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Prediction of cutting force in turning of UD-GFRP using mathematical model and simulated annealing

Meenu GUPTA, Surinder Kumar GILL

《机械工程前沿（英文）》 2012年 第7卷 第4期   页码 417-426 doi: 10.1007/s11465-012-0343-2

摘要：

Glass fiber reinforced plastics (GFRPs) composite is considered to be an alternative to heavy exortic materials. According to the need for accurate machining of composites has increased enormously. During machining, the obtaining cutting force is an important aspect. The present investigation deals with the study and development of a cutting force prediction model for the machining of unidirectional glass fiber reinforced plastics (UD-GFRP) composite using regression modeling and optimization by simulated annealing. The process parameters considered include cutting speed, feed rate and depth of cut. The predicted values radial cutting force model is compared with the experimental values. The results of prediction are quite close with the experimental values. The influences of different parameters in machining of UD-GFRP composite have been analyzed.

关键词： UD-GFRP     ANOVA     radial cutting force     PCD tool     Taguchi method     regression analysis     simulated annealing     multi objective techniques    

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Prediction of cutting forces in machining of unidirectional glass fiber reinforced plastics composite

Surinder Kumar GILL, Meenu GUPTA, P. S. SATSANGI

《机械工程前沿（英文）》 2013年 第8卷 第2期   页码 187-200 doi: 10.1007/s11465-013-0262-x

摘要：

Machining of plastic materials has become increasingly important in any engineering industry subsequently the prediction of cutting forces. Forces quality has greater influence on components, which are coming in contact with each other. So it becomes necessary to measure and study machined forces and its behavior. In this research work, experimental investigations are conducted to determine the effects of cutting conditions and tool geometry on the cutting forces in the turning of the unidirectional glass fiber reinforced plastics (UD-GFRP) composites. In this experimental study, carbide tool (K10) having different tool nose radius and tool rake angle is used. Experiments are conducted based on the established Taguchi’s technique L18 orthogonal array on a lathe machine. It is found that the depth of cut is the cutting parameter, which has greater influence on cutting forces. The effect of the tool nose radius and tool rake angles on the cutting forces are also considerably significant. Based on statistical analysis, multiple regression model for cutting forces is derived with satisfactory coefficient (R2). This model proved to be highly preferment for predicting cutting forces.

关键词： unidirectional glass fiber reinforced plastics (UD-GFRP) composites     machining     cutting forces (tangential     feed and radial force)     ANOVA     regression modeling     carbide tool (K10)    

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Improved analytical model for residual stress prediction in orthogonal cutting

null

《机械工程前沿（英文）》 2014年 第9卷 第3期   页码 249-256 doi: 10.1007/s11465-014-0310-1

摘要：

The analytical model of residual stress in orthogonal cutting proposed by Jiann is an important tool for residual stress prediction in orthogonal cutting. In application of the model, a problem of low precision of the surface residual stress prediction is found. By theoretical analysis, several shortages of Jiann’s model are picked out, including: inappropriate boundary conditions, unreasonable calculation method of thermal stress, ignorance of stress constraint and cyclic loading algorithm. These shortages may directly lead to the low precision of the surface residual stress prediction. To eliminate these shortages and make the prediction more accurate, an improved model is proposed. In this model, a new contact boundary condition between tool and workpiece is used to make it in accord with the real cutting process; an improved calculation method of thermal stress is adopted; a stress constraint is added according to the volume-constancy of plastic deformation; and the accumulative effect of the stresses during cyclic loading is considered. At last, an experiment for measuring residual stress in cutting AISI 1045 steel is conducted. Also, Jiann’s model and the improved model are simulated under the same conditions with cutting experiment. The comparisons show that the surface residual stresses predicted by the improved model is closer to the experimental results than the results predicted by Jiann’s model.

