on trajectory analysis","authors":"Zhipeng Cheng , Xuanping Wang , Hang Gao , Dongming Guo","doi":"10.1016/j.precisioneng.2024.09.017","DOIUrl":"10.1016/j.precisioneng.2024.09.017","url":null,"abstract":"<div><div>During the water dissolution polishing process of soft brittle materials, the pad's groove geometry plays a significant role in determining the performance. This not only affects the flow of the slurry but also directly impacts the overall distribution of the water core on the pad surface, thereby influencing the polishing effect. A trajectory model of the water core on the workpiece surface was established through kinematic analysis and the characteristics and effects of the pad's groove geometry in circular, radial, composite, and grid were studied combined with the trajectory analysis. The coefficient of variation and power spectral density were established to evaluate the trajectory uniformity. The trajectory density distribution was quantitatively analyzed to obtain a better understanding of the material removal uniformity. The simulation and experiment results indicated that the existence of groove geometry will greatly affect the flow of slurry and the surface quality. The grid groove had a better distribution of water core, which means better material removal. There exists a tradeoff between the number of grooves and their spacing. These insights offer a fresh perspective and serve as a valuable reference for further research and analysis into the groove characteristics of pads.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"91 ","pages":"Pages 290-299"},"PeriodicalIF":3.5,"publicationDate":"2024-09-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417837","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In the ultrasonic elliptical vibration cutting (UEVC) process, the surface morphology suffers from the large fluctuation of ridge height and residual height, which has restricted the development of UEVC technology. Therefore, on the basis of the elliptical plane swinging strategy along a short axis, a surface topography improvement method (i.e., swing ultrasonic elliptical vibration turning (SUEVT)) for two-dimensional ultrasonic vibration plane turning is proposed in this study. The core idea of the method is to swing the ultrasonic elliptical vibration plane along the short axis to form a machining inclination angle, which reduces the ridge height of the machined morphology to a certain extent, thereby optimizing the surface microstructure and reducing the surface roughness. First, this study establishes a mathematical model of the tool tip trajectory of ultrasonic elliptical vibration under different swing angles, theoretically analyzes the influence of swing angles on the tool tip trajectory and surface topography, and provides a theoretical basis for revealing the surface topography formation mechanism of SUEVT. Second, an engineering practice scheme of SUEVT is proposed, and a processing experiment platform is built. Finally, cutting experiments of SUEVT for TC4 titanium alloy were conducted, studying the influence of swing angles on surface topography and roughness and assessing the feasibility of the method. Results showed that compared with ultrasonic elliptical vibration turning (UEVT), SUEVT has certain advantages in improving surface morphology. When the swing angle of SUEVT is 15°, the surface roughness decreases the most, reaching 19.00 %. Under the condition of SUEVT θ = 15°, the surface roughness decreases first and then increases with the increase in spindle speed, while it is proportional to the feed speed and ultrasonic power. The method proposed in this study can provide new methods and new ideas for ultrasonic elliptical vibration high surface quality machining.
{"title":"Investigation on two-dimensional ultrasonic vibration plane turning method based on elliptical plane swinging strategy along short axis","authors":"Yuanhao Ma, Gang Jin, Zhanjie Li, Xiaofan Deng, Huaixin Lin, Guangyu Wang, Xin Zhang","doi":"10.1016/j.precisioneng.2024.09.016","DOIUrl":"10.1016/j.precisioneng.2024.09.016","url":null,"abstract":"<div><div>In the ultrasonic elliptical vibration cutting (UEVC) process, the surface morphology suffers from the large fluctuation of ridge height and residual height, which has restricted the development of UEVC technology. Therefore, on the basis of the elliptical plane swinging strategy along a short axis, a surface topography improvement method (i.e., swing ultrasonic elliptical vibration turning (SUEVT)) for two-dimensional ultrasonic vibration plane turning is proposed in this study. The core idea of the method is to swing the ultrasonic elliptical vibration plane along the short axis to form a machining inclination angle, which reduces the ridge height of the machined morphology to a certain extent, thereby optimizing the surface microstructure and reducing the surface roughness. First, this study establishes a mathematical model of the tool tip trajectory of ultrasonic elliptical vibration under different swing angles, theoretically analyzes the influence of swing angles on the tool tip trajectory and surface topography, and provides a theoretical basis for revealing the surface topography formation mechanism of SUEVT. Second, an engineering practice scheme of SUEVT is proposed, and a processing experiment platform is built. Finally, cutting experiments of SUEVT for TC4 titanium alloy were conducted, studying the influence of swing angles on surface topography and roughness and assessing the feasibility of the method. Results showed that compared with ultrasonic elliptical vibration turning (UEVT), SUEVT has certain advantages in improving surface morphology. When the swing angle of SUEVT is 15°, the surface roughness decreases the most, reaching 19.00 %. Under the condition of SUEVT <em>θ</em> = 15°, the surface roughness decreases first and then increases with the increase in spindle speed, while it is proportional to the feed speed and ultrasonic power. The method proposed in this study can provide new methods and new ideas for ultrasonic elliptical vibration high surface quality machining.</div></div>","PeriodicalId":54589,"journal":{"name":"Precision Engineering-Journal of the International Societies for Precision Engineering and Nanotechnology","volume":"91 ","pages":"Pages 185-198"},"PeriodicalIF":3.5,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142313005","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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