The gears of new energy vehicles are required to withstand higher rotational speeds and greater loads,which puts forward higher precision essentials for gear manufacturing.However,machining process parameters can caus...The gears of new energy vehicles are required to withstand higher rotational speeds and greater loads,which puts forward higher precision essentials for gear manufacturing.However,machining process parameters can cause changes in cutting force/heat,resulting in affecting gear machining precision.Therefore,this paper studies the effect of different process parameters on gear machining precision.A multi-objective optimization model is established for the relationship between process parameters and tooth surface deviations,tooth profile deviations,and tooth lead deviations through the cutting speed,feed rate,and cutting depth of the worm wheel gear grinding machine.The response surface method(RSM)is used for experimental design,and the corresponding experimental results and optimal process parameters are obtained.Subsequently,gray relational analysis-principal component analysis(GRA-PCA),particle swarm optimization(PSO),and genetic algorithm-particle swarm optimization(GA-PSO)methods are used to analyze the experimental results and obtain different optimal process parameters.The results show that optimal process parameters obtained by the GRA-PCA,PSO,and GA-PSO methods improve the gear machining precision.Moreover,the gear machining precision obtained by GA-PSO is superior to other methods.展开更多
Cam mechanics is one of the most popular devices for generating irregular motions and is widely used in automatic equipment,such as textile machines,internal combustion engines,and other automatic devices.In order to ...Cam mechanics is one of the most popular devices for generating irregular motions and is widely used in automatic equipment,such as textile machines,internal combustion engines,and other automatic devices.In order to obtain a positive motion from the follower using a rotating cam,its shape should be correctly designed and manufactured.The development of an adequate CAD/CAM system for a cam profile CNC grinding machine is necessary to manufacture high-precision cams.The purpose of this study is the development of a CAD/CAM system and profile measuring device for a CNC grinding machine to obtain an optimal grinding speed with a constant surface roughness.Three types of disk cams were manufactured using the proposed algorithm and procedures to verify effectiveness of the developed CAD/CAM system.展开更多
Be directed against the development trend of modern CNC grinding machine towards high precision and high efficiency, some general weaknesses of existing camber grinding machine are analyzed in detail. In order to deve...Be directed against the development trend of modern CNC grinding machine towards high precision and high efficiency, some general weaknesses of existing camber grinding machine are analyzed in detail. In order to develop new type CNC camber grinding machine that can grind complex die, and genuinely achieved accurate feed and high efficient grinding, a new type camber grinding machine is put forward, called non-transmission virtual-shaft CNC camber grinding machine. Its feed system is a parallel mechanism that is directly driven by linear step motor. Therefore, traditional transmission types, such as the ball lead-screw mechanisms, the gears, the hydraulic transmission system, etc. are cancelled, and the feed system of new type CNC camber grinding machine can truly possess non-creep, good accuracy retentiveness a wide range of feed-speed change, high kinematical accuracy and positioning precision, etc. In order to realize that the cutting motion is provided with high grinding speed, step-less speed variation, high rotational accuracy, good dynamic performance, and non-transmission, the driving technology of hollow rotor motor is applied to drive the spindle of new type grinding machine,thus leading to the elimination of the transmission parts of cutting motion. The principle structure model of new type camber grinding machine is advanced. The selection, control gist and driving circuit line of the linear step motor are expounded. The main technology characteristics and application advantages of non-transmission virtual-shaft CNC camber grinding machine are introduced.展开更多
As is known to all, grinding force is one of the most important parameters to evaluate the whole process of grinding. Generally, the grinding force is resolved to three component forces, namely, normal grinding force ...As is known to all, grinding force is one of the most important parameters to evaluate the whole process of grinding. Generally, the grinding force is resolved to three component forces, namely, normal grinding force F n, tangential grinding force F t and a component force acting along the direction of longitudinal feed which is usually neglected because of insignificance. The normal grinding force F n has influence upon surface deformation and roughness of workpiece, while the tangential grinding force F t mainly affect power consumption and service life of grinding wheel. In order to study deep into the process of the unsteady state grinding, we set up a measurement system to monitor the change of grinding force during the course of grinding and try to find some difference in the change of grinding force between the steady state grinding and unsteady state grinding. In the test, the normal and tangential grinding forces, F n and F t were measured by using a set of equipments including sensor, amplifier, oscilloscope and computer monitor. From the results, we can conclude that: 1) In the unsteady state grinding process, the values of the grinding forces are much lower than those of the steady state grinding process and the grinding force ratio showed a nonlinear fluctuation. 2) The tendency of the grinding forces in the process of the unsteady state grinding proved the existence of the cutting and micro-cutting actions. 3) Because the grinding force signals of the unsteady state grinding are much weaker than those of the steady state grinding, to obtain accurate value of the grinding forces, wave filtering is needed to be done. The whole process to filter the perturbation wave can be separated into three steps in order, changing the grinding force signals from analog signals into digital signals, FFT (fast Fourier transform) treatment to the digital signals, and IFFT(inversion fast Fourier transform) treatment to the digital signals after spectrum limitation.展开更多