关键词： residual stress     analytical model     orthogonal cutting     cutting force     cutting temperature    

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Cutting Force Model for a Small-diameter Helical Milling Cutter

LI Xiwen, YANG Shuzi, YANG Mingjin, XIE Shouyong

《机械工程前沿（英文）》 2007年 第2卷 第3期   页码 272-277 doi: 10.1007/s11465-007-0047-1

摘要： In the milling process, the major flank wear land area (two-dimensional measurement for the wear) of a small-diameter milling cutter, as wear standard, can reflect actual changes of the wear land of the cutter. By analyzing the wearing characteristics of the cutter, a cutting force model based on the major flank wear land area is established. Characteristic parameters such as pressure parameter and friction parameter are calculated by substituting tested data into their corresponding equations. The cutting force model for the helical milling cutter is validated by experiments. The computational and experimental results show that the cutting force model is almost consistent with the actual cutting conditions. Thus, the cutting force model established in the research can provide a theoretical foundation for monitoring the condition of a milling process that uses a small-diameter helical milling cutter.

关键词： computational     corresponding     helical milling     theoretical foundation     Characteristic    

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Research on the dynamic mechanical characteristics and turning tool life under the conditions of excessively heavy-duty turning

Genghuang HE, Xianli LIU, Fugang YAN

《机械工程前沿（英文）》 2012年 第7卷 第3期   页码 329-334 doi: 10.1007/s11465-012-0303-x

摘要：

The dynamic mechanical characteristics of excessively heavy-duty cutting were analyzed based on the cutting experiments with 2.25Cr-1Mo-0.25V steel used in hydrogenated cylindrical shells. By investigating the influence of dynamic mechanical characteristics on the tools’ failure in limited heavy-duty cutting processes, the model of dynamic shearing force in the cutting area was established. However, the experimental results showed that the dynamic shear flow stress in the cutting area greatly influenced the tools’ fatigue. The heavy-duty cutting tool was damaged in the form of a shearing fracture. Through a comprehensive analysis of the theory, the critical condition of the tools’ fracture under extreme loading was established.

关键词： extreme loading cutting     shear flow stress     dynamic cutting force     fatigue fracture    

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3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of

A. DAVOUDINEJAD, P. PARENTI, M. ANNONI

《机械工程前沿（英文）》 2017年 第12卷 第2期   页码 203-214 doi: 10.1007/s11465-017-0421-6

摘要：

Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling (3D FEM) approach for the micro end-milling of Al6061-T6. Finite element (FE) simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects of mill helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.

关键词： 3D finite element modeling     micro end-milling     cutting force     chip formation     burr formation    

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A hybrid deep learning model for robust prediction of the dimensional accuracy in precision milling of thin-walled structural components

《机械工程前沿（英文）》 2022年 第17卷 第3期 doi: 10.1007/s11465-022-0688-0

摘要： The use of artificial intelligence to process sensor data and predict the dimensional accuracy of machined parts is of great interest to the manufacturing community and can facilitate the intelligent production of many key engineering components. In this study, we develop a predictive model of the dimensional accuracy for precision milling of thin-walled structural components. The aim is to classify three typical features of a structural component—squares, slots, and holes—into various categories based on their dimensional errors (i.e., “high precision,” “pass,” and “unqualified”). Two different types of classification schemes have been considered in this study: those that perform feature extraction by using the convolutional neural networks and those based on an explicit feature extraction procedure. The classification accuracy of the popular machine learning methods has been evaluated in comparison with the proposed deep learning model. Based on the experimental data collected during the milling experiments, the proposed model proved to be capable of predicting dimensional accuracy using cutting parameters (i.e., “static features”) and cutting-force data (i.e., “dynamic features”). The average classification accuracy obtained using the proposed deep learning model was 9.55% higher than the best machine learning algorithm considered in this paper. Moreover, the robustness of the hybrid model has been studied by considering the white Gaussian and coherent noises. Hence, the proposed hybrid model provides an efficient way of fusing different sources of process data and can be adopted for prediction of the machining quality in noisy environments.

