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Liang Y.,Harbin Institute of Technology | Chen W.,Harbin Institute of Technology | Chen W.,University of Strathclyde | An C.,Chengdu Fine Optic Engineering Research Center | And 3 more authors.
Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science | Year: 2014

Flycutting is a major machining process for flat-surface machining, which is a typical intermittent-machining process. This paper is dedicated to study the influence of the intermittent-machining force on the workpiece surface generation. In the present study, some defects are identified on the machined surface and found to be corresponded to the tool-tip vibration by the dynamic analysis and the surface-generation simulation. A theoretical model is proposed to capture the dominant factor based on the characteristic. It reveals that the defects are attributed to the changing period of the intermittent-machining force and the dynamic performance of the machine tool. Hence, a surface-generation model is proposed to take account of the tool-tip vibration and the changing of the cutting locus. The simulation results have been found to agree well with the experimental results. © IMechE 2013. Source


Chen W.,Harbin Institute of Technology | Liang Y.,Harbin Institute of Technology | Sun Y.,Harbin Institute of Technology | Bai Q.,Harbin Institute of Technology | An C.,Chengdu Fine Optic Engineering Research Center
JVC/Journal of Vibration and Control | Year: 2015

The pressure distribution in an aerostatic bearing has an important effect on the performance of the associated mechanical equipment. To more accurately predict performance, a new dynamic modeling method has been developed that takes into account the pressure distribution in the bearing by integrating the principle of flow equilibrium and finite element theory. The direct corresponding relationship between the fluid film characteristics and spindle dynamic performance is established using this method. The simulation and experimental results show that the new dynamic modeling method for the aerostatic bearing is more efficient and reliable than traditional modeling methods. © The Author(s) 2014. Source


Chen W.,Harbin Institute of Technology | Lu L.,Harbin Institute of Technology | Liang Y.,Harbin Institute of Technology | Sun Y.,Harbin Institute of Technology | And 2 more authors.
Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering | Year: 2015

The flatness of the KH2PO4 (KDP) crystal has important effect on the inertial confinement fusion system. The method to improve the flatness of KDP crystal and its implementation in the machine tool design is presented in this paper. The finite element model of the whole machine tool is built up to describe the tool tip displacement with the cutting force along the cutting path. The influence of the axial and radial bearing stiffness of the aerostatic spindle on the machined surface flatness is discussed. Furthermore, a novel adjusting mechanism which is used to adjust the squareness between the spindle and the slide is designed, and a new machining process is proposed to improve the flatness of the machined surface. The machining trials are carried out to evaluate and validate the effectiveness of the presented approach and simulation. © 2015 Institution of Mechanical Engineers. Source


Sun Y.,Harbin Institute of Technology | Chen W.,Harbin Institute of Technology | Liang Y.,Harbin Institute of Technology | An C.,Chengdu Fine Optic Engineering Research Center | And 2 more authors.
International Journal of Advanced Manufacturing Technology | Year: 2014

This paper presents an error budget methodology for designing and characterizing machines used to manufacture or inspect parts with spatial frequency-based specifications. In this methodology, the static and dynamic error are considered in the error budget; the static error affects the figure accuracy, while the dynamic error introduces the spatial frequency domain error. The error caused by the components of the machine tool, the cutting process and the external interference, are considered in this paper. Using the error budget, it is able to minimize risk during initial stages by ensuring that the machine will produce components that meet specifications before the machine is actually built or purchased. This methodology is used to predict and improve the performance of an ultraprecision flycutting machine tool. © 2014, Springer-Verlag London. Source


Wang S.,Harbin Institute of Technology | Wang S.,Chengdu Fine Optic Engineering Research Center | An C.,Chengdu Fine Optic Engineering Research Center | Zhang F.,Harbin Institute of Technology | And 3 more authors.
International Journal of Machine Tools and Manufacture | Year: 2016

As a typical brittle material, Potassium Dihydrogen Phosphate (KDP) crystal exhibits anisotropic mechanical property during processing. The most general method to produce smooth and crack-free KDP surface is single point diamond fly-cutting (SPDF). In processing KDP by SPDF, cutting direction has great influence on the cutting force and the quality of the machined surface. Thus, selecting an optimal cutting direction is of great significance in decreasing the cutting force and improving the surface quality. In this paper, influence of cutting direction on the brittle ductile transition (BDT) depth and cutting force in machining KDP crystal has been investigated. Cutting experiments are carried out on the (001), Doubler and Tripler plane of KDP crystal to find out the change law of cutting force and BDT depth related to cutting direction. Theoretical models for calculating the cutting force and conditions for achieving crack-free surface in cutting by circular edge cutter have also been established. The predicted results coincide well with the experiment results, which have proved the validity of the proposed models. The experimental results in this study can provide guidelines for optimizing the processing parameters in fly-cutting of KDP crystal, and the theoretical models can be extended to study the cutting mechanism of other brittle materials. © 2016 Elsevier Ltd. All rights reserved. Source

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