In conventional grinding theory, it is obvious that there must be a very high hardness difference between grains of the grinding wheel and workpieces. The best grinding wheels are those giving the lowest "natural...In conventional grinding theory, it is obvious that there must be a very high hardness difference between grains of the grinding wheel and workpieces. The best grinding wheels are those giving the lowest "natural limiting surface roughness" while cutting at appreciable plunge velocities. With the development of new materials and new machining processes, conventional theories of grinding techniques are no longer suitable to explain many phenomena in the course of grinding procedures. In dealing with precision or ultra-precision grinding processes of advanced ceramics, many results of experiments and practical production have shown that grinding with super hard materials wheels is not the only method to machine advanced ceramics. This paper is intended to propose a new grinding theory named as unsteady-state grinding technique evolved from some phenomena that can not be explained by conventional grinding theory. Unsteady-state grinding technique means the technique which can make the surface roughness of the materials, especially hard and brittle, be up to the standard of ultra-precision machining by utilizing common wheels characteristic of inferior self-sharpening and wear-resistance. In the process of machining, the common wheel need to be redressed about 3～5 times and the time between two redressings is about 3～5 minutes. As a validation of the new grinding technology, experimental work was performed to prove the existence of the unsteady state in the process of ultra-precision grinding with common abrasive wheel-pink fused alumina wheel. From the results of the observation of the wheel topography, the whole grinding process in unsteady state was separated into three stages namely cutting by grains peaks, micro-cutting by micro edges of the broken grains and rubbing without material removal, which is different from conventional grinding theory. For the difference of hardness between grinding wheel and workpiece material is not so apparent, some people have doubts about whether the cutting especially micro-cutting actions exist in the process of unsteady state grinding. By utilizing the common abrasive wheel newly redressed to grind the finished surface of silicon nitride glut and comparing the finished surface with the damaged surface in SEM pattern and surface roughness, the existence of cutting and micro- cutting actions in the unsteady state grinding process was confirmed.展开更多
The formed principle and CNC grinding machining method of isometric polygonal profile are studied deeply and systematically. Equation about section curve of isometric polygon profile is set up by means of geometric pr...The formed principle and CNC grinding machining method of isometric polygonal profile are studied deeply and systematically. Equation about section curve of isometric polygon profile is set up by means of geometric principle. With the use of differential geometry theory, the curve is proved to be with geometric feature of convex curve. It is referred to as Isometric Polygonal Curve (IPC), because that is a kind of convex curve on which the distance between any parallel tangent lines is equal. Isometric Polygonal Profile (IPP) or Isometric Polygonal Cone Profile (IPCP) or Isometric Polygonal Topless Cone (IPTC) is formed with the IPC and straight line as generating curve. But the machining and measuring of the IPCP are so inconvenient that it has little value. Keeping in mind the characteristic of the IPP and IPTC, this paper puts forward the program method of CNC grinding machining. Isometric polygonal profile connection is a kind of polygonal profile connection. It has the superiority over keys (prismatic key & spline etc), and can be suit for the situations such as high rotative velocity, large torque, high precision, and small fixed room and vibration. Nowadays, some countries such as America, Russia, German and Switzerland applied CNC machining to the machining of polygon surface coupling parts, which makes their applications in machine productions such as motor engine, heavy machine increase day by day. But reports about concrete machining technology of isometric polygonal profile and programming of CNC machining program are very few. CNC grinding of the IPP and IPTC is one kind of the precision machining technology. It is of great importance to the popularization of the IPP and IPTC connection. From the forming mechanism, we can see that the machining and measuring of the IPP and IPTC are convenient, and therefore they have the value of the popularization. But the machining and measuring of the IPCP are so inconvenient that it has little value. In the programming the CNC grinding of the IPP and IPTC, it is more reasonable to calculate the coordinate of node according to the approaching method of equal error arc. According to the method of CNC grinding mentioned above to design the grinding machine, the structure is simple and of economical and practical.展开更多
In order to meet the technical requirements of grinding the circumferential cutting edge of indexable inserts, thermo-mechanical properties of bowl-shaped grinding wheel in high speed grinding process and the influenc...In order to meet the technical requirements of grinding the circumferential cutting edge of indexable inserts, thermo-mechanical properties of bowl-shaped grinding wheel in high speed grinding process and the influence of dimension variations of the grinding wheel on machining accuracy were investigated. Firstly, the variation trends of the dimension due to centrifugal force generated in different wheel speeds were studied and the effect of stress stiffening and spin softening was presented. Triangular heat flux distribution model was adopted to determine temperature distribution in grinding process. Temperature field cloud pictures were obtained by the finite element software. Then, dimension variation trends of wheel structure were acquired by considering the thermo-mechanical characteristic under combined action of centrifugal force and grinding heat at different speeds. A method of online dynamic monitoring and automatic compensation for dimension error of indexable insert was proposed. By experimental verification, the precision of the inserts satisfies the requirement of processing.展开更多