关键词： precision milling     dimensional accuracy     cutting force     convolutional neural networks     coherent noise    

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Molecular dynamics modeling of a single diamond abrasive grain in grinding

Angelos P. MARKOPOULOS,Ioannis K. SAVVOPOULOS,Nikolaos E. KARKALOS,Dimitrios E. MANOLAKOS

《机械工程前沿（英文）》 2015年 第10卷 第2期   页码 168-175 doi: 10.1007/s11465-015-0337-y

摘要：

In this paper the nano-metric simulation of grinding of copper with diamond abrasive grains, using the molecular dynamics (MD) method, is considered. An MD model of nano-scale grinding, where a single diamond abrasive grain performs cutting of a copper workpiece, is presented. The Morse potential function is used to simulate the interactions between the atoms involved in the procedure. In the proposed model, the abrasive grain follows a curved path with decreasing depth of cut within the workpiece to simulate the actual material removal process. Three different initial depths of cut, namely 4 ?, 8 ? and 12 ?, are tested, and the influence of the depth of cut on chip formation, cutting forces and workpiece temperatures are thoroughly investigated. The simulation results indicate that with the increase of the initial depth of cut, average cutting forces also increase and therefore the temperatures on the machined surface and within the workpiece increase as well. Furthermore, the effects of the different values of the simulation variables on the chip formation mechanism are studied and discussed. With the appropriate modifications, the proposed model can be used for the simulation of various nano-machining processes and operations, in which continuum mechanics cannot be applied or experimental techniques are subjected to limitations.

关键词： molecular dynamics     abrasive process     chip formation     cutting force     temperature    

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Calculation method of radial stress and deformation on conic threaded connections with interference fit

Shoujun CHEN, Qiang LI, Qi AN,

《机械工程前沿（英文）》 2010年 第5卷 第3期   页码 302-307 doi: 10.1007/s11465-010-0018-9

摘要： This paper presents a calculation method for radial stress distribution and deformation on conic threaded connections with interference fit. Based on elastic mechanics, a new calculation model is established using the thick-walled-cylindrical theory. A sample calculation for API 88.9 mm conic threaded connection indicates that the method proposed in this paper is reasonable, and the finite element analysis (FEA) method is used to validate the proposed method. The results obtained by the proposed method and FEA method are identical. The model offers a new way of calculating the radial stress and deformation on conic thread connections with interference fit.

关键词： conic threaded connections     interference fit     radial stress     deformation     finite element analysis (FEA)    

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Hierarchical ZSM-5 zeolite with radial mesopores: Preparation, formation mechanism and application for

Darui Wang, Hongmin Sun, Wei Liu, Zhenhao Shen, Weimin Yang

《化学科学与工程前沿（英文）》 2020年 第14卷 第2期   页码 248-257 doi: 10.1007/s11705-019-1853-9

摘要： Hierarchical ZSM-5 zeolite with radial mesopores is controllably synthesized using piperidine in a NaOH solution. The piperidine molecules enter the zeolite micropores and protect the zeolite framework from extensive desilication. The areas containing fewer aluminum atoms contain fewer piperidine protectant molecules and so they dissolve first. Small amounts of mesopores are then gradually generated in areas with more aluminum atoms and more piperidine protectant. In this manner, radial mesopores are formed in the ZSM-5 zeolite with a maximal preservation of the micropores and active sites. The optimal hierarchical ZSM-5 zeolite, prepared with a molar ratio of piperidine to zeolite of 0.03, had a mesopore surface area of 136 m ·g and a solid yield of 80%. The incorporation of the radial mesopores results in micropores that are interconnected which shortened the average diffusion path length. Compared to the parent zeolite, the hierarchical ZSM-5 zeolite possesses more accessible acid sites and has a higher catalytic activity and a longer lifetime for the alkylation of benzene.

关键词： hierarchical ZSM-5 zeolite     protective desilication     piperidine     radial mesopores     benzene alkylation    

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Crystallographic orientation effect on cutting-based single atomic layer removal

Wenkun XIE, Fengzhou FANG

《机械工程前沿（英文）》 2020年 第15卷 第4期   页码 631-644 doi: 10.1007/s11465-020-0599-x

摘要： The ever-increasing requirements for the scalable manufacturing of atomic-scale devices emphasize the significance of developing atomic-scale manufacturing technology. The mechanism of a single atomic layer removal in cutting is the key basic theoretical foundation for atomic-scale mechanical cutting. Material anisotropy is among the key decisive factors that could not be neglected in cutting at such a scale. In the present study, the crystallographic orientation effect on the cutting-based single atomic layer removal of monocrystalline copper is investigated by molecular dynamics simulation. When undeformed chip thickness is in the atomic scale, two kinds of single atomic layer removal mechanisms exist in cutting-based single atomic layer removal, namely, dislocation motion and extrusion, due to the differing atomic structures on different crystallographic planes. On close-packed crystallographic plane, the material removal is dominated by the shear stress-driven dislocation motion, whereas on non-close packed crystallographic planes, extrusion-dominated material removal dominates. To obtain an atomic, defect-free processed surface, the cutting needs to be conducted on the close-packed crystallographic planes of monocrystalline copper.

关键词： ACSM     single atomic layer removal mechanism     crystallographic orientation effect     mechanical cutting     Manufacturing III    

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Modeling of the minimum cutting thickness in micro cutting with consideration of the friction aroundthe cutting zone

Tianfeng ZHOU, Ying WANG, Benshuai RUAN, Zhiqiang LIANG, Xibin WANG

《机械工程前沿（英文）》 2020年 第15卷 第1期   页码 81-88 doi: 10.1007/s11465-019-0561-y

摘要： Friction modeling between the tool and the workpiece plays an important role in predicting the minimum cutting thickness during TC4 micro machining and finite element method (FEM) cutting simulation. In this study, a new three-region friction modeling is proposed to illustrate the material flow mechanism around the friction zone in micro cutting; estimate the stress distributions on the rake, edge, and clearance faces of the tool; and predict the stagnation point location and the minimum cutting thickness. The friction modeling is established by determining the distribution of normal and shear stress. Then, it is applied to calculate the stagnation point location on the edge face and predict the minimum cutting thickness. The stagnation point and the minimum cutting thickness are also observed and illustrated in the FEM simulation. Micro cutting experiments are conducted to validate the accuracy of the friction and the minimum cutting thickness modeling. Comparison results show that the proposed friction model illustrates the relationship between the normal and sheer stress on the tool surface, thereby validating the modeling method of the minimum cutting thickness in micro cutting.

关键词： tool friction     minimum cutting thickness     finite element method     tool edge radius     micro cutting    

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Different manipulation mode analysis of a radial symmetrical hexapod robot with leg–arm integration

《机械工程前沿（英文）》 2022年 第17卷 第1期   页码 8-8 doi: 10.1007/s11465-021-0664-0

摘要： With the widespread application of legged robot in various fields, the demand for a robot with high locomotion and manipulation ability is increasing. Adding an extra arm is a useful but general method for a legged robot to obtain manipulation ability. Hence, this paper proposes a novel hexapod robot with two integrated leg–arm limbs that obtain dexterous manipulation functions besides locomotion ability without adding an extra arm. The manipulation modes can be divided into coordinated manipulation condition and single-limb manipulation condition. The former condition mainly includes fixed coordinated clamping case and fixed coordinated shearing case. For the fixed coordinated clamping case, the degrees of freedom (DOFs) analysis of equivalent parallel mechanism by using screw theory and the constraint equation of two integrated limbs are established. For the fixed coordinated shearing case, the coordinated working space is determined, and an ideal coordinated manipulation ball is presented to guide the coordinated shearing task. In addition, the constraint analysis of two adjacent integrated limbs is performed. Then, mobile manipulation with one integrated leg–arm limb while using pentapod gait is discussed as the single-limb manipulation condition, including gait switching analysis between hexapod gait and pentapod gait, different pentapod gaits analysis, and a complex six-DOF manipulation while walking. Corresponding experiments are implemented, including clamping tasks with two integrated limbs, coordinated shearing task by using two integrated limbs, and mobile manipulation with pentapod gait. This robot provides a new approach to building a multifunctional locomotion platform.