基金Projects(U22B2084,52275483,52075142)supported by the National Natural Science Foundation of ChinaProject(2023ZY01050)supported by the Ministry of Industry and Information Technology High Quality Development,China。
文摘The gears of new energy vehicles are required to withstand higher rotational speeds and greater loads,which puts forward higher precision essentials for gear manufacturing.However,machining process parameters can cause changes in cutting force/heat,resulting in affecting gear machining precision.Therefore,this paper studies the effect of different process parameters on gear machining precision.A multi-objective optimization model is established for the relationship between process parameters and tooth surface deviations,tooth profile deviations,and tooth lead deviations through the cutting speed,feed rate,and cutting depth of the worm wheel gear grinding machine.The response surface method(RSM)is used for experimental design,and the corresponding experimental results and optimal process parameters are obtained.Subsequently,gray relational analysis-principal component analysis(GRA-PCA),particle swarm optimization(PSO),and genetic algorithm-particle swarm optimization(GA-PSO)methods are used to analyze the experimental results and obtain different optimal process parameters.The results show that optimal process parameters obtained by the GRA-PCA,PSO,and GA-PSO methods improve the gear machining precision.Moreover,the gear machining precision obtained by GA-PSO is superior to other methods.
基金Project(RTI04-01-03) supported by the Regional Technology Innovation Program of Ministry of Knowledge Economy (MKE),Korea
文摘Cam mechanics is one of the most popular devices for generating irregular motions and is widely used in automatic equipment,such as textile machines,internal combustion engines,and other automatic devices.In order to obtain a positive motion from the follower using a rotating cam,its shape should be correctly designed and manufactured.The development of an adequate CAD/CAM system for a cam profile CNC grinding machine is necessary to manufacture high-precision cams.The purpose of this study is the development of a CAD/CAM system and profile measuring device for a CNC grinding machine to obtain an optimal grinding speed with a constant surface roughness.Three types of disk cams were manufactured using the proposed algorithm and procedures to verify effectiveness of the developed CAD/CAM system.
文摘Be directed against the development trend of modern CNC grinding machine towards high precision and high efficiency, some general weaknesses of existing camber grinding machine are analyzed in detail. In order to develop new type CNC camber grinding machine that can grind complex die, and genuinely achieved accurate feed and high efficient grinding, a new type camber grinding machine is put forward, called non-transmission virtual-shaft CNC camber grinding machine. Its feed system is a parallel mechanism that is directly driven by linear step motor. Therefore, traditional transmission types, such as the ball lead-screw mechanisms, the gears, the hydraulic transmission system, etc. are cancelled, and the feed system of new type CNC camber grinding machine can truly possess non-creep, good accuracy retentiveness a wide range of feed-speed change, high kinematical accuracy and positioning precision, etc. In order to realize that the cutting motion is provided with high grinding speed, step-less speed variation, high rotational accuracy, good dynamic performance, and non-transmission, the driving technology of hollow rotor motor is applied to drive the spindle of new type grinding machine,thus leading to the elimination of the transmission parts of cutting motion. The principle structure model of new type camber grinding machine is advanced. The selection, control gist and driving circuit line of the linear step motor are expounded. The main technology characteristics and application advantages of non-transmission virtual-shaft CNC camber grinding machine are introduced.
文摘As is known to all, grinding force is one of the most important parameters to evaluate the whole process of grinding. Generally, the grinding force is resolved to three component forces, namely, normal grinding force F n, tangential grinding force F t and a component force acting along the direction of longitudinal feed which is usually neglected because of insignificance. The normal grinding force F n has influence upon surface deformation and roughness of workpiece, while the tangential grinding force F t mainly affect power consumption and service life of grinding wheel. In order to study deep into the process of the unsteady state grinding, we set up a measurement system to monitor the change of grinding force during the course of grinding and try to find some difference in the change of grinding force between the steady state grinding and unsteady state grinding. In the test, the normal and tangential grinding forces, F n and F t were measured by using a set of equipments including sensor, amplifier, oscilloscope and computer monitor. From the results, we can conclude that: 1) In the unsteady state grinding process, the values of the grinding forces are much lower than those of the steady state grinding process and the grinding force ratio showed a nonlinear fluctuation. 2) The tendency of the grinding forces in the process of the unsteady state grinding proved the existence of the cutting and micro-cutting actions. 3) Because the grinding force signals of the unsteady state grinding are much weaker than those of the steady state grinding, to obtain accurate value of the grinding forces, wave filtering is needed to be done. The whole process to filter the perturbation wave can be separated into three steps in order, changing the grinding force signals from analog signals into digital signals, FFT (fast Fourier transform) treatment to the digital signals, and IFFT(inversion fast Fourier transform) treatment to the digital signals after spectrum limitation.