关键词： leg–arm integration     hexapod robot     fixed coordinated manipulation     mobile manipulation    

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Comparison of optimal capacitor placement methods in radial distribution system with load growth and

Veera Venkata Satya Naryana MURTY, Ashwani KUMAR

《能源前沿（英文）》 2013年 第7卷 第2期   页码 197-213 doi: 10.1007/s11708-013-0249-7

摘要： In this paper, a combined power loss sensitivity (PLS) index-based approach is proposed to determine the optimal location of the capacitors in the radial distribution system (RDS) based on the real and reactive combined loss sensitivity index, as capacitor placement not only reduces real power loss with voltage profile improvement but also reduces reactive power loss due to the reactive power compensation in the network. The results have been obtained with the existing methods of power loss index (PLI) and index vector (IV) method for comparison. Besides, the optimal placement has been obtained with the proposed method as well as existing methods and the total kVar support has been obtained. In addition, the results of net cost savings for the 10-, 34-, and 69-bus systems are obtained for comparison. Moreover, the results have been obtained for a large system of 85 buses to validate the results with combined sensitivity based approach. Furthermore, the load growth factor has been considered in the study which is essential for the planning and expansion of the existing systems, whereas the impact of the realistic load model as ZIP load model has been considered for the study of all the systems.

关键词： load growth     load models     reactive power compensation     radial distribution system     power loss index (PLI)     power loss sensitivity (PLS)     index vector (IV)    

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A total torque index for dynamic performance evaluation of a radial symmetric six-legged robot

Kejia LI, Xilun DING, Marco CECCARELL

《机械工程前沿（英文）》 2012年 第7卷 第2期   页码 219-230 doi: 10.1007/s11465-012-0320-9

摘要：

This article focuses on the dynamic index and performance of a radial symmetric six-legged robot. At first the structure of the robot is described in brief and its inverse kinematics is presented. Then the dynamic model is formulated as based on the Lagrange equations. A novel index of total torque is proposed by considering the posture of the supporting legs. The new index can be used to optimize the leg’s structure and operation for consuming minimum power and avoiding unstable postures of the robot. A characterization of the proposed six-legged robot is obtained by a parametric analysis of robot performance through simulation using the presented dynamic model. Main influences are outlined as well as the usefulness of the proposed performance index.

关键词： six-legged robots     dynamic modeling     performance index    

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标题 作者 时间 类型 操作

Prediction of cutting force in turning of UD-GFRP using mathematical model and simulated annealing

Meenu GUPTA, Surinder Kumar GILL

期刊论文

Prediction of cutting forces in machining of unidirectional glass fiber reinforced plastics composite

Surinder Kumar GILL, Meenu GUPTA, P. S. SATSANGI

期刊论文

Improved analytical model for residual stress prediction in orthogonal cutting

null

期刊论文

Cutting Force Model for a Small-diameter Helical Milling Cutter

LI Xiwen, YANG Shuzi, YANG Mingjin, XIE Shouyong

期刊论文

Research on the dynamic mechanical characteristics and turning tool life under the conditions of excessively heavy-duty turning

Genghuang HE, Xianli LIU, Fugang YAN

期刊论文

3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of

A. DAVOUDINEJAD, P. PARENTI, M. ANNONI

期刊论文

A hybrid deep learning model for robust prediction of the dimensional accuracy in precision milling of thin-walled structural components

期刊论文

Molecular dynamics modeling of a single diamond abrasive grain in grinding

Angelos P. MARKOPOULOS,Ioannis K. SAVVOPOULOS,Nikolaos E. KARKALOS,Dimitrios E. MANOLAKOS

期刊论文

Calculation method of radial stress and deformation on conic threaded connections with interference fit

Shoujun CHEN, Qiang LI, Qi AN,

期刊论文

Hierarchical ZSM-5 zeolite with radial mesopores: Preparation, formation mechanism and application for

Darui Wang, Hongmin Sun, Wei Liu, Zhenhao Shen, Weimin Yang

期刊论文

Crystallographic orientation effect on cutting-based single atomic layer removal

Wenkun XIE, Fengzhou FANG

期刊论文

Modeling of the minimum cutting thickness in micro cutting with consideration of the friction aroundthe cutting zone

Tianfeng ZHOU, Ying WANG, Benshuai RUAN, Zhiqiang LIANG, Xibin WANG

期刊论文

Different manipulation mode analysis of a radial symmetrical hexapod robot with leg–arm integration

期刊论文

Comparison of optimal capacitor placement methods in radial distribution system with load growth and

Veera Venkata Satya Naryana MURTY, Ashwani KUMAR

期刊论文

A total torque index for dynamic performance evaluation of a radial symmetric six-legged robot

Kejia LI, Xilun DING, Marco CECCARELL

期刊论文