文摘In conventional grinding theory, it is obvious that there must be a very high hardness difference between grains of the grinding wheel and workpieces. The best grinding wheels are those giving the lowest "natural limiting surface roughness" while cutting at appreciable plunge velocities. With the development of new materials and new machining processes, conventional theories of grinding techniques are no longer suitable to explain many phenomena in the course of grinding procedures. In dealing with precision or ultra-precision grinding processes of advanced ceramics, many results of experiments and practical production have shown that grinding with super hard materials wheels is not the only method to machine advanced ceramics. This paper is intended to propose a new grinding theory named as unsteady-state grinding technique evolved from some phenomena that can not be explained by conventional grinding theory. Unsteady-state grinding technique means the technique which can make the surface roughness of the materials, especially hard and brittle, be up to the standard of ultra-precision machining by utilizing common wheels characteristic of inferior self-sharpening and wear-resistance. In the process of machining, the common wheel need to be redressed about 3～5 times and the time between two redressings is about 3～5 minutes. As a validation of the new grinding technology, experimental work was performed to prove the existence of the unsteady state in the process of ultra-precision grinding with common abrasive wheel-pink fused alumina wheel. From the results of the observation of the wheel topography, the whole grinding process in unsteady state was separated into three stages namely cutting by grains peaks, micro-cutting by micro edges of the broken grains and rubbing without material removal, which is different from conventional grinding theory. For the difference of hardness between grinding wheel and workpiece material is not so apparent, some people have doubts about whether the cutting especially micro-cutting actions exist in the process of unsteady state grinding. By utilizing the common abrasive wheel newly redressed to grind the finished surface of silicon nitride glut and comparing the finished surface with the damaged surface in SEM pattern and surface roughness, the existence of cutting and micro- cutting actions in the unsteady state grinding process was confirmed.
文摘The formed principle and CNC grinding machining method of isometric polygonal profile are studied deeply and systematically. Equation about section curve of isometric polygon profile is set up by means of geometric principle. With the use of differential geometry theory, the curve is proved to be with geometric feature of convex curve. It is referred to as Isometric Polygonal Curve (IPC), because that is a kind of convex curve on which the distance between any parallel tangent lines is equal. Isometric Polygonal Profile (IPP) or Isometric Polygonal Cone Profile (IPCP) or Isometric Polygonal Topless Cone (IPTC) is formed with the IPC and straight line as generating curve. But the machining and measuring of the IPCP are so inconvenient that it has little value. Keeping in mind the characteristic of the IPP and IPTC, this paper puts forward the program method of CNC grinding machining. Isometric polygonal profile connection is a kind of polygonal profile connection. It has the superiority over keys (prismatic key & spline etc), and can be suit for the situations such as high rotative velocity, large torque, high precision, and small fixed room and vibration. Nowadays, some countries such as America, Russia, German and Switzerland applied CNC machining to the machining of polygon surface coupling parts, which makes their applications in machine productions such as motor engine, heavy machine increase day by day. But reports about concrete machining technology of isometric polygonal profile and programming of CNC machining program are very few. CNC grinding of the IPP and IPTC is one kind of the precision machining technology. It is of great importance to the popularization of the IPP and IPTC connection. From the forming mechanism, we can see that the machining and measuring of the IPP and IPTC are convenient, and therefore they have the value of the popularization. But the machining and measuring of the IPCP are so inconvenient that it has little value. In the programming the CNC grinding of the IPP and IPTC, it is more reasonable to calculate the coordinate of node according to the approaching method of equal error arc. According to the method of CNC grinding mentioned above to design the grinding machine, the structure is simple and of economical and practical.
基金Project(2010ZX04001-162)supported by the National Science and Technology Major Project of China
文摘In order to meet the technical requirements of grinding the circumferential cutting edge of indexable inserts, thermo-mechanical properties of bowl-shaped grinding wheel in high speed grinding process and the influence of dimension variations of the grinding wheel on machining accuracy were investigated. Firstly, the variation trends of the dimension due to centrifugal force generated in different wheel speeds were studied and the effect of stress stiffening and spin softening was presented. Triangular heat flux distribution model was adopted to determine temperature distribution in grinding process. Temperature field cloud pictures were obtained by the finite element software. Then, dimension variation trends of wheel structure were acquired by considering the thermo-mechanical characteristic under combined action of centrifugal force and grinding heat at different speeds. A method of online dynamic monitoring and automatic compensation for dimension error of indexable insert was proposed. By experimental verification, the precision of the inserts satisfies the requirement of processing